Komatsu PC210-8 Page 463 Shop Manual Download

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30 Testing and adjusting

UEN00229-01

PC210, 230, 240-8

01900

Pressure Switch 1

Swing

ON•OFF

PUMP

Travel

ON•OFF

PUMP

Boom Lower

ON•OFF

PUMP

Boom Raise

ON•OFF

PUMP

Arm Curl

ON•OFF

PUMP

Arm Dump

ON•OFF

PUMP

01901

Pressure Switch 2

Bucket Curl

ON•OFF

PUMP

Bucket Dump

ON•OFF

PUMP

Service

ON•OFF

PUMP

Travel Steering

ON•OFF

PUMP

02300

Solenoid Valve 1

Travel Junction

ON•OFF

PUMP

Swing Brake

ON•OFF

PUMP

Merge-divider

ON•OFF

PUMP

2-Stage Relief

ON•OFF

PUMP

Travel Speed

ON•OFF

PUMP

02301

Solenoid Valve 2

Service Return

ON•OFF

PUMP

02200

Switch Input 1

Lever Sw.

ON•OFF

PUMP

Swing Release Sw.

ON•OFF

PUMP

Swing Brake Sw.

ON•OFF

PUMP

02201

Switch Input 2

Model Select 1

ON•OFF

PUMP

Model Select 2

ON•OFF

PUMP

Model Select 3

ON•OFF

PUMP

Model Select 4

ON•OFF

PUMP

Model Select 5

ON•OFF

PUMP

Overload Alarm

ON•OFF

PUMP

02202

Switch Input 3

Key Switch (ACC)

ON•OFF

PUMP

02204

Switch Input 5

Window Limit SW.

ON•OFF

PUMP

P Limit SW.

ON•OFF

PUMP

W Limit SW.

ON•OFF

PUMP

04500

Monitor input 1

Key Switch

ON•OFF

MON

Start ON•OFF

MON

Preheat

ON•OFF

MON

Light

ON•OFF

MON

Rad. Level

ON•OFF

MON

04501

Monitor Input 2

Air cleaner

ON•OFF

MON

Eng. Oil Level

ON•OFF

MON

Battery Charge

ON•OFF

MON

04502

Monitor Input 3

Swing Brake Sw.

ON•OFF

MON

04503

Monitor Function
Switches

ON•OFF

MON

ON•OFF

MON

ON•OFF

MON

ON•OFF

MON

ON•OFF

MON

ON•OFF

MON

04504

Monitor 1st & 2nd
Row Switches

SW1

ON•OFF

MON

SW2

ON•OFF

MON

SW3

ON•OFF

MON

SW4

ON•OFF

MON

SW5

ON•OFF

MON

SW6

ON•OFF

MON

Code

No.

Monitoring item (Display on screen)

Unit (Initial setting: ISO)

Com-

ponent

charge

Remarks

ISO

meter

inch

Summary of Contents for PC210-8

Page 1: ...00084 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 K500...

Page 2: ......

Page 3: ...C230NHD 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...

Page 4: ...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 syst...

Page 5: ...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 U...

Page 6: ...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 sys...

Page 7: ...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...

Page 8: ...al 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...

Page 9: ...ilure 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 I...

Page 10: ...hort 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...

Page 11: ...arm does not sound or does not stop sounding 48 E 23 Air conditioner does not operate normally including air conditioner abnormality record 50 E 24 When starting switch is turned OFF service meter is...

Page 12: ...olant temperature becomes too high overheating 22 S 15 Abnormal noise is made 23 S 16 Vibration is excessive 24 S 17 Diesel Particulate Filter System 25 Troubleshooting of Auto Grease system UEN00247...

Page 13: ...installation of hydraulic pump assembly 17 Removal and installation of oil seal in hydraulic pump input shaft 22 Disassembly and assembly of work equipment PPC valve assembly 23 Disassembly and assem...

Page 14: ...Electrical diagrams and drawings For PC210 K51095 K52292 PC230 K50114 K50200 and PC240 K50304 K50595 13 Electrical circuit diagram 1 5 13 Electrical circuit diagram 2 5 15 Electrical circuit diagram 3...

Page 15: ...00 Index and foreword UEN00093 06 PC210 230 240 8 13...

Page 17: ...p PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 00 Index and foreword 1 Foreword and general information Foreword and general information 2 Safety notice 2 How to read the shop manual 6 Explanation...

Page 18: ...s when grinding parts with a grinder etc 4 When carrying out any operation with 2 or more workers always agree on the oper ating procedure before starting Always inform your fellow workers before star...

Page 19: ...ver which is under internal pressure or under pressure from a spring always leave 2 bolts in diagonal positions Loosen those bolts gradually and alternately to release the pressure and then remove the...

Page 20: ...wide hanging angle from the hook When hoisting a load with 2 or more ropes the force subjected to each rope will increase with the hanging angle The table below shows the variation of allowa ble load...

Page 21: ...hile the slung load is swinging 6 Do not raise or lower a load while the crane is moving longitudinally or laterally 7 Do not drag a sling 8 When lifting up a load stop it just after it leaves the gro...

Page 22: ...The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting 40 Troubleshooting This section explains how to find out failed parts and how to repair them...

Page 23: ...icated with International System of units SI For reference con ventionally used Gravitational System of units is indicated in parentheses Symbol Item Remarks k Safety Special safety precautions are ne...

Page 24: ...the range of differ ence from the standard size is called the tolerance q The tolerance with the symbols of or is indicated on the right side of the standard size a The tolerance may be indicated in...

Page 25: ...ence is in the standard range 4 Repair limit and allowable value q The size of a part changes because of wear and deformation while it is used The limit of changed size is called the repair limit q If...

Page 26: ...ith other electrical components fit ted in boxes or cases wiring harnesses are more likely to be affected by the direct effects of rain water heat or vibration Furthermore during inspection and repair...

Page 27: ...er does enter it is difficult for it to be drained Therefore if water should get into the con nector the pins will be short circuited by the water so if any water gets in immedi ately dry the connecto...

Page 28: ...r pull with one hand 2 When removing from clips q Both of the connector and clip have stoppers which are engaged with each other when the connector is installed q When removing a connector from a clip...

Page 29: ...position of the connector correctly and then insert it securely For connectors with lock stopper push in the connector until the stop per clicks into position 3 Correct any protrusion of the boot and...

Page 30: ...in the air may cause defective contact so remove all oil and water from the com pressed air before blowing with air 2 Dry the inside of the connector with a dryer If water gets inside the connector us...

Page 31: ...sconnect all wiring harness con nectors connected to the controller Fit an arc welding ground close to the welding point 5 Points to remember when troubleshooting electric circuits 1 Always turn the p...

Page 32: ...Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop and the per formance should be checked with special test equipment 3 Sealing opening...

Page 33: ...new oil and will shorten the life of the hydraulic oil 6 Flushing operations After disassembling and assembling the equip ment or changing the oil use flushing oil to remove the contaminants sludge a...

Page 34: ...ndicates colour of wire by colour code Colour codes are shown in Table 3 Indicates size of wire by nominal No Size Nominal No is shown in Table 2 Indicates type of wire by symbol Type symbol and mater...

Page 35: ...5 23 d approx 1 0 1 2 1 5 1 9 1 9 2 3 2 4 3 0 Cov er D AVS Standard 2 0 2 2 2 5 2 9 2 9 3 5 3 6 AV Standard 4 6 AEX Standard 2 0 2 2 2 7 3 0 3 1 3 8 4 6 Nominal No 8 15 20 30 40 50 60 85 100 Conductor...

Page 36: ...ed LW Blue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW R...

Page 37: ...pter 3 Fig 1 a The adapter can be pushed in about 3 5 mm a Do not hold rubber cap portion 4 2 After hose joint 2 is pushed into adapter 3 press rubber cap portion 4 against adapter 3 until it clicks F...

Page 38: ...he hexag onal portion at the male end Fig 6 2 While holding the condition of Step 1 turn lever 8 to the right clockwise Fig 7 3 While holding the condition of Steps 1 and 2 pull out whole body 7 to di...

Page 39: ...nd Fig 10 2 While holding the condition of Step 1 push cover 10 straight until it contacts contact surface b of the hexagonal por tion at the male end Fig 11 3 While holding the condition of Steps 1 a...

Page 40: ...iameter of bolt Width across flats Tightening torque mm mm Nm kgm 6 10 11 8 14 7 1 2 1 5 8 13 27 34 2 8 3 5 10 17 59 74 6 0 7 5 12 19 98 123 10 0 12 5 14 22 153 190 15 5 19 5 16 24 235 285 23 5 29 5 1...

Page 41: ...Width across flats Tightening torque Nm kgm mm mm Range Target 02 14 Varies depending on type of connec tor 35 63 3 5 6 5 44 4 5 03 04 20 84 132 8 5 13 5 103 10 5 05 06 24 128 186 13 0 19 0 157 16 0...

Page 42: ...e below Nominal No of hose Width across flats Tightening torque Nm kgm Taper seal Face seal Range Target Thread size mm Nominal No Number of threads type of thread Thread diame ter mm Ref erence 02 19...

Page 43: ...Taper screws a Unless there are special instructions tighten the taper screws unit inch of the 102 107 and 114 engine series to the torque below Thread size Tightening torque inch Nm kgm 1 16 3 1 0 31...

Page 44: ...le so divide it by 10 move the decimal point one place to the left to convert it to 55 mm 2 Carry out the same procedure as above to convert 55 mm to 2 165 inches 3 The original value 550 mm was divid...

Page 45: ...6 79 37 81 57 83 78 85 98 40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03 50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07 60 132 28 134 48 136 69 138 89 141...

Page 46: ...173 6 180 8 188 1 195 3 202 5 209 8 30 217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1 40 289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4 50 361 7 368 9 376 1 383 4 390 6 397...

Page 47: ...7 1 451 1 465 1 479 1 493 1 508 1 522 1 536 1 550 110 1 565 1 579 1 593 1 607 1 621 1 636 1 650 1 664 1 678 1 693 120 1 707 1 721 1 735 1 749 1 764 1 778 1 792 1 806 1 821 1 835 130 1 849 1 863 1 877...

Page 48: ...3 2 7 2 19 66 2 12 2 54 129 2 31 7 89 192 2 26 1 15 5 0 6 7 20 68 0 12 8 55 131 0 32 2 90 194 0 25 6 14 6 8 6 1 21 69 8 13 3 56 132 8 32 8 91 195 8 25 0 13 8 6 5 6 22 71 6 13 9 57 134 6 33 3 92 197 6...

Page 49: ...00 Index and foreword UEN00094 00 PC210 230 240 8 33...

Page 51: ...8 K50001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 01 Specification 1 Specification and technical data Specific...

Page 52: ...80 2 540 D Shoe width mm 600 700 500 550 E Cab height mm 3 035 3 060 F Tail swing radius mm 2 800 G Overall track length mm 4 080 4 450 4 305 H Tumbler centre dis tance mm 3 270 3 655 3 460 Min ground...

Page 53: ...C Max digging height mm 10 000 D Max vertical wall digging depth mm 5 980 E Max dumping height mm 7 110 F Min dumping height mm 2 645 G Max reach at ground level mm 9 700 Check item Unit PC240LC 8 PC2...

Page 54: ...5 5 Lo 2 6 Mi 3 6 Hi 5 4 Gradability degree 35 Ground pressure Standard shoe kPa kg cm2 49 0 50 39 2 0 40 53 9 0 55 54 9 0 56 Dimensions Overall length mm 9 425 Overall width mm 2 500 Overall crawler...

Page 55: ...rouser 45 on one side Assembly type triple grouser 49 on one side Assembly type triple grouser 47 on one side Hydraulic system Hydraulic pump Type and numbers HPV112 112 Variable displacement piston t...

Page 56: ...km h Lo 3 0 Mi 4 1 Hi 5 5 Gradability degree 35 Ground pressure Standard shoe kPa kg cm2 44 1 0 45 52 0 0 53 Dimensions Overall length mm 9 885 Overall width upper structure mm 2 710 Overall crawler...

Page 57: ...y type triple grosser 49 on one side Hydraulic system Hydraulic pump Type and number HPV95 95 Variable displacement piston type 2 Delivery l min Piston 219 5 x 2 Set pressure MPa kg cm2 Piston 37 2 38...

Page 58: ...rame 1 886 Cab 480 Operator s seat 35 Counterweight 4 000 4 300 Swing machinery 174 Control valve 235 Swing motor 51 5 Travel motor 93 x 2 Centre swivel joint 36 Track frame assembly Not including pip...

Page 59: ...50001 and up Boom assembly 1 393 Arm assembly 2 9M 791 Bucket assembly 900 Boom cylinder assembly 173 x 2 Arm cylinder assembly 223 Bucket cylinder assembly std 133 Bucket cylinder assembly large 159...

Page 60: ...Revolving frame 2 023 Cab 480 Operator s seat 35 Counterweight 5 250 Swing machinery 218 Control valve 235 Swing motor 51 5 Travel motor 93 x 2 Centre swivel joint 36 Track frame assembly Not includin...

Page 61: ...p Boom assembly 1 273 Arm assembly 3 0M 947 Bucket assembly 1 070 Boom cylinder assembly 200 x 2 Arm cylinder assembly 265 Bucket cylinder assembly std 160 Bucket cylinder assembly large 190 Link larg...

Page 62: ...draulic system Power train oil 20 C 50 C TO10 Hydraulic oil 20 C 50 C HO46 HM Grease fitting Hyper grease Note 3 20 C 50 C G2 TE Lithium EP grease 20 C 50 C G2 LI Cooling system Supercoolant AF NAC 30...

Page 63: ...01 Specification UEN00095 02 PC210 230 240 8 13...

Page 65: ...and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 10 Structure function and maintenance standard 1 Engine and cooling system Engine and cooling...

Page 66: ...2 PC210 230 240 8 Engine and cooling system 1 Engine related parts 1 1 Drive plate 2 Torsion spring 3 Stopper pin 4 Friction plate 5 Muffler 6 Rear engine mount 7 Front engine mount 8 Damper assembly...

Page 67: ...oler and fuel cooler 1 1 Reservoir tank 2 Fan 3 Shroud 4 Radiator cap 5 Radiator inlet hose 6 Net 7 Radiator outlet hose 8 Radiator 9 Oil cooler 10 Aftercooler 11 Fuel cooler Specifications Radiator A...

Page 68: ...UEN00096 01 10 Structure function and maintenance standard 4 PC210 230 240 8 Diesel Particulate Filter 1 1 Diesel Particulate Filter 1...

Page 69: ...standard UEN00096 01 PC210 230 240 8 5 Diesel Particulate Filter Component Parts 1 1 Inlet 2 Catalyst 3 Filter 4 Outlet 5 Gasket 6 Ring Clamp 7 Mount 8 In Cab Monitor 9 Pressure Sensor 10 Hose sensor...

Page 70: ...g channels The particulate matter is deposited on the surface and in the pores of the channel walls The filtered exhaust gas flows out through the open ends of the channels it has crossed into Regener...

Page 71: ...10 Structure function and maintenance standard UEN00096 01 PC210 230 240 8 7...

Page 73: ...0NLC 8 Machine model Serial number PC210 8 K50001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 10 Structure functio...

Page 74: ...wer train 1 1 Idler 2 Center swivel joint 3 Control valve 4 Final drive 5 Travel motor HMV110ADT 2 6 Hydraulic pump PC210 230 HPV112 112 PC240 HPV95 95 7 Engine SAA6D107E 1 8 Travel speed solenoid val...

Page 75: ...10 Structure function and maintenance standard UEN00097 00 PC210 230 240 8 3...

Page 76: ...UEN00097 00 10 Structure function and maintenance standard 4 PC210 230 240 8 Final drive 1...

Page 77: ...No Check item Criteria Remedy 14 Backlash between No 2 sun gear and No 2 planetary gear Standard clearance Clearance limit Replace 0 13 0 47 1 00 15 Backlash between No 1 plane tary gear and gear hub...

Page 78: ...UEN00097 00 10 Structure function and maintenance standard 6 PC210 230 240 8 Swing machinery 1 PC210 8 PC210LC 210NLC PC230NHD 8...

Page 79: ...1 sun gear and No 1 planetary gear 0 16 0 50 1 00 15 Backlash between No 1 plane tary gear and ring gear 0 18 0 59 1 10 16 Backlash between No 1 plane tary carrier and No 2 sun gear 0 39 0 71 1 20 17...

Page 80: ...UEN00097 00 10 Structure function and maintenance standard 8 PC210 230 240 8 PC240LC PC240NLC 8...

Page 81: ...1 sun gear and No 1 planetary gear 0 16 0 50 1 00 15 Backlash between No 1 plane tary gear and ring gear 0 18 0 59 1 10 16 Backlash between No 1 plane tary carrier and No 2 sun gear 0 35 0 64 1 20 17...

Page 82: ...Ball 3 Swing circle outer race a Inner race soft zone S position b Outer race soft zone S position Specifications Reduction ratio 96 13 7 385 Amount of filled grease 14 6 l G2 LI 716 814 Nm 73 83 Kgm...

Page 83: ...eth 92 2 Ball 3 Swing circle outer race a Inner race soft zone S position b Outer race soft zone S position Specifications Reduction ratio 92 13 7 077 Amount of filled grease 15 8 l G2 LI Unit mm No C...

Page 85: ...rial number PC210 8 K50001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 10 Structure function and maintenance stand...

Page 86: ...1 PC210 240 8 1 Idler 2 Track frame 3 Carrier roller 4 Final drive 5 Track roller 6 Track shoe 7 Center guard 8 Front guard q The dimensions and the number of track roll ers depend on the model but th...

Page 87: ...9 51 49 Unit mm No Check item Criteria Remedy 9 Vertical width of idler guide Standard size Tolerance Repair limit Build up welding or replace Track frame 107 Idler support 105 10 Horizontal width of...

Page 88: ...UEN00098 00 10 Structure function and maintenance standard 4 PC210 230 240 8 Idler 1 PC210 240 8...

Page 89: ...tread 19 25 5 Total width 159 6 Width of tread 37 5 7 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 65 0 250 0 350 0 164 0 0...

Page 90: ...3 Width of tread 43 4 Thickness of tread 23 16 5 Width of flange 14 6 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Shaft Hole 40 0 170 0 190 0 301 0...

Page 91: ...tal width 225 5 Width of tread 44 5 6 Width of flange 25 5 7 Clearance between shaft and bushing Standard size Tolerance Standard clearance Clearance limit Replace bushing Shaft Hole 60 0 215 0 315 0...

Page 92: ...00 10 Structure function and maintenance standard 8 PC210 230 240 8 Track shoe 1 PC210 240 8 a P portion shows the link of bushing press fitting end 1 Triple grouser shoe 2 Road liner 3 Swamp shoe 4 F...

Page 93: ...or replace 105 97 5 Thickness of link metal bushing press fitting portion 28 5 20 5 6 Shoe bolt pitch 160 4 Adjust or replace 7 124 4 8 62 9 Link Inside width 84 8 10 Overall width 45 4 11 Tread width...

Page 94: ...51 21 Interference between bushing and link Standard size Tolerance Standard interfer ence Adjust or replace Shaft Hole 59 0 434 0 394 0 074 0 000 0 320 0 434 22 Interference between regular pin and l...

Page 95: ...10 Structure function and maintenance standard UEN00098 00 PC210 230 240 8 11...

Page 96: ...UEN00098 00 10 Structure function and maintenance standard 12 PC210 230 240 8 Triple grouser shoe Swamp shoe Road liner...

Page 97: ...riteria Remedy 1 Height Standard size Repair limit Build up welding or replace 26 16 2 Thickness 10 3 Length of base 26 4 Length of base 19 5 Length at tip 20 6 Length at tip 14 7 Length at tip 19 8 T...

Page 99: ...er PC210 8 K50001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 10 Structure function and maintenance standard 1 Hyd...

Page 100: ...valve 17 Attachment PPC valve 18 Hydraulic drift prevention valve 19 Accumulator 20 Solenoid valve assembly 20A PPC lock solenoid valve 20B 2 stage relief solenoid valve 20C Swing brake solenoid valv...

Page 101: ...10 Structure function and maintenance standard UEN00099 01 PC210 230 240 8 3 B Y 21 21D 21C 21B 21A Y 21E...

Page 102: ...rt cap 3 Filter element 4 Strainer 5 Bypass valve 6 Suction strainer 7 Sight gauge Safety valve Relief cracking pressure 16 7 6 9 kPa 0 17 0 07 kg cm2 Suction cracking pressure 0 0 49 kPa 0 0 005 kg c...

Page 103: ...1 PC210 230 Type HPV112 112 1 2 A A 34 3 44 1 Nm 3 5 4 5 Kgm 11 8 14 7 Nm 1 2 1 5 Kgm 58 8 78 4 Nm 6 8 Kgm 58 8 78 4 Nm 6 8 Kgm SUCTION 132 157 Nm 13 5 16 Kgm PLSFC PLSRC PD1R PENF PEPPC PMR PENR PEP...

Page 104: ...UEN00099 01 10 Structure function and maintenance standard 6 PC210 230 240 8 Hydraulic pump 1 PC240 Type HPV95 95...

Page 105: ...Drain plug PENF Front control pressure detection port PENR Rear control pressure detection port PEPC EPC basic pressure port PEPCC EPC basic pressure detection port PFC Front pump delivery pressure de...

Page 106: ...ft 2 Cradle 3 Front case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 End cap 10 Rear shaft 11 Rear case 12 Servo piston 13 PC valve 7 8 13 7 Nm 0 8 1 4 Kgm 58 8 78 4 Nm 6 8 Kgm 58 8...

Page 107: ...and maintenance standard UEN00099 01 PC210 230 240 8 9 PC240 1 Front shaft 2 Cradle 3 Front case 4 Rocker cam 5 Shoe 6 Piston 7 Cylinder block 8 Valve plate 9 End cap 10 Rear shaft 11 Rear case 12 Ser...

Page 108: ...constitute the spherical bearing q Rocker cam 4 has flat surface A and shoe 5 is always pressed against this surface while sliding in a circular movement q Rocker cam 4 conducts high pressure oil to t...

Page 109: ...this way piston 6 slides on the inside of cylinder block 7 so a difference between vol umes E and F is created inside cylinder block 7 q A single piston suction and discharges the oil by the amount F...

Page 110: ...l surface rocker cam 4 slides on the surface while continuing revolving movement q Space of the pressure receiving area of servo piston 12 are not identical on the left side and right side Main pump d...

Page 111: ...ain pump pressure PP and control valve outlet port pressure PLS q Main pump pressure PP pressure PLS called the LS pressure coming from the con trol valve output and pressure PSIG called the LS select...

Page 112: ...essure of the EPC valve for the LS valve entering port G also changes the position of spool 6 Setting force of the spring is changed q Before the engine is started servo piston 12 is pushed to the rig...

Page 113: ...The PC valve is connected to the drain port so the pressure across circuits D and K becomes drain pressure PT The operation of the PC valve is explained later q The pressure at the large diameter end...

Page 114: ...ssure PP pushes spool 6 to the right q When spool 6 moves main pump pressure PP flows from port C to port D and from port K it enters the large diameter end of the piston q Main pump pressure PP also...

Page 115: ...at the intermediate position Spool 6 will be stopped at a position where the distance of the opening from port D to port E and the dis tance from port C to port D is almost the same q At this point t...

Page 116: ...e engine hose power q If the pump discharge pressure increases due to increased load during operation this valve decreases the pump delivery q And if the pump delivery pressure goes low it increases t...

Page 117: ...the com bined spool pushing force is balanced by the setting force of springs 4 and 6 as well as the pump pressures PP1 self pressure and PP2 another pump s pressure q The pressure port C pressure ou...

Page 118: ...ng piston 2 q Spring load of springs 4 and 6 is also affected by the command current X to PC EPC valve solenoid q Port C of the PC valve is connected to port E of the LS valve q Self pressure PP1 ente...

Page 119: ...n nected q As a result the pressure on port C rises and the pressure on the large diameter end of the piston also rises Thus the leftward move of servo piston 9 is stopped q Servo piston 9 stop positi...

Page 120: ...the large diameter end of servo piston 9 stopping servo piston 9 q If main pump pressure PP2 increases further and spool 3 moves further to the right main pump pressure PP1 flows to port C and acts t...

Page 121: ...es further the relationship between average pump pressure PP1 PP2 2 and pump delivery Q is proportional to the force of the PC EPC valve solenoid and moves in parallel q Namely the force of PC EPC val...

Page 122: ...in between to con trol the current flowing to PC EPC valve sole noid 1 q The current becomes constant so the force pushing piston 2 is also constant q If the main pump pressures PP1 and PP2 are low t...

Page 123: ...s light and is balanced at the position in the figure above q In this case the pressure from port B flows to port C so servo piston 9 moves to the right smaller pump delivery and stops at a position t...

Page 124: ...01 10 Structure function and maintenance standard 26 PC210 230 240 8 3 LS PC EPC valve C To LS PC valve P From self pressure reducing valve T To tank 1 Connector 2 Coil 3 Body 4 Spring 5 Spool 6 Rod 7...

Page 125: ...ure in proportion to the size of the signal and outputs it to the LS PC valve Operation 1 When signal current is 0 coil is deenergized q When there is no signal current flowing from the controller to...

Page 126: ...and port T are connected q Spool 5 moves up and down so that the pro pulsion force of plunger 7 may be balance with pressure of port C spring load of spring 4 q The circuit pressure between the EPC va...

Page 127: ...PC210 230 240 8 29 Pilot oil filter 1 For breaker 1 Filter 2 Case 3 Head cover 4 Relief valve Specifications Rated pressure 6 57 MPa 67 kg cm2 Flow rate 16 l min Relief valve cracking pressure 0 15 M...

Page 129: ...ine model Serial number PC210 8 K50001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 10 Structure function and maint...

Page 130: ...ctor solenoid valve C To tank IS1 From controller IS2 From controller P1 From bucket PPC and EPC valves P2 From bucket PPC and EPC valves P3 From L H Travel PPC valve P4 From L H Travel PPC valve P5 F...

Page 131: ...10 Structure function and maintenance standard UEN00100 00 PC210 230 240 8 3 General view PC210 230 8...

Page 132: ...UEN00100 00 10 Structure function and maintenance standard 4 PC210 230 240 8 PC240 8...

Page 133: ...10 Structure function and maintenance standard UEN00100 00 PC210 230 240 8 5...

Page 134: ...UEN00100 00 10 Structure function and maintenance standard 6 PC210 230 240 8 Sectional view 1 5...

Page 135: ...compensation valve Left swing 14 Pressure compensation valve R H travel forward 15 Pressure compensation valve Arm in 16 Main relief valve 17 Unload valve 18 Main relief valve 19 Spool Service 3 20 S...

Page 136: ...UEN00100 00 10 Structure function and maintenance standard 8 PC210 230 240 8 2 5...

Page 137: ...ction valve R H travel forward 14 Safety suction valve Arm in 15 LS shuttle valve Arm 16 LS shuttle valve R H travel 17 LS select valve 18 LS shuttle valve Boom 19 LS shuttle valve L H travel 20 LS sh...

Page 138: ...UEN00100 00 10 Structure function and maintenance standard 10 PC210 230 240 8 3 5...

Page 139: ...Reverse 18 Pressure compensation valve Reverse Swing valve 19 LS select valve 20 Pressure compensation valve L H 21 Spool 22 Pressure compensation valve R H Unit mm No Check item Criteria Remedy 23 C...

Page 140: ...UEN00100 00 10 Structure function and maintenance standard 12 PC210 230 240 8 4 5...

Page 141: ...ard 20 Suction valve Reverse 21 Pressure compensation valve Reverse Bucket valve 22 LS shuttle valve 23 Pressure compensation valve Curl 24 Spool 25 Safety suction valve Curl 26 Safety suction valve D...

Page 142: ...ervice valve 1 1 LS shuttle valve 2 Pressure compensation valve 3 Spool 4 2 stage safety suction valve 5 Safety suction valve Service valves 2 and 3 6 LS shuttle valve 7 Pressure compensation valve 8...

Page 143: ...nfluenced by load q Controllability enabling digging even with fine control q Ease of compound operation ensured by flow divider function using area of opening of spool during compound operations q En...

Page 144: ...is constant q LS differential pressure PLS Pump dis charge pressure PP LS pressure PLS q The pump swash plate angle shifts toward the maximum position if LS differential pressure PLS is lower than th...

Page 145: ...side of the control valve to bal ance the load q When actuators are operated together the pressure difference P between the upstream inlet port and downstream outlet port of the spool of each valve be...

Page 146: ...lustration shows the actuator 6 in the merge mode with stroke end at the time of relief 1 Front pump 2 Rear pump 3 Main relief valve 4 Unload valve 5 Merge divider valve 6 Control valve 7 Actuator 8 P...

Page 147: ...10 Structure function and maintenance standard UEN00100 00 PC210 230 240 8 19...

Page 148: ...UEN00100 00 10 Structure function and maintenance standard 20 PC210 230 240 8 Functions and operation by valve 1 Hydraulic circuit diagram and the name of valves 1...

Page 149: ...26 LS select valve 27 Merge divider valve 28 Arm quick return valve 29 Self pressure reducing valve 30 Travel junction valve 31 Back pressure valve 32 Cooler check valve 33 Main relief valve bucket si...

Page 150: ...e of pump circuit 3 is received by the end of valve 2 q Since the control valve is in neutral position pressure of LS circuit 1 is 0 MPa 0 kg cm2 q Pressurized oil of pump circuit 3 stops at valve 2 a...

Page 151: ...he cylinder reaches the stroke end the main relief valve opens q The pump delivery Q is relieved to the tank See the system diagram q The pump discharge pressure PP and LS pressure PLS become approxim...

Page 152: ...e spool meter in of pres sure compensation valve 3 and leads to LS shuttle valve 7 as the LS pressure q Connected to actuator port B via valve 4 and makes LS pressure C actuator load pres sure q Inlet...

Page 153: ...ses the residual pressure in LS pressure circuit 6 from orifices a and b q Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pres sure q Bypass flow from LS bypass valv...

Page 154: ...d valve 2 to the closing direction Integrated pressure compensation valve q High stress may occur when valve 2 collides with valve chamber seat portion C if a high peak pressure is generated in the ac...

Page 155: ...ool meter in upstream pressure of port A is the pump pressure the spool meter in differential pressure upstream pressure port A pressure downstream pressure port B pressure becomes equivalent to all t...

Page 156: ...tream pressure will be equal to the maximum load pressure and the pressure will be divided according to the opening area ratio q If area ratio 1 or over The spool meter in downstream pressure will be...

Page 157: ...ressure in the springing chamber B 1 Hydraulic pump 2 Valve 3 Pressure compensation valve inner shuttle valve 4 Piston Function q Shuttle valve 3 is pushed to the right by port A pressure and cuts off...

Page 158: ...function and maintenance standard 30 PC210 230 240 8 2 In the case of travel Outline q Since no holding pressure is generated at port A of the travel circuit a pressure compensa tion valve without sh...

Page 159: ...n q Provides the regeneration circuit from the cyl inder bottom to the cylinder head when the boom is lowered and increases flow to the cyl inder bottom Operation q If the cylinder head pressure is lo...

Page 160: ...nance standard 32 PC210 230 240 8 2 If the cylinder head pressure is higher than the bottom pressure digging work etc Function q Check valve 6 provided to regeneration cir cuit C closes to shut off th...

Page 161: ...eneration circuit pro vided from the cylinder head to the bottom increases the cylinder speed as the cylinder flow involves the pump delivery plus regener ated flow Operation q If the cylinder head pr...

Page 162: ...nd maintenance standard 34 PC210 230 240 8 2 If the cylinder head pressure is lower than the bottom pressure Function q Check valve 6 provided to regeneration cir cuit C closes to shut off the flow fr...

Page 163: ...or divides to respective control valve group q Merges and divides LS circuit pressure Operation q Since selector signal IS1 is OFF output pres sure from EPC valve is 0 kg cm2 q Main spool 1 is pressed...

Page 164: ...d ports E and F are divided q Pressurized oil discharged from the two pumps are sent to respective control valves P1 pressure To bucket L H travel and boom P2 pressure To swing R H travel and arm q Wh...

Page 165: ...ravel spool 7 Arm spool 8 LS shuttle valve 9 LS circuit Operation 1 If pilot pressure BP is OFF q Since pilot pressure BP is OFF piston 3 is pressed to the left by spring 2 q When swing operated swing...

Page 166: ...nd supplies it as control pressure for the solenoid valves EPC valves etc Operation 1 While engine is stopped q Poppet 11 is pressed by spring 12 against the seat and port PR is not connected to TS q...

Page 167: ...14 moves to close the pass between ports P2 and PR q Pressure P2 is reduced by the opening at this time and adjusted to a constant pressure the set pressure and supplied as pressure PR 3 When load pre...

Page 168: ...sure is gen erated q If pressure PR of self pressure reducing valve becomes abnormally high ball 16 con tracts spring 15 and becomes separated from the seat q Allows the pressurized oil to TS from por...

Page 169: ...e supplied evenly to both travel motors to improve machine s straight travel performance q When the machine is steered outside pilot pressure PST closes the travel junction valve to improve steering p...

Page 170: ...0 travel junction spool 2 is pressed by the force of spring 1 against the right side and the pass between ports PTL and PTR is open q If the oil flow rates to the L H and R H travel motors become diff...

Page 171: ...arm dumping bucket dig ging or operating dump q When controlling the stroke of the boom arm and or bucket pilot pressure of travel PPC valve passes through the circuit inside the con trol valves to ac...

Page 172: ...lose orifice 5 and shut off stroke regulation signal chamber a and the drain circuit of the travel PPC valve q At this time the right travel reverse or forward lever is set PPC pressure is applied thr...

Page 173: ...10 Structure function and maintenance standard UEN00100 00 PC210 230 240 8 45...

Page 174: ...UEN00100 00 10 Structure function and maintenance standard 46 PC210 230 240 8 Hydraulic drift prevention valve 1 For the boom and arm...

Page 175: ...5 Check valve 6 Spring Unit mm No Check item Criteria Remedy 7 Check valve spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installed length Inst...

Page 176: ...q Chambers a and b are shut off q No pressurized oil flows between the control valve and the work equipment cylinder q Accordingly the work equipment is held in position q If the work equipment cylind...

Page 177: ...ambers a and b are interconnected q Pressurized oil flows from the control valve to the work equipment cylinder If the piping is bursted q If piping A bursts between the control valve and the work equ...

Page 178: ...y position 1st stage stroke q At this point chambers a and b are not interconnected q Pilot pressure further rises and reaches Pilot pressure Force of spring 2 area of d q Spool 1 moves further to the...

Page 179: ...m side flows to orifice a o chamber b o orifice c o drain T and the pressure in chamber b lowers q If the pressure of chamber b drops lower than that of port A pressure receiving force of the pressure...

Page 180: ...essure from the PPC valve to 0 kg cm2 q The pressurized oil that has flowed and been drained through orifice a in valve 2 is closed by pilot piston 1 q The holding pressure on the arm bottom side work...

Page 181: ...the control valve is con nected with port T through orifice b of valve 1 2 While engine is running q Output pressure PR of the self pressure reducing valve is applied via the control valve to spring...

Page 182: ...e of relief valve is determined by spring 1 installed load 1st stage q Respective setting is not required for both the 1st and 2nd stages Setting the 1st stage com pletes the setting of the 2nd stage...

Page 183: ...ad without lever opera tion if high load is applied to the cylinder q Improves work efficiency and reduces machine body vibration Operation q The safety set pressure is determined by spring 1 installe...

Page 184: ...ed to section A via passage B q Piston 2 works on the pressure receiving bore portion d2 d1 of section A q This pilot pressure contracts spring 3 and piston 2 moves to the right until making con tact...

Page 185: ...10 Structure function and maintenance standard UEN00100 00 PC210 230 240 8 57...

Page 187: ...30NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 10 Structure function and maintenance standard 1 Hydraulic system Part 3 Hydraulic system Part 3 3 Swing motor 3 Centre swivel jo...

Page 188: ...e function and maintenance standard 2 PC210 230 240 8 Attachment circuit selector valve 54 Quick coupler control valve For PC210 K50001 K51094 PC230 K50001 K50113 and PC240 K50001 K50303 56 Function 5...

Page 189: ...noid valve MA From control valve MB From control valve S From control valve T To tank 1 Reverse prevention valve 2 Safety valve Specifications Models Item PC210 230 8K PC240 8K Type KMF125ABE 6 Theore...

Page 190: ...UEN00160 03 10 Structure function and maintenance standard 4 PC210 230 240 8...

Page 191: ...re spring 14 Check valve 15 Check valve spring 16 Shuttle valve 17 Shuttle valve spring Unit mm No Check item Criteria Remedy Standard size Repair limit 18 Check valve spring Free length x Outside dia...

Page 192: ...t T q Brake piston 7 is pushed down by brake spring 1 q Disc 5 and plate 6 are pushed together and the brake is applied 2 When solenoid valve is energized Operation q As the swing brake solenoid valve...

Page 193: ...orque is generated in the motor and the motor starts to rotate q The pressurized oil from the outlet port of the motor passes from port MB through the con trol valve 6 and returns to the tank 2 When s...

Page 194: ...UEN00160 03 10 Structure function and maintenance standard 8 PC210 230 240 8 Reverse prevention valve...

Page 195: ...ndard UEN00160 03 PC210 230 240 8 9 MA From control valve MB From control valve T1 To tank T2 To tank 1 Valve body 2 Spool MA side 3 Spring MA side 4 Plug MA side 5 Spool MB side 6 Spring MB side 7 Pl...

Page 196: ...nce in areas of circles D1 D2 of spool 5 and moves spool 5 to the left side q Port MB o chamber e will be intercon nected q Since pressure MA is lower than the set pres sure of spring 3 spool 2 does n...

Page 197: ...10 Structure function and maintenance standard UEN00160 03 PC210 230 240 8 11...

Page 198: ...UEN00160 03 10 Structure function and maintenance standard 12 PC210 230 240 8 Centre swivel joint 1...

Page 199: ...travel motor port PA B2 From control valve port B5 C1 To R H travel motor port PA C2 From control valve port A2 D1 To R H travel motor port PB D2 From control valve port B2 E To L H and R H travel mot...

Page 200: ...UEN00160 03 10 Structure function and maintenance standard 14 PC210 230 240 8...

Page 201: ...e PA From control valve PB From control valve T To tank Specifications Models Item PC210 8K PC230 240 8K Type HMV110ADT 3 Theoretical displacement Min 78 6 cm3 rev 74 cm3 rev Max 106 2 cm3 rev 110 7 c...

Page 202: ...UEN00160 03 10 Structure function and maintenance standard 16 PC210 230 240 8...

Page 203: ...lance valve 19 Ring 20 Spool return spring 21 Brake piston 22 Plate 23 Disc 24 Ball Unit mm No Check item Criteria Remedy Standard size Repair limit 25 Check valve spring Free length x Outside diamete...

Page 204: ...nd cover 8 by pressing check valve 22 is shut off by regulator valve 9 q Fulcrum a of rocker cam 4 is eccentric to the working point b of the combined force of the propulsion force of cylinder 6 q The...

Page 205: ...the self pressure reducing valve flows to port P q Regulator valve 9 is pushed to the left q The pressurized oil from the control valve passes through passage d in regulator valve 9 and enters regulat...

Page 206: ...erated pressurized oil from the pump activates counterbalance valve spool 19 opening the parking brake circuit q The pressurized oil is conducted to chamber e of brake piston 12 and compresses spring...

Page 207: ...circuit q The pressurized oil in chamber e of brake piston 12 passes through orifice f of brake piston 12 and is drained to the motor case q Brake piston 12 is pushed to the right by spring 11 q Plat...

Page 208: ...g in run away and inviting a very dan gerous situation q These valves are used to prevent above by controlling the machine to travel according to the engine speed pump delivery Operation when pressuri...

Page 209: ...Pressure in chamber S1 is released via ori fices E1 and E2 q As the pressure in chamber S1 goes below the spool selector pressure spool 19 is returned to the left by spring 20 and outlet port MB is th...

Page 210: ...the pressure in chamber S1 q When it drops beyond the spool switching pressure spool 19 is returned to the left by spring 20 reducing the pressure at outlet passage B1 q The motor tries to continue ro...

Page 211: ...10 Structure function and maintenance standard UEN00160 03 PC210 230 240 8 25 q The pump pressure rises providing a large tractional force to the valve...

Page 212: ...0 230 240 8 PPC valve 1 Work equipment and swing PPC valve 1 P From self pressure reducing valve P1 L H PPC Arm out R H PPC Boom lower P2 L H PPC Arm in R H PPC Boom raise P3 L H PPC Swing left R H PP...

Page 213: ...240 K50001 K50595 Unit mm No Check item Criteria Remedy 12 Centring spring for ports P3 and P4 Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installat...

Page 214: ...1 moves up and down until the force of metering spring 2 is balanced with the pressure at port P1 q The relationship of the position of spool 1 and body 10 fine control hole f is in the middle betwee...

Page 215: ...pplied until the pressure at port P1 recovers to the level equivalent to the lever position q When the spool of the control valve returns the oil in drain chamber D flows in from fine control hole f i...

Page 216: ...cture function and maintenance standard 30 PC210 230 240 8 Travel PPC valve 1 P From self pressure reducing valve P1 L H reverse P2 L H forward P3 R H reverse P4 R H forward P5 Travel signal P6 Steeri...

Page 217: ...10 Structure function and maintenance standard UEN00160 03 PC210 230 240 8 31...

Page 218: ...ool spring Unit mm No Check item Criteria Remedy 11 Centring spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Installation length Installation loa...

Page 219: ...ressure at port P1 becomes higher spool 1 is pushed back and fine con trol hole f is shut off from pump pressure chamber PP At almost the same time it is connected to drain chamber D to release the pr...

Page 220: ...il 4 At full stroke q Lever 5 pushes down piston 4 and retainer 9 pushes down spool 1 q Fine control hole f is shut off from drain chamber D and is interconnected to pump pressure chamber PP q Therefo...

Page 221: ...function and maintenance standard UEN00160 03 PC210 230 240 8 35 Operation 1 When in neutral q No output is made from respective output ports from port P1 to P4 travel signal port P5 and steering sig...

Page 222: ...ion shows the circuit for travelling straight forward q When operating L H motor forward port P2 output and R H motor forward port P4 out put pressure of both L H spring chamber k and R H spring chamb...

Page 223: ...the difference of the pilot pressure between both sides is higher than a certain level the pilot pressure is output as the steer ing signal q The pressure in left spring chamber k of steering signal...

Page 224: ...illustration shows the circuit for travelling left reverse and right forward q When operating L H motor reverse port P1 output and R H motor forward port P4 out put pressure of the R H spring chamber...

Page 225: ...10 Structure function and maintenance standard UEN00160 03 PC210 230 240 8 39 Service PPC valve with EPC valve 1 a For the details of operation see the paragraph of Work equipment swing PPC valve...

Page 226: ...Lever 4 Plate 5 Retainer 6 Block 7 Body 8 EPC valve Unit mm No Check item Criteria Remedy 9 Centring spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diame...

Page 227: ...reducing valve T To hydraulic tank 1 Body 2 Plug 3 Spool 4 Push pin 5 Coil 6 Plunger 7 Connector Unit mm No Check item Criteria Remedy 8 Return spring Standard size Repair limit If damaged or deformed...

Page 228: ...pressure in proportion to the size of the signal and outputs it to the control valve Operation 1 When signal current is 0 coil is deenergized q When there is no signal current flowing from the control...

Page 229: ...T are con nected q Spool 2 moves up and down so that the pro pulsion force of plunger 6 may be balance with pressure of port C spring load of spring 3 q The circuit pressure between the EPC valve and...

Page 230: ...UEN00160 03 10 Structure function and maintenance standard 44 PC210 230 240 8 Service PPC valve 1 a For the details of operation see the paragraph of Work equipment swing PPC valve...

Page 231: ...2 Piston 3 Lever 4 Plate 5 Retainer 6 Body Unit mm No Check item Criteria Remedy 7 Centring spring Standard size Repair limit If damaged or deformed replace spring Free length x Outside diameter Insta...

Page 232: ...UEN00160 03 10 Structure function and maintenance standard 46 PC210 230 240 8 Valve control 1...

Page 233: ...er 6 R H PPC valve 7 R H work equipment control lever 8 Solenoid block 9 Accumulator 10 Control valve 11 Hydraulic pump 12 Junction box 13 L H work equipment control lever 14 L H PPC valve Lever posit...

Page 234: ...e function and maintenance standard 48 PC210 230 240 8 ATT EPC Valve Assembly 1 For PC210 K51095 and up PC230 K50114 and up and PC240 K50304 and up 1C Pc T 2 P Pd 1D 1B Pb 4 P3 4 P1 4 4 P2 3 1A Pa 3 P...

Page 235: ...LH PPC N B RH delivery to work equipment ATT EPC Valve 1 For details of structure function and operation See 1 EPC valve on page 41 Shuttle Valve 3 and 4 The shuttle valve allows either the RH attach...

Page 236: ...UEN00160 03 10 Structure function and maintenance standard 50 PC210 230 240 8 Solenoid valve 1 PPC lock travel junction ATT selector travel speed swing brake and 2 stage relief solenoid valves...

Page 237: ...or Operation When solenoid is turned off q Since the signal current does not flow from the controller solenoid 9 is deenergized For this reason spool 10 is pushed to the left by spring 11 Since port P...

Page 238: ...UEN00160 03 10 Structure function and maintenance standard 52 PC210 230 240 8 PPC Accumulator 1 1 Gas plug 2 Shell 3 Poppet 4 Holder 5 Bladder 6 Oil port Specifications Gas capacity 300 cc for PPC...

Page 239: ...40 8 53 Return oil filter 1 For breaker 1 Drain plug 2 Filter 3 Case 4 Head cover 5 Relief valve Specifications Rated pressure 6 9 MPa 70 kg cm2 Flow rate 200 l min Relief valve cracking pressure 0 34...

Page 240: ...selector solenoid valve T To hydraulic tank TS To hydraulic tank V To control valve 1 Spool 2 Spring Unit mm No Check item Criteria Remedy 3 Spool return spring Standard size Repair limit If damaged...

Page 241: ...eaker is installed q Spool 1 is pressed to the left by the force of spring 2 q Ports ATT and V are interconnected and ports ATT and T are shut off Attachment is thus interconnected to the control valv...

Page 242: ...ck coupler cylinder is reached the pressure at the cylinder will be the set pressure of the regulating valve 1 q The pressure regulating valve can be adjusted according to the specification of the cou...

Page 243: ...ce standard UEN00160 03 PC210 230 240 8 57 Schematic P Supply pressure from main valve T To tank B Supply to quick coupler lock and hold direction B1 Pressure checking port for B line B2 Spare A Suppl...

Page 244: ...sure at the cylinder will be the set pressure of the regulating valve 1 q The pressure regulating valve can be adjusted according to the specification of the coupler The minimum setting is 1MPa and th...

Page 245: ...ircuit pressure is below the setting of the pressure switch 25 5Kg cm2 and main pump pressure is greater than 35Kg cm2 the buzzer sounds to warn the circuit pressure is low This buzzer can not be canc...

Page 246: ...UEN00160 03 10 Structure function and maintenance standard 60 PC210 230 240 8 Hydraulic cylinder 1 PC210 8K PC210LC PC210NLC PC230NHD 8K Boom cylinder Arm cylinder Bucket cylinder...

Page 247: ...Arm 80 0 025 0 076 0 222 0 047 0 072 0 298 0 398 2 Clearance between pis ton rod support shaft and bushing Boom 80 0 030 0 060 0 190 0 070 0 100 0 250 1 0 Replace pin or bushing Arm 80 0 030 0 076 0...

Page 248: ...UEN00160 03 10 Structure function and maintenance standard 62 PC210 230 240 8 PC240LC 8K and PC240NLC 8K Boom cylinder Arm cylinder Bucket cylinder A...

Page 249: ...Arm 90 0 036 0 090 0 257 0 048 0 084 0 347 0 447 2 Clearance between pis ton rod support shaft and bushing Boom 80 0 030 0 060 0 190 0 070 0 100 0 250 1 0 Replace pin or bushing Arm 80 0 030 0 076 0...

Page 251: ...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 10 St...

Page 252: ...UEN00101 00 10 Structure function and maintenance standard 2 PC210 230 240 8 Work equipment 1 Dimensions of components 1...

Page 253: ...and bucket and bushing 80 0 030 0 076 0 337 0 273 0 303 0 413 1 0 6 Clearance between pin con necting links and bushing 70 0 030 0 076 0 335 0 275 0 305 0 411 1 0 Unit mm No Check item Criteria Remedy...

Page 254: ...UEN00101 00 10 Structure function and maintenance standard 4 PC210 230 240 8 1 Dimension of arm...

Page 255: ...09 3 1 5 0 1 3 305 5 0 5 0 5 305 5 0 5 0 5 4 90 0 054 0 000 90 0 054 0 054 5 407 1 1 423 9 1 6 187 2 0 5 206 1 0 5 7 829 1 1 918 6 1 8 2 919 3 037 6 9 2 630 5 1 2 562 8 1 10 410 1 465 1 11 640 0 2 585...

Page 256: ...UEN00101 00 10 Structure function and maintenance standard 6 PC210 230 240 8 2 Dimension of bucket...

Page 257: ...ize Tolerance Standard size Tolerance 1 457 6 0 5 442 4 0 5 2 22 0 5 59 2 0 5 3 92 45 97 37 4 458 1 446 3 5 1 477 3 1 540 5 6 158 6 185 6 7 8 15 54 7 48 9 80 0 1 0 1 80 0 1 0 1 10 326 5 1 326 5 1 11 5...

Page 259: ...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 10 Structure...

Page 260: ...PC210 230 240 8 Cab and its attachments 1 Air conditioner piping 1 1 Air conditioner unit 2 Hot water pickup piping 3 Air conditioner compressor 4 Refrigerant piping 5 Condenser 6 Hot water return pip...

Page 261: ...10 Structure function and maintenance standard UEN00102 00 PC210 230 240 8 3...

Page 263: ...er PC210 8 K50001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 10 Structure function and maintenance standard 1 Ele...

Page 264: ...rom the fuel control dial and sets the engine speed to the speed set by the fuel control dial Engine speed control q The fuel control dial sends a signal voltage cor responding to the rotation angle t...

Page 265: ...10 Structure function and maintenance standard UEN00103 03 PC210 230 240 8 3 Component 1 Fuel control dial 1 Knob 2 Dial 3 Spring 4 Ball 5 Potentiometer 6 Connector...

Page 266: ...rning knob 1 rotates the shaft of potentiom eter 5 q The rotation of the shaft changes the resist ance of the variable resistor in potentiometer 5 sending any throttle signal to the engine controller...

Page 267: ...15 Coolant temperature sensor 16 5V electric power supply for sensor 17 Oil pressure switch Never connect to NC or malfunctions or failures will occur CN CE01 Pin No Signal name Title panel 18 NC 19...

Page 268: ...ut output 1 NC 2 NC 3 NC 4 NC 5 NC 6 NC 7 NC 8 NC 9 Fuel control dial 10 NC 11 NC 12 NC 13 NC 14 NC 15 NC 16 NC 17 NC 18 NC 19 NC Never connect to NC or malfunctions or failures will occur CN CE02 Pin...

Page 269: ...10 Structure function and maintenance standard UEN00103 03 PC210 230 240 8 7 Coolant temperature sensor 1 Sensor 2 O ring 3 Connector Oil pressure switch 1 Connector 2 Sensor 3 O ring...

Page 270: ...UEN00103 03 10 Structure function and maintenance standard 8 PC210 230 240 8 Rotation sensor 1 Connector 2 Sensor 3 O ring Boost pressure and temperature sensor 1 Connector 2 Sensor 3 O ring...

Page 271: ...ucture function and maintenance standard UEN00103 03 PC210 230 240 8 9 WIF water in fuel detection sensor 1 Connector 2 Tube 3 Sensor 4 O ring Engine oil level sensor 1 Connector 2 Bracket 3 Float 4 S...

Page 272: ...N00103 03 10 Structure function and maintenance standard 10 PC210 230 240 8 Electrical control system 1 Machine control system diagram FOR PC210 K50001 K51094 PC230 K50001 K50113 and PC240 K50001 K503...

Page 273: ...10 Structure function and maintenance standard UEN00103 03 PC210 230 240 8 11...

Page 274: ...UEN00103 03 10 Structure function and maintenance standard 12 PC210 230 240 8 Machine control system diagram FOR PC210 K51095 and up PC230K50114 and up and PC240 K50304 and up...

Page 275: ...10 Structure function and maintenance standard UEN00103 03 PC210 230 240 8 13...

Page 276: ...UEN00103 03 10 Structure function and maintenance standard 14 PC210 230 240 8 1 Engine and pump composite control function...

Page 277: ...ol dial and actual engine speed 1 Control method in each mode P mode E mode and ATT mode q Matching point q In P E or ATT mode engine speed is always controlled so that it is kept around the match ing...

Page 278: ...eeping the engine torque at a constant level along the equal engine horsepower curve q The controller controls pump delivery Q so that the engine torque can be kept at a con stant level along the equa...

Page 279: ...If the machine travels in L mode the working mode and engine speed N do not change but the pump absorption torque is increased 3 Function to control when emergency pump drive switch is turned on q Eve...

Page 280: ...e function and maintenance standard 18 PC210 230 240 8 2 Pump and valve control function Function q The machine is matched to various types of work properly with the 2 stage relief function to increas...

Page 281: ...f function q The relief pressure in the normal work is 34 8 MPa 355 kg cm2 If the 2 stage relief function is turned on however the relief pressure rises to about 37 2 MPa 380 kg cm2 By this opera tion...

Page 282: ...me e g when digging up a large rock q Pressing the L H knob switch in P E or ATT mode increases a hydraulic force by approxi mately 7 and horsepower by approximately 3 increasing a digging force At th...

Page 283: ...to the speed set with the fuel control dial Operation When control levers are set in neutral q If all the control levers are kept to NEUTRAL for 4 sec during operation at a engine speed above a decel...

Page 284: ...n Function q The engine automatic warm up function increases the engine speed to warm up the engine if coolant temperature is too low after the engine starts The overheat prevention function reduces t...

Page 285: ...dle Monitor alarm lamp Lights up Alarm buzzer Sounds Coolant temperature hydraulic oil temperature Below 105 C Fuel control dial Return to low idle position once Under above condition controller is se...

Page 286: ...UEN00103 03 10 Structure function and maintenance standard 24 PC210 230 240 8 6 Swing control function Function The swing lock and swing holding brake function are provided as a swing control function...

Page 287: ...topped on a slope the upper structure may swing by its gravity 2 Quick hydraulic oil warm up function when swing lock switch is turned on q If swing lock switch 2 is turned on the pump cut off functio...

Page 288: ...0 230 240 8 7 Travel control function Function q The machine is provided with a function that ensures travel performance best fit to the type of work and jobsite by controlling pumps during travel or...

Page 289: ...l ling in Mi q The travel speed automatically changes to Mi when the machine is travelling in Hi 3 Automatic change by pump discharge pressure If the travel pressure is kept to 24 5 MPa 250 kg cm2 at...

Page 290: ...ion is available only with the attach ment specification q The function acts as follows according to the flow command and working mode from the monitor 1 It throttles the attachment PPC pressure and c...

Page 291: ...onitor Attachment operation switches depending on the working mode selected 1 Att mode Double acting 2 way flow e g crusher open close q If either the RH pedal or the RH lever pro portional switch are...

Page 292: ...nction q This function is available only with the 2nd attachment specification q The function acts as follows according to the flow command when the following working mode is selected 1 ATT 2 mode Dou...

Page 293: ...onnector Specifications Type of contacts Normally open contacts Operating ON pressure 0 5 0 1 MPa 5 0 1 0 kg cm2 Resetting OFF pressure 0 3 0 05 MPa 3 0 0 5 kg cm2 Function q The junction block has 2...

Page 294: ...ation q The oil pressure is applied to the diaphragm of the oil pressure sensor from the pressure intake part the diaphragm is deformed q The deformation in the diaphragm causes the resistance of the...

Page 295: ...and maintenance standard UEN00103 03 PC210 230 240 8 33 3 Pump pressure sensor 1 Sensor 2 Connector Operation q The relationship between the pressure applied to sensors P and output voltage E is show...

Page 296: ...g switch 1 Switch 2 Wire 3 Cover 4 Connector Specification q Switching pressure 25 5 bar rising Function q The quick coupler circuit has one pressure switch q This sensor detects the circuit pressure...

Page 297: ...and maintenance standard UEN00103 03 PC210 230 240 8 35 Auto Grease pressure switch 1 Switch 2 Wire 3 Cover 4 Connector Specification q Switching pressure 150 bar Function q The auto grease circuit ha...

Page 298: ...the obtained information on the panel Contents displayed on the panel are largely divided into the following 1 Alarm when an abnormality occurs on the machine 2 Machine condition Temperature of cool...

Page 299: ...ine monitor has the functions to dis play various items and the functions to select modes and electric parts q The machine monitor has a CPU Central Processing Unit in it to process display and output...

Page 300: ...095 and up PC230 K50114 and up and PC240 K50304 and up CN CM03 Pin No Signal name Input output 1 RS232C CD for communica tion terminal Input 2 RS232C RXD for communica tion terminal Input 3 RS232C SG...

Page 301: ...5 Pin No Signal name Input output 1 Electric power supply for cam era Output 2 Camera NTSC signal input 1 Input 3 Camera NTSC signal input 2 Input 4 Camera NTSC signal input 3 Input 5 Electric power s...

Page 302: ...UEN00103 03 10 Structure function and maintenance standard 40 PC210 230 240 8 1...

Page 303: ...10 Structure function and maintenance standard UEN00103 03 PC210 230 240 8 41 Monitor control display portion 1...

Page 304: ...cleaner clogging monitor 23 Water separator monitor Precautions on the machine monitor display q The liquid crystal display panel may have black spots which do not light up or bright spots which stay...

Page 305: ...eating Preheater operates at low temperature and symbol keeps lighting up for up to about 30 seconds and then goes off after engine starts Manual preheating Time after setting Display of symbol 0 30 s...

Page 306: ...cannot be obtained due to disconnection of CAN Gauge Range Temperature or vol ume Indicator Buzzer sound Engine coolant tem perature C A1 105 Red Q A2 102 Red A3 100 Off A4 85 Off A5 60 Off A6 30 Whi...

Page 307: ...bol Display item Check before starting item While engine is stopped While engine is running Engine oil pressure q Lights up and buzzer sounds when abnormal Battery charge q Lights up when abnormal Rad...

Page 308: ...ion Working mode P E L B ATT Displays set mode Travel speed Displays set speed Auto deceleration ON OFF Displays operating condition ECO indicator ECO indicator Green Work load is light medium Orange...

Page 309: ...sounds Depending on the alarm buzzer type it does not stop even if you press the buzzer cancel switch Auto deceleration switch The auto deceleration switch toggles the auto deceleration function on an...

Page 310: ...tem Selects item on upper side Selects bottom item after top item Holds monitoring F1 Select item Selects page on lower side Selects top page after bottom page F2 Select item Selects page on upper sid...

Page 311: ...o Hi o Lo The travel speed setting is confirmable on the travel speed monitor The relationship between the speed setting and the monitor display is shown in the table below Window washer switch While...

Page 312: ...on with the air conditioner is disconnected or spurting out damper A M damper or refrigerant has a problem the following screen appears Camera screen display function 1 q For an optional camera equipp...

Page 313: ...normal screen q If an abnormality corresponding to an alarm item with the camera screen displayed the alarm monitor appears on the upper left of the screen If it appears return to the normal screen w...

Page 314: ...230 240 8 Service meter time selector function 1 q Pressing F4 on the normal screen when the service meter is displayed in the top centre of the screen switches the display to the time and doing so w...

Page 315: ...sets the remaining time to return to the nor mal screen No operation at least 30 sec Returns to the nor mal screen q The table below shows the maintenance items and replacement intervals The time rema...

Page 316: ...from carelessly being reset q The default password is 000000 q Enabling the password lock on an attachment equipped machine locks the breaker attach ment setting screen at the same time a For informa...

Page 317: ...n F6 Switches to the setting screen for the selected item No operation at least 30 sec Returns to the nor mal screen In user mode no switch operation at least 30 sec returns to the previous screen Bre...

Page 318: ...t setting screen switches to the breaker setting screen On this screen select the breaker setting selection screen or breaker flow rate setting screen F3 Selects highlights an item one down F4 Selects...

Page 319: ...reaker mode F3 Selects highlights an item one down F4 Selects highlights an item one up F5 Returns to the breaker setting menu screen F6 Switches to the flow rate level setting screen for the selected...

Page 320: ...he attachment setting menu F6 Specifies the selected highlighted item as a flow rate in attachment mode q Selecting No attachment disables selec tion of attachment mode on the working mode selection s...

Page 321: ...tem one up F5 Returns to the breaker attachment setting screen F6 Switches to the setting screen for the selected highlighted item 1 Attachment setting selection screen q On this screen you can alloca...

Page 322: ...change the set flow rate F3 Decreases the flow rate F4 Increases the flow rate F5 Returns to the flow rate setting screen without changing the flow rate F6 Returns to the flow rate setting screen afte...

Page 323: ...s F6 and the entered value will be sent q Messages will be deleted when their validity expire or a new message is received q When no message has not been received No message appears at the blue part o...

Page 324: ...hted item Clock adjustment q Selecting the Clock adjustment from the user menu and pressing F6 switches to the clock adjustment screen q On this screen you can change the setting of the time displayed...

Page 325: ...an Russian and Turkish F3 Selects highlights an item one down F4 Selects highlights an item one up F5 Cancels the changes to return to the user menu F6 Cancels the changes to return to the user menu N...

Page 326: ...on is made at least 5 min and the engine is running at idle q No error or caution excluding low hydraulic oil temperature is occurring This screen switches to the normal screen if one of the following...

Page 327: ...sec q When these switches are released the LCD goes out a Continuous operation of the machine monitor may display blue bright spots on this screen it is quite normal Display LCD check function 1 q Con...

Page 328: ...de 2 are displayed on the portion for the hydraulic oil temperature gauge q If multiple user codes or failure codes are issued they are displayed alternately every 2 sec The drawing below shows the ca...

Page 329: ...ither side of a sensor of contact type is always connected to the chassis ground Hydraulic oil level sensor 1 1 Connector 2 Bracket 3 Float 4 Switch Sensor name Type of sensor When normal When abnorma...

Page 330: ...UEN00103 03 10 Structure function and maintenance standard 68 PC210 230 240 8 Fuel level sensor 1 1 Float 2 Connector 3 Cover 4 Variable resistor Air cleaner clogging sensor 1...

Page 331: ...10 Structure function and maintenance standard UEN00103 03 PC210 230 240 8 69 Coolant level sensor 1 1 Reserve tank 2 Float 3 Sensor 4 Connector...

Page 332: ...UEN00103 03 10 Structure function and maintenance standard 70 PC210 230 240 8 PPC Levers 1 LH PPC Lever 1 1 Lever 2 Gaiter 3 Harness 4 Connector 1 2 3 4...

Page 333: ...10 Structure function and maintenance standard UEN00103 03 PC210 230 240 8 71 RH PPC Lever 1 1 Lever 2 Gaiter 3 Harness 4 Connector 1 2 3 4...

Page 334: ...ansmits various kinds of machine information wirelessly Persons to operate the KOMTRAX can refer to the infor mation at office to provide various kinds of services for customers q Information transmit...

Page 335: ...nal name Input output A 1 Electric power supply Input A 2 NC 1 A 3 NC 1 A 4 Electric power supply switching Output A 5 NC 1 A 6 NC 1 A 7 GND Input A 8 GND Input A 9 Modem power control 1 2 Input A 10...

Page 337: ...ine model Serial number PC210 8 K52393 and up PC210LC 8 K52393 and up PC210NLC 8 K52393 and up PC230NHD 8 K50213 and up PC240LC 8 K50630 and up PC240NLC 8 K50630 and up 10 Structure function and maint...

Page 338: ...d 2 PC210 230 240 8 Outline of Auto Grease System 1 2 1 3 4 10 11 12 13 14 16 18 9 8 6 5 7 17 15 KSP00100 In Cab Display Distribution Block Distribution Block Distribution Block 1 2 3 4 6 5 7 8 9 10 1...

Page 339: ...ease pressure will be exceeded when q a malfunction of the grease pressure switch which is mounted in the system occurs q a malfunction in the cable of the grease pressure switch occurs The grease pre...

Page 340: ...unit The metering units are mounted on a brass distribution block per group see figure 2 These primary grease lines are connected The blocks are deliverable with 2 3 4 5 6 7 8 9 12 14 18 20 21 or 22...

Page 341: ...alarm follows d The Display The display continuously indicates the adjusted operating mode with green lamps A yellow lamp lights when the minimum grease level is reached and a red lamp lights when a m...

Page 342: ...during the pumping phase The duration of the re grease phase depends on the duration of the pumping phase This dependency is expressed in the parame ter bmf bleeding multiplication factor Example When...

Page 343: ...automatic greasing system are dis cussed The pump unit metering units grease pressure valve control unit signal lamp and display are dis cussed a Pump unit The pump unit consists of various parts The...

Page 344: ...al in the cabin indicates when the minimum level has been reached A grease follower piston 1 is located in the reservoir above the grease This piston follows the level of the grease When the grease le...

Page 345: ...asing point The principle of operation of the metering unit is explained in the four phases below Phase1 In this phase the metering unit has not yet filled with grease see figure 4 2 While in operatio...

Page 346: ...to the secondary grease line After a while the pressure drops in primary channel B during the pressure decrease phase of the greasing cycle This has no influence on the metering unit Phase 4 In this p...

Page 347: ...A see figure 4 7 While the grease pressure is built up piston 6 is pushed to the right Chamber 1 is connected to channel A through the channels 7 8 and 9 As soon as the pressure in chamber 1 is more t...

Page 348: ...cific parts or the complete greasing system for malfunctions are connected to the control unit The control unit controls the greasing system by q the parameters that are saved in the control unit To r...

Page 349: ...re stored in the control unit adjustment range 1 60 minutes At a normal average pumping phase shorter than 5 minutes the maximum pumping phase is adjusted as follows multiply the normal pumping time b...

Page 350: ...ile greasing alternately through lines A and B thus 5 times A and 5 times B But the control unit also shuts off the pump when the grease pressure is not reached 10 times successively when greasing thr...

Page 351: ...display or wiring of the in cab display is defective Check in cab dis play and wiring and replace if necessary Yellow lamp 5 flashing Minimum level in the reservoir has been reached Reset by refillin...

Page 353: ...rial number PC210 8 K50001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 20 Standard value table 1 Standard service...

Page 354: ...At sudden acceleration Max 5 5 At relief 4 4 Valve clearance Normal temperature Intake valve mm 0 25 0 152 0 381 Exhaust valve mm 0 51 0 381 0 762 Compression pressure Oil temperature 40 60 C Compres...

Page 355: ...e clearance Normal temperature Intake valve mm 0 25 0 152 0 381 Exhaust valve mm 0 51 0 381 0 762 Compression pressure Oil temperature 40 60 C Compression pressure MPa kg cm2 Min 2 41 Min 24 6 1 69 17...

Page 356: ...when auto deceleration is operated Engine at high idle Auto deceleration switch in ON condition All control levers in NEUTRAL condition rpm 1 400 100 1 400 100 Spool stroke Boom control valve Engine s...

Page 357: ...ssure with all measurement circuits relieved Normal relief MPa kg cm2 34 8 1 0 355 10 33 3 36 8 340 375 Power max MPa kg cm2 37 3 1 0 380 10 36 3 39 2 370 400 Arm relief Normal relief MPa kg cm2 34 8...

Page 358: ...1 sec 24 2 2 5 Max 30 Hydraulic drift of swing Hydraulic oil temperature Within operating range Engine stopped Keeping upper structure transverse on slope of 15 Notching a mating mark on inner and ou...

Page 359: ...ydraulic oil temperature Within operating range Engine stopped Parking machine on slope of 12 with sprocket facing upslope Sliding distance for 5 minutes For measuring posture see Travel 4 mm 0 0 Leak...

Page 360: ...easuring posture see Work equipment 2 RAISE sec 3 3 0 4 Max 4 7 LOWER sec 2 4 0 3 Max 3 7 Arm Hydraulic oil temperature Within operating range Engine running at high idle Working mode P mode Time requ...

Page 361: ...ng posture see Work equipment 7 sec Max 1 0 Max 3 6 Internal leakage Cylinders Hydraulic oil temperature Within operating range Engine running at high idle Leakage amount for one minute with cylinder...

Page 362: ...mount and the engine speed at the point of measurement and use them as a base for calculating the pump discharge amount at the specified speed Applicable model PC210 210LC 210NLC 230NHD 8 Cate gory It...

Page 363: ...Engine at high idle Auto deceleration switch in ON condition All control levers in NEUTRAL condition rpm 1 400 100 1 400 100 Spool stroke Boom control valve Engine stopped For measuring point see Cont...

Page 364: ...with all measurement circuits relieved Normal relief MPa kg cm2 34 8 1 0 355 10 33 3 36 8 340 375 Power max MPa kg cm2 37 3 1 0 380 10 36 3 39 2 370 400 Arm relief Normal relief MPa kg cm2 34 8 1 0 3...

Page 365: ...g at high idle Working mode P mode Time required for 5 more turns after making initial one turn For measuring posture see Swing 1 sec 25 7 2 8 Max 31 Hydraulic drift of swing Hydraulic oil temperature...

Page 366: ...th sprocket facing upslope Sliding distance for 5 minutes For measuring posture see Travel 4 mm 0 0 Leakage of travel motor Hydraulic oil temperature Within operating range Engine at high idle Travell...

Page 367: ...posture see Work equipment 2 RAISE sec 3 4 0 5 0 3 Max 4 9 LOWER sec 2 7 0 3 Max 4 4 Arm Hydraulic oil temperature Within operating range Engine running at high idle Working mode P mode Time required...

Page 368: ...sture see Work equipment 7 sec Max 1 0 Max 3 6 Internal leakage Cylinders Hydraulic oil temperature Within operating range Engine running at high idle Leakage amount for one minute with cylinder or tr...

Page 369: ...rge amount and the engine speed at the point of measurement and use them as a base for calculating the pump discharge amount at the specified speed Applicable model PC240LC 240NLC 8 Cate gory Item Mea...

Page 370: ...measur ing performance and measurement procedure Control valve spool stroke Swing 1 Swing brake angle time taken to start swing time taken to swing Swing 2 Hydraulic drift of swing Travel 1 Travel sp...

Page 371: ...0227 01 PC210 230 240 8 19 Travel 4 Hydraulic drift of travel Work equipment 1 Hydraulic drift of work equipment Work equipment 2 Boom speed Work equipment 3 Arm speed Work equipment 4 Bucket speed Wo...

Page 372: ...UEN00227 01 20 Standard value table 20 PC210 230 240 8 Work equipment 6 Arm time lag Work equipment 7 Bucket time lag Work equipment 8 Characteristics of PC flow control valve...

Page 373: ...20 Standard value table UEN00227 01 PC210 230 240 8 21...

Page 375: ...ng Part 1 3 Tools for testing adjusting and troubleshooting 3 Measuring engine speed 6 Measuring intake air pressure boost pressure 7 Checking exhaust gas colour 8 Adjusting valve clearance 9 Measurin...

Page 376: ...ntrol 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...

Page 377: ...ydraulic tester 1 Pressure gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 58 8 MPa 600 kg cm2 2 799 401 2320 Hydraulic tester 1 Pressure gauge...

Page 378: ...aulic tester 1 Pressure gauge 2 5 5 9 39 2 58 8 MPa 25 60 400 600 kg cm2 790 261 1204 Digital hydraulic tester 1 Pressure gauge 58 8 MPa 600 kg cm2 2 799 401 3100 Adapter 1 Size 02 Measuring PPC valve...

Page 379: ...the machine monitor controllers sensors actuators electrical equipment and wiring harnesses see Trou bleshooting General information on troubleshooting List of T boxes and T adapters Removal and inst...

Page 380: ...ine and operate the arm cyl inder to the IN stroke end 2 Set the fuel control dial in the high idle MAX position and set the working mode in the power mode P 3 Operate the left work equipment control...

Page 381: ...e at middle or higher speed and bleed oil from the hose a Insert the connecting parts of the gauge and hose about a half and open the self seal on the hose side repeatedly and the oil will be drained...

Page 382: ...inishing checking remove the measuring tools and return the removed parts 2 Checking with smoke meter A2 1 Insert probe 1 of smoke meter A2 in the outlet of the exhaust pipe and fix it to the exhaust...

Page 383: ...b of the rotation sensor ring to projection top a of front cover a Projection top a must be within the range of wide slit b when it is seen from the air conditioner compressor side a If you can see t...

Page 384: ...Locknut 24 4 Nm 2 45 0 41 kgm a After tightening the locknut check the valve clearance again 7 Rotate the crankshaft forward by 1 turn and set wide slit b to projection top a according to step 4 8 Ad...

Page 385: ...u do not need to remove the rocker arm assembly on the intake side 3 Remove fuel tube 3 and then remove inlet connector 7 in the cylinder head a The inlet connector is connecting the fuel tube to the...

Page 386: ...ine oil SAE15W 40 to the O ring of injector 4 and cylinder head 2 Install injector 4 with the fuel inlet hole directed to the air intake manifold 3 Install injector clamp 6 and tighten the mounting bo...

Page 387: ...2 Install tool and adapter 1 of blow by checker D1 or blow by tool D2 to breather hose 1 and connect gauge 2 3 Start the engine set the working mode in the power mode P and turn the swing lock switch...

Page 388: ...1 Open the side cover of the pump room and remove oil pressure pickup plug 1 from the engine oil filter 2 Install nipple 1 of hydraulic tester E1 and con nect hydraulic tester E2 3 Start the engine a...

Page 389: ...entering it If a filter other than the genuine one is used the fuel system may have a trouble Accordingly never use such a filter Releasing residual pressure from fuel system 1 a Pressure is generate...

Page 390: ...e 1 of hydrau lic tester F1 and connect them to oil pres sure gauge 2 a Use the oil pressure gauge of 2 5 MPa 25 kg cm2 3 Run the engine at low idle and measure the pressure in the fuel low pressure c...

Page 391: ...le and measure the pressure in the fuel return circuit a If the pressure in the fuel return circuit is in the following range it is normal k If the engine cannot be started you may measure the fuel pr...

Page 392: ...g the engine with the starting motor Do not rotate for more than 20 seconds continu ously however for protection of the starting motor 5 After finishing measurement remove the measuring tools and retu...

Page 393: ...3 to the return hose side to prevent the fuel from leaking 4 Run the engine at low idle and measure the return rate from the injector a If the return rate from the injector is in the following range i...

Page 394: ...level ground and lower the work equipment to the ground 1 Fill the fuel tank with fuel a Add fuel until the float of the sight gauge reaches the maximum position 2 Open the side cover of the pump roo...

Page 395: ...30 Testing and adjusting UEN00228 04 PC210 230 240 8 21 a Air bleeding route of fuel circuit Fuel tank o Pre filter o Feed pump o Main filter o Metering unit o Fuel tank...

Page 396: ...inly around the high pressure circuit parts coated with the colour checker for fuel leakage a If any fuel leakage is detected repair it and check again from step 2 4 Run the engine at low idle 5 Check...

Page 397: ...ting a If the belt deflection is abnormal adjust it according to the following procedure 1 Loosen bolts 1 and 2 2 Move compressor 3 and bracket 4 together to adjust the belt tension 3 After positionin...

Page 398: ...set the bucket tip to the height of the under side of the revolving frame a At this time the front of the upper structure lowers and the rear rises 3 Set dial gauge H to the 0 point 4 Set the arm almo...

Page 399: ...d maximum clearance a 10 30 mm Adjusting a If the track shoe tension is abnormal adjust it according to the following procedure 1 Increasing tension 1 Add grease through grease fitting 1 with a grease...

Page 400: ...osen the valve more than 1 turn If it is loosened more it may jump out because of the high pressure grease in it 2 To check that the tension is normal run the engine at low idle and move the machine f...

Page 401: ...fol lowing condition q Hydraulic oil temperature Within operat ing range 1 Preparation work 1 Open the side cover of the pump room and remove oil pressure pickup plugs 1 and 2 q 1 Front pump discharge...

Page 402: ...e engine and move the cylinder to be measured to the stroke end 2 Set the working mode in the power mode P 3 Run the engine at high idle operate the right and left work equipment control levers to rel...

Page 403: ...travel lever and pedal check the position and locking direction of the locked sprocket again a The pressure measured when the main relief valve of the control valve is relieved is indicated The trave...

Page 404: ...y valve 8 of the swing motor according to the following procedure 1 While fixing adjustment screw 9 loosen locknut 10 2 Turn adjustment screw 9 to adjust the pressure a If the adjustment screw is q Tu...

Page 405: ...nnect oil pressure gauge 1 of hydraulic tester K1 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 3 Start the engine set the working mode in the power mode P and turn the auto decelerator OFF 4 Run...

Page 406: ...ston inlet pressure a Measure the PC valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously and compare them 1 Open the side cover of the pump room and remove oil...

Page 407: ...alve or the servo piston is abnormal the PC valve output pres sure servo piston inlet pressure is the same as the pump discharge pressure or almost 0 6 After finishing measurement remove the measuring...

Page 408: ...PC valve a If either of the following phenomena occurs and the PC valve seems to be defective adjust PC valves 7 and 8 according to the proce dure shown below q As the working load increases the engi...

Page 409: ...in reverse 2 Turn adjustment screw 10 clockwise or coun terclockwise to adjust a Turn the adjustment screw q Clockwise when the work equipment speed is low to increase pump absorption torque and q Cou...

Page 410: ...Measure the LS valve output pressure servo piston inlet pressure and pump discharge pressure simultaneously and compare them 1 Open the side cover of the pump room and remove oil pressure pickup plug...

Page 411: ...mely run the track shoe pushed up idle a Do not operate the travel lever to the stroke end but stop it halfway a Measuring condition and method of judgment If the pressures are in the following ratio...

Page 412: ...he LS pressure to the low pressure side lower side Since the differential pressure gauge needs a 12V power source connect it to a battery a When using oil pressure gauge in M1 Use the oil pressure gau...

Page 413: ...the track shoe idle and measure the oil pressure k While checking the safety around the machine extremely run the track shoe pushed up idle a Do not operate the travel lever to the stroke end but stop...

Page 414: ...LS differential pressure is abnormal adjust the LS valve according to the following procedure q 8 Front pump LS valve q 9 Rear pump LS valve 1 While fixing adjustment screw 10 loosen locknut 11 2 Tur...

Page 415: ...nd adjusting UEN00228 04 PC210 230 240 8 41 3 Locknut 49 68 6 Nm 5 7 kgm 4 After finishing adjustment check again that the LS differential pressure is normal according to the above described measureme...

Page 416: ...f hydraulic tester N1 and con nect it to oil pressure gauge 2 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 a The figure shows the measuring tools con nected to outlet hose 1 of the PPC lock solen...

Page 417: ...3 a If the output pressure is as follows the solenoid valve is normal 6 After finishing measurement remove the measuring tools and return the removed parts Solenoid valve Output pressure OFF Demagneti...

Page 418: ...ch is ON Signals other than swing single signal are ON Swing single signal is ON OFF Other than above condition Operating condition Operation Work equipment swing and travel signals All are OFF OFF An...

Page 419: ...ts of the PPC piping on the control valve of 1 attachment installation specification The col ours in are the colours of the bands installed for distinction of the pipes a The figure at right shows the...

Page 420: ...and connect the discon nected hose again 3 Install nipple 1 of hydraulic tester P1 and con nect it to oil pressure gauge 2 a Use the oil pressure gauge of 5 9 MPa 60 kg cm2 a The figure shows the meas...

Page 421: ...ng to the follow ing procedure 1 Remove the work equipment and swing PPC valve assembly 2 Remove bellows 1 3 Loosen locknut 2 and tighten disc 3 until it touches the heads of 4 pistons 4 a Do not move...

Page 422: ...it will be necessary to operate one of the main control circuits Set the swing lock to ON and operate the swing lever NOTE When delivered from the factory the regu lated pressure is set to 4MPa 41kg c...

Page 423: ...rate the arm control lever in the IN position q If the lowering speed is increased at this time the cylinder packing is defective q If the lowering speed does not change at this time the control valve...

Page 424: ...ure the lowering distance a Operate the control lever while the starting switch is in the ON position a If the pressure in the accumulator is lost run the engine for about 5 seconds to heighten the pr...

Page 425: ...he starting switch ON and set the lock lever in the FREE position and then operate the right and left work equipment control levers forward backward to the right and to the left a The control valve is...

Page 426: ...care not to lower the boom 4 Start measuring the oil leakage 30 sec onds after relieving is started and meas ure for 1 minute 5 After finishing measurement return the removed parts 2 Measuring oil lea...

Page 427: ...07379 00640 Flange 06 3 Run the engine at high idle and relieve the bucket circuit by curling the bucket k Take care not to dump the bucket 4 Start measuring the oil leakage 30 sec onds after relievin...

Page 428: ...07376 70422 Plug 04 4 Run the engine at high idle relieve the travel circuit and measure the oil leakage k Before operating the travel lever check the position and locking direction of the locked spr...

Page 429: ...from cylinder Bleeding air from swing motor Bleeding air from travel motor Checking oil level and starting operation Replacing hydraulic oil Cleaning strainer q q q q See note q See note q Replacing...

Page 430: ...switch in the ON position and hold the fuel control dial in the MAX position for 3 sec onds and the automatic warm up opera tion is reset 3 Bleeding air from cylinder a If a cylinder is replaced bleed...

Page 431: ...oil oozes out through the air bleeder 3 After the oil oozes out tighten air bleeder 2 3 Air bleeder 27 5 35 3 Nm 2 8 3 6 kgm 6 Checking oil level and starting work 1 Run the engine retract the arm cy...

Page 432: ...nal undercover from the rear of the operator s cab a Perform this step only when the additional undercover is installed 2 Check the tightening torque of the mounting bolt 2 of the lock plate 1 3 Bolt...

Page 433: ...30 Testing and adjusting UEN00228 04 PC210 230 240 8 59...

Page 434: ...UEN00228 04 30 Testing and adjusting 60 PC210 230 240 8 For PC210 K50001 K51094 PC230 K50001 K50113 and PC240 K50001 K50303 Adjusting mirrors 1 1...

Page 435: ...irrors so that the operator can see persons or things 1 m high and about 30 cm in diameter at the right and left rear of the machine Adjusting mirrors c1 and d1 Adjust the mirrors so that the operator...

Page 436: ...UEN00228 04 30 Testing and adjusting 62 PC210 230 240 8 For PC210 K51095 and up PC230 K50114 and up and PC240 K50304 and up Adjusting mirrors 1 e e A...

Page 437: ...rrors so that the operator can see persons or things 1 m high and about 30 cm in diameter at the right and left rear of the machine Adjusting mirror d1 Adjust the mirror so that the operator can see t...

Page 439: ...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 30 Testing and...

Page 440: ...UEN00229 01 30 Testing and adjusting 2 PC210 230 240 8 Testing and adjusting Part 2 1 Special functions of machine monitor 1 Air conditioner specification...

Page 441: ...e monitor Switch sec tion 1 Numeral 1 input switch Auto decelerator switch 2 Numeral 2 input switch Working mode selector switch 3 Numeral 3 input switch Travel speed shifting switch 4 Numeral 4 input...

Page 442: ...mode and travel speed 8p Phone number entry 37p A Display of ordinary screen 8p Default Working mode with key ON 38p A Display of end screen 9p Setting of unit 39p B Selection of auto deceleration 9p...

Page 443: ...time when starting switch is turned ON to time when screen changes to ordi nary screen and display after starting switch is turned OFF B Display Function when switch of machine monitor is operated C...

Page 444: ...de is set or Display of check before starting a The following screen may be displayed instead of the above Display of inputting password screen a If this screen is displayed call the person responsibl...

Page 445: ...ment other than the breaker is used while the working mode is set to the breaker mode B the machine may move unexpectedly or may not operate normally or the hydraulic components may be dam aged a Afte...

Page 446: ...d indicates the length of the time after the maintenance interval a Set or change the maintenance function in the service mode a After display of this screen is finished the screen changes to Display...

Page 447: ...of working mode Select a working mode according to the following procedure 1 While the ordinary screen is displayed press the working mode selector switch and the working mode selection screen is disp...

Page 448: ...is displayed The buzzer sounds intermittently while this screen is displayed q If the setting is confirmed on this screen the screen changes to the ordinary screen If No is selected Working mode is s...

Page 449: ...onitor a is not displayed Operation of window washer While the ordinary screen is displayed if the win dow washer switch is pressed the washing liquid is splashed only while the switch is held down a...

Page 450: ...ny control lever for 10 seconds the screen changes to the ordinary screen and displays the error information a When two or more cameras are connected the image of one of them or the images of two of t...

Page 451: ...nishing mainte nance more operations are necessary See Maintenance record in the service mode Setting and display of user mode Including KOMTRAX messages for user While the ordinary screen is displaye...

Page 452: ...n the service mode Setting and display of user mode Including KOMTRAX messages for user While the ordinary screen is displayed press F6 and the user menu screen is displayed a There are following item...

Page 453: ...erating con dition the energy saving guidance screen is dis played automatically to urge the operator to the energy saving operation a The energy saving guidance is displayed when the following condit...

Page 454: ...the setting of the working mode If the breaker is being used select the breaker mode B a To return to the ordinary screen press F5 Display of user code and failure code If an abnormality which display...

Page 455: ...g on the cause of the problem it may not be possible to release it In any case have inspection carried out immediately E10 Engine controller power source error Engine controller drive system circuit e...

Page 456: ...ts points which do not go off for the reason of its characteristics If the number of the bright points and black points does not exceed 10 those points are not a failure or a defect a To return to the...

Page 457: ...nput numeral Return to ordi nary screen q F6 Confirm input numeral a Default password 000000 a If the input password is correct the screen changes to the next screen a If the input password is incorre...

Page 458: ...UEN00229 01 30 Testing and adjusting 20 PC210 230 240 8 5 If the screen to notify completion of setting is displayed and then the ordinary screen is dis played the password is changed successfully...

Page 459: ...Confirm selection a You may enter a 2 digit code with the numeral input switches to select the menu of that code and confirm it with F6 a The items which can be selected in the service menu are as fo...

Page 460: ...nction switches Select an item with F3 or F4 and confirm it with F6 a Selection with numeral input switches Enter a 5 digit code and the item of that code is selected directly Confirm that item with F...

Page 461: ...monitoring selection menu screen 6 Changing machine setting mode To change the setting of the working mode travel speed or auto deceleration during moni toring operate the corresponding switch under t...

Page 462: ...ivider Sol Curr LS mA mA mA PUMP 01700 Service Sol Curr mA mA mA PUMP 03200 Battery Voltage V V V PUMP 03203 Battery Power Supply V V V ENG 04300 Battery Charge Vol V V V MON 36400 Rail Pressure MPa k...

Page 463: ...ect 2 ON OFF PUMP Model Select 3 ON OFF PUMP Model Select 4 ON OFF PUMP Model Select 5 ON OFF PUMP Overload Alarm ON OFF PUMP 02202 Switch Input 3 Key Switch ACC ON OFF PUMP 02204 Switch Input 5 Windo...

Page 464: ...N OFF ENG WIF Water In Fuel 20216 ECM Build Version ENG 20217 ECM CAL Data Ver ENG 18900 ECM Internal Temp C C F ENG 20400 ECM Serial No ENG 20227 Monitor Ass y P N MON 20402 Monitor Serial No MON 202...

Page 465: ...pecification and heaterless speci fication are different from each other in the display of 03 Air conditioning system which may not be displayed in the heater less specification 3 Information displaye...

Page 466: ...oner specification The heater specification and heaterless speci fication are different from each other in the display of 03 Air conditioning system which may not be displayed in the heater less speci...

Page 467: ...ect the item to be reset with F3 or F4 and press F6 a To reset all items together Press F2 and all the items are reset regardless of selection of the items a If E is displayed on the left of a fail ur...

Page 468: ...High Error q ENG Electrical system E11 CA123 Chg Air Press Sensor Low Error q ENG Electrical system E14 CA131 Throttle Sensor High Error q ENG Electrical system E14 CA132 Throttle Sensor Low Error q E...

Page 469: ...ectrical system E11 CA449 Rail Press Very High Error q ENG Electrical system E11 CA451 Rail Press Sensor High Error q ENG Electrical system E11 CA452 Rail Press Sensor Low Error q ENG Electrical syste...

Page 470: ...Sensor Abnormality PUMP Electrical system DHSAMA Swing RH PPC Press Sensor Abnormality PUMP Electrical system DHSBMA Swing LH PPC Press Sensor Abnormality PUMP Electrical system DHSDMA Bucket Dump PP...

Page 471: ...Rev Short PUMP Electrical system For PC210 K51095 and up PC230 K50114 and up and PC240 K50304 and up DXEAKA Service Current EPC1 Open Circuit PUMP Electrical system DXEAKB Service Current EPC1 Short C...

Page 472: ...is notified to the operator the buzzer sounds The operator can stop the buzzer with the alarm buzzer cancel switch e Since the caution monitor is also turned ON its function sounds the buzzer a Compon...

Page 473: ...cord of that code and confirm it with F6 3 Information displayed on abnormality record screen On the air conditioning system or heater sys tem screen the following information is dis played a System C...

Page 474: ...q F1 Move to next page screen q F2 Move to previous page screen q F3 Move to lower item q F4 Move to upper item q F5 Return to service menu screen a You may enter a 2 digit code with the numeral inpu...

Page 475: ...ing items can be selected on the Change of maintenance mode screen 3 Contents of setting of Maintenance mode on off After selecting Maintenance mode on off if the screen is displayed set ON or OFF wit...

Page 476: ...r ON Lower q F5 Cancel setting before confirmation and return to Maintenance mode change screen q F6 Confirm setting of upper or lower line a After the setting of the upper and lower lines is confirme...

Page 477: ...hanging telephone No After the Phone number entry screen is dis played register or change the telephone No q F2 Reset all input No q F3 Move to left position if not blank q F4 Move to right position i...

Page 478: ...switches q Power mode P is displayed when key is ON q Economy mode E is displayed when key is ON q Lifting mode L is displayed when key is ON q Breaker mode B is displayed when key is ON q Attachment...

Page 479: ...screen 2 Selecting sub menu After the Default screen is displayed select Unit with the function switches or numeral input switches a Select this item similarly to an item on the Service menu screen 3...

Page 480: ...function switches or numeral input switches a Select this item similarly to an item on the Service menu screen 3 Selecting With Without After the With Without attachment screen is displayed select the...

Page 481: ...attachment screen is displayed select the setting with the function switches q Without When attachment is not installed q With When attachment is installed q F3 Move to lower item q F4 Move to upper i...

Page 482: ...Password screen is displayed q F3 Move to lower item q F4 Move to upper item q F5 Cancel selection and return to Default screen q F6 Confirm selection and return to Default screen 4 Displaying attach...

Page 483: ...s displayed in reverse position as seen directly used as front or side mon itor q F3 Move to left item q F4 Move to right item q F5 Cancel setting before confirmation and return to Default screen q F6...

Page 484: ...lecting display setting After the ECO display screen is displayed select the setting with the function switches q ON Display ECO q OFF Do not display ECO q F3 Move to left item q F4 Move to right item...

Page 485: ...ervice menu screen 2 Selecting sub menu After the Default screen is displayed select Breaker Detect with the function switches or numeral input switches a Select this item similarly to an item on the...

Page 486: ...Select this item similarly to an item on the Service menu screen 3 Selecting absorption torque After the Pump Absorption Torque F screen is displayed select a set value on the right side with the fun...

Page 487: ...Select this item similarly to an item on the Service menu screen 3 Selecting absorption torque After the Pump Absorption Torque R screen is displayed select a set value on the right side with the func...

Page 488: ...r numeral input switches a Select this item similarly to an item on the Service menu screen 3 Selecting travel Lo speed After the Low Speed setting screen is dis played select a set value on the right...

Page 489: ...Attachment Flow Adjustment with the function switches or numeral input switches a Select this item similarly to an item on the Service menu screen 3 Selecting distribution of oil flow After the scree...

Page 490: ...the function switches or numeral input switches a Select this item similarly to an item on the Service menu screen 3 Selecting distribution of EPC current After the screen of Attachment Flow Adjust m...

Page 491: ...es a Select this item similarly to an item on the Service menu screen 3 Selecting distribution of EPC current After the screen of Attachment Flow Adjust ment is displayed select a set value on the rig...

Page 492: ...ionship between set value and distri bution of current to attachment EPC Code Set value Distribution of flow to attachment 049 048 066 065 0 35 mA 1 30 mA 2 25 mA 3 20 mA 4 15 mA 5 10 mA 6 5 mA 7 0 mA...

Page 493: ...2 Selecting sub menu After the Default screen is displayed input 20 to enter the Specification menu NB not displayed on the default menu 3 Selecting Proportional Spec After the specification menu is d...

Page 494: ...mes yellow a If the machine monitor resets a Cut Out cylinder but the engine controller cannot reset that Cut Out cylinder the back ground of the cylinder No becomes red a One or more cylinders can be...

Page 495: ...torage of the machine it may be worn or damaged because of insufficient lubrication with oil To prevent this the function to lubricate the engine before starting it by cranking it without injecting fu...

Page 496: ...rting motor 4 Finishing no injection cranking After completing the no injection cranking operation press F6 and finish of no injection cranking is displayed and the screen returns to the Service menu...

Page 497: ...and time side and mea surement starts a The display unit of the fuel changes according to the unit set with the default unit setting function SI and meter l h inch gal h 3 Display and function during...

Page 498: ...screen is dis played select Terminal Status with the func tion switches or numeral input switches a Select this item similarly to an item on the Service menu screen a The following figure shows the di...

Page 499: ...h the function switches or numeral input switches a Select this item similarly to an item on the Service menu screen a The following figure shows the display when Model TH300 KOMTRAX is installed When...

Page 500: ...erial No of the KOMTRAX communication MODEM 1 Selecting menu Select KOMTRAX Settings on the service menu screen 2 Selecting sub menu After the KOMTRAX settings screen is dis played select Modem S N wi...

Page 501: ...ettings on the service menu screen 2 Selecting sub menu After the KOMTRAX settings screen is dis played select IP Address with the function switches or numeral input switches a Select this item simila...

Page 502: ...rom a message transmitted to the operator in the operator mode a Since this message is special for the ser viceman the message monitor is not dis played when it is received as in the operator mode 3 D...

Page 503: ...30 Testing and adjusting UEN00229 01 PC210 230 240 8 65...

Page 505: ...PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 30 Testing and adjusting 1 Testing and adjusting Part 3 Testing and adjusting...

Page 506: ...ou touch the high voltage circuit directly you may get an electric shock To avoid this observe the following precau tions when testing 1 The following connectors are used in the high voltage circuit q...

Page 507: ...Remove cover 1 a The cover is fixed with clips Remove it by pull it up a While removing the cover discon nect connector M04 of the cigarette lighter 3 Remove 1 mounting bolt and duct 3 4 Insert or con...

Page 508: ...stall the adapters to only the wiring harness side a The connectors of the pump control ler have a special locking mecha nism Disconnect them according to steps a c and connect them according to steps...

Page 509: ...below Disconnection a Slide lever b Unlock c Disconnect connector Connection d Connect connector e Lock f Slide lever a Removal and installation of sensor A deep socket is necessary for removal and i...

Page 510: ...pecial locking mecha nism Disconnect it according to steps a b and connect it according to steps c d as shown below Disconnection a Unlock b Discon nect connector Connection c Connect connector d Lock...

Page 511: ...diode does not have conductivity Defective The indicated value changes The diode has conductivity Normal Note In the case of a silicon diode a value in the range from 460 to 600 is indi cated 2 When...

Page 512: ...UEN00230 00 30 Testing and adjusting 8 PC210 230 240 8...

Page 513: ...case oil T Final drive case oil T Machinery case oil T Ambient temperature Altitude C m Operator s opinion Result of visual inspection Mechanical equipment system fault history Electrical equipment s...

Page 514: ...UEN00230 00 30 Testing and adjusting 10 PC210 230 240 8 Items related to engine...

Page 515: ...30 Testing and adjusting UEN00230 00 PC210 230 240 8 11 Items related to oil pressure BB Warning 1 Test points reversed on PC210 230 8 pump...

Page 516: ...Max 0 98 Max 100 1 96 200 7 Engine oil pressure ON OFF All levers in neutral rpm 1 300 1 500 1 300 1 500 No Check item Checking condition Unit Standard value for new machine Service limit value Mea su...

Page 517: ...in neutral D1 D1 D2 D2 5 LS valve Right track driven idle Lever moved halfway E1 E2 Left track driven idle Lever moved halfway E1 E2 6 Swing motor safety valve Swing lock Right swing relief F F Swing...

Page 518: ...Work ing mode Left knob switch Operation of work equipment F pump main R pump main F pump F R pump R LS EPC 9 PC EPC F valve PC EPC R valve MIN P OFF All levers in neutral J1 J1 MAX J2 J2 E J3 J3 L J4...

Page 519: ...oil T Final drive case oil T Machinery case oil T Ambient temperature Altitude C m Operator s opinion Result of visual inspection Mechanical equipment system fault history Electrical equipment system...

Page 520: ...UEN00230 00 30 Testing and adjusting 16 PC210 230 240 8 Items related to engine...

Page 521: ...30 Testing and adjusting UEN00230 00 PC210 230 240 8 17 Items related to engine A A...

Page 522: ...rpm 1 850 2 050 1 850 2 050 6 Blow by pressure kPa mmH2O Max 0 98 Max 100 1 96 200 7 Engine oil pressure ON OFF All levers in neutral rpm 1 300 1 500 1 300 1 500 No Check item Checking condition Unit...

Page 523: ...in neutral D1 D1 D2 D2 5 LS valve Right track driven idle Lever moved halfway E1 E2 Left track driven idle Lever moved halfway E1 E2 6 Swing motor safety valve Swing lock Right swing relief F F Swing...

Page 524: ...ol dial Work ing mode Left knob switch Operation of work equipment F pump main R pump main PC EPC F PC EPC R LS EPC 9 PC EPC F valve PC EPC R valve MIN P OFF All levers in neutral J1 J1 MAX J2 J2 E J3...

Page 525: ...30 Testing and adjusting UEN00230 00 PC210 230 240 8 21...

Page 527: ...001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 40 Troubleshooting 1 General information on troubleshooting General information on troubleshooting 2 Points to remember when troubleshooting...

Page 528: ...also lose the confidence of the user or operator For this reason when carrying out trouble shooting it is necessary to carry out thorough prior investigation and to carry out trouble shooting in accor...

Page 529: ...40 Troubleshooting UEN00231 03 PC210 230 240 8 3 Sequence of events in troubleshooting 1...

Page 530: ...Electric electrical equipment 1 Check of battery terminals and wiring for loose ness and corrosion Re tighten or replace 2 Check of alternator terminals and wiring for looseness and corrosion Re tight...

Page 531: ...ccording to the recorded code a If an electrical system failure code is recorded delete all the codes and reproduce them and then see if the trouble is still detected a An error code of the mechanical...

Page 532: ...is excessive or exhaust smoke is blue S 8 13 Oil becomes contaminated quickly S 9 14 Fuel consumption is excessive S 10 15 Oil is in coolant or coolant spurts back or coolant level goes down S 11 16 O...

Page 533: ...eration or swing speed is low H 24 51 Upper structure overruns remarkably when it stops swinging H 25 52 Large shock is made when upper structure stops swinging H 26 53 Large sound is made when upper...

Page 534: ...or cannot be set in service mode E 25 70 Monitoring function does not display lever control signal normally E 26 Other phenomena 71 KOMTRAX system does not operate normally E 27 No Phenomena looking l...

Page 535: ...ze Nominal No is shown in Table 2 and Table 3 Indicates type of wire by symbol Type symbol and material of wire are shown in Table 1 Since AV AVS AVSS and CAVS are classified by size nominal No they a...

Page 536: ...8 4 6 AVSS Standard 2 7 2 7 Nominal No 8 15 20 30 40 50 60 85 100 Conductor Number of strands Diameter of strand 50 0 45 84 0 45 41 0 80 70 0 80 85 0 80 108 0 80 127 0 80 169 0 80 217 0 80 Sectional...

Page 537: ...LW Blue White BrW Brown White LY Blue Yellow BrY Brown Yellow O Orange Ch Charcoal P Pink Dg Dark green R Red G Green RB Red Black GB Green Black RG Red Green GL Green Blue RL Red Blue Gr Gray RW Red...

Page 538: ...1 Part No 08055 00181 Part No 08055 00191 799 601 7010 2 799 601 7020 Part No 08055 00282 Part No 08055 00292 3 799 601 7030 Part No 08055 00381 Part No 08055 00391 4 799 601 7040 Part No 08055 00481...

Page 539: ...Male female housing Female male housing T adapter Part No 6 799 601 7050 Part No 08055 10681 Part No 08055 10691 8 799 601 7060 Part No 08055 10881 Part No 08055 10891 12 799 601 7310 Part No 08055 11...

Page 540: ...adapter Part No 16 799 601 7320 Part No 08055 11681 Part No 08055 11691 Terminal part No Electric wire size 0 85 Grommet Black Q ty 20 Terminal part No Electric wire size 0 85 Grommet Black Q ty 20 T...

Page 541: ...No 1 Part No 08056 00171 Part No 08056 00181 799 601 7080 2 799 601 7090 Part No 08056 00271 Part No 08056 00281 3 799 601 7110 Part No 08056 00371 Part No 08056 00381 4 799 601 7120 Part No 08056 004...

Page 542: ...e housing Female male housing T adapter Part No 8 799 601 7140 Part No 08056 10871 Part No 08056 10881 10 White 799 601 7150 Part No 08056 11071 Part No 08056 11081 12 White 799 601 7350 Part No 08056...

Page 543: ...210 230 240 8 17 No of pins S type connector Male female housing Female male housing T adapter Part No 10 Blue 12 Blue 799 601 7160 Part No 08056 11272 Part No 08056 11282 16 Blue 799 601 7170 Part No...

Page 544: ...2 2640 Q ty 5 Body part No 79A 222 2630 Q ty 5 11 Body part No 79A 222 2680 Q ty 5 Body part No 79A 222 2670 Q ty 5 5 799 601 2710 Body part No 79A 222 2620 Q ty 5 Body part No 79A 222 2610 Q ty 5 9 7...

Page 545: ...le housing Female male housing T adapter Part No 17 799 601 2730 Body part No 79A 222 2730 Q ty 2 Body part No 79A 222 2720 Q ty 2 21 799 601 2740 Body part No 79A 222 2750 Q ty 2 Body part No 79A 222...

Page 546: ...of pins No of pins AMP040 type connector Male female housing Female male housing T adapter Part No 8 799 601 7180 Housing part No 79A 222 3430 Q ty 5 12 799 601 7190 Housing part No 79A 222 3440 Q ty...

Page 547: ...AMP070 type connector Male female housing Female male housing T adapter Part No 10 799 601 7510 Part No 08195 10210 12 799 601 7520 Part No 08195 12210 14 799 601 7530 Part No 08195 14210 18 799 601...

Page 548: ...pe connector Male female housing Female male housing T adapter Part No 2 No of pins Connector for PA Male female housing Female male housing T adapter Part No 9 No of pins Bendix MS connector Male fem...

Page 549: ...08027 10210 Natural colour 08027 10220 Black Part No 08027 10260 Natural colour 08027 10270 Black 3 Part No 08027 10310 Part No 08027 10360 4 Part No 08027 10410 Natural colour 08027 10420 Black Part...

Page 550: ...female housing Female male housing T adapter Part No 8 Part No 08027 10810 Natural colour 08027 10820 Black Part No 08027 10860 Natural colour 08027 10870 Black No of pins Connector for relay Socket...

Page 551: ...40 Troubleshooting UEN00231 03 PC210 230 240 8 25 No of pins F type connector Male female housing Female male housing T adapter Part No 4...

Page 552: ...4101 08191 14102 08191 14105 08191 14106 Pin female terminal Pin male terminal 799 601 9210 Part No 08191 12201 08191 12202 08191 12205 08191 12206 Part No 08191 13101 08191 13102 08191 13105 08191 13...

Page 553: ...le terminal 799 601 9230 Part No 08191 31201 08191 31202 Part No 08191 34101 08191 34102 Pin female terminal Pin male terminal 799 601 9230 Part No 08191 32201 08191 32202 Part No 08191 33101 08191 33...

Page 554: ...91 51202 Part No 08191 54101 08191 54102 Pin female terminal Pin male terminal 799 601 9250 Part No 08191 52201 08191 52202 Part No 08191 53101 08191 53102 24 16 6 Pin male terminal Pin female termina...

Page 555: ...ale terminal Pin male terminal 799 601 9270 Part No 08191 72201 08191 72202 08191 72205 08191 72206 Part No 08191 73101 08191 73102 08191 73105 08191 73106 24 23 8 Pin male terminal Pin female termina...

Page 556: ...ug Body receptacle T adapter Part No 24 31 9 Pin male terminal Pin female terminal 799 601 9290 Part No 08191 91203 08191 91204 08191 91205 08191 91206 Part No 08191 94103 08191 94104 08191 94105 0819...

Page 557: ...type Part No 08192 12100 normal type 08192 22100 fine wire type 3 799 601 9030 Part No 08192 13200 normal type 08192 23200 fine wire type Part No 08192 13100 normal type 08192 23100 fine wire type 4...

Page 558: ...60 8B 799 601 9070 8G 799 601 9080 8BR 799 601 9090 Part No 08192 1820 normal type 08192 2820 fine wire type Part No 08192 1810 normal type 08192 2810 fine wire type 12 12GR 799 601 9110 12B 799 601 9...

Page 559: ...on end No of pins DTP Series connector Body plug Body receptacle T adapter Part No 2 _ _ 4 799 601 4260 Part No 6261 81 2810 _ No of pins DTHD Series connector Body plug Body receptacle T adapter Part...

Page 560: ...ale pin female housing Female pin male housing T adapter Part No 24 799 601 9360 Kit 799 601 9300 Part No 08194 01101 40 A 799 601 9350 Kit 799 601 9300 Part No 08194 02101 40 B 799 601 9350 Kit 799 6...

Page 561: ...r Male pin female housing Female pin male housing T adapter Part No 60 06a 799 601 4390 Part No 207 06 K1050 a 06 Key position No of pins DRC12 16 Series connector DRC12 Male pin female housing DRC 16...

Page 562: ...C210 230 240 8 AMP connector for pump controller CH700 No of pins Controller side plug T adapter Part No 81 799 601 4280 Harness side receptacle Part No 7880 70 9040 40 Controller side plug Harness si...

Page 563: ...ide plug Harness side receptacle T adapter Part No 4 799 601 4380 Common rail fuel pressure sensor 95 107 114 engine Sensor side plug Harness side receptacle 799 601 4190 Kit 799 601 4101 Kit 799 601...

Page 564: ...4101 Kit 799 601 4201 Boost air intake pressure sensor 125 170 12V140 engine Sensor side plug Harness side receptacle 799 601 4250 Kit 799 601 4101 Kit 799 601 4201 3 G sensor fuel supply pump speed s...

Page 565: ...9 601 4110 Kit 799 601 4101 Kit 799 601 4201 A Without pin 4 A Without pin 4 AMP connector for engine No of pin Common rail fuel sensor 125 140 170 12V140 engine Sensor side plug Harness side receptac...

Page 566: ...d sensor 95 107 114 125 140 170 12V140 engine and CAM sensor 95 107 114 engine Sensor side plug Harness side receptacle 799 601 4130 Kit 799 601 4101 Kit 799 601 4201 3 EGR gas pressure sensor 125 140...

Page 567: ...pin 2 A Without pin 2 PACKARD connector for engine No of pins Temperature sensor of coolant fuel and lubricating oil 95 107 114 125 140 170 12V140 engine Sensor side plug Harness side receptacle T ada...

Page 568: ...0 normal type 08192 22200 fine wire type Part No 08192 12100 normal type 08192 22100 fine wire type EGR by pass valve stroke sensor 125 140 170 engine Body plug Body receptacle 799 601 9040 Kit 799 60...

Page 569: ...3460 Adapter for BENDIX MS 10 MS 10P q q 799 601 3510 Adapter for BENDIX MS 5 MS 5S q q 799 601 3520 Adapter for BENDIX MS 17 MS 17P q q 799 601 3530 Adapter for BENDIX MS 19 MS 19P q q 799 601 2910 A...

Page 570: ...70 10 07 10 q 799 601 7520 Adapter for 070 12 07 12 q 799 601 7530 Adapter for 070 14 07 14 q 799 601 7540 Adapter for 070 18 07 18 q 799 601 7550 Adapter for 070 20 07 20 q 799 601 7360 Adapter for r...

Page 571: ...ocket for engine CRI T3 Temperature sensor 2 C q q 795 799 5540 Socket for engine HPI T2 Socket for engine CRI T3 TIM 2 A q q 795 799 5460 Adapter for engine HPI T2 3 q 795 799 5470 Adapter for engine...

Page 572: ...C60 q 799 601 4390 Socket for controller 95 ENG 60 q 799 601 4280 Box for controller PUMP 121 q 799 601 9720 Adapter for controller HST 16 HST16A q 799 601 9710 Adapter for controller HST 16 HST16B q...

Page 573: ...40 Troubleshooting UEN00231 03 PC210 230 240 8 47...

Page 575: ...y of code Part 1 3 Failure codes table 3 Before carrying out troubleshooting when failure code is displayed 9 Information in troubleshooting table 14 Failure code 989L00 Engine Controller Lock Caution...

Page 576: ...ensor 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 Ambien...

Page 577: ...il Overheat e PUMP Mechani cal system E10 CA111 EMC Critical Internal Failure q ENG Electrical system E10 CA115 Eng Ne and Bkup Speed Sens Error q ENG Electrical system E11 CA122 Chg Air Press Sensor...

Page 578: ...ity q ENG Electrical system E10 CA351 Injectors Drive Circuit Error q ENG Electrical system E15 CA352 Sens Supply 1 Volt Low Error q ENG Electrical system E15 CA386 Sens Supply 1 Volt High Error q ENG...

Page 579: ...id Htr Relay Volt Low Error q ENG Electrical system E01 D19JKZ Personal Code Relay Abnormality q MON2 Electrical system D862KA GPS Antenna Discon MON2 Electrical system DA25KP 5V Sensor 1 Power Abnorm...

Page 580: ...P Electrical system DWA2KB Service Sol Short PUMP Electrical system DWK0KA 2 stage Relief Sol Discon PUMP Electrical system DWK0KB 2 stage Relief Sol Short PUMP Electrical system E02 DXA8KA PC EPC F S...

Page 581: ...rt Circuit PUMP Electrical system DXE7KA Service Current EPC2 Open Circuit PUMP Electrical system DXE7KB Service Current EPC2 Short Circuit PUMP Electrical system DXE8KA Service Current EPC3 Open Circ...

Page 582: ...rive switch is operated in emergency Swing holding brake solenoid valve When swing holding brake release switch is operated 2 30 A Pump controller Solenoid power supply 3 10 A PPC oil pressure lock so...

Page 583: ...ng brake solenoid valve When swing holding brake release switch is operated 2 30 A Pump controller Solenoid power supply 3 10 A PPC oil pressure lock solenoid valve Starting motor cut out relay PPC lo...

Page 584: ...UEN00240 01 40 Troubleshooting 10 PC210 230 240 8 Locations of fusible links Location of fuse box and fuse Nos PC240 PC210 230 F04 F05...

Page 585: ...nged q The auto decelerator does not work or is not reset q The travel speed does not change q The power maximizing function does not work q The swing holding brake cannot be reset automatically q The...

Page 586: ...KA DW91KB Travel junction solenoid system q DWA2KA DWA2KB Service solenoid system q DWK0KA DWK0KB 2 stage relief solenoid system q DXA8KA DXA8KB PC EPC F solenoid system q DXA9KA DXA9KB PC EPC R solen...

Page 587: ...q DWK0KA DWK0KB 2 stage relief solenoid system q DXA8KA DXA8KB PC EPC F solenoid system q DXA9KA DXA9KB PC EPC R solenoid system q DXE0KA DXE0KB LS EPC solenoid system q DXE4KA DXE4KB Service current...

Page 588: ...ty Contents of description Standard value in normal state to judge possible causes Remarks on judgment Troubles in wiring harness Disconnection Connector is connected imperfectly or wiring harness is...

Page 589: ...lectric circuit diagram related to troubleshooting Connector No Indicates Model Number of pins and Color Connector No and pin No from each branching merg ing point Shows the ends of branch or source o...

Page 590: ...of machine monitor This trouble may be caused by replacement of machine monitor User code Failure code Trouble Engine controller lock caution 2 Machine monitor system 989M00 Contents of trouble Engin...

Page 591: ...Trouble Air cleaner clogging Machine monitor system AA10NX Contents of trouble While engine was running signal circuit of air cleaner clogging switch detected clogging of air cleaner sensor contact o...

Page 592: ...battery may not be charged Related infor mation Signal voltage of alternator can be checked with monitoring function Code 04300 Charge voltage Method of reproducing failure code Start engine Possible...

Page 593: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 19 Circuit diagram related to preheating starting of engine and charge of battery...

Page 594: ...m may be defective Carry out troubleshooting for E 8 Emergency stop item lights up while engine is running in E mode User code Failure code Trouble Engine oil level low Machine monitor system B BAZK C...

Page 595: ...system If cause 1 is not detected engine coolant temperature gauge sys tem may be defective Carry out troubleshooting for E 9 Engine coolant temperature gauge does not work normally in E mode User cod...

Page 596: ...oducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Overheating of hydraulic oil when system is norma...

Page 597: ...ed sensor are abnormal Action of controller None in particular Problem that appears on machine Engine stops Engine does not start Related infor mation Method of reproducing failure code Start engine P...

Page 598: ...S IMT Voltage Between 3 1 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of tro...

Page 599: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 25 Circuit diagram related to boost pressure temperature sensor Combination sensor...

Page 600: ...oltage Between 3 1 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble an...

Page 601: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 27 Circuit diagram related to boost pressure temperature sensor Combination sensor...

Page 602: ...al a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting P20 Voltage Between 1 3 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Acco...

Page 603: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 29 Circuit diagram related to fuel control dial...

Page 604: ...epare with starting switch OFF then turn starting switch ON and carry out troubleshooting P20 Voltage Between 1 3 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly...

Page 605: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 31 Circuit diagram related to fuel control dial...

Page 606: ...160 kz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch...

Page 607: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 33 Circuit diagram related to coolant temperature sensor...

Page 608: ...ce Between A B 0 18 160 kz Between B chassis ground Min 100 kz 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshooting withou...

Page 609: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 35 Circuit diagram related to coolant temperature sensor...

Page 610: ...ON BOOST PRESS IMT male Resistance Between 2 1 0 18 160 kz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry...

Page 611: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 37 Circuit diagram related to boost pressure temperature sensor Combination sensor...

Page 612: ...ning starting switch ON BOOST PRESS IMT male Resistance Between 2 1 0 18 160 kz Between 2 chassis ground Min 100 kz 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with star...

Page 613: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 39 Circuit diagram related to boost pressure temperature sensor Combination sensor...

Page 614: ...function Code 18500 Boost temperature Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting...

Page 615: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 41...

Page 616: ...t connector with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect sensors and wiring harness at right in order and carry out operation to reproduce trouble If...

Page 617: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 43 Circuit diagram related to sensor power supply 2...

Page 618: ...Between 1 2 Power supply 4 75 5 25V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then j...

Page 619: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 45 Circuit diagram related to ambient pressure sensor...

Page 620: ...Power supply 4 75 5 25V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Grou...

Page 621: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 47 Circuit diagram related to ambient pressure sensor...

Page 622: ...at appears on machine Engine output lowers Related infor mation Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in no...

Page 623: ...ed infor mation Engine speed can be checked with monitoring function Code 01002 Engine speed Method of reproducing failure code Run engine at high idle Possible causes and standard value in normal sta...

Page 624: ...alue in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective sensor or wiring harness a Disconnect connector with starting switch OFF then turn starting switch ON a...

Page 625: ...1 chassis ground Min 100 kz 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wirin...

Page 626: ...out turning starting switch ON Wiring harness between CE01 female 2 CP3 PUMP REGULATOR female 1 Resis tance Max 10 z Wiring harness between CE01 female 32 CP3 PUMP REGULATOR female 2 Resis tance Max 1...

Page 627: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 53...

Page 628: ...g harness between CE01 female 45 INJ CYL 1 female 1 Resis tance Max 2 z Wiring harness between CE01 female 53 INJ CYL 1 female 2 Resis tance Max 2 z 4 Ground fault in wiring har ness Short circuit wit...

Page 629: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 55 Circuit diagram related to No 1 injector...

Page 630: ...g harness between CE01 female 46 INJ CYL 5 female 1 Resis tance Max 2 z Wiring harness between CE01 female 60 INJ CYL 5 female 2 Resis tance Max 2 z 4 Ground fault in wiring har ness Short circuit wit...

Page 631: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 57 Circuit diagram related to No 5 injector...

Page 632: ...g harness between CE01 female 55 INJ CYL 3 female 1 Resis tance Max 2 z Wiring harness between CE01 female 52 INJ CYL 3 female 2 Resis tance Max 2 z 4 Ground fault in wiring har ness Short circuit wit...

Page 633: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 59 Circuit diagram related to No 3 injector...

Page 634: ...g harness between CE01 female 57 INJ CYL 6 female 1 Resis tance Max 2 z Wiring harness between CE01 female 59 INJ CYL 6 female 2 Resis tance Max 2 z 4 Ground fault in wiring har ness Short circuit wit...

Page 635: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 61 Circuit diagram related to No 6 injector...

Page 636: ...g harness between CE01 female 54 INJ CYL 2 female 1 Resis tance Max 2 z Wiring harness between CE01 female 51 INJ CYL 2 female 2 Resis tance Max 2 z 4 Ground fault in wiring har ness Short circuit wit...

Page 637: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 63 Circuit diagram related to No 2 injector...

Page 638: ...g harness between CE01 female 56 INJ CYL 4 female 1 Resis tance Max 2 z Wiring harness between CE01 female 58 INJ CYL 4 female 2 Resis tance Max 2 z 4 Ground fault in wiring har ness Short circuit wit...

Page 639: ...40 Troubleshooting UEN00240 01 PC210 230 240 8 65 Circuit diagram related to No 4 injector...

Page 641: ...A342 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...

Page 642: ...ode 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...

Page 643: ...ler Action of controller None in particular Problem that appears on machine Continues normal operation Engine stops or does not start Related infor mation Method of reproducing failure code Turn start...

Page 644: ...se No 19 If fuse is broken circuit probably has ground fault 3 Defective relay for engine controller power supply a Prepare with starting switch OFF then turn starting switch ON and carry out troubles...

Page 645: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 5 Circuit diagram related to engine controller...

Page 646: ...onnect connector with starting switch OFF then turn starting switch ON and carry out troubleshooting Disconnect sensor and wiring harness at right in order and carry out operation to reproduce trouble...

Page 647: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 7 Circuit diagram related to sensor power supply 1...

Page 648: ...wers Related infor mation Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting...

Page 649: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 9...

Page 650: ...ing har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between CE01...

Page 651: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 11 Circuit diagram related to water in fuel sensor...

Page 652: ...chassis ground Min 100 kz 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring...

Page 653: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 13 Circuit diagram related to water in fuel sensor...

Page 654: ...hassis ground Max 10 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning s...

Page 655: ...e controller with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is defective 5 Disconnection in wiring har ness Disconnection in wiring or d...

Page 656: ...rness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend breakage push in or expansion of pin Moisture or dirt in connect...

Page 657: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 17 Circuit diagram related to engine controller power supply...

Page 658: ...ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective battery voltage a Prepare with starting switch OFF then carry out tro...

Page 659: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 19 Circuit diagram related to engine controller power supply...

Page 660: ...rcuit There may be air in low pressure circuit Check it directly according to the following procedure 1 Remove pressure pickup plug outlet side of fuel main filter 2 Operate feed pump of fuel pre filt...

Page 661: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 21...

Page 662: ...n 3 1 Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge...

Page 663: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 23 Circuit diagram related to common rail pressure sensor...

Page 664: ...Power supply 4 75 5 25 V Voltage is measured with wiring harness connected Accordingly if voltage is abnormal check wiring harness and controller too for another cause of trouble and then judge 3 Gro...

Page 665: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 25 Circuit diagram related to common rail pressure sensor...

Page 666: ...lly high Check related parts directly 3 Defective engine controller If causes 1 2 are not detected engine controller may be defective Since trouble is in system troubleshooting cannot be carried out U...

Page 667: ...s a For check of pressure in fuel low pressure circuit see Testing and adjusting Checking fuel pressure Pressure in fuel low pressure circuit During cranking if engine cannot be started 0 3 1 1 MPa 3...

Page 668: ...or Engine Ne speed sensor may be broken or may have improper clearance Check it directly 4 Breakage of rotation sensor wheel Rotation sensor wheel may be broken Check it directly 5 Disconnection in wi...

Page 669: ...ng parts between engine Ne speed sensor engine wiring harness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend breakage...

Page 670: ...or wheel on crankshaft side Rotation sensor wheel on crankshaft side may be installed defec tively or broken Check it according to the following procedure 1 Set No 1 cylinder at compression top dead c...

Page 671: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 31...

Page 672: ...se is broken circuit probably has ground fault 5 Defective relay for engine controller power supply a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting Replac...

Page 673: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 33 Circuit diagram related to engine controller power supply...

Page 674: ...eed sensor may be broken or may have improper clearance Check it directly 4 Breakage of rotation sensor ring Rotation sensor ring may be broken Check it directly 5 Disconnection in wiring har ness Dis...

Page 675: ...ng parts between engine Bkup speed sensor engine wir ing harness engine controller may be defective Check them directly Looseness of connector breakage of lock or breakage of seal Corrosion bend break...

Page 676: ...e 46 K02 female A Resis tance Max 1 z Wiring harness between CM02 female 10 C01 female 64 CE02 female 47 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circu...

Page 677: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 37 Circuit diagram related to CAN communication...

Page 678: ...ode Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Short circuit in wiring har ness with another wiring ha...

Page 679: ...use Standard value in normal state Remarks on troubleshooting 1 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshooting without...

Page 680: ...ontroller Limits output and continues operation Problem that appears on machine Engine does not start easily Exhaust gas becomes black Engine output lowers Related infor mation Common rail pressure ca...

Page 681: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 41...

Page 682: ...ion in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between CE01 female 2 CP3 PUMP REGU...

Page 683: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 43 Circuit diagram related to supply pump actuator metering unit...

Page 684: ...lace automatic preheater relay R18 with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is defective 2 Disconnection in wiring har ness Discon...

Page 685: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 45 Circuit diagram related to engine preheater starting motor charging system...

Page 686: ...roubleshooting Troubleshooting by replacement Replace automatic preheater relay R18 with another relay and perform reproducing operation If E of failure code goes off at this time replaced relay is de...

Page 687: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 47 Circuit diagram related to engine preheater starting motor charging system...

Page 688: ...ort circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Troubleshooting for relay unit R07 male Resistance Between 1 2 300 600 z a Prepare with...

Page 689: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 49 Circuit diagram related to engine preheater starting motor charging system...

Page 690: ...of controller None in particular If cause of failure disappears system resets itself Problem that appears on machine GPS cannot measure position Related infor mation Method of reproducing failure code...

Page 691: ...then turn starting switch ON and carry out troubleshooting Disconnect sensors at right in order and carry out operation to reproduce trouble If E of failure code goes off when a sensor is disconnected...

Page 692: ...female 3 Bucket CURL PPC pressure sensor system Voltage Max 1 V Wiring harness between C01 female 9 J06 P03 female 3 Swing LEFT PPC pressure sensor system Voltage Max 1 V Wiring harness between C01 f...

Page 693: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 53 Circuit diagram related to pump controller 5V sensor power supply output 1 Overload alarm monitor non display specification...

Page 694: ...UEN00241 01 40 Troubleshooting 54 PC210 230 240 8...

Page 695: ...n turn starting switch ON and carry out troubleshooting Disconnect sensors at right in order and carry out operation to reproduce trouble If E of failure code goes off when a sensor is disconnected th...

Page 696: ...01 female 3 Bucket CURL PPC pressure sensor system Voltage Max 1 V Wiring harness between C01 female 9 J06 P03 female 3 Swing LEFT PPC pressure sensor system Voltage Max 1 V Wiring harness between C01...

Page 697: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 57 Circuit diagram related to pump controller 5V sensor power supply output 1 Overload alarm monitor display specification...

Page 698: ...election connector Internal discon nection or short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON S30 female Resistance Between 1 2 4 7 8...

Page 699: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 59 Circuit diagram related to model selection connector PC210 210LC 8...

Page 700: ...scon nection or short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON S30 female Resistance Between 2 4 7 8 Min 1 Mz Between 1 3 8 Max 1 z...

Page 701: ...40 Troubleshooting UEN00241 01 PC210 230 240 8 61 Circuit diagram related to model selection connector PC240LC 8...

Page 703: ...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...

Page 704: ...W45KA 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 Serv...

Page 705: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 3...

Page 706: ...ng harness between CM02 female 8 9 C01 female 45 CE02 female 46 K02 female A Resis tance Max 1 z Wiring harness between CM02 female 10 C01 female 64 CE02 female 47 K02 female B Resis tance Max 1 z 2 G...

Page 707: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 5 Circuit diagram related to CAN communication...

Page 708: ...s started Action of machine monitor None in particular If cause of failure disappears system resets itself Problem that appears on machine Related infor mation Method of reproducing failure code Turn...

Page 709: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 7...

Page 710: ...A Resis tance Max 1 z Wiring harness between CM02 female 10 C01 female 64 CE02 female 47 K02 female B Resis tance Max 1 z 2 Ground fault in wiring har ness Short circuit with GND circuit a Prepare wit...

Page 711: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 9 Circuit diagram related to CAN communication...

Page 712: ...h monitoring function Code 04402 Hydraulic oil temperature sensor voltage Method of reproducing failure code Start engine Possible causes and standard value in normal state Cause Standard value in nor...

Page 713: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 11...

Page 714: ...Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P25 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If...

Page 715: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 13 Circuit diagram related to F pump pressure sensor...

Page 716: ...epare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P26 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If vo...

Page 717: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 15 Circuit diagram related to R pump pressure sensor...

Page 718: ...ith starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P04 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If voltage i...

Page 719: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 17 Circuit diagram related to arm curl PPC pressure sensor...

Page 720: ...Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P01 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If...

Page 721: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 19 Circuit diagram related to bucket curl PPC pressure sensor...

Page 722: ...pare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P06 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If vol...

Page 723: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 21 Circuit diagram related to boom raise PPC pressure sensor...

Page 724: ...defect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P07 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3...

Page 725: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 23 Circuit diagram related to swing right PPC pressure sensor...

Page 726: ...fect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P03 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4...

Page 727: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 25 Circuit diagram related to swing left PPC pressure sensor...

Page 728: ...Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P05 Voltage Between 3 1 Power supply 4 5 5 5 V Between 2 1 Signal 0 3 4 5 V If...

Page 729: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 27 Circuit diagram related to bucket dump PPC pressure sensor...

Page 730: ...m pressure sensor Internal defect a Prepare with starting switch OFF then turn starting switch ON or start engine and carry out troubleshooting in each case P46 Voltage Between 3 1 Power supply 4 5 5...

Page 731: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 29 Circuit diagram related to overload alarm pressure sensor...

Page 732: ...d can be checked with monitoring function Code 02300 Solenoid 1 Method of reproducing failure code Start engine Set travel speed to High Operate travel lever Possible causes and standard value in norm...

Page 733: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 31 Circuit diagram related to travel speed shifting solenoid...

Page 734: ...f travel speed shifting solenoid can be checked with monitoring function Code 02300 Solenoid 1 Method of reproducing failure code Start engine Set travel speed to High Operate travel lever Possible ca...

Page 735: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 33 Circuit diagram related to travel speed shifting solenoid...

Page 736: ...holding brake solenoid Internal dis connection a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON V03 male Resistance Between 1 2 20 60 z 2 Defective...

Page 737: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 35 Circuit diagram related to swing holding brake solenoid...

Page 738: ...of swing holding brake solenoid can be checked with monitoring function Code 02300 Solenoid 1 Method of reproducing failure code Start engine Swing with left work equipment control lever Possible caus...

Page 739: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 37 Circuit diagram related to swing holding brake solenoid...

Page 740: ...art engine Steer machine with right and left travel levers Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective travel junctio...

Page 741: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 39 Circuit diagram related to travel junction solenoid...

Page 742: ...ing failure code Start engine Steer machine with right and left travel levers Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defec...

Page 743: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 41 Circuit diagram related to travel junction solenoid...

Page 744: ...cing failure code Turn starting switch ON Set machine in mode other than breaker mode B Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooti...

Page 745: ...on Code 02301 Solenoid 2 Method of reproducing failure code Turn starting switch ON Set machine in breaker mode B Possible causes and standard value in normal state Cause Standard value in normal stat...

Page 746: ...de Turn starting switch ON Set machine in mode other than L Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective 2 stage relie...

Page 747: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 45 Circuit diagram related to 2 stage relief solenoid...

Page 748: ...roducing failure code Turn starting switch ON Set machine in working mode L Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defecti...

Page 749: ...40 Troubleshooting UEN00242 01 PC210 230 240 8 47 Circuit diagram related to 2 stage relief solenoid...

Page 751: ...of code Part 4 3 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 DXE0...

Page 752: ...7KB 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 D...

Page 753: ...ternal disconnection a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON V11 male Resistance Between 1 2 7 14 z 2 Defective emergency pump drive switch...

Page 754: ...UEN00243 01 40 Troubleshooting 4 PC210 230 240 8 Circuit diagram related to PC EPC F solenoid and PC EPC R solenoid...

Page 755: ...efective PC EPC F sole noid Internal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON V11 male Resistance Between 1 2...

Page 756: ...UEN00243 01 40 Troubleshooting 6 PC210 230 240 8 Circuit diagram related to PC EPC F solenoid and PC EPC R solenoid...

Page 757: ...th starting switch OFF then carry out troubleshooting without turning starting switch ON V12 male Resistance Between 1 2 7 14 z 2 Defective emergency pump drive switch Internal discon nection a Prepar...

Page 758: ...UEN00243 01 40 Troubleshooting 8 PC210 230 240 8 Circuit diagram related to PC EPC F solenoid and PC EPC R solenoid...

Page 759: ...ective PC EPC R sole noid Internal short circuit or ground fault a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON V12 male Resistance Between 1 2 7...

Page 760: ...UEN00243 01 40 Troubleshooting 10 PC210 230 240 8 Circuit diagram related to PC EPC F solenoid and PC EPC R solenoid...

Page 761: ...of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective LS EPC solenoid Inte...

Page 762: ...UEN00243 01 40 Troubleshooting 12 PC210 230 240 8 Circuit diagram related to LS EPC solenoid...

Page 763: ...current Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective LS EP...

Page 764: ...UEN00243 01 40 Troubleshooting 14 PC210 230 240 8 Circuit diagram related to LS EPC solenoid...

Page 765: ...ting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid Internal...

Page 766: ...UEN00243 01 40 Troubleshooting 16 PC210 230 240 8 Circuit diagram related to service EPC solenoid...

Page 767: ...lure code Turn starting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC...

Page 768: ...UEN00243 01 40 Troubleshooting 18 PC210 230 240 8 Circuit diagram related to service EPC solenoid...

Page 769: ...rent Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge div...

Page 770: ...UEN00243 01 40 Troubleshooting 20 PC210 230 240 8 Circuit diagram related to merge divider main EPC solenoid...

Page 771: ...der main EPC solenoid current Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshoot...

Page 772: ...UEN00243 01 40 Troubleshooting 22 PC210 230 240 8 Circuit diagram related to merge divider main EPC solenoid...

Page 773: ...t Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective merge divide...

Page 774: ...UEN00243 01 40 Troubleshooting 24 PC210 230 240 8 Circuit diagram related to merge divider LS EPC solenoid...

Page 775: ...der LS EPC solenoid current Method of reproducing failure code Turn starting switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshootin...

Page 776: ...UEN00243 01 40 Troubleshooting 26 PC210 230 240 8 Circuit diagram related to merge divider LS EPC solenoid...

Page 777: ...andard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal disconnection a Prepare with starting switch OFF then carry out troubleshooting without turning starting switc...

Page 778: ...UEN00243 01 40 Troubleshooting 28 PC210 230 240 8 Circuit diagram related to windshield wiper and window washer...

Page 779: ...ue in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal disconnection a Prepare with starting switch OFF then carry out troubleshooting wit...

Page 780: ...UEN00243 01 40 Troubleshooting 30 PC210 230 240 8 Circuit diagram related to windshield wiper and window washer...

Page 781: ...urning starting switch ON M06 male Resistance Between 1 2 5 20 z Between 1 2 chassis ground Min 1 Mz 3 Defective assembled type diode D02 Internal short cir cuit a Prepare with starting switch OFF the...

Page 782: ...UEN00243 01 40 Troubleshooting 32 PC210 230 240 8 Circuit diagram related to windshield wiper and window washer...

Page 783: ...of reproducing failure code Turn starting switch ON Turn washer switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defectiv...

Page 784: ...UEN00243 01 40 Troubleshooting 34 PC210 230 240 8 Circuit diagram related to windshield wiper and window washer...

Page 785: ...tarting switch ON Set wiper switch to INT or ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal sho...

Page 786: ...UEN00243 01 40 Troubleshooting 36 PC210 230 240 8 Circuit diagram related to windshield wiper and window washer...

Page 787: ...g switch ON Set wiper switch to INT or ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective wiper motor Inter nal short cir...

Page 788: ...UEN00243 01 40 Troubleshooting 38 PC210 230 240 8 Circuit diagram related to windshield wiper and window washer...

Page 789: ...arting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid Interna...

Page 790: ...ailure code Turn starting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EP...

Page 791: ...rting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid Internal...

Page 792: ...ilure code Turn starting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC...

Page 793: ...rting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid Internal...

Page 794: ...ilure code Turn starting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC...

Page 795: ...rting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC sole noid Internal...

Page 796: ...lure code Turn starting switch ON Set in attachment mode ATT Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective service EPC...

Page 797: ...c e RH EPC 1st S e r v i c e RH EPC 2nd S e r v i c e LH EPC S e r v i c e EPC 1 S e r v i c e EPC 2 S e r v i c e EPC 3 S e r v i c e EPC 4 1 s t A t t LH EPC 1 s t A t t RH EPC 2 n d A t t LH EPC 2...

Page 798: ...UEN00243 01 40 Troubleshooting 48 PC210 230 240 8...

Page 799: ...switch OFF then turn starting switch ON and carry out troubleshooting Monitoring function code 42008 Lever potentio 1 Volt Main Lever slide sw Neutral 2 5 0 3 V Lever slide sw Upper max 4 0 4 6 V Lev...

Page 800: ...ing switch ON Wiring harness between M22 female 9 M22 female 6 Measure it disconnecting M22 connector Resistance Min 100 kz 5 Ground fault in wiring harness No secure GND from pump con troller a Prepa...

Page 801: ...switch OFF then turn starting switch ON and carry out troubleshooting Monitoring function code 42010 Lever potentio 2 Volt Main Lever slide sw Neutral 2 5 0 3 V Lever slide sw Upper max 4 0 4 6 V Lev...

Page 802: ...ing switch ON Wiring harness between M23 female 9 M23 female 6 Measure it disconnecting M23 connector Resistance Min 100 kz 5 Ground fault in wiring harness No secure GND from pump con troller a Prepa...

Page 803: ...ng switch OFF then turn starting switch ON and carry out troubleshooting Monitoring function code 42009 Lever potentio 1 Volt Main Lever slide sw Neutral 2 5 0 3 V Lever slide sw Upper max 0 4 1 0 V L...

Page 804: ...ing switch ON Wiring harness between M22 female 8 M22 female 6 Measure it disconnecting M22 connector Resistance Min 100 kz 5 Ground fault in wiring harness No secure GND from pump con troller a Prepa...

Page 805: ...ng switch OFF then turn starting switch ON and carry out troubleshooting Monitoring function code 42011 Lever potentio 2 Volt Main Lever slide sw Neutral 2 5 0 3 V Lever slide sw Upper max 0 4 1 0 V L...

Page 806: ...ing switch ON Wiring harness between M23 female 8 M23 female 6 Measure it disconnecting M23 connector Resistance Min 100 kz 5 Ground fault in wiring harness No secure GND from pump con troller a Prepa...

Page 807: ...ow 4 5 volts or above 5 5 volts Action of controller Turns output to service EPC solenoids EPC1 EPC2 OFF Even if cause of failure disappears system does not reset itself until starting switch is turne...

Page 808: ...ow 4 5 volts or above 5 5 volts Action of controller Turns output to service EPC solenoids EPC3 EPC4 OFF Even if cause of failure disappears system does not reset itself until starting switch is turne...

Page 809: ...9 M23 M22 H14 Potentio Power 5 V 1st Service Potentio ANALOG GND 2nd Service Potentio 2nd Service Potentio 1st Service Potentio Sub Main Sub Main C01 Pump Controller Sub Potentio 2 Main Potentio 2 Sub...

Page 810: ...UEN00243 01 40 Troubleshooting 60 PC210 230 240 8...

Page 812: ...62 UEN00243 01...

Page 813: ...table 7 E 1 When starting switch turned ON machine monitor displays nothing 8 E 2 When starting switch turned ON before starting engine basic check item lights up 10 E 3 Engine does not start Engine d...

Page 814: ...37 E 19 Windshield wiper and window washer do not operate 40 E 20 Power maximising function does not operate normally 42 E 21 Swing holding brake does not operate normally 46 E 22 Travel alarm does n...

Page 815: ...valve When pump drive switch is operated in emergency Swing holding brake solenoid valve When swing holding brake release switch is operated 2 30 A Pump controller Solenoid power supply 3 10 A PPC oi...

Page 816: ...lve When swing holding brake release switch is operated 2 30 A Pump controller Solenoid power supply 3 10 A PPC oil pressure lock solenoid valve Starting motor cut out relay PPC lock Starting motor cu...

Page 817: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 5...

Page 818: ...UEN00244 02 40 Troubleshooting 6 PC210 230 240 8 Locations of fusible links Location of fuse box and fuse Nos PC210 230 PC240 F04 F05...

Page 819: ...er source 24 V circuit is in contact with power source 24 V circuit Short circuit Independent wiring harnesses are in contact with each other abnormally Precautions for troubleshooting 1 Method of ind...

Page 820: ...ection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness...

Page 821: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 9 Circuit diagram related to machine monitor power supply...

Page 822: ...l in radiator sub tank may be low Check it and add coolant if necessary 2 Defective radiator coolant level switch Internal discon nection a Prepare with starting switch OFF then carry out troubleshoot...

Page 823: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 11 Circuit diagram related to radiator coolant level switch...

Page 824: ...ngine oil level switch Internal disconnec tion a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON P44 male Engine oil level Resistance Between 1 chass...

Page 825: ...15 male Starting switch Resistance Between 1 4 OFF Min 1 Mz START Max 1 z 4 Defective lock lever switch Internal disconnection a Prepare with starting switch OFF then carry out troubleshooting without...

Page 826: ...relay B heater relay battery relay B Resist ance Max 1 z Wiring harness between starting motor safety relay E chassis ground Resist ance Max 1 z Wiring harness between starting motor safety relay C st...

Page 827: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 15 Circuit diagram related to preheating starting of engine and charge of battery...

Page 828: ...Starting switch Voltage Between 16 chassis ground OFF Max 1 V HEAT 20 30 V Trouble 2 When starting switch is turned to HEAT position intake air heater mounting part does not become warm Related inform...

Page 829: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 17 Circuit diagram related to preheating starting of engine and charge of battery...

Page 830: ...10 C turbocharger protection function operates to keep the engine speed at low idle Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting...

Page 831: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 19...

Page 832: ...1 male Resistance Between 1 2 20 60 z Between 1 chassis ground Min 1 Mz 4 Defective assembled type diode D01 Internal short cir cuit a Prepare with starting switch OFF then carry out troubleshooting w...

Page 833: ...arks on troubleshooting 1 Defective lock lever switch Internal short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON S14 female Lock lever...

Page 834: ...n 1 chas sis ground Middle or higher 27 5 29 5 V 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out trouble...

Page 835: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 23 Circuit diagram related to preheating starting of engine and charge of battery...

Page 836: ...and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Clogging of air cleaner when system is normal Air cleaner may be clogged Check it then clean or re...

Page 837: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 25 Circuit diagram related to air cleaner clogging switch...

Page 838: ...8800 WIF sensor condition Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Water separator is full when system is normal Water separ...

Page 839: ...smitted to machine monitor through communication system Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraulic oil temperature Possible causes and standard value in nor...

Page 840: ...ature sensor sys tem may be defective Carry out troubleshooting for failure codes CA144 and CA145 2 Defective machine monitor If cause 1 is not detected machine monitor may be defective Since trouble...

Page 841: ...Between 2 chassis ground Min 1 Mz 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting witho...

Page 842: ...emperature sensor are input to pump controller and then transmitted to machine monitor through communication system Hydraulic oil temperature can be checked with monitoring function Code 04401 Hydraul...

Page 843: ...s ground FULL 7 11 z EMPTY 85 95 z 2 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting witho...

Page 844: ...on Signal voltage of fuel level sensor can be checked with monitoring function Code 04200 Fuel level sensor voltage Possible causes and standard value in normal state Cause Standard value in normal st...

Page 845: ...black points points which are not lighted and bright points points which do not go off for the reason of its characteristics If the number of the bright points and black points does not exceed 10 thos...

Page 846: ...rmal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective PPC pressure sig nal a Start engine and carry out troubleshooting with monitoring func tion Monitoring code Item...

Page 847: ...troubleshooting 1 Defective machine monitor Machine monitor may be defective Since trouble is in system troubleshooting cannot be carried out Trouble 2 When working mode is changed setting of engine...

Page 848: ...e 2 When travel speed is shifted actual travel speed does not change Related infor mation If cause 1 occurs actual travel speed does not lower when travel speed is shifted to Lo Possible causes and st...

Page 849: ...Related infor mation Condition of signal of alarm buzzer cancel switch can be checked with monitoring function Code 04503 Monitor 1st 2nd line switches Possible causes and standard value in normal st...

Page 850: ...tion Code 04503 Monitor 1st 2nd line switches Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective machine monitor Machine mon...

Page 851: ...06 Power Supply 9 7 F01 FUSE BOX 1 2 V40 Quick Coupler Solenoid 17 22 H15 T01 1 2 4 5 S50 1 5 9 10 RH CONSOLE Quick Coupler SW S42 7 H14 4 8 D03 6 BUZZER ON SIGNAL CM02 Monitor Panel 1 59 C01 Quick Co...

Page 852: ...led to front Min 1 Mz When retracted to rear Max 1 z 2 Defective wiper motor Inter nal disconnection a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch O...

Page 853: ...ate Related infor mation Condition of window washer switch signal can be checked with monitoring function Code 04504 Monitor 1st 2nd line switches Possible causes and standard value in normal state Ca...

Page 854: ...out troubleshooting without turning starting switch ON S11 male Left knob switch Resistance Between 1 2 Released Min 1 Mz Pressed Max 1 z 3 Disconnection in wiring har ness Disconnection in wiring or...

Page 855: ...Switch input 1 Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short Short circuit with 24V circuit in wiring harness a Prepar...

Page 856: ...itch Resistance Between 2 10 Released Min 1 Mz Pressed Max 1 z 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting switch OFF then car...

Page 857: ...Switch input 1 Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Hot short Short circuit with 24V circuit in wiring harness a Prepar...

Page 858: ...out troubleshooting without turning starting switch ON Wiring harness between CM02 female 5 J02 S04 female 5 C01 female 19 Resist ance Min 1 Mz 4 Defective machine monitor a Prepare with starting swi...

Page 859: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 47 Circuit diagram related to swing holding brake solenoid...

Page 860: ...h GND circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between F01 15 J03 M14 female 1 circuit branch end Resist ance Min 1 M...

Page 861: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 49 Circuit diagram related to travel alarm and travel PPC oil pressure switch...

Page 862: ...ault See cause 4 2 Defective fuse in unit If fuse in unit is broken circuit in unit probably has ground fault See cause 4 3 Disconnection in wiring har ness Disconnection in wiring or defective contac...

Page 863: ...igh 3 Defective blower motor Internal defect a Prepare with starting switch OFF then turn starting switch ON and carry out troubleshooting MB wiring side Air conditioner switch Voltage Between 1 2 Air...

Page 864: ...1 Mz Wiring harness between R20 female 4 MB wiring side 1 Resist ance Min 1 Mz Wiring harness between MB wiring side 2 PTR wiring side 3 Resist ance Min 1 Mz Wiring harness between PTR wiring side 2...

Page 865: ...ective compressor Inter nal defect Compressor may be defective Check it directly 6 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nector a Prepare with starting s...

Page 866: ...ND circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between N10 male 2 CM02 female 8 9 C01 female 45 CE02 female 46 K02 femal...

Page 867: ...tch ON Turn air conditioner A C switch ON Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Defective internal air sensor Internal di...

Page 868: ...s on troubleshooting 1 Defective air flow sensor Internal disconnection or short circuit a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON THF device...

Page 869: ...itch ON Wiring harness between ACW wiring side 3 P31 female 1 Resist ance Max 1 z Wiring harness between ACW wiring side 15 P31 female 2 Resist ance Max 1 z 3 Short circuit in wiring har ness with GND...

Page 870: ...n MV1 wiring side 7 ACW wiring side 23 Resist ance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshooting without tu...

Page 871: ...iring side 7 ACW wiring side 22 Resist ance Max 1 z 3 Ground fault in wiring har ness Short circuit with GND circuit a Prepare with starting switch OFF then carry out troubleshooting without turning s...

Page 872: ...s may be insufficient Check it directly 2 Defective high and low pres sure switches Internal dis connection a Prepare with starting switch OFF then carry out troubleshooting without turning starting s...

Page 873: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 61 Circuit diagram related to air conditioner...

Page 874: ...turned ON if machine monitor displays nothing backup power supply system may be defective In this case carry out troubleshooting for E 1 When starting switch turned ON machine monitor displays nothing...

Page 875: ...e Standard value in normal state Remarks on troubleshooting 1 Defective arm curl PPC pres sure sensor system Carry out troubleshooting for failure code DHS3MA Trouble 3 Bucket curl operation is not di...

Page 876: ...repare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between C01 female 14 P02 female 1 Resist ance Max 1 z Wiring harness between P02 femal...

Page 877: ...are with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between C01 female 15 P08 female 1 Resist ance Max 1 z Wiring harness between P08 female 2...

Page 878: ...y out troubleshooting without turning starting switch ON D02 male Continuity Between 8 4 There is continuity 3 Disconnection in wiring har ness Disconnection in wiring or defective contact in con nect...

Page 879: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 67 Circuit diagram related to travel PPC pressure switch and travel alarm...

Page 880: ...or a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between C01 female 36 P10 female 2 Resist ance Max 1 z Wiring harness between P10...

Page 881: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 69...

Page 882: ...fective contact in con nector a Prepare with starting switch OFF then carry out troubleshooting without turning starting switch ON Wiring harness between C01 female 62 S10 female 1 S11 female 1 Resist...

Page 883: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 71 Circuit diagram related to service PPC pressure switch...

Page 884: ...tarting switch ON and check Setting condition or termi nal screen Check item Normal display Communication start check Completion 2 Defective GPS a Turn starting switch ON and check Condition of positi...

Page 885: ...40 Troubleshooting UEN00244 02 PC210 230 240 8 73...

Page 887: ...4 System diagram of hydraulic and mechanical system 4 Information in troubleshooting table 6 H 1 Speed or power of whole work equipment swing and travel is low 7 H 2 Engine speed lowers extremely or...

Page 888: ...Machine deviates during travel 20 H 19 Travel speed is low 21 H 20 Machine is not steered well or steering power is low 22 H 21 Travel speed does not change or travel speed is low high 23 H 22 Travel...

Page 889: ...40 Troubleshooting UEN00245 02 PC210 230 240 8 3...

Page 890: ...UEN00245 02 40 Troubleshooting 4 PC210 230 240 8 Troubleshooting of hydraulic and mechanical system H mode 1 System diagram of hydraulic and mechanical system 1...

Page 891: ...Troubleshooting UEN00245 02 PC210 230 240 8 5 a This system diagram is a rough general hydraulic circuit diagram made as reference material for trou bleshooting of the hydraulic and mechanical system...

Page 892: ...ble Trouble which occurred in machine Related information Information related to detected trouble or troubleshooting Possible causes and standard value in normal state Cause Standard value in normal s...

Page 893: ...nction of self reducing pressure valve a Prepare with engine stopped then run engine at high idle and carry out troubleshooting Control levers Control circuit basic pressure All levers in neutral 2 84...

Page 894: ...re Operation of levers and oil pressure ratio All levers in neutral Travel with no load Lever operated half way Pump discharge pressure Almost same pressure 1 PC valve output pressure Approx 0 6 Appro...

Page 895: ...kg cm2 High idle 0 52 0 91 MPa 5 3 9 3 kg cm2 3 Defective adjustment or malfunction of PC valve a Prepare with engine stopped then run engine at high idle and carry out troubleshooting Measured oil pr...

Page 896: ...3 Defective piston pump Piston pump may have malfunction or internal defect Check it by following method 1 Remove pump discharge pressure pickup plugs F and R 2 Crank engine at flywheel manually 3 If...

Page 897: ...all troubleshooting in power mode P of working mode Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting 1 Malfunction of LS EPC valve a...

Page 898: ...on Check it directly 7 Malfunction of boom control valve pressure compensa tion valve Pressure compensation valve of boom control valve may have mal function Check it directly 8 Malfunction of boom co...

Page 899: ...ction of arm control valve pressure compensa tion valve Pressure compensation valve of arm control valve may have mal function Check it directly 8 Malfunction of arm control valve regeneration valve R...

Page 900: ...efective seal of bucket control valve safety suction valve Safety suction valve of bucket control valve may have malfunction or defective seal Check it directly 5 Malfunction of service con trol valve...

Page 901: ...rge Related information Carry out all troubleshooting in power mode P of working mode Possible causes and standard value in normal state Cause Standard value in normal state Remarks on troubleshooting...

Page 902: ...trol lever Leakage from bucket cylinder Bucket curl relief 20 cc min 2 Defective seal of bucket control valve spool Seal of bucket control valve spool may be defective Check it directly 3 Defective se...

Page 903: ...of control valve may have malfunction Check it directly 3 Malfunction of control valve safety suction valve Safety suction valve of control valve may have malfunction Check it directly a This safety s...

Page 904: ...e output pressure OFF 0 MPa 0 kg cm2 ON 2 9 MPa 30 kg cm2 2 Malfunction of main relief valve Main relief valve may have malfunction Check it directly Trouble In compound operation of work equipment sp...

Page 905: ...d value in normal state Remarks on troubleshooting 1 Malfunction or defective seal of swing control valve LS selector valve LS selector valve of control valve may have malfunction or defec tive seal C...

Page 906: ...n of levers and oil pressure ratio All levers in neutral Travel with no load Lever operated half way Pump discharge pressure Almost same pressure 1 PC valve output pressure Approx 0 6 Approx 3 5 If oi...

Page 907: ...high idle and carry out troubleshooting Measured oil pressure Travel lever LS EPC valve output pressure Lo Neutral Approx 2 9 MPa Approx 30 kg cm2 Hi Operated 0 MPa 0 kg cm2 4 Malfunction of travel c...

Page 908: ...divider main valve Merge divider main valve may have malfunction Check it directly 7 Malfunction of merge divider LS valve Merge divider LS valve may have malfunction Check it directly 8 Malfunction...

Page 909: ...troubleshooting with monitoring function Travel speed Travel lever Monitoring code 01500 Lo Operated 663 mA PC210 8 578 mA PC240 8 Reference Mi 424 mA PC210 8 641 mA PC240 8 Hi 0 mA a Prepare with eng...

Page 910: ...sides or on right and left sides may be checked by replacing them with each other and seeing change of condition 3 Defective seal of travel motor check valve Seal of check valve of travel control val...

Page 911: ...it directly 3 Malfunction of swing motor parking brake Parking brake of swing motor may have malfunction Check it directly 4 Defective adjustment or malfunction of swing motor safety valve a Prepare w...

Page 912: ...output pressure Neutral 0 MPa 0 kg cm2 Left swing Right swing 2 84 3 43 MPa 29 35 kg cm2 2 Malfunction of swing control valve spool Spool of swing control valve may have malfunction Check it directly...

Page 913: ...control lever Leakage from swing motor ON Swing relief Max 10 l min 6 Defective swing machinery Swing machinery may have internal defect Check it directly a It may be check by abnormal sound abnormal...

Page 914: ...swinging in only one direction Related information Carry out all troubleshooting in power mode P of working mode Possible causes and standard value in normal state Cause Standard value in normal stat...

Page 915: ...ecked by replacing them with each other and seeing change of con dition 3 Malfunction of swing motor shockless valve Shockless valve of swing motor may have malfunction Check it directly Trouble Large...

Page 916: ...ng is large when swing holding brake is released Related information When swing holding brake release switch is in release position swing holding brake is released and upper structure is secured by on...

Page 917: ...stopped then run engine at high idle and carry out troubleshooting Working mode ATT return selector solenoid valve output pressure ATT mode 0 MPa 0 kg cm2 B mode 2 9 MPa 30 kg cm2 2 Malfunction of AT...

Page 918: ...hooting 1 Pressure setting too low for particular quick coupler If there is insufficient pressure achieved at the quick coupler cylinder then it wont move Adjust pressure according to quick coupler sp...

Page 919: ...le 1 P51 female 1 resistance above 1M V40 female 1 S42 female 1 and 10 resistance above 1M 4 Directional control valve malfunction Directional control valve may have a malfunction eg sticking spool Ch...

Page 920: ...to retract the quick coupler cylinder a Prepare with starting switch OFF then turn starting switch ON but quick coupler switch OFF and carry out troubleshooting V40 female between 1 2 Voltage below 1...

Page 921: ...in insufficient pressure being available Measure pressure as explained in Testing and Adjusting Section 30 then check if pressure can be adjusted if it can t replace complete pressure reducer 6 Pilot...

Page 922: ...F01 FUSE BOX 1 2 V40 Quick Coupler Solenoid 17 22 H15 T01 1 2 4 5 S50 1 5 9 10 RH CONSOLE Quick Coupler SW S42 7 H14 4 8 D03 6 BUZZER ON SIGNAL CM02 Monitor Panel 1 59 C01 Quick Coupler Circuit Low P...

Page 923: ...40 Troubleshooting UEN00245 02 PC210 230 240 8 37 1...

Page 925: ...t 3 S 1 Starting performance is poor 6 S 2 Engine does not start 7 S 3 Engine does not pick up smoothly 10 S 4 Engine stops during operations 11 S 5 Engine does not rotate smoothly 12 S 6 Engine lack...

Page 926: ...UEN00246 02 40 Troubleshooting 2 PC210 230 240 8 S 15 Abnormal noise is made 23 S 16 Vibration is excessive 24 S 17 Diesel Particulate Filter System 25...

Page 927: ...ator depending on their level Check items Simple check items used by the serviceman to narrow the causes They correspond to C in the chart on the right Causes Items to be narrowed from the questions...

Page 928: ...g Exhaust gas is black Let us assume that Clogged air cleaner is taken to be the cause of black exhaust gas Three symptoms have causal relationship with this problem Exhaust gas slowly became black Po...

Page 929: ...PC210 230 240 8 5 If we look from these three symptoms to find the causes we find that there is a relationship with five causes Let us explain here the method of using this causal relationship to pin...

Page 930: ...eated or when temperature is low preheating monitor does not indicate normally w During operation charge level monitor indicates abnormal charge w w Dust indicator is red w Air breather hole of fuel t...

Page 931: ...N there is no operating sound from battery relay Q w Check items When starting switch is turned to START starting pinion does not move out Q Q w When starting switch is turned to START starting pinion...

Page 932: ...s not been carried out according to Operation and Mainte nance Manual w E Q When fuel tank is inspected it is found to be empty w Air breather hole of fuel tank cap is clogged Q w Rust and water are f...

Page 933: ...e normally w Dust indicator is red w Air breather hole of fuel tank cap is clogged Q Rust and water are found when fuel tank is drained w When fuel filter is removed there is not fuel in it w Fuel is...

Page 934: ...Dust indicator is red w Air breather hole of fuel tank cap is clogged w Rust and water are found when fuel tank is drained w Fuel is leaking from fuel piping w When priming pump is operated it makes n...

Page 935: ...gine stopped w Q Q Q Non specified fuel is being used Q Q Q Replacement of filters has not been carried out according to Operation and Maintenance Manual w Fuel level monitor indicates low level if mo...

Page 936: ...d range Q Q Occurs at low idle Q Q Q Q Q Occurs even when speed is raised Q Q Q Occurs on slopes w Replacement of filters has not been carried out according to Operation and Maintenance Manual w When...

Page 937: ...r is red w w Air breather hole of fuel tank cap is clogged w w Fuel is leaking from fuel piping w Output becomes insufficient after short stop of operation w Check items Colour of exhaust gas Black w...

Page 938: ...UEN00246 02 40 Troubleshooting 14 PC210 230 240 8 1 Displayed failure codes CA559 and CA2249 2 Displayed failure codes CA122 and CA123...

Page 939: ...ntly w Power was lost Suddenly w Q Q Q Gradually Q Q Q Q Dust indicator is red w Muffler is crushed w Air leaks between turbocharger and cylinder head clamp is loosened w Check items Engine is operate...

Page 940: ...E E E Oil consumption suddenly increased w Q Oil must be added more frequently w Q Oil becomes contaminated quickly Q Q w Outside of engine is dirty with oil w w w w w There are loose piping clamps in...

Page 941: ...ir history Degree of use of machine Operated for long period E E E Non specified fuel is being used Q Q Engine oil must be added more frequently w Metal particles are found when oil is drained Q Q w I...

Page 942: ...han for other machines of same model Q Q Q Q Gradually increased Q Q Suddenly increased Q Q There is external leakage of fuel from engine w Combustion is irregular w Engine oil level rises and oil sme...

Page 943: ...of use of machine Operated for long period E E Oil level Suddenly increased Q Q Q Gradually increased Q Q Hard water is being used as coolant Q Q Oil level has risen oil is milky Q Q w Check items The...

Page 944: ...nt of filters has not been carried out according to Operation and Maintenance Manual w Oil pressure monitor if installed Indicates pressure drop at low idle w Indicates pressure drop at low high idle...

Page 945: ...must be added more frequently Q Q There is oil in coolant Q Q Q Q w Oil smells of diesel fuel w w Oil is milky Q Q When engine is started drops of water come from muffler Q Check items When radiator...

Page 946: ...d oil is milky w Q Fan belt tension is low w Check items When fan belt is turned it has play w Milky oil is floating on coolant w There are excessive air bubbles in radiator coolant spurts back w When...

Page 947: ...chine Operated for long period E Condition of abnormal noise Gradually occurred Q Q Sudden occurred Q Q Q Non specified fuel is being used Q Oil must be added more frequently w Metal particles are fou...

Page 948: ...plicable machine side Questions Confirm recent repair history Degree of use of machine Operated for long period E E E Condition of vibration Suddenly increased Q Q Gradually increased Q Q Q Non specif...

Page 949: ...unnecessary idling Turn off engine when not in use Back pressure displayed no longer falls to base value Message Filter full Audible alarm Filter is overfilled with soot Build up of incombustible mate...

Page 951: ...K50213 and up PC240LC 8 K50630 and up PC240NLC 8 K50630 and up 40 Troubleshooting 1 Troubleshooting of Auto Grease system Finding malfunctions 2 Malfunction reports of the display 2 General 4 Malfunc...

Page 952: ...cause of this no pressure can be built up b Air in the system Within the maximum pumping time insufficient pressure is built up c Broken grease pressure switch d O ring damaged or left out when replac...

Page 953: ...after com munication is restored b Pump is switched off because the pres sure switch did not switch during a sequence of successive cycles b See Cause and Solution of point 1 of the signal lamp table...

Page 954: ...7 All greasing points con tain an excessive amount of grease The adjusted greasing interval for the con cerning application is to short Adjust a longer greasing time interval with the push button if p...

Page 955: ...re is reached 5 Therefore turn off the contact switch when the switching pressure has been reached The test cycle is ended If the grease pressure switch functions properly the cable should be checked...

Page 956: ...st push button on the pump The pump should start in the second channel and the pressure gauge will quickly increase to the maximum adjusted grease pressure of 230 to 250 bar The first channel should b...

Page 957: ...in lines from the pump to the distribution blocks When there is only little leak it may be impossible to establish the leak with the operating pump Therefore switch off the pump when the maximum press...

Page 959: ...001 and up PC210LC 8 K50001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 50 Disassembly and assembly1 Disassembly and assembly related info...

Page 960: ...i e locally made parts a General tools that are necessary for removal or installation are described as 1 2 etc and their part names part numbers and quantities are not described Removal q The Removal...

Page 961: ...th 79 T means that they can not be supplied from Komatsu in Japan i e locally made parts a General tools that are necessary for removal or installation are described as 1 2 etc and their part names pa...

Page 962: ...140 50 g Polyethylene container Quick setting adhesive Setting time Within 5 sec to 3 min Used mainly to stick metals rubbers plastics and woods Aron alpha 201 790 129 9130 2 g Polyethylene container...

Page 963: ...heat resistance than grease with molybdenum disulphide Body dirt is not distinctive due to white color Biological grease G2 B G2 BT For heat resistance and heavy load SYG2 400B SYGA 16CNB SYG2 400BT...

Page 964: ...un super 560 22M 54 27210 320ml ECOCART special con tainer To be used as glass adhesive compound Term of validity 6 months after manufac turing Cooking compound Sunstar pengiun seal No 2505 417 926 39...

Page 965: ...N Installation of engine rear seal Cylinder head assem bly fuel injector assem bly 3 795 799 6700 Primer t 1 N Removal of fuel injector 4 795 799 1131 Gear t 1 Positioning with 3RD and 4TH cylinder To...

Page 966: ...1613 31645 Washer t 2 790 105 2100 Jack t 1 790 101 1102 Hydraulic pump t 1 7 790 331 1110 Wrench t 1 Angle tightening of bolt Carrier roller assembly L 1 790 434 1660 Installer t 1 Installation of fl...

Page 967: ...2560 Nut 2 790 101 2650 Adapter 2 Control valve assembly T 2 796 946 1310 Guide 21 8 t 1 Replacement of pressure compensation valve seal For 723 46 40100 796 946 1610 Guide 21 4 t 1 For 723 46 41100...

Page 968: ...nch assembly t 1 Removal and installation of piston assembly 790 102 4310 Pin t 2 3 790 720 1000 Expander q 1 Installation of piston ring 4 796 720 1670 Rubber band for boom and arm q 1 07281 01279 Cl...

Page 969: ...101 1102 Pump 294kN 30ton t 1 Air conditioner assem bly X 1 799 703 1200 Service tool kit t 1 Filling of air conditioning gas 799 703 1100 Vacuum pump 100V t 1 799 703 1111 Vacuum pump 220V t 1 799 7...

Page 970: ...9 00 50 Disassembly and assembly 12 PC210 230 240 8 Sketches of special tools 1 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches A8 Plate F1 Pus...

Page 971: ...50 Disassembly and assembly UEN00659 00 PC210 230 240 8 13 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches F3 Plate J2 Push tool...

Page 972: ...UEN00659 00 50 Disassembly and assembly 14 PC210 230 240 8 Note Komatsu cannot accept any responsibility for special tools manufactured according to these sketches J6 Push tool S Push tool...

Page 973: ...50 Disassembly and assembly UEN00659 00 PC210 230 240 8 15...

Page 975: ...ed 2 Removal and installation of fuel supply pump assembly 2 Removal and installation of fuel injector assembly 4 Removal and installation of engine front seal 11 Removal and installation of engine re...

Page 976: ...isconnect fuel filter hoses 2 and 3 from fuel supply pump 16 a Remove dirt on the connector in advance Because dirt sometimes makes lock L fit tight a Pull out the hose while pushing lock L from both...

Page 977: ...gure Refer to Removal 1 q How to install high pressure pipe 9 1 Tighten the sleeve nuts by hand both sides 2 Tighten the sleeve nuts in the order of firstly the pump side then the common rail side 3 S...

Page 978: ...el filter and bracket assembly 5 5 Disconnect bracket 6 1 6 Remove hose tube and air intake connector assembly 7 2 a Remove it without separating from the bracket a Mark the hose edge and tube to show...

Page 979: ...head screwdriver 1 13 Disconnect connector 19 a As you cannot hold the connector remove it as follows using two flat head screw drivers 1 Keep pushing the lock of connector 19 with flat had screwdrive...

Page 980: ...at the damper side with mark 2 M2 at the engine speed sen sor side a Be careful that the aligning position is not the 1st and 6th cylinder top position but the 3rd and 4th cylinder top position a Mar...

Page 981: ...ove six inlet connectors 33 a Remove and flush dirt etc off the sur rounding area in advance to prevent them from entering the connector holes a Tool A5 remover is adopted for removing inlet connector...

Page 982: ...fitted together 4 Assemble fuel injector assembly 35 to the cylinder head with its fuel inlet hole facing the intake manifold side 5 Tighten bolts 34 three or four turns 6 Coat the head side B part of...

Page 983: ...est of installation in the reverse order to removal 1 3 Bracket mounting bolt 43 6 Nm 4 4 0 6 kgm 2 3 Air intake connector mounting bolt 24 4 Nm 2 4 0 4 kgm q MIKALOR clamp a Use a new clamp a Align t...

Page 984: ...es 51 and 56 2 Common rail 25 side of high pres sure pipes 51 and 56 3 Head side of high pressure pipes 52 53 54 and 55 4 Common rail 25 side of high pres sure pipes 52 53 54 and 55 5 Tighten the slee...

Page 985: ...ut aside air conditioner con denser 1 5 Remove bracket 2 6 Remove cover 3 7 Remove nets 4 and 5 a Hydraulic oil cooler hoses H1 and H2 have already been removed with removal 8 Remove fan guards 6 and...

Page 986: ...that the end corners and lip sliding surfaces of the crankshaft are free from flaw burr and rust of the housing a When installing the seal do not coat the shaft and seal lip with oil grease etc Also...

Page 987: ...0 5 kgm in diagonal order 4 90 5 a Tool A6 wrench is adopted for angle tightening Refer to the tool list Refer to the tool list q When an angle tightening tool is not used Put marks on the vibration d...

Page 988: ...ve damper assembly 2 4 Remove mounting bolt 3 and insert guide bolts 2 1 a Width across flats 18 mm 5 Lift temporarily flywheel assembly 4 and pull out flywheel assembly 4 a Be careful not to let the...

Page 989: ...the oil seal de grease clean and dry the crankshaft sealing face and the seal lip face to prevent oil leak age 2 Insert pilot 5 to crankshaft 6 and push oil seal 5 into flywheel housing 7 3 Push in o...

Page 990: ...h faucet joint portion a or the outer perimeter surface of the flywheel at a right angle 3 Rotate the flywheel 360 and measure the difference of the maximum swing of the dial gauge indicator a Check t...

Page 991: ...The frame between the control valve and the engine should be kept installed as a foothold 4 Disconnect fuel filter hoses 2 and 3 from fuel supply pump FSP a Remove dirt on the connector in advance Bec...

Page 992: ...ct connector 18 a Pull out connector 18 in the direction of the arrow while pushing up its lock with flat head screwdriver 1 20 Disconnect connector 19 a As you cannot hold the connector remove it as...

Page 993: ...emove six bellows 23 a Cylinder head side only 24 Disconnect six high pressure pipes 24 at the cylinder head side 9 25 Remove common rail and high pressure pipe assembly 25 10 26 Remove protection cov...

Page 994: ...emove fan 32 15 a Keep the fan dropped down 34 Loosen air conditioner compressor bracket mounting bolts 33 and 34 35 Remove air conditioner compressor drive belt 35 16 36 Disconnect connector AC02 36...

Page 995: ...ector while pushing lock L2 43 Remove blow by duct 45 44 Disconnect fuel return tube 46 45 Remove head cover 48 46 By cranking align mark 1 M1 at the damper side with mark 2 M2 at the engine speed sen...

Page 996: ...remove six inlet connectors 54 a Remove and flush dirt etc off the sur rounding area in advance to prevent them from entering the connector holes a Tool A5 remover is adopted for removing inlet conne...

Page 997: ...a Check that the gasket is properly matched with the cylinder head holes 3 Set cylinder head assembly 61 on the cylinder block screw in mounting bolts 60 by hand a few turns and tighten them according...

Page 998: ...der 65 to fuel injector 62 with concavity and convexity A fitted together 4 Assemble fuel injector assembly 56 to the cylinder head with its fuel inlet hole facing the intake manifold side 5 Tighten b...

Page 999: ...ted in the push rod socket 3 Mounting bolt 36 5 Nm 3 7 0 5 kgm 2 Adjust the valve clearances a Refer to the Adjusting of Valve Clear ance section in the TESTING AND ADJUSTING chapter of this manual 3...

Page 1000: ...marking position a Reference Depth of insertion 60mm aftercooler side a Set bridge BR under the clamp tightening bolt as the lap with band BR is Min 5mm a Align the clamp to the original position a Im...

Page 1001: ...76 2 Common rail side of high pressure pipes 76 and 71 3 Head side of high pressure pipes 72 73 74 and 75 4 Common rail side of high pressure pipes 72 73 74 and 75 3 Tighten the sleeve nut of high pre...

Page 1002: ...of 53 6 Nm 5 4 0 6 kgm Third time in the order of 1 4 Tighten to a torque of 53 6 Nm 5 4 0 6 kgm 15 3 Fan mounting bolt 43 6 Nm 4 4 0 6 kgm 16 a Refer to the Inspection and Adjustment of Air Compress...

Page 1003: ...ne cooling water 6 Coolant Approx 21l PC210 230 Approx 20 4l PC240 4 Open up the engine hood 5 Disconnect reservoir tank hose 2 6 Remove cover 3 7 Remove hose and tube assembly 4 1 a Remove it without...

Page 1004: ...e original hose installation positions See figure below 10 Disconnect radiator hose 7 2 a Mark the hose edge and tube to show the original hose installation positions Refer to the above figure 11 Move...

Page 1005: ...less than 16Nm 1 6kgm tighten it until the hand gap is adhered BDG size is 0 2 a Align the hose to the original position marking position a Align the clamp to the original position a Reference Inserte...

Page 1006: ...1 Turn the upper structure by 90 degrees 2 Remove cover 1 3 Open up the engine hood 4 Remove hydraulic oil cooler drain plug 2 to drain the hydraulic oil a Loosen upper side return hose 7 of the hydra...

Page 1007: ...heat insulating seal material sponge of the radiator peripheral part is not damaged If the heat insulating seal material sponge is damaged replace it to the new one Confirm from the under cover side...

Page 1008: ...structure by 90 degrees 2 Remove cover 1 3 Open up the engine hood 4 Disconnect reservoir tank hose 2 5 Remove cover 3 6 Remove hose and tube assembly 4 1 a MIKALOR clamp a Mark the hose edge and tub...

Page 1009: ...hose and tube assembly 4 a Use brand new article for MIKALOR clamp a Align the hose to the original position marking position a Inserted air hose length q Aftercooler side 60 mm q Engine side A 80 mm...

Page 1010: ...concav ity B Removal and installation of fuel cooler assembly Removal a If the fuel is too much drain the fuel in order to stop the fuel flow from the fuel tank return hose 1 Disconnect fuel hose 1 a...

Page 1011: ...by 90 degrees 2 Remove hydraulic tank strainer and stop oil flow out using tool A10 A11 a If tool A10 A11 are not used remove the drain plug and drain oil from the hydraulic tank and piping 6 Hydraul...

Page 1012: ...nless removing cover 17 a The hatched area is made of rubber lower side 14 Remove air cleaner band 14 15 Remove flame 15 16 Remove cover 16 and 17 17 Remove flame 18 18 Remove cover 19 19 Remove flame...

Page 1013: ...g air intake connector C replace the gasket 23 Disconnect radiator hose 25 3 a Mark the hose edge and tube to show the original hose installation positions 24 Disconnect heater hose 26 25 Remove fan g...

Page 1014: ...ove air conditioner compressor assembly 35 a Remove air conditioner compressor as sembly in one piece with the bracket and put them on the counter weight 37 Disconnect ribbon heater connector E01 38 3...

Page 1015: ...clamp 50 48 Disconnect clamp 51 PC240 8 only 49 Remove filter and bracket assembly 52 a Put it on hose bracket HB PC210 230 8 PC240 8 50 Disconnect six hoses q 53 Rear load pressure input port hose Co...

Page 1016: ...t 59 to the original position Install it to the pump PC210 230 8 PC240 8 55 Disconnect pump wiring connectors at four points q 65 V12 PC EPC R solenoid valve Color band yellow q 66 P22 hydraulic oil t...

Page 1017: ...ect connectors AB 76 and E12 77 61 Remove alternator 78 62 Disconnect heater hose 79 63 Remove three bolts and disconnect radiator hose and flange assembly 80 8 64 Disconnect engine ground 81 65 Remov...

Page 1018: ...it at the three points i e two points at the engine and one point at the hydraulic pump Recommended lifting tool A9 Refer to the special tool list is proposed from Cum mins a Before removing the assem...

Page 1019: ...position marking position a Align the clamp to the original position a Reference Inserted air hose length 49mm 3 Radiator hose clamp 10 8 11 8 Nm 1 1 1 2 kgm 4 3 Tube clamp 10 0 11 0 Nm 1 02 1 12 kgm...

Page 1020: ...nd then check the water level 5 Coolant Approx 21l PC210 230 Approx 20 4l PC240 q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port to the specified level Let the oil...

Page 1021: ...50 Disassembly and assembly UEN00660 00 PC210 230 240 8 47...

Page 1023: ...8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 50 Disassembly and assembly1 Power train Power train 2 Removal and installation of final drive assembly 2 Disassembly and assembly of f...

Page 1024: ...d selector hose 2 the motor hose 3 and the drain hose 5 a PC210 8 PC210LC 8 PC210NLC 8 4 Temporarily hoist the final drive assembly 6 5 Remove 18 mounting bolts 7 and hoist final drive assembly 6 to r...

Page 1025: ...ng bolts 265 309 Nm 27 31 5 kgm Average torque 275 Nm or more 28 kgm or more q Refilling with oil Fill the power train oil TO30 via the oil filler port to the specified level Start the engine to circu...

Page 1026: ...Remove No 1 carrier assembly 3 2 Disassemble No 1 carrier assembly as follows 1 Insert pin 4 and drive shaft 5 out of carrier 6 a After removing the shaft remove pin 4 2 Remove thrust washer 7 gear 8...

Page 1027: ...No 2 carrier assembly 14 4 No 2 carrier assembly 35 kg 2 Remove thrust washer 15 3 Disassemble No 2 carrier assembly as follows 1 Insert pin 16 and drive shaft 17 out of carrier 18 a After removing t...

Page 1028: ...d remove from travel motor 2 Remove bearing 26 3 Remove bearing outer races 27 and 28 12 Remove floating seals 30 and 31 from travel motor 29 a The floating seal 30 may be on the hub assembly 25 13 Us...

Page 1029: ...er floating seal installation apply a thin coat of power train oil TO30 on the sliding surfaces 2 Install bearing 32 to travel motor 29 a Warm the inner race of the bearing 32 to 50 70 C with heater a...

Page 1030: ...size a under the condi tion described in 6 above 8 Measure thickness b off the inde pendent nut 24 9 Determine Calculate a b c 10 Use the tool J1 to tighten nut 24 until the following condition is met...

Page 1031: ...ry gear Take care so the thrust washer is not damaged 3 Insert pin 16 a When inserting the pin take care so that any of the three pawls on the circumference Portion f may not touch the thin walled por...

Page 1032: ...the pin holes on the shaft 5 and the carrier and install the shaft 5 by tapping it lightly with a plastic hammer a Install the shaft rotating the plan etary gear Take care so the thrust washer is not...

Page 1033: ...all cover 1 2 Cover mounting surface liquid gasket LG 6 3 Mounting bolts 98 123 Nm 10 12 5 kgm 15 Oil refill Tighten drain plug and fill power train oil TO30 from the oil filler port 5 Final drive cas...

Page 1034: ...4 No 1 carrier assembly 1 Remove No 1 carrier assembly 3 2 Disassemble No 1 carrier assembly in the following procedure 1 Drive pin 4 into pin 5 to remove pin 5 from carrier 6 a Remove pin 4 from pin...

Page 1035: ...No 2 sun gear 14 9 Washer Remove washer 15 10 No 2 carrier assembly 1 Remove No 2 carrier assembly 16 2 Disassemble No 2 carrier assembly in the following procedure 1 Drive pin 17 into pin 18 to remov...

Page 1036: ...ompletely and inspect them for any foreign material or damage Apply power train oil TO30 on the sliding surfaces before assembly 1 Travel motor assembly 1 Set floating seal 31 to the tool J5 a Install...

Page 1037: ...or any foreign material and then apply a thin coat of power train oil TO30 on it 2 Use an eyebolt 2 to set hub assembly 26 to travel motor a When hub assembly is difficult to install install it by lig...

Page 1038: ...orce 294 N or less 30 kg or less a If the tangential force starting force is not normal disassemble again to find the cause 8 Install lock 24 2 Mounting bolt Liquid adhesive LT 2 a Do not apply the li...

Page 1039: ...the pin hole to prevent the pin from coming out a When assembling of the No 2 carrier assembly is complete check that all gears rotate smoothly 2 Install No 2 carrier assembly 16 a Align the 4 lower...

Page 1040: ...a Replace pin with new one a Before inserting the pin check the orientation so that the 3 pawls h on the outer circumfer ence of the pin do not seat on the thin portion of the carrier a After inserti...

Page 1041: ...6 2 Use the tool J7 to tighten 20 mounting bolts 3 mounting bolts first time 147 Nm 15 kgm second time 85 95 rotating angle 13 Oil refill Tighten drain plug and fill power train oil TO30 from the oil...

Page 1042: ...ion tag to each piping to avoid a mistake in the position of installation later 1 Remove cover 1 2 Open engine hood 2 and remove cover 3 3 Disconnect hose 4 and 5 If equipped 4 Disconnect the bracket...

Page 1043: ...lift them a Lift them with full attention until surpass the hose of the center swivel joint 4 Swing motor and swing machinery Assembly 250 kg Installation q Installation is done in the reverse order o...

Page 1044: ...Assembly into block 1 2 Oil drain Loosen drain plug 39 and drain the oil inside the swing machinery case 1 6 Swing machinery case Approx 6 7l 3 Remove drain hose 1 4 Remove 6 pcs of the mounting bolt...

Page 1045: ...move plate 10 3 Reverse carrier 34 and remove snap ring 35 a PC210 8 PC210LC 8 PC210NLC 8 PC230 8 a PC240LC 8 PC240NLC 8 3 Using push tool 2 remove shaft 11 from carrier 34 q Input pin press reference...

Page 1046: ...ft remove pin 16 2 Remove thrust washer 19 gear 20 and bearing 21 3 Remove plate 22 a PC210 8 PC210LC 8 PC210NLC 8 PC230 8 a PC240LC 8 PC240NLC 8 11 Shaft and case Assembly 1 Reverse shaft and case As...

Page 1047: ...0LC 8 PC240NLC 8 13 Remove spacer 41 and O ring 42 from shaft 26 14 Remove bearing 31 from case 30 a Apply a suitable tool on the circumference of the outer race thick line Q section strike the tool o...

Page 1048: ...Outside perimeter of oil seal Gasket sealant LG 6 a When press fitting take care so that gas ket sealant LG 6 will not stick to the lip surface of the oil seal a If tool F3 is not used use the push t...

Page 1049: ...14 press fit inner race section of bearing 27 a Put in push tool 14 for the cases that the case Assembly is inclined a lot a If case Assembly 32 is inclined strike the flange section lightly and corr...

Page 1050: ...ign pin hole location of shaft 17 and career and install shaft 17 a Install the shaft rotating the plan etary gear Take care so the thrust washer is not damaged 5 Insert pin 16 a As inserting the pin...

Page 1051: ...the position illustrated in the following figure and then install it 3 mounting bolts 157 196Nm 16 20 kgm 9 Install O ring 37 a PC210 8 PC210LC 8 PC210NLC 8 PC230 8 a PC240LC 8 PC240NLC 8 10 No 1 car...

Page 1052: ...PC210 8 PC210LC 8 PC210NLC 8 PC230 8 a PC240LC 8 PC240NLC 8 2 Install No 1 carrier assembly 4 11 No 1 sun gear Assembly Install No 1 sun gear 3 a When installing the No 1 sun gear be careful not to in...

Page 1053: ...and convex portion of the case d section as mentioned in the drawing and install them c d Above mentioned a PC240LC 8 PC240NLC 8 q Align the relation between the positions of the motor port g section...

Page 1054: ...tion q Installation is done in the reverse order of removal 1 a Let the soft zone position S mark of an inner race a and the soft zone position S mark of an outer race b to be right side of the body a...

Page 1055: ...50 Disassembly and assembly UEN00661 00 PC210 230 240 8 33...

Page 1057: ...and up 50 Disassembly and assembly1 Under carriage and frame Under carriage and frame 2 Disassembly and assembly of carrier roller 2 Disassembly and assembly of track roller assembly 5 Disassembly and...

Page 1058: ...ove followings from carrier roller 1 q Roller 4 ring 5 assembly shaft 2 and cover 3 q Press fitting force reference 59 kN 6 000 kg Min a The press fitted shaft 2 and ring 5 and also roller 4 and cover...

Page 1059: ...g seal completely wash and de grease and dry both O ring and the surfaces where the O ring and the floating seal will contact each other hatched in the sketch And take care that there is no dust stick...

Page 1060: ...2 mm put washer 7 between push tool 6 and roller 4 then press fit ring 5 to shaft 2 a The thickness of washer 7 is 1 8 0 2 mm a Use push tool 5 to support shaft 2 on it 5 Using push tool 8 press fit c...

Page 1061: ...of oil is filled in drain it at this timing or underlay some cloth to pre vent any careless smearing 4 Pull out other side floating seal 6 from roller 4 shaft 5 and collar 8 assembly 5 Remove pin 7 a...

Page 1062: ...shown as a in the illustration falls within the range of 7 11 mm 4 Using tool L2 install floating seals 6b and 3b to roller 4 a As to notes for installation of floating seals 6b and 3b refer to a mark...

Page 1063: ...and idler 4 3 Detach idler the 4 from shaft 5 and support assembly 7 a Since 250cc of oil is filled in drain it at this timing or underlay some cloth to prevent any careless smearing 4 Remove floating...

Page 1064: ...assembly a Completely wash de grease and dry both O rings and the surfaces shown hatched in the illustration of floating seals where they contact each other a Coat the sliding surface of the floating...

Page 1065: ...other a Coat the sliding surface of the floating seal with oil and be careful not to let any dirt or dust get stuck to it a After inserting the floating seal verify that the inclination of the seal i...

Page 1066: ...pressure slowly and release the tension of the spring a Free length of spring 556 mm 3 Remove yoke 6 and cylinder 7 from spring 5 4 Remove snap ring 8 dust seal 9 and bushing 10 one after the other f...

Page 1067: ...er 7 and yoke 6 to spring 5 and set them to tool M1 2 Sliding portion of cylinder Grease G2 LI 5 Apply hydraulic pressure slowly to com press the spring and then tighten nut 4 so that the installed le...

Page 1068: ...1 between track frame and track shoe 3 Remove sprocket 2 sling as follows 1 Remove fixing bolt 1 1 a Before removing the final fixing bolt Place block 2 under sprocket 2 2 Put sprocket 2 on block 2 ma...

Page 1069: ...2 Locate master pin 2 at around the center of lower track shoes and between two track rollers 3 Set blocks 1 under both track shoes at idler and sprocket 4 Using tool R remove master pin 2 2 a Press...

Page 1070: ...bushing and the master pin shown hatched Grease Nigutaite LYK 2 from nihon grease co ltd part no 44392708 a When replacing dust seals apply some grease on the end surfaces of bushing and the contact s...

Page 1071: ...sembly referring to the Disassembling Work Equip ment Assembly section in this manual 3 Disconnect four boom cylinder hoses 1 a Plug the hose to stop oil flow out 4 Sling boom cylinder assembly 2 5 Re...

Page 1072: ...ear and left and right k When dismounting the revolving frame assembly take care so that it does not hit the center swivel joint assembly 4 Revolving frame assembly PC210 230 8 5 100kg PC240 8 5 500kg...

Page 1073: ...0 kgm PC240 1 180 1 470 Nm 120 150 kgm 2 a Installing and adjusting counterweight 1 Using shims adjust the differences in level or gaps between the counter weight and the exterior of body work a Shims...

Page 1075: ...ivel joint assembly 2 Disassembly and assembly of center swivel joint assembly 4 Removal and installation of hydraulic tank assembly 5 Removal and installation of control valve assembly 8 Disassembly...

Page 1076: ...from the travel motor q 1 Center swivel joint T port L H travel motor T port q 2 Center swivel joint T port R H travel motor T port q 3 Center swivel joint B port L H travel motor PA port q 4 Center s...

Page 1077: ...shows the machine body as seen from above a S Sprocket A D Port name q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port to the specified level Let the oil circulate i...

Page 1078: ...shaft 8 4 Set swivel shaft 8 to block then using push tool tap swivel rotor 7 with a plastic hammer to install 2 Contact surface of rotor shaft Grease G2 LI a When installing rotor be extremely caref...

Page 1079: ...to avoid a mistake in the position of installation later 1 Swing to right 45 degree For hydraulic tank oil drain 2 Remove cover 1 3 Drain hydraulic tank oil 1 6 Hydraulic tank Approx 234l PC210 230 Ap...

Page 1080: ...er a Hose band color Yellow 10 Disconnect filter bracket 11 11 Remove flame 12 12 Disconnect drain hose 13 through 18 q 13 Solenoid valve drain q 14 Main valve drain q 15 Pressure reducing valve drain...

Page 1081: ...th band BR is Min 5mm a Align the clamp to the original position 3 Clamp 20 22 Nm 2 0 2 2 kgm a Impact wrench is not applicable to use a When the tightening torque force is less than 16 Nm 1 6 kgm tig...

Page 1082: ...a For the way not to drain the hydraulic tank oil by using oil stopper see Removal and installation of hydraulic pump assembly 3 Disconnect drain hose 2 through 8 Band q 2 No color q 3 Red q 4 No colo...

Page 1083: ...ght swing Hose band no color R H travel forward Hose band green Arm digging Hose band blue 15 Disconnect hose 19 Hose band brown q 19 PST port hose solenoid 16 Disconnect hose 20 through 23 a Hose ban...

Page 1084: ...Between control valve and hydraulic tank a Reference rear figure 24 Disconnect hose 32 through 36 from the rear side q 32 PP1 port pump rear pump q 33 PPS2 port hose front pump Hose band blue q 34 PR...

Page 1085: ...the top A 1 port hose OPT A1 port hose bucket head side A2 port hose Swivel joint B port A3 port tube boom bottom side A4 port hose Swing motor MA port A5 port hose Swivel joint C port A6 port hose a...

Page 1086: ...ydraulic tank Refill hydraulic oil through the oil filler port to the specified level Let the oil circulate in the hydraulic system by starting the engine Then check the oil level again 5 Hydraulic ta...

Page 1087: ...the tool fitted to the piston Symbol Part number Part name Necessity Q ty N R Sketch T 2 796 946 1310 Guide 21 8 t 1 For 723 46 40100 796 946 1610 Guide 21 4 t 1 For 723 46 41100 796 946 1810 Guide 2...

Page 1088: ...ol T4 fitted to piston 2 for about one minutes so that seal 5 and 6 are adapted well a Check that there is no protrusion or cut on the seal 6 Assemble the piston in the sleeve a If it is found difficu...

Page 1089: ...assemble the control valve assembly q When assemble spool 7 and 8 to the valve chamber turn drill hole H1 and H2 to the direction as the diagram a In the same way for section H H K K L L M M q Filter...

Page 1090: ...q Tighten back pressure valve boom lock valve arm quick return valve arm check valve and mounting bolts in the same order as that for the control valve cover 3 Back pressure valve boom lock valve arm...

Page 1091: ...ntification tag to each piping to avoid a mistake in the position of installation later 1 Swing to right 45 degree For hydraulic tank oil drain 2 Remove hydraulic tank strainer and stop oil flow out u...

Page 1092: ...ct clamp 14 14 Remove filter and bracket assembly 15 a Put it on hose bracket HB 15 Disconnect six hoses q 16 Rear load pressure input port hose Color band No color q 17 18 EPC basic pressure port hos...

Page 1093: ...18 Drain oil from the damper case 6 Damper case Approx 0 65l 19 Disconnect pump wiring connectors at four points q 27 V12 PC EPC R solenoid valve Color band yellow q 28 P22 hydraulic oil temperature C...

Page 1094: ...Remove muffler bracket 34 24 Lift off hydraulic pump Ass y 35 to remove the mounting bolt 1 a Muffler drain tube 36 is double tightened PC210 230 8 PC240 8 25 Lift off hydraulic pump Ass y 37 to remov...

Page 1095: ...r case Refill hydraulic oil through the oil filler port to the specified level 5 Damper case EO30 CD Approx 0 65l q Refilling with oil hydraulic tank Refill hydraulic oil through the oil filler port t...

Page 1096: ...then remove spacer 2 3 Pry off oil seal 3 with a screwdriver 1 a Use care in removing the oil seal so that the shaft may not be damaged Installation q Installation is done in the reverse order of remo...

Page 1097: ...y 2 Piston 8 Grease G2 LI a When assembling piston 8 coat the piston outer periphery and body hole inner periphery with grease 3 Mounting bolt for plate 5 11 8 14 7Nm 1 2 1 5 kgm 2 Joint 4 sliding por...

Page 1098: ...G2 LI to the swaying part of shaft 6 the contact surfaces of lever 7 and piston 1 contact surfaces of damper 9 lever and pin 8 2 Applying quantity of grease G2 LI Swing part of shaft 6 4 8cc all aroun...

Page 1099: ...ize M12 x Pitch 1 75 Symbol Part number Part name Necessity Q ty N R Sketch U 1 790 502 1003 Cylinder repair stand q 1 790 101 1102 Pump q 1 2 790 102 4300 Wrench assembly t 1 790 102 4310 Pin t 2 3 7...

Page 1100: ...assem bly 4 q When not using tool U2 use the drill holes H 10 2 places and loosen piston assembly 4 Remove plunger q Boom and arm cylinder only 5 Remove collar 6 q Boom and arm cylinder only 6 Remove...

Page 1101: ...into position Warm it in warm water 50 60 C before installing it 1 Disassembly of recoil spring assembly 1 Using tool U5 press fit bushing 20 2 Assemble buffer ring 19 3 Assemble rod packing 18 4 Usi...

Page 1102: ...is a small amount of play at the tip of the plunger a Put a mark on the end face of the rod so that the processing hole position of cap 8 is visual from outside q Arm cylinder only 6 Assemble piston...

Page 1103: ...m a After tightening the piston check that there is play in plunger 5 q Boom arm cylinder only 2 Machine one of the hole used to install screw 3 a Align a drill horizontal with the V groove of the thr...

Page 1104: ...then insert a Check that the ring is not broken and has not come out then push in fully 9 Tighten head assembly 1 with mounting bolts 3 Mounting bolt Variable 2 pieces boom specification 10 Install pi...

Page 1105: ...3 4 spanner 2 Remove directional control valve 3 using 7 8 spanner q In case of malfunction of the coil or the direc tional control valve replace them as complete units INSTALLATION q Install in rever...

Page 1107: ...LC 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 50 Disassem...

Page 1108: ...er as well as locations of the shims used 7 Start the engine and then retract the piston rod a Bind the piston rod with wire etc and put it down the blocking tools so that the piston rod does not slip...

Page 1109: ...nstallation is done in the reverse order of removal 1 q Demolition spec a When tightening the locknut make sure that 0 5 1 5 mm clearance is maintained between the plate and nut after the tightening 2...

Page 1110: ...clearance c between the foot s end face of boom 13 and bracket 14 to 1 mm or less by use of shims Thickness of standard shim 2 0 2 5 3 0 and 3 5 mm q Air bleeding Bleed the air from the circuit betwe...

Page 1111: ...50 Disassembly and assembly UEN00664 00 PC210 230 240 8 5...

Page 1113: ...0001 and up PC210NLC 8 K50001 and up PC230NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 50 Disassembly and assembly1 Cab related Cab related 2 Removal and installation of operat...

Page 1114: ...ve floor mat 3 4 Refer to Removal and installation of monitor assembly and remove monitor assembly 4 5 Remove cover 5 and 6 6 Remove cover duct assembly 7 7 Insert key 8 turn it right and open the out...

Page 1115: ...connector M10 27 from the opera tor s cab If equipped 21 Disconnect cab wiring intermediate connectors H09 28 H08 29 and H16 30 a Cut tie wrap T 22 Disconnect radio antenna 31 23 Remove ducts 32 and 3...

Page 1116: ...k plate 43 1 33 Remove bolt 44 2 34 Dismount 6 mounting bolts 45 and mounting nuts 46 a Check the bolt length beforehand 35 Lift off and remove operator s cab assembly 47 4 Operator s cab assembly 470...

Page 1117: ...eplacing front window glass 4 remove front window assembly 5 It is impossible to replace only the front window glass while the front window assembly is installed to the opera tor s cab a For the proce...

Page 1118: ...3 etc or hold them by winding them onto something and move the wire to the right and left to cut the adhesive and dam rubber Since the wire may be broken by the fric tional heat apply lubricant to the...

Page 1119: ...f manufacture Do not use the primer after this limit a Use the primer within 2 hours after un packing it a Even if the primer is packed again just after it is unpacked use it within 24 hours after it...

Page 1120: ...etc is applied by mistake wipe it off with white gasoline 4 Apply the glass primer to the sticking sur faces of window glass 9 2 Glass primer Sunstar primer for glass 580 super a Do not apply the pri...

Page 1121: ...uld be taken to not to float the dam rubber of each sticking cor ner a When sticking dam rubber 6 around a frame do not lap its finishing end over the starting end Or make clearance of about 5mm betwe...

Page 1122: ...inside it will be seen through the transparent part of the glass 5 Position the new window glass 1 Check the clearance between the window glass and the operator s cab on the right left upper and lower...

Page 1123: ...ne seal 580 super W a The using limit of the adhesive is 4 months after the date of manufacture Do not use the adhesive after this limit a Keep the adhesive in a dark place where the temperature is be...

Page 1124: ...evenly with same height level a Apply adhesive 15 additionally to additional dam rubber 6a of right side window glass and additional dam rubber 6b of door lower window glass 7 Install the window glass...

Page 1125: ...er trim seal 16 with caulking mate rial in range s with dimensions t and u After applying the primer to glass 4 of section A A apply the adhesive as caulking material q Caulking dimension t 2 mm q Cau...

Page 1126: ...the window glass remove any excess of the primer and adhesive from the operator s cab and window glass a By using the white gasoline wipe off the adhesive before it is dried up a When cleaning the gla...

Page 1127: ...eft corner block are used to hang the pull up assist cable in the following step 6 3 Release the rear lock of the cab 4 Lower the front window assembly carefully a little Put out rollers 5 and 6 under...

Page 1128: ...though the rail opening portion and lower it gradually 8 Lower front window assembly 10 completely a Do not let the front window assembly touch the monitor 9 Twist front window assembly 13 to the rig...

Page 1129: ...ise the front window assembly and fix it with the rear locks on both sides a Check that the locks in the rear of the operator s cab are securely fastened 4 Install right corner block 2 a Fully tighten...

Page 1130: ...ight and left locks 16 and 17 do not work normally 1 Loosen lock fitting bolt 18 move lock 16 forward and then tighten the bolt again a The same applies to the right side 2 After moving the lock reche...

Page 1131: ...switch works a Limit switch 19 is used to prevent the windshield wiper from moving when turning the wiper switch on by mistake when the front window assembly is in Open position If the wiper operates...

Page 1132: ...One turn of rubber stopper 18 to the left is equivalent to squashing the rubber for approxi mately 1 5 mm a When the front window assembly is in Open position the front window assembly must be push in...

Page 1133: ...y 1 After finishing the adjustment of steps 6 9 check that latching efforts of both right and left locks 16 and 17 are even a Check the latching efforts on both Close side in the front of the opera to...

Page 1134: ...r structure by 90 degrees 2 Drain the engine cooling water 6 Coolant Approx 21l PC210 230 Approx 20 4l PC240 3 Remove the operator s cab assembly by refer ring Removal and installation of operator s c...

Page 1135: ...ct hose 19 a Check the connecting point a Plug the hose to stop oil flow out a Disconnect the work equipment PPC at joint box side 17 Disconnect hose 20 a Check the connecting point a Plug the hose to...

Page 1136: ...move cover 38 32 Disconnect clamp 39 33 Disconnect PPC hose 40 of the work equip ment From the top the color of the band is White Brown None Blue Black Green Red Yellow a Prepare an oil sump 34 Pull o...

Page 1137: ...ing connector of the air condi tioner hose a Check that there is no defect or deterioration on the O ring a When connecting the refrigerant piping coat the O ring with compressor oil for new refriger...

Page 1139: ...0NHD 8 K50001 and up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 50 Disassembly and assembly1 Electric components Electric components 2 Removal and installation of air conditioner unit assembly 2...

Page 1140: ...134a k If the air conditioner gas R134a gets inside one s eyes it may cause blindness Therefore make sure to wear protective glasses when collecting or filling the gas Collecting and filling work must...

Page 1141: ...ck pin 18 and remove duct 19 15 Remove ducts 20 and 21 a Cut tie wrap 16 Remove ducts 22 and 23 a Cut tie wrap 17 Remove duct 24 upper and lower 18 Remove duct 25 upper and lower 19 Disconnect plate 2...

Page 1142: ...ioner circuit hoses use care so that dirt water may not enter a Make sure before the installation that there is O ring at the piping connector of the air condi tioner hose a Check that there is no def...

Page 1143: ...y discon nect switch and take out the disconnect key For machine with no battery disconnect switch Cut off power wait for approx one minute after turning off the engine starting key and then disconnec...

Page 1144: ...d then disconnect the negative ter minal of the battery 1 Remove cap 1 2 Remove cover 2 and then disconnect wiring connector P31 3 for air conditioner sunlight sensor S 3 Remove duct 4 4 Remove cover...

Page 1145: ...40 8 7 Installation 1 2 1 Temporary install monitor assembly 6 with 4 mounting bolts and then install cover 5 2 With cover 5 installed tighten the mounting bolts of monitor assembly q Carry out the re...

Page 1146: ...y disconnect switch Cut off power wait for approx one minute after turning off the engine starting key and then disconnect the negative ter minal of the battery 1 Remove cover 1 2 Disconnect relay R08...

Page 1147: ...he negative ter minal of the battery 1 Turn the upper structure by 90 degrees 2 Remove cover 1 3 Open the engine hood 4 Disconnect connectors CE02 2 and 3 from the engine controller a The connector is...

Page 1148: ...UEN00666 01 50 Disassembly and assembly 10 PC210 230 240 8 2 Remove O ring 7 with tweezers 1...

Page 1149: ...50 Disassembly and assembly UEN00666 01 PC210 230 240 8 11...

Page 1151: ...up PC240LC 8 K50001 and up PC240NLC 8 K50001 and up 90 Diagrams and drawings 1 Hydraulic diagrams and drawings Hydraulic diagrams and drawings for PC210 K50001 K51094 PC230 K50001 K50113 and PC240 K5...

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Page 1153: ...3 UEN00112 03 Hydraulic diagrams and drawings for PC210 K50001 K51094 PC230 K50001 K50113 and PC240 K50001 K50303 1 Hydraulic circuit diagram 1 2 1...

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Page 1155: ...5 UEN00112 03 Hydraulic circuit diagram 2 2 1...

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Page 1157: ...7 UEN00112 03 Hydraulic diagrams and drawings For PC210 K51095 and up PC230 K50114 and up and PC240 K50304 and up 1 Hydraulic circuit diagram 1 2 1...

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Page 1161: ...UEN00112 03 PC210 230 240 8 11...

Page 1163: ...0001 K51094 PC230 K50001 K50113 and PC240 K50001 K50303 3 Electrical circuit diagram 1 5 3 Electrical circuit diagram 2 5 5 Electrical circuit diagram 3 5 7 Electrical circuit diagram 4 5 9 Electrical...

Page 1164: ...1 5 23 Electrical circuit diagram 2 5 25 Electrical circuit diagram 3 5 27 Electrical circuit diagram 4 5 29 Electrical circuit diagram 5 5 31 Connector arrangement diagram 33 Electrical circuit diag...

Page 1165: ...UEN00113 04 3 Electrical diagrams and drawings for PC210 K50001 K51094 PC230 K50001 K50113 and PC240 K50001 K50303 Electrical circuit diagram 1 5...

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Page 1175: ...UEN00113 04 13 Electrical diagrams and drawings For PC210 K51095 K52292 PC230 K50114 K50200 and PC240 K50304 K50595 Electrical circuit diagram 1 5...

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Page 1185: ...UEN00113 04 23 Electrical diagrams and drawings for PC210 K52293 and up PC230 K50201 and up and PC240 K50596 and up Electrical circuit diagram 1 5...

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Summary of Contents for PC210-8

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Komatsu PC210-8, Shop Manual

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Summary of Contents for PC210-8

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