Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

UEN00084-07 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Shop Manual.pdf
UEN00084 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Shop Manual.pdf
SEAM02050307 - Hydraulic Excavator PC200-3, PC210-3, PC220-3, PC240-3, PC280-3 Operation & Maintenance Manual.pdf
UEAM004904 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Operation & Maintenance Manual.pdf
UEAM004912 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 3,330 pages
File Format: PDF
Language: English

SEAM02050307 - Hydraulic Excavator PC200-3, PC210-3, PC220-3, PC240-3, PC280-3 Operation & Maintenance Manual...2
UEAM004904 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Operation & Maintenance Manual...83
  FOREWORD...85
    FOREWORD...86
    SAFETY INFORMATION...87
      NOISE (PC210,210LC,210NLC, PC230NHD)...89
      NOISE (PC240LC,240NLC)...90
      Vibration levels...91
        Guide to Reduce Vibration Levels on Machine...91
    INTRODUCTION...93
      DIRECTIONS OF MACHINE...93
      BREAKING-IN THE NEW MACHINE...94
    PRODUCT INFORMATION...95
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...95
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...95
      SERVICE METER LOCATION...96
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...96
      MACHINE SERIAL PLATES...97
        STANDARD SERIAL PLATE...97
      FOREWORD...98
      SAFETY...98
      OPERATION...100
      MAINTENANCE...102
      SPECIFICATIONS...104
      ATTACHMENTS AND OPTIONS...105
      SUPER LONG FRONT BOOM AND ARM PC210/240-8...107
      INDEX...108
      COLOPHON...108
  SAFETY...109
    SAFETY INFORMATION...110
    SAFETY LABELS...112
      LOCATION OF SAFETY LABELS...112
      SAFETY LABELS...113
    SAFETY INFORMATION...120
      SAFETY RULES...120
      IF PROBLEMS ARE FOUND...120
      WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...120
      FIRE EXTINGUISHER AND FIRST AID KIT...120
      SAFETY EQUIPMENT...121
      KEEP MACHINE CLEAN...121
      KEEP OPERATOR'S COMPARTMENT CLEAN...121
      LEAVING OPERATOR'S SEAT WITH LOCK...121
      HANDRAILS AND STEPS...122
      MOUNTING AND DISMOUNTING...123
      NO PERSONS ON ATTACHMENTS...123
      DO NOT GET CAUGHT IN ARTICULATED PORTION...123
      BURN PREVENTION...123
      ACTION IF FIRE OCCURS...125
      WINDSHIELD WASHER FLUID...125
      FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...125
      ATTACHMENT INSTALLATION...125
      ATTACHMENT COMBINATIONS...126
      CAB WINDOW GLASSES...126
      UNAUTHORIZED MODIFICATIONS...126
      SAFETY AT JOBSITE...126
      WORKING ON LOOSE GROUND...126
      DISTANCE TO HIGH VOLTAGE CABLES...127
      ENSURE GOOD VISIBILITY...127
      VENTILATION FOR ENCLOSED AREA...128
      SIGNALMAN'S SIGNAL AND SIGNS...128
      EMERGENCY EXIT FROM OPERATOR'S CAB...128
      ELECTROMAGNETIC INTERFERENCE...128
      ASBESTOS DUST HAZARD PREVENTION...129
    SAFETY MACHINE OPERATION...130
      STARTING ENGINE...130
        CHECKS BEFORE STARTING ENGINE...130
        SAFETY RULES FOR STARTING ENGINE...131
        STARTING ENGINE IN COLD WEATHER...131
      OPERATION...132
        CHECKS BEFORE OPERATION...132
        SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...132
        SAFETY RULES FOR TRAVELLING...133
        TRAVELLING ON SLOPES...134
        OPERATIONS ON SLOPES...135
        PROHIBITED OPERATIONS...135
        OPERATIONS ON SNOW...137
        PARKING MACHINE...137
      TRANSPORTATION...138
        LOADING AND UNLOADING...138
        SHIPPING THE MACHINE...139
      BATTERY...140
        STARTING ENGINE WITH BOOSTER CABLES...141
      TOWING...142
        SAFETY RULES FOR TOWING...142
      LIFTING OBJECTS WITH BUCKET...143
        SAFETY RULES FOR LIFTING OBJECTS...143
    SAFETY MAINTENANCE INFORMATION...144
      WARNING TAG...144
      KEEP WORK PLACE CLEAN AND TIDY...144
      APPOINT LEADER WHEN WORKING WITH OTHERS...144
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...145
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...146
      PROPER TOOLS...146
      ACCUMULATOR...147
      HANDLING GAS SPRING...147
      PERSONNEL...148
      ATTACHMENTS...148
      WORK UNDER THE MACHINE...148
      NOISE...149
      WHEN USING HAMMER...149
      WELDING WORKS...149
      REMOVING BATTERY TERMINALS...149
      SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...150
      DO NOT DISASSEMBLE RECOIL SPRINGS...150
      SAFETY RULES FOR HIGH-PRESSURE OIL...150
  OPERATION...153
    MACHINE VIEW ILLUSTRATIONS...154
      OVERALL MACHINE VIEW...154
      CONTROLS AND GAUGES...155
    DETAILED CONTROLS AND GAUGES...156
      MONITORING SYSTEM...156
        Basic Operation of Machine Monitor...157
        Basic Check Monitors...161
        Caution Monitors...163
        Emergency Monitors...166
        Meter Display Portion...168
        Monitor Switches Portion...175
        Handling Function Switches...184
      SWITCHES...220
      CONTROL LEVERS AND PEDALS...225
      CEILING WINDOW...228
      WINDSHIELD...228
      EMERGENCY ESCAPE HAMMER...234
      DOOR LOCK...234
      CAP WITH LOCK...235
      DRINK BOX...237
      MAGAZINE BOX...237
      ASHTRAY...237
      AIR CONDITIONER CONTROLS...238
        Air Conditioner Control Panel...238
        Method of Operation...243
        Use Air Conditioner with Care...250
        Air Conditioner Maintenance...250
      RADIO...251
        Control Panel...251
        Controls of Radio...253
        Use Radio with Care...255
        Space for radio cassette...255
      AUXILIARY ELECTRIC POWER...256
        24V power source...256
        12V power source...256
      FUSE...257
      FUSIBLE LINK...258
      CONTROLLER...258
      TOOL BOX...258
      GREASE GUN HOLDER...258
    MACHINE OPERATIONS AND CONTROLS...259
      BEFORE STARTING ENGINE...259
        Walk-around Checks...259
      REFUELLING PUMP...260
        Checks Before Starting...261
        Adjustment...268
        Seat Belt...272
        Operations Before Starting Engine...273
      STARTING ENGINE...275
      AFTER STARTING ENGINE...278
        Warming Up Engine...279
        Warming Up Hydraulic Equipment...281
        Operation After Completion Of Warming-Up Operation...287
      STOPPING THE ENGINE...289
      MACHINE OPERATION...290
        Preparations for Moving the Machine...290
        Moving Machine Forward...291
        Moving Machine Backward...292
        Stopping Machine...293
      STEERING THE MACHINE...294
        Steering...294
      SWINGING...296
      WORK EQUIPMENT CONTROLS AND OPERATIONS...297
      WORKING MODE...299
      PROHIBITED OPERATIONS...301
      GENERAL OPERATION INFORMATION...303
      TRAVELLING ON SLOPES...305
      ESCAPE FROM MUD...307
        Track on One Side Stuck...307
        Tracks on Both Sides Stuck...307
      RECOMMENDED APPLICATIONS...308
        Backhoe Work...308
        Shovel Work...308
        Ditching Work...308
        Loading Work...309
      BUCKET REPLACEMENT AND INVERSION...310
        Replacement...310
        Inversion...312
      PARKING MACHINE...313
      CHECK AFTER SHUT OFF ENGINE...315
      MACHINE INSPECTION AFTER DAILY WORK...315
      LOCKING...315
    TRANSPORTATION...316
      TRANSPORTATION PROCEDURE...316
      SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-8 AND PC230NHD-8...316
      LOADING AND UNLOADING WITH TRAILER...318
        Loading...319
        Securing Machine...322
        Unloading...326
      LIFTING MACHINE...328
    COLD WEATHER OPERATION...330
      COLD WEATHER OPERATION INFORMATION...330
        Fuel and Lubricants...330
        Cooling System Coolant...330
        Battery...331
      AFTER DAILY WORK COMPLETION...332
      AFTER COLD WEATHER SEASON...332
    LONG TERM STORAGE...333
      BEFORE STORAGE...333
      DURING STORAGE...333
      AFTER STORAGE...334
      STARTING MACHINE AFTER LONG-TERM STORAGE...334
    TROUBLES AND ACTIONS...335
      RUNNING OUT OF FUEL...335
      PHENOMENA THAT ARE NOT FAILURES...335
      TOWING THE MACHINE...336
      LIGHTWEIGHT TOWING HOLE...337
      SEVERE JOB CONDITION...337
      DISCHARGED BATTERY...338
        Battery Removal and Installation...338
        Battery Charges...339
        Starting Engine with Booster Cables...340
      OTHER TROUBLE...342
        Electrical System...342
        Chassis...343
        Engine...344
        Electronic Control System...346
        Point of Contact to Telephone when Error Occurs...346
  MAINTENANCE...347
    MAINTENANCE INFORMATION...348
    OUTLINE OF SERVICE...351
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...351
        OIL...351
        FUEL...352
        COOLANT AND WATER FOR DILUTION...352
        GREASE...353
        CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...353
        STORING OIL AND FUEL...354
        FILTERS...354
      EXPLANATION OF LUBRICATION CHART DECAL...355
      ELECTRIC SYSTEM MAINTENANCE...357
    WEAR PARTS...358
      WEAR PARTS LIST...358
    RECOMMENDED FUEL, COOLANT, AND LUBRICANT...359
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...361
    TIGHTENING TORQUE SPECIFICATIONS...362
      TIGHTENING TORQUE LIST...362
    SAFETY CRITICAL PARTS...363
      SAFETY CRITICAL PARTS LIST...363
    MAINTENANCE SCHEDULE...364
      MAINTENANCE SCHEDULE CHART...364
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...366
    MAINTENANCE PROCEDURE...367
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...367
      INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)...367
      WHEN REQUIRED...368
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...368
        CLEAN INSIDE OF COOLING SYSTEM...373
        CHECK AND TIGHTEN TRACK SHOE BOLTS...376
        CHECK AND ADJUST TRACK TENSION...377
        REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...379
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...382
        ADJUST BUCKET CLEARANCE...383
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...384
        CHECK AND MAINTENANCE AIR CONDITIONER...385
        WASH WASHABLE FLOOR...386
        BLEEDING AIR FROM HYDRAULIC SYSTEM...389
      CHECK BEFORE STARTING...391
      EVERY 100 HOURS MAINTENANCE...392
        LUBRICATING...392
      EVERY 250 HOURS MAINTENANCE...394
        CHECK LEVEL OF BATTERY ELECTROLYTE...394
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...396
      EVERY 500 HOURS MAINTENANCE...397
        LUBRICATING...397
        LUBRICATE SWING CIRCLE...398
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...399
        REPLACE FUEL PRE-FILTER CARTRIDGE...401
        CHECK SWING PINION GREASE LEVEL, ADD GREASE...403
        CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...404
        CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...406
        REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...407
        CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...408
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...409
      EVERY 1000 HOURS MAINTENANCE...410
        REPLACE HYDRAULIC OIL FILTER ELEMENT...410
        CHANGE OIL IN SWING MACHINERY CASE...411
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...412
        REPLACE FUEL MAIN FILTER CARTRIDGE...413
        CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...414
        REPLACE CORROSION RESISTOR CARTRIDGE...415
        CHECK FAN BELT TENSION AND REPLACE FAN BELT...415
        CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)...415
      EVERY 2000 HOURS MAINTENANCE...416
        CHANGE OIL IN FINAL DRIVE CASE...416
        CLEAN HYDRAULIC TANK STRAINER...417
        CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...418
        CHECK ALTERNATOR, STARTING MOTOR...421
        CHECK ENGINE VALVE CLEARANCE, ADJUST...421
      EVERY 4000 HOURS MAINTENANCE...422
        CHECK WATER PUMP...422
        CHECK VIBRATION DAMPER...422
        REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...423
        CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER...424
        CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...424
        CHECK OPERATING CONDITION OF COMPRESSOR...425
      EVERY 5000 HOURS MAINTENANCE...426
        CHANGE OIL IN HYDRAULIC TANK...426
      EVERY 8000 HOURS MAINTENANCE...427
        REPLACE FUEL SPRAY PREVENTION CAP...427
        REPLACE HIGH-PRESSURE PIPING CLAMP...427
  SPECIFICATIONS...429
    SPECIFICATIONS...430
      MONOBOOM WORKING RANGE...432
      PC210-8 WORKING RANGE (2-PIECE BOOM)...434
      PC230-8 WORKING RANGE (2-PIECE BOOM)...434
      PC240-8 WORKING RANGE (2-PIECE BOOM)...434
      EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC, PC210NLC, PC230NHD-8...436
        PC210-8...437
        PC210LC-8...438
        PC210NLC-8...439
        PC230NHD-8...440
      EXPLANATION OF LIFTING CAPACITY CHART PC240LC, PC240NLC-8...441
        PC240LC-8...442
        PC240NLC-8...443
      EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC, PC210NLC-8, pc230nhd-8 2 PIECE BOOM...444
        PC210-8...445
        PC210LC-8...446
        PC210NLC-8...447
        PC230NHD-8...448
      EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-8 2 PIECE BOOM)...449
      PC240LC-8, PC240NLC-8 2 PIECE BOOM...450
  ATTACHMENTS AND OPTIONS...453
    GENERAL PRECAUTIONS FOR SAFETY...454
      PRECAUTIONS WHEN SELECTING...454
      READ THE INSTRUCTION MANUAL THOROUGHLY...454
      PRECAUTIONS WHEN REMOVING OR INSTALLING...454
      PRECAUTIONS WHEN USING...455
    HYDRAULIC QUICK COUPLER PIPING...456
      LOCATIONS...456
      OPERATION...457
    BUCKET WITH HOOK...459
      HOOK CONDITION...459
      PROHIBITED OPERATIONS...459
    MACHINE READY FOR ATTACHMENT...460
      LOCATIONS...460
      HYDRAULIC CIRCUIT...465
        Switching Hydraulic Circuit...465
        Adjusting Oil Flow...465
        Switching Between Breaker and General Attachment...465
        Hydraulic Circuit Connection...466
        Oil Flow Path...467
        Replace Additional Breaker Filter Element...468
        Replace Additional Breaker Pilot Filter Element...470
      ATTACHMENT REMOVAL AND INSTALLATION...472
        Attachment Removal...472
        Attachment Installation...474
      ATTACHMENT OPERATIONS...476
        When Using Breaker...476
        When Using General Attachment Such as Crusher...478
      LONG TERM STORAGE...479
      SPECIFICATIONS...479
    ATTACHMENT GUIDE...480
      COMBINATIONS OF WORK EQUIPMENT...480
      SELECTION OF TRACK SHOES...483
        METHOD OF SELECTING SHOES...483
      SELECTION OF BUCKET TEETH...484
        METHOD OF SELECTING TEETH...484
      STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH...484
      HANDLING OF RUBBER PAD SHOE AND ROAD LINER...485
        Working Environment...485
        Working Conditions...485
        Storage and Maintenance...486
        Extent of Damage to Rubber...486
        Check Road Liner...486
        Replace Road Liner...486
      TRAPEZOIDAL BUCKET...487
      HANDLING EXTENSION ARM...488
      HANDLING CLAMSHELL BUCKET...489
        CONTROLS (AUXILIARY HYDRAULIC CIRCUITS)...490
        CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING...491
        CRUSHER CONTROL PEDAL FOR ROTATION...492
    RECOMMENDED ATTACHMENT OPERATIONS...493
      HYDRAULIC BREAKER...493
    PC210/230-8 2-PC BOOM...498
      FEATURES OF 2-PIECE BOOM & ARM...498
      OPERATION...498
        BEFORE STORAGE POSTURE WHEN LEAVING MACHINE...500
        Lifting...500
        TESTING AND ADJUSTING...501
        PERODIC MAINTENANCE...501
      TRANSPORTATION...502
      LUBRICATING...503
        Every 500 Hours...503
    PC240-8 2-PC BOOM...504
      FEATURES OF 2-PIECE BOOM & ARM...504
      OPERATION...505
        TESTING AND ADJUSTING...507
      TRANSPORTATION...508
    PC240-8 STRAIGHT BOOM...509
      GENERAL VIEW OF MACHINE...509
      CAUTION ITEMS...509
      CONTROL (AUXILIARY HYDRAULIC CIRCUITS)...510
      CRUSHER CONTROL PEDAL FOR OPENING AND CLOSING...511
      CRUSHER CONTROL BUTTON FOR ROTATION...512
      CEILING WINDOW WIPER SWITCH (3)...513
      WORKING RANGE (PC 240 STRAIGHT BOOM)...514
      TRANSPORTATION (Straight Boom equipment)...515
    HANDLING MACHINES EQUIPPED WITH KOMTRAX...516
      BASIC PRECAUTIONS...516
  SUPER LONG FRONT BOOM AND ARM PC210/240-8...517
    OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM...518
      WORKING MODES...519
        CHECKS BEFORE STARTING...520
        USING SUPER LONG FRONT...521
        METHOD OF WORK...522
        WHEN TRAVELLING...522
      CONTROL LEVERS, PEDALS...523
      ‘WEEDCUTTER’ MACHINE CONTROL LEVERS, PEDALS...526
        RIGHT CONTROL LEVER BUTTONS (5 & 6)...526
        LEFT WORK EQUIPMENT CONTROL LEVER (7 & 8)...527
        ATTACHMENT FLOW SELECTOR (9)...528
      TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE...529
        INSTALLATION OF SUPPORTING LINK...529
        TRANSPORTATION OF SUPER LONG FRONT MACHINE...530
      WORKING RANGE OF SUPER LONG FRONT...531
      LIFTING CAPACITY PC210 LC 15 m SUPER LONG FRONT...532
      LIFTING CAPACITY PC210 NLC 15 m SUPER LONG FRONT...533
      LIFTING CAPACITY PC240 LC 18 m SUPER LONG FRONT...534
      LIFTING CAPACITY PC240 NLC 18 m SUPER LONG FRONT...535
    MAINTENANCE...536
      SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT...536
      EVERY 50 HOURS SERVICE...537
        LUBRICATING...537
      EVERY 100 HOURS SERVICE...538
        LUBRICATING...538
  INDEX...541
    Numerics...543
    <A>...543
    <B>...543
    <C>...543
    <D>...543
    <E>...543
    <F>...543
    <G>...543
    <H>...543
    <I>...543
    <K>...543
    <L>...543
    <M>...543
    <N>...544
    <O>...544
    <P>...544
    <R>...544
    <S>...544
    <T>...544
    <V>...544
    <W>...544
    <Y>...544
  COLOPHON...545
UEAM004912 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Operation & Maintenance Manual...547
  FOREWORD...549
    FOREWORD...550
    SAFETY INFORMATION...551
      NOISE (PC210,210LC,210NLC, PC230NHD)...553
      NOISE (PC240LC,240NLC)...554
      Vibration levels...555
        Guide to Reduce Vibration Levels on Machine...555
    INTRODUCTION...557
      DIRECTIONS OF MACHINE...557
      OPERATOR PROTECTIVE STRUCTURE...557
      VISIBILITY FOR OPERATOR...557
      BREAKING-IN THE NEW MACHINE...558
    PRODUCT INFORMATION...559
      PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...559
      ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...559
      SERVICE METER LOCATION...560
      TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...560
      MACHINE SERIAL PLATES...561
        SERIAL PLATE (WHERE FITTED)...561
      DECLARATION OF CONFORMITY...562
      FOREWORD...563
      SAFETY...563
      OPERATION...565
      MAINTENANCE...568
      SPECIFICATIONS...570
      ATTACHMENTS AND OPTIONS...571
      SUPER LONG FRONT BOOM AND ARM PC210/240-8...573
      PC240LC/NLC-8 HIGH REACH DEMOLITION...573
      INDEX...574
      COLOPHON...574
  SAFETY...575
    SAFETY INFORMATION...576
    SAFETY LABELS...578
      LOCATION OF SAFETY LABELS...578
      SAFETY LABELS...579
    SAFETY INFORMATION...590
      SAFETY RULES...590
      IF PROBLEMS ARE FOUND...590
      WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...590
      FIRE EXTINGUISHER AND FIRST AID KIT...590
      SAFETY EQUIPMENT...591
      KEEP MACHINE CLEAN...591
      KEEP OPERATOR'S COMPARTMENT CLEAN...591
      LEAVING OPERATOR'S SEAT WITH LOCK...591
      HANDRAILS AND STEPS...592
      MOUNTING AND DISMOUNTING...593
      LIFTING OF PERSONNEL PROHIBITED...593
      NO PERSONS ON ATTACHMENTS...593
      DO NOT GET CAUGHT IN ARTICULATED PORTION...593
      BURN PREVENTION...593
      ACTION IF FIRE OCCURS...595
      WINDSHIELD WASHER FLUID...595
      PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES...595
      FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...596
      ACTIONS IN THE EVENT OF DAMAGE TO SAFETY STRUCTURES...597
      ATTACHMENT INSTALLATION...597
      ATTACHMENT COMBINATIONS...597
      CAB WINDOW GLASSES...597
      UNAUTHORIZED MODIFICATIONS...597
      SAFETY AT JOBSITE...598
      WORKING ON LOOSE GROUND...598
      DISTANCE TO HIGH VOLTAGE CABLES...598
      ENSURE GOOD VISIBILITY...599
      VENTILATION FOR ENCLOSED AREA...600
      SIGNALMAN'S SIGNAL AND SIGNS...600
      EMERGENCY EXIT FROM OPERATOR'S CAB...600
      ELECTROMAGNETIC INTERFERENCE...600
      ASBESTOS DUST HAZARD PREVENTION...601
    SAFETY MACHINE OPERATION...602
      STARTING ENGINE...602
        CHECKS BEFORE STARTING ENGINE...602
        SAFETY RULES FOR STARTING ENGINE...603
        STARTING ENGINE IN COLD WEATHER...603
      OPERATION...604
        CHECKS BEFORE OPERATION...604
        SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...604
        SAFETY RULES FOR TRAVELLING...605
        TRAVELLING ON SLOPES...606
        OPERATIONS ON SLOPES...607
        PROHIBITED OPERATIONS...607
        OPERATIONS ON SNOW...609
        PARKING MACHINE...609
      TRANSPORTATION...610
        LOADING AND UNLOADING...610
        SHIPPING THE MACHINE...611
      Turn off the battery disconnect switch to the OFF position...612
      BATTERY...612
        STARTING ENGINE WITH BOOSTER CABLES...613
      TOWING...614
        SAFETY RULES FOR TOWING...614
      LIFTING OBJECTS WITH BUCKET LINK LIFTING DEVICE (OPTIONAL EQUIPMENT)...615
        SAFETY RULES FOR LIFTING OBJECTS...615
      LIFTING OBJECTS WITH BUCKET...617
        SAFETY RULES FOR LIFTING OBJECTS...617
    SAFETY MAINTENANCE INFORMATION...618
      WARNING TAG...618
      KEEP WORK PLACE CLEAN AND TIDY...618
      STABILITY...618
      GUARDS...618
      END OF SERVICE LIFE...618
      APPOINT LEADER WHEN WORKING WITH OTHERS...619
      STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...619
      TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...620
      PROPER TOOLS...620
      ACCUMULATOR...621
      HANDLING GAS SPRING...621
      PERSONNEL...622
      ATTACHMENTS...622
      WORK UNDER THE MACHINE...622
      NOISE...623
      WHEN USING HAMMER...623
      WELDING WORKS...623
      REMOVING BATTERY CABLES (for machines not fitted with battery disconnect switch only)...623
      SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...624
      DO NOT DISASSEMBLE RECOIL SPRINGS...624
      SAFETY RULES FOR HIGH-PRESSURE OIL...624
  OPERATION...627
    MACHINE VIEW ILLUSTRATIONS...629
      OVERALL MACHINE VIEW...629
      CONTROLS AND GAUGES...630
    DETAILED CONTROLS AND GAUGES...632
      MONITORING SYSTEM...632
        Basic Operation of Machine Monitor...633
        Basic Check Monitors...637
        Caution Monitors...639
        Emergency Monitors...642
        Meter Display Portion...644
        Monitor Switches Portion...651
        Handling Function Switches...660
        Attachment 2 Setting...682
      SWITCHES...700
        Quick Coupler Switches...704
      DIESEL PARTICULATE FILTER (DPF) MONITOR...706
      CONTROL LEVERS AND PEDALS...708
      CEILING WINDOW...711
      WINDSHIELD...711
      EMERGENCY ESCAPE HAMMER...717
      DOOR LOCK...717
      CAP WITH LOCK...718
      DRINK BOX...720
      MAGAZINE BOX...720
      ASHTRAY...720
      AIR CONDITIONER CONTROLS...721
        Air Conditioner Control Panel...721
        Method of Operation...726
        Use Air Conditioner with Care...733
        Air Conditioner Maintenance...733
        Battery Disconnect Switch...734
      RADIO...735
        Control Panel...735
        Controls of Radio...737
        Use Radio with Care...739
        Space for radio cassette...739
      AUXILIARY ELECTRIC POWER...740
        24V power source...740
        12V power source...740
      FUSE...741
      FUSIBLE LINK...742
      CONTROLLER...742
      TOOL BOX...742
      GREASE GUN HOLDER...743
    MACHINE OPERATIONS AND CONTROLS...744
      BEFORE STARTING ENGINE...744
        Walk-around Checks...744
      REFUELLING PUMP...746
        Checks Before Starting...748
        Adjustment...755
        Seat Belt...761
        Operations Before Starting Engine...762
      STARTING ENGINE...765
      AFTER STARTING ENGINE...768
        Warming Up Engine...769
        Warming Up Hydraulic Equipment...771
        Operation After Completion Of Warming-Up Operation...777
      STOPPING THE ENGINE...779
      MACHINE OPERATION...780
        Preparations for Moving the Machine...780
        Moving Machine Forward...781
        Moving Machine Backward...782
        Stopping Machine...783
      STEERING THE MACHINE...784
        Steering...784
      SWINGING...786
      WORK EQUIPMENT CONTROLS AND OPERATIONS...787
      WORKING MODE...789
      PROHIBITED OPERATIONS...791
      GENERAL OPERATION INFORMATION...793
      TRAVELLING ON SLOPES...795
      ESCAPE FROM MUD...797
        Track on One Side Stuck...797
        Tracks on Both Sides Stuck...797
      RECOMMENDED APPLICATIONS...798
        Backhoe Work...798
        Shovel Work...798
        Ditching Work...798
        Loading Work...799
      BUCKET REPLACEMENT AND INVERSION...800
        Replacement...800
        Inversion...802
      PARKING MACHINE...803
      CHECK AFTER SHUT OFF ENGINE...805
      MACHINE INSPECTION AFTER DAILY WORK...805
      LOCKING...805
    TRANSPORTATION...806
      TRANSPORTATION PROCEDURE...806
      SPECIAL TRANSPORTATION INSTRUCTIONS FOR PC210NLC-8 AND PC230NHD-8...806
      LOADING AND UNLOADING WITH TRAILER...808
        Loading...809
        Securing Machine...812
        Unloading...817
      LIFTING MACHINE...819
    COLD WEATHER OPERATION...821
      COLD WEATHER OPERATION INFORMATION...821
        Fuel and Lubricants...821
        Cooling System Coolant...821
        Battery...822
      AFTER DAILY WORK COMPLETION...823
      AFTER COLD WEATHER SEASON...823
    LONG TERM STORAGE...824
      BEFORE STORAGE...824
      DURING STORAGE...825
      AFTER STORAGE...826
      STARTING MACHINE AFTER LONG-TERM STORAGE...826
    TROUBLES AND ACTIONS...827
      RUNNING OUT OF FUEL...827
      PHENOMENA THAT ARE NOT FAILURES...827
      TOWING THE MACHINE...828
      LIGHTWEIGHT TOWING HOLE...829
      SEVERE JOB CONDITION...829
      DISCHARGED BATTERY...830
        Battery Removal and Installation...830
        Battery Charges...831
        Starting Engine with Booster Cables...832
      OTHER TROUBLE...835
        Electrical System...835
        Chassis...836
        Engine...837
        Electronic Control System...839
        Point of Contact to Telephone when Error Occurs...839
  MAINTENANCE...841
    MAINTENANCE INFORMATION...842
    OUTLINE OF SERVICE...845
      HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...845
        OIL...845
        FUEL...846
        COOLANT AND WATER FOR DILUTION...846
        GREASE...847
        CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...848
        STORING OIL AND FUEL...849
        FILTERS...849
      EXPLANATION OF LUBRICATION CHART DECAL...850
      ELECTRIC SYSTEM MAINTENANCE...852
    WEAR PARTS...853
      WEAR PARTS LIST...853
    RECOMMENDED FUEL, COOLANT AND LUBRICANT...854
      RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL...856
    TIGHTENING TORQUE SPECIFICATIONS...857
      TIGHTENING TORQUE LIST...857
    SAFETY CRITICAL PARTS...858
      SAFETY CRITICAL PARTS LIST...858
    MAINTENANCE SCHEDULE...859
      MAINTENANCE SCHEDULE CHART...859
      MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...861
    MAINTENANCE PROCEDURE...862
      INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...862
      INITIAL 500 HOURS MAINTENANCE (ONLY AFTER THE FIRST 500 HOURS)...862
      WHEN REQUIRED...863
        CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...863
        CLEAN INSIDE OF COOLING SYSTEM...868
        COOLANT DENSITY TABLE...869
        CHECK AND TIGHTEN TRACK SHOE BOLTS...871
        CHECK AND ADJUST TRACK TENSION...872
        REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...874
        REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...877
        ADJUST BUCKET CLEARANCE...878
        CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...879
        CHECK AND MAINTENANCE AIR CONDITIONER...880
        WASH WASHABLE FLOOR...881
        BLEEDING AIR FROM HYDRAULIC SYSTEM...884
        CHECK AND TIGHTEN DIESEL PARTICULATE FILTER CLAMPS...886
      CHECK BEFORE STARTING...887
      EVERY 100 HOURS MAINTENANCE...888
        LUBRICATING (MANUAL GREASE SYSTEMS)...888
      EVERY 250 HOURS MAINTENANCE...890
        CHECK LEVEL OF BATTERY ELECTROLYTE...890
        CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...892
      EVERY 500 HOURS MAINTENANCE...893
        LUBRICATING (MANUAL GREASE SYSTEMS)...893
        LUBRICATE SWING CIRCLE (MANUAL GREASE SYSTEMS)...894
        CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...895
        REPLACE FUEL PRE-FILTER CARTRIDGE...897
        CHECK SWING PINION GREASE LEVEL, ADD GREASE...899
        CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTERCOOLER FINS, FUEL COOLER FINS, AND CONDENSER FINS (ONLY MACHINES EQUIPPED WITH AIR CONDITIONER)...900
        CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...902
        REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...903
        CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL...904
        CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...905
      EVERY 1000 HOURS MAINTENANCE...906
        REPLACE HYDRAULIC OIL FILTER ELEMENT...906
        REPLACE PILOT FILTER ELEMENT...907
        Replace Additional Breaker Filter Element...909
        CHANGE OIL IN SWING MACHINERY CASE...911
        CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...912
        REPLACE FUEL MAIN FILTER CARTRIDGE...913
        CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...914
        CHECK FAN BELT TENSION AND REPLACE FAN BELT...914
        CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)...914
        CLEAN DIESEL PARTICULATE FILTER...915
      EVERY 2000 HOURS MAINTENANCE...918
        CHANGE OIL IN FINAL DRIVE CASE...918
        CLEAN HYDRAULIC TANK STRAINER...919
        CHECKING CHARGE PRESSURE OF NITROGEN GAS IN ACCUMULATOR (FOR CONTROL CIRCUIT)...920
        CHECK ALTERNATOR, STARTING MOTOR...923
        CHECK ENGINE VALVE CLEARANCE, ADJUST...923
      EVERY 4000 HOURS MAINTENANCE...924
        CHECK WATER PUMP...924
        CHECK VIBRATION DAMPER...924
        REPLACE ACCUMULATOR (FOR CONTROL CIRCUIT)...925
        CHECK FOR LOOSENESS OF HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER...926
        CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...926
        CHECK OPERATING CONDITION OF COMPRESSOR...927
      EVERY 5000 HOURS MAINTENANCE...928
        CHANGE OIL IN HYDRAULIC TANK...928
      EVERY 8000 HOURS MAINTENANCE...929
        REPLACE FUEL SPRAY PREVENTION CAP...929
        REPLACE HIGH-PRESSURE PIPING CLAMP...929
    AUTOMATIC GREASE SYSTEM...930
      Filling the grease reservoir...931
      Method of filling grease reservoir...932
      Recommended Komatsu pumps for filling grease reservoir...932
      Indication on the in-cab display...933
      Tests...934
      Maintenance...934
    END OF SERVICE LIFE...935
  SPECIFICATIONS...937
    SPECIFICATIONS...938
      MONOBOOM WORKING RANGE...940
      PC210-8 WORKING RANGE (2-PIECE BOOM)...942
      PC230-8 WORKING RANGE (2-PIECE BOOM)...942
      PC240-8 WORKING RANGE (2-PIECE BOOM)...942
      EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC, PC210NLC, PC230NHD-8 1-PIECE BOOM...944
        PC210-8...945
        PC210LC-8...946
        PC210NLC-8...947
        PC230NHD-8...948
      EXPLANATION OF LIFTING CAPACITY CHART PC240LC, PC240NLC-8 1-PIECE BOOM...949
        PC240LC-8...950
        PC240NLC-8...951
      EXPLANATION OF LIFTING CAPACITY CHART PC210, PC210LC, PC210NLC, PC230NHD-8 2 PIECE BOOM...952
        PC210-8...953
        PC210LC-8...954
        PC210NLC-8...955
        PC230NHD-8...956
      EXPLANATION OF LIFTING CAPACITY CHART (PC240LC,NLC-8 2 PIECE BOOM)...957
      PC240LC-8, PC240NLC-8 2 PIECE BOOM...958
  ATTACHMENTS AND OPTIONS...961
    GENERAL PRECAUTIONS FOR SAFETY...962
      PRECAUTIONS WHEN SELECTING...962
      READ THE INSTRUCTION MANUAL THOROUGHLY...962
      PRECAUTIONS WHEN REMOVING OR INSTALLING...962
      PRECAUTIONS WHEN USING...963
    SPECIFICATIONS...964
      ARM/PIN INFORMATION - PC210/230/240-8...964
    HYDRAULIC QUICK COUPLER PIPING...965
      LOCATIONS...965
      OPERATION...966
    BUCKET WITH HOOK...968
      HOOK CONDITION...968
      PROHIBITED OPERATIONS...968
    MACHINE READY FOR ATTACHMENT...969
      LOCATIONS...969
      HYDRAULIC CIRCUIT...975
        Switching Hydraulic Circuit...975
        Adjusting Oil Flow...975
        Switching Between Breaker and General Attachment...975
        Hydraulic Circuit Connection...976
        Oil Flow Path...977
      ATTACHMENT REMOVAL AND INSTALLATION...978
        Attachment Removal...978
        Attachment Installation...980
      ATTACHMENT OPERATIONS...982
        Operation When Using Breaker...982
        Operation When Using General Attachment 1 (e.g. Crusher)...985
        Operation When Using Attachment 2 (e.g clamshell rotation, crusher rotation)...987
      LONG TERM STORAGE...987
    ATTACHMENT GUIDE...988
      COMBINATIONS OF WORK EQUIPMENT...988
      SELECTION OF TRACK SHOES...991
        METHOD OF SELECTING SHOES...991
      SELECTION OF BUCKET TEETH...992
        METHOD OF SELECTING TEETH...992
      STANDARDS FOR SELECTING VERTICAL PIN TYPE AND HORIZONTAL PIN TYPE TEETH...992
      HANDLING OF RUBBER PAD SHOE AND ROAD LINER...993
        Working Environment...993
        Working Conditions...993
        Storage and Maintenance...994
        Extent of Damage to Rubber...994
        Check Road Liner...994
        Replace Road Liner...994
      TRAPEZOIDAL BUCKET...995
      HANDLING EXTENSION ARM...996
      HANDLING CLAMSHELL BUCKET...997
    RECOMMENDED ATTACHMENT OPERATIONS...998
      HYDRAULIC BREAKER...998
    PC210/230-8 2-PC BOOM...1003
      FEATURES OF 2-PIECE BOOM & ARM...1003
      OPERATION...1003
        BEFORE STORAGE POSTURE WHEN LEAVING MACHINE...1005
        Lifting...1005
        TESTING AND ADJUSTING...1006
        PERODIC MAINTENANCE...1006
      TRANSPORTATION...1007
      LUBRICATING (MANUAL GREASE SYSTEM)...1008
        Every 500 Hours...1008
    PC240-8 2-PC BOOM...1009
      FEATURES OF 2-PIECE BOOM & ARM...1009
      OPERATION...1010
        TESTING AND ADJUSTING...1012
      TRANSPORTATION...1013
    PC240-8 STRAIGHT BOOM...1014
      GENERAL VIEW OF MACHINE...1014
      CAUTION ITEMS...1014
      WORKING RANGE (PC 240 STRAIGHT BOOM)...1015
      TRANSPORTATION (Straight Boom equipment)...1016
    HANDLING MACHINES EQUIPPED WITH KOMTRAX...1017
      BASIC PRECAUTIONS...1017
  SUPER LONG FRONT BOOM AND ARM PC210/240-8...1019
    OPERATION INSTRUCTION FOR SUPER LONG FRONT BOOM AND ARM...1020
      WORKING MODES...1021
        CHECKS BEFORE STARTING...1022
        USING SUPER LONG FRONT...1023
        METHOD OF WORK PC210LC-8 (15m), PC210NLC-8 (15m)...1024
        WHEN TRAVELLING...1024
        METHOD OF WORK PC240LC-8 (18m), PC240NLC-8 (18m)...1025
        WHEN TRAVELLING...1025
      CONTROL LEVERS, PEDALS...1026
      TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE...1029
        INSTALLATION OF SUPPORTING LINK...1029
        TRANSPORTATION OF SUPER LONG FRONT MACHINE...1030
      WORKING RANGE OF SUPER LONG FRONT...1031
      LIFTING CAPACITY PC210 LC 15 m SUPER LONG FRONT...1032
      LIFTING CAPACITY PC210 NLC 15 m SUPER LONG FRONT...1033
      LIFTING CAPACITY PC240 LC 18 m SUPER LONG FRONT...1034
      LIFTING CAPACITY PC240 NLC 18 m SUPER LONG FRONT...1035
    MAINTENANCE...1036
      SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT...1036
      EVERY 50 HOURS SERVICE...1037
        LUBRICATING (MANUAL GREASE SYSTEM)...1037
      EVERY 100 HOURS SERVICE...1038
        LUBRICATING (MANUAL GREASE SYSTEM)...1038
  PC240LC/NLC-8 HIGH REACH DEMOLITION...1041
    GENERAL VIEW OF MACHINE...1042
      CAUTION ITEMS...1043
      TRAVEL POSTURE...1043
    OPERATION INSTRUCTIONS...1044
      WORK EQUIPMENT CONTROL LEVERS...1044
        ATTACHMENT ROTATION (with auto-deceleration)...1045
        CRUSHER CONTROL FOR OPENING AND CLOSING...1046
      MACHINE OPERATIONS AND CONTROLS...1047
        BEFORE STARTING ENGINE...1047
        PROHIBITION OF WORK AT THE STROKE END OF A CYLINDER...1051
        Confirmation and inspection before and after work...1051
        PROHIBITION OF WORK WITH HYDRAULIC BREAKER...1051
        PROHIBITION OF WORK WITH DIGGING ATTACHMENT...1051
        WORKING RANGE AND USING RANGE OF BOOM...1052
        POSTURE WHEN LEAVING MACHINE...1053
    SPECIFICATIONS...1054
      GROUND PRESSURE TABLE...1054
      WORKING RANGE...1054
      TRANSPORT DIMENSIONS...1055
  INDEX...1057
    Numerics...1059
    <A>...1059
    <B>...1059
    <C>...1059
    <D>...1059
    <E>...1059
    <F>...1059
    <G>...1059
    <H>...1059
    <I>...1059
    <K>...1059
    <L>...1059
    <M>...1059
    <N>...1060
    <O>...1060
    <P>...1060
    <R>...1060
    <S>...1060
    <T>...1060
    <V>...1060
    <W>...1061
    <Y>...1061
  COLOPHON...1063
UEN00084 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Shop Manual...1065
  00 Index and foreword...1067
    Index...1067
      Organization list of the shop manual...1068
      Table of contents...1070
  00 Index and foreword...1079
    Foreword and general information...1079
      Foreword and general information...1080
        Safety notice...1080
        How to read the shop manual...1084
        Explanation of terms for maintenance standard...1086
        Handling electric equipment and hydraulic component...1088
        How to read electric wire code...1096
        Method of disassembling and connecting push-pull type coupler...1099
        Standard tightening torque table...1102
        Conversion table...1106
  01 Specification...1113
    Specification and technical data...1113
      Specification and technical data...1114
        Specification dimension drawings...1114
        Working range diagram...1115
        Specifications...1116
        Weight table...1120
        Table of fuel, coolant and lubricants...1124
  10 Structure, function and maintenance standard...1127
    Engine and cooling system...1127
      Engine and cooling system...1128
        Engine related parts...1128
        Radiator, oil cooler, aftercooler and fuel cooler...1129
  10 Structure, function and maintenance standard...1131
    Power train...1131
      Power train...1132
        Power train...1132
        Final drive...1134
        Swing machinery...1136
        Swing circle...1140
  10 Structure, function and maintenance standard...1143
    Undercarriage and frame...1143
      Undercarriage and frame...1144
        Track frame and recoil spring...1144
        Idler...1146
        Carrier roller...1148
        Track roller...1149
        Track shoe...1150
  10 Structure, function and maintenance standard...1157
    Hydraulic system, Part 1...1157
      Hydraulic system, Part 1...1158
        Hydraulic equipment layout drawing...1158
      Hydraulic tank and filter...1160
        Hydraulic pump...1161
        Hydraulic pump...1162
        Pilot oil filter...1185
  10 Structure, function and maintenance standard...1187
    Hydraulic system, Part 2...1187
      Hydraulic system, Part 2...1188
        Control valve...1188
        CLSS...1201
        Functions and operation by valve...1206
        Hydraulic drift prevention valve...1232
  10 Structure, function and maintenance standard...1245
    Hydraulic system, Part 3...1245
      Hydraulic system, Part 3...1247
        Swing motor...1247
        Center swivel joint...1256
        Travel motor...1259
        PPC valve...1270
        Valve control...1292
        Solenoid valve...1294
        PPC Accumulator...1296
        Return oil filter...1297
        Attachment circuit selector valve...1298
        Hydraulic cylinder...1300
  10 Structure, function and maintenance standard...1305
    Work equipment...1305
      Work equipment...1306
        Dimensions of components...1306
  10 Structure, function and maintenance standard...1313
    Cab and its attachments...1313
      Cab and its attachments...1314
        Air conditioner piping...1314
  10 Structure, function and maintenance standard...1317
    Electrical system...1317
      Electrical system...1318
        Engine control...1318
        Electrical control system...1326
        Monitor system...1346
        Sensor...1373
        KOMTRAX terminal system...1376
  20 Standard value table...1379
    Standard service value table...1379
      Standard service value table...1380
        Standard value table for engine related parts...1380
        Standard value table for chassis related parts...1382
  30 Testing and adjusting...1401
    Testing and adjusting, Part 1...1401
      Testing and adjusting, Part 1...1403
        Tools for testing, adjusting, and troubleshooting...1403
        Measuring engine speed...1406
        Measuring intake air pressure (boost pressure)...1407
        Checking exhaust gas color...1408
        Adjusting valve clearance...1409
        Measuring compression pressure...1411
        Measuring blow-by pressure...1413
        Measuring engine oil pressure...1414
        Handling fuel system parts...1415
        Releasing residual pressure from fuel system...1415
        Measuring fuel pressure...1416
        Measuring fuel return rate and leakage...1418
        Bleeding air from fuel circuit...1420
        Checking fuel circuit for leakage...1422
        Checking and adjusting air conditioner compressor belt tension...1423
        Measuring swing circle bearing clearance...1424
        Checking and adjusting track shoe tension...1425
        Measuring and adjusting oil pressure in work equipment, swing, and travel circuits...1427
        Measuring control circuit basic pressure...1431
        Measuring and adjusting oil pressure in pump PC control circuit...1432
        Measuring and adjusting oil pressure in pump LS control circuit...1436
        Measuring solenoid valve output pressure...1442
        Measuring PPC valve output pressure...1445
        Adjusting play of work equipment and swing PPC valves...1447
        Checking parts which cause hydraulic drift of work equipment...1448
        Releasing residual pressure from hydraulic circuit...1450
        Measuring oil leakage...1451
        Bleeding air from each part...1454
        Checking cab tipping stopper...1457
        Adjusting mirrors...1458
  30 Testing and adjusting...1461
    Testing and adjusting, Part 2...1461
      Testing and adjusting, Part 2...1462
        Special functions of machine monitor...1462
  30 Testing and adjusting...1519
    Testing and adjusting, Part 3...1519
      Testing and adjusting, Part 3...1520
        Handling high-voltage circuit of engine controller...1520
        Preparation work for troubleshooting of electrical system...1521
        Procedure for testing diodes...1525
        Pm Clinic service...1527
        Warning...1529
        Pm Clinic service...1533
  40 Troubleshooting...1541
    General information on troubleshooting...1541
      General information on troubleshooting...1542
        Points to remember when troubleshooting...1542
        Sequence of events in troubleshooting...1543
        Check before troubleshooting...1544
        Classification and procedures for troubleshooting...1545
        How to read electric wire code...1549
        Connection table for connector pin numbers...1552
        T-boxes and T-adapters table...1575
  40 Troubleshooting...1579
    Troubleshooting by failure code (Display of code), Part 1...1579
      Troubleshooting by failure code (Display of code), Part 1...1581
        Failure codes table...1581
        Before carrying out troubleshooting when failure code is displayed...1586
        Information in troubleshooting table...1590
        Failure code [989L00] Engine Controller Lock Caution 1...1592
        Failure code [989M00] Engine Controller Lock Caution 2...1592
        Failure code [989N00] Engine Controller Lock Caution 3...1593
        Failure code [AA10NX] Air Cleaner Clogging...1593
        Failure code [AB00KE] Charge Voltage Low...1594
        Failure code [B@BAZG] Eng Oil Press. Low...1596
        Failure code [B@BAZK] Eng Oil Level Low...1596
        Failure code [B@BCNS] Eng Water Overheat...1597
        Failure code [B@BCZK] Eng Water Level Low...1597
        Failure code [B@HANS] Hydr Oil Overheat...1598
        Failure code [CA111] EMC Critical Internal Failure...1598
        Failure code [CA115] Eng Ne and Bkup Speed Sens Error...1599
        Failure code [CA122] Chg Air Press Sensor High Error...1600
        Failure code [CA123] Chg Air Press Sensor Low Error...1602
        Failure code [CA131] Throttle Sensor High Error...1604
        Failure code [CA132] Throttle Sensor Low Error...1606
        Failure code [CA144] Coolant Temp Sens High Error...1608
        Failure code [CA145] Coolant Temp Sens Low Error...1610
        Failure code [CA153] Chg Air Temp Sensor High Error...1612
        Failure code [CA154] Chg Air Temp Sensor Low Error...1614
        Failure code [CA155] Chg Air Temp High Speed Derate...1616
        Failure code [CA187] Sens Supply 2 Volt Low Error...1618
        Failure code [CA221] Ambient Press Sens High Error...1620
        Failure code [CA222] Ambient Press Sens Low Error...1622
        Failure code [CA227] Sens Supply 2 Volt High Error...1624
        Failure code [CA234] Eng Overspeed...1625
        Failure code [CA238] Ne Speed Sens Supply Volt Error...1626
        Failure code [CA271] IMV/PCV1 Short Error...1627
        Failure code [CA272] IMV/PCV1 Open Error...1628
        Failure code [CA322] Inj #1 (L#1) Open/Short Error...1630
        Failure code [CA323] Inj #5 (L#5) Open/Short Error...1632
        Failure code [CA324] Inj #3 (L#3) Open/Short Error...1634
        Failure code [CA325] Inj #6 (L#6) Open/Short Error...1636
        Failure code [CA331] Inj #2 (L#2) Open/Short Error...1638
        Failure code [CA332] Inj #4 (L#4) Open/Short Error...1640
  40 Troubleshooting...1643
    Troubleshooting by failure code (Display of code), Part 2...1643
      Troubleshooting by failure code (Display of code), Part 2...1645
        Failure code [CA342] Calibration Code Incompatibility...1645
        Failure code [CA351] Injectors Drive Circuit Error...1646
        Failure code [CA352] Sens Supply 1 Volt Low Error...1648
        Failure code [CA386] Sens Supply 1 Volt High Error...1650
        Failure code [CA428] Water in Fuel Sensor High Error...1652
        Failure code [CA429] Water in Fuel Sensor Low Error...1654
        Failure code [CA435] Eng Oil Press Sw Error...1656
        Failure code [CA441] Battery Voltage Low Error...1657
        Failure code [CA442] Battery Voltage High Error...1660
        Failure code [CA449] Rail Press Very High Error...1662
        Failure code [CA451] Rail Press Sensor High Error...1664
        Failure code [CA452] Rail Press Sensor Low Error...1666
        Failure code [CA488] Chg Air Temp High Torque Derate...1668
        Failure code [CA553] Rail Press High Error...1668
        Failure code [CA559] Rail Press Low Error...1669
        Failure code [CA689] Eng Ne Speed Sensor Error...1670
        Failure code [CA731] Eng Bkup Speed Sens Phase Error...1672
        Failure code [CA757] All Continuous Data Lost Error...1674
        Failure code [CA778] Eng Bkup Speed Sensor Error...1676
        Failure code [CA1633] KOMNET Datalink Timeout Error...1678
        Failure code [CA2185] Throt Sens Sup Volt High Error...1680
        Failure code [CA2186] Throt Sens Sup Volt Low Error...1681
        Failure code [CA2249] Rail Press Very Low Error...1682
        Failure code [CA2311] IMV Solenoid Error...1684
        Failure code [CA2555] Grid Htr Relay Volt High Error...1686
        Failure code [CA2556] Grid Htr Relay Volt Low Error...1688
        Failure code [D19JKZ] Personal Code Relay Abnormality...1690
        Failure code [D862KA] GPS Antenna Discon...1692
        Failure code [DA25KP] 5V Sensor 1 Power Abnormality...1693
        Failure code [DA29KQ] Model Selection Abnormality...1700
  40 Troubleshooting...1705
    Troubleshooting by failure code (Display of code), Part 3...1705
      Troubleshooting by failure code (Display of code), Part 3...1708
        Failure code [DA2RMC] CAN Discon (Pump Con Detected)...1708
        Failure code [DAFGMC] GPS Module Error...1710
        Failure code [DAFRMC] CAN Discon (Monitor Detected)...1712
        Failure code [DGH2KB] Hydr Oil Sensor Short...1714
        Failure code [DHPAMA] F Pump Press Sensor Abnormality...1716
        Failure code [DHPBMA] R Pump Press Sensor Abnormality...1718
        Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality...1720
        Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...1722
        Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality...1724
        Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality...1726
        Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality...1728
        Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...1730
        Failure code [DHX1MA] Overload Sensor Abnormality (Analog)...1732
        Failure code [DW43KA] Travel Speed Sol Discon...1734
        Failure code [DW43KB] Travel Speed Sol Short...1736
        Failure code [DW45KA] Swing Brake Sol Discon...1738
        Failure code [DW45KB] Swing Brake Sol Short...1740
        Failure code [DW91KA] Travel Junction Sol Discon...1742
        Failure code [DW91KB] Travel Junction Sol Short...1744
        Failure code [DWA2KA] Service Sol Discon...1746
        Failure code [DWA2KB] Service Sol Short...1747
        Failure code [DWK0KA] 2-stage Relief Sol Discon...1748
        Failure code [DWK0KB] 2-stage Relief Sol Short...1750
  40 Troubleshooting...1753
    Troubleshooting by failure code (Display of code), Part 4...1753
      Troubleshooting by failure code (Display of code), Part 4...1756
        Failure code [DXA8KA] PC-EPC (F) Sol Discon...1756
        Failure code [DXA8KB] PC-EPC (F) Sol Short...1758
        Failure code [DXA9KA] PC-EPC (R) Sol Discon...1760
        Failure code [DXA9KB] PC-EPC (R) Sol Short...1762
        Failure code [DXE0KA] LS-EPC Sol Discon...1764
        Failure code [DXE0KB] LS-EPC Sol Short...1766
        Failure code [DXE4KA] Service Current EPC Discon...1768
        Failure code [DXE4KB] Service Current EPC Short...1770
        Failure code [DXE5KA] Merge-divider Main Sol Discon...1772
        Failure code [DXE5KB] Merge-divider Main Sol Short...1774
        Failure code [DXE6KA] Merge-divider LS Sol Discon...1776
        Failure code [DXE6KB] Merge-divider LS Sol Short...1778
        Failure code [DY20KA] Wiper Working Abnormality...1780
        Failure code [DY20MA] Wiper Parking Abnormality...1782
        Failure code [DY2CKA] Washer Drive Discon...1784
        Failure code [DY2CKB] Washer Drive Short...1786
        Failure code [DY2DKB] Wiper Drive (For) Short...1788
        Failure code [DY2EKB] Wiper Drive (Rev) Short...1790
  40 Troubleshooting...1793
    Troubleshooting of electrical system (E-mode)...1793
      Troubleshooting of electrical system (E-mode)...1795
        Before carrying out troubleshooting of electrical system...1795
        Information in troubleshooting table...1797
        E-1 When starting switch turned ON, machine monitor displays nothing...1798
        E-2 When starting switch turned ON (before starting engine), basic check item lights up...1800
        E-3 Engine does not start (Engine does not turn)...1803
        E-4 Preheater does not operate...1806
        E-5 Automatic warm-up system does not operate (in cold season)...1808
        E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked...1810
        E-7 Precaution lights up while engine is running...1812
        E-8 Emergency stop item lights up while engine is running...1817
        E-9 Engine coolant temperature gauge does not indicate normally...1818
        E-10 Hydraulic oil temperature gauge does not indicate normally...1819
        E-11 Fuel level gauge does not indicate normally...1821
        E-12 Contents of display by machine monitor are different from applicable machine...1823
        E-13 Machine monitor does not display some items...1823
        E-14 Function switch does not work...1823
        E-15 Auto-decelerator does not operate normally...1824
        E-16 Working mode does not change...1825
        E-17 Travel speed does not change...1826
        E-18 Alarm buzzer cannot be stopped...1827
        E-19 Windshield wiper and window washer do not operate...1828
        E-20 Power maximizing function does not operate normally...1830
        E-21 Swing holding brake does not operate normally...1832
        E-22 Travel alarm does not sound or does not stop sounding...1834
        E-23 Air conditioner does not operate normally (including air conditioner abnormality record)...1836
        E-24 When starting switch is turned OFF, service meter is not displayed...1848
        E-25 Machine monitor cannot be set in service mode...1848
        E-26 Monitoring function does not display lever control signal normally...1849
        E-27 KOMTRAX system does not operate normally...1858
  40 Troubleshooting...1861
    Troubleshooting of hydraulic and mechanical system (H-mode)...1861
      Troubleshooting of hydraulic and mechanical system (H-mode)...1864
        System diagram of hydraulic and mechanical system...1864
        Information in troubleshooting table...1866
        H-1 Speed or power of whole work equipment, swing, and travel is low...1867
        H-2 Engine speed lowers extremely or engine stalls...1869
        H-3 Work equipment, swing, and travel systems do not work...1870
        H-4 Abnormal sound comes out from around hydraulic pump...1870
        H-5 Auto-decelerator does not operate...1871
        H-6 Fine control performance or response is low...1871
        H-7 Speed or power of boom is low...1872
        H-8 Speed or power of arm is low...1873
        H-9 Speed or power of bucket is low...1874
        H-10 Work equipment does not move singly...1874
        H-11 Hydraulic drift of work equipment is large...1875
        H-12 Time lag of work equipment is large...1877
        H-13 When part of work equipment is relieved singly, other parts of work equipment move...1877
        H-14 Power maximizing function does not work...1878
        H-15 In compound operation of work equipment, speed of part loaded more is low...1878
        H-16 When machine swings and raises boom simultaneously, boom rising speed is low...1879
        H-17 When machine swings and travels simultaneously, travel speed lowers largely...1879
        H-18 Machine deviates during travel...1880
        H-19 Travel speed is low...1881
        H-20 Machine is not steered well or steering power is low...1882
        H-21 Travel speed does not change or travel speed is low/high...1883
        H-22 Travel system does not move (only one side)...1884
        H-23 Upper structure does not swing...1885
        H-24 Swing acceleration or swing speed is low...1887
        H-25 Upper structure overruns remarkably when it stops swinging...1888
        H-26 Large shock is made when upper structure stops swinging...1889
        H-27 Large sound is made when upper structure stops swinging...1889
        H-28 Hydraulic drift of swing is large...1890
        H-29 Attachment circuit is not changed...1891
        H-30 Oil flow in attachment circuit cannot be controlled...1891
  40 Troubleshooting...1893
    Troubleshooting of engine (S-mode)...1893
      Troubleshooting of engine (S-mode)...1895
        Method of using troubleshooting chart...1895
        S-1 Starting performance is poor...1898
        S-2 Engine does not start...1899
        S-3 Engine does not pick up smoothly...1902
        S-4 Engine stops during operations...1903
        S-5 Engine does not rotate smoothly...1904
        S-6 Engine lack output (or lacks power)...1905
        S-7 Exhaust smoke is black (incomplete combustion)...1906
        S-8 Oil consumption is excessive (or exhaust smoke is blue)...1907
        S-9 Oil becomes contaminated quickly...1908
        S-10 Fuel consumption is excessive...1909
        S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...1910
        S-12 Oil pressure drops...1911
        S-13 Oil level rises (Entry of coolant/fuel)...1912
        S-14 Coolant temperature becomes too high (overheating)...1913
        S-15 Abnormal noise is made...1914
        S-16 Vibration is excessive...1915
  50 Disassembly and assembly...1917
    Disassembly and assembly related information...1917
      Disassembly and assembly related information...1918
        How to read this manual...1918
        List of adhesives...1920
        Special tool list...1923
        Sketches of special tools...1928
  50 Disassembly and assembly...1933
    Engine cooling related...1933
      Engine cooling related...1934
        Removal and installation of fuel supply pump assembly...1934
        Removal and installation of fuel injector assembly...1936
        Removal and installation of engine front seal...1943
        Removal and installation of engine rear seal...1946
        Removal and installation of cylinder head assembly...1949
        Removal and installation of radiator assembly...1961
        Removal and installation of assembly hydraulic oil cooler assembly...1964
        Removal and installation of aftercooler assembly...1966
        Removal and installation of fuel cooler assembly...1968
        Removal and installation of engine and hydraulic pump assemblies...1969
  50 Disassembly and assembly...1981
    Power train...1981
      Power train...1982
        Removal and installation of final drive assembly...1982
        Disassembly and assembly of final drive assembly...1984
        Removal and installation of swing motor and swing machinery assembly...2000
        Disassembly and assembly of swing motor and swing machinery assembly...2002
        Removal and installation of swing circle assembly...2012
  50 Disassembly and assembly...2015
    Under carriage and frame...2015
      Under carriage and frame...2016
        Disassembly and assembly of carrier roller...2016
        Disassembly and assembly of track roller assembly...2019
        Disassembly and assembly of idler assembly...2021
        Disassembly and assembly of recoil spring...2024
        Removal and installation of sprocket...2026
        Expansion and installation of track shoe assembly...2027
        Removal and installation of revolving frame assembly...2029
        Removal and installation of counterweight assembly...2031
  50 Disassembly and assembly...2033
    Hydraulic system...2033
      Hydraulic system...2034
        Removal and installation of center swivel joint assembly...2034
        Disassembly and assembly of center swivel joint assembly...2036
        Removal and installation of hydraulic tank assembly...2037
        Removal and installation of control valve assembly...2040
        Disassembly and assembly of control valve assembly...2045
        Removal and installation of hydraulic pump assembly...2049
        Removal and installation of oil seal in hydraulic pump input shaft...2054
        Disassembly and assembly of work equipment PPC valve assembly...2055
        Disassembly and assembly of travel PPC valve assembly...2056
        Disassembly and assembly of hydraulic cylinder assembly...2057
  50 Disassembly and assembly...2065
    Work equipment...2065
      Work equipment...2066
        Removal and installation of the work equipment assembly...2066
  50 Disassembly and assembly...2071
    Cab related...2071
      Cab related...2072
        Removal and installation of operator's cab assembly...2072
        Removal and installation of operator cab glass (stuck glass)...2075
        Removal and installation of front window assembly...2085
        Removal and installation of floor frame assembly...2092
  50 Disassembly and assembly...2097
    Electric components...2097
      Electric components...2098
        Removal and installation of air conditioner unit assembly...2098
        Removal and installation of KOMTRAX communication modem assembly...2101
        Removal and installation of monitor assembly...2102
        Removal and installation of pump controller assembly...2104
        Removal and installation of engine controller assembly...2105
  90 Diagrams and drawings...2107
    Hydraulic diagrams and drawings...2107
      Hydraulic diagrams and drawings...2109
        Hydraulic circuit diagram...2109
  90 Diagrams and drawings...2113
    Electrical diagrams and drawings...2113
      Electrical diagrams and drawings...2115
        Electrical circuit diagram (1/5)...2115
        Electrical circuit diagram (2/5)...2117
        Electrical circuit diagram (3/5)...2119
        Electrical circuit diagram (4/5)...2121
        Electrical circuit diagram (5/5)...2123
UEN00084-07 - Hydraulic Excavator PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Shop Manual...2127
  00 Index and foreword...2129
    Index...2129
      Organization list of the shop manual...2130
      Table of contents...2132
  00 Index and foreword...2143
    Foreword and general information...2143
      Foreword and general information...2144
        Safety notice...2144
        How to read the shop manual...2148
        Explanation of terms for maintenance standard...2150
        Handling electric equipment and hydraulic component...2152
        How to read electric wire code...2160
        Method of disassembling and connecting push-pull type coupler...2163
        Standard tightening torque table...2166
        Conversion table...2170
  01 Specification...2177
    Specification and technical data...2177
      Specification and technical data...2178
        Specification dimension drawings...2178
        Working range diagram...2179
        Specifications...2180
        Weight table...2184
        Table of fuel, coolant and lubricants...2188
  10 Structure, function and maintenance standard...2191
    Engine and cooling system...2191
      Engine and cooling system...2192
        Engine related parts...2192
        Radiator, oil cooler, aftercooler and fuel cooler...2193
      Diesel Particulate Filter...2194
        Diesel Particulate Filter - Component Parts...2195
        System Description...2196
        Regeneration...2196
  10 Structure, function and maintenance standard...2199
    Power train...2199
      Power train...2200
        Power train...2200
        Final drive...2202
        Swing machinery...2204
        Swing circle...2208
  10 Structure, function and maintenance standard...2211
    Undercarriage and frame...2211
      Undercarriage and frame...2212
        Track frame and recoil spring...2212
        Idler...2214
        Carrier roller...2216
        Track roller...2217
        Track shoe...2218
  10 Structure, function and maintenance standard...2225
    Hydraulic system, Part 1...2225
      Hydraulic system, Part 1...2226
        Hydraulic equipment layout drawing...2226
      Hydraulic tank and filter...2228
        Hydraulic pump...2229
        Hydraulic pump...2230
        Pilot oil filter...2253
  10 Structure, function and maintenance standard...2255
    Hydraulic system, Part 2...2255
      Hydraulic system, Part 2...2256
        Control valve...2256
        CLSS...2269
        Functions and operation by valve...2274
        Hydraulic drift prevention valve...2300
  10 Structure, function and maintenance standard...2313
    Hydraulic system, Part 3...2313
      Hydraulic system, Part 3...2315
        Swing motor...2315
        Centre swivel joint...2324
        Travel motor...2327
        PPC valve...2338
        Valve control...2358
        ATT EPC Valve Assembly...2360
        Solenoid valve...2362
        PPC Accumulator...2364
        Return oil filter...2365
        Attachment circuit selector valve...2366
        Quick coupler control valve - For PC210 K50001 ~ K51094, PC230 K50001 ~ K50113 and PC240 K50001~K50303...2368
        Quick coupler control valve - For PC210 K51095 - K53243, PC230 K50114 - K50286 and PC240 K50304 - K51093.)...2370
        Quick coupler control valve - For PC210 K53424 and up, PC230 K50287 and up and PC240 K51094 and up...2372
        Hydraulic cylinder...2374
  10 Structure, function and maintenance standard...2379
    Work equipment...2379
      Work equipment...2380
        Dimensions of components...2380
  10 Structure, function and maintenance standard...2387
    Cab and its attachments...2387
      Cab and its attachments...2388
        Air conditioner piping...2388
  10 Structure, function and maintenance standard...2391
    Electrical system...2391
      Electrical system...2392
        Engine control...2392
        Electrical control system...2400
        Monitor system...2426
        Sensor...2457
        PPC Levers...2460
        KOMTRAX terminal system...2462
  10 Structure, function and maintenance standard...2465
    Auto Grease system...2465
      Outline of Auto Grease System...2466
  20 Standard value table...2481
    Standard service value table...2481
      Standard service value table...2482
        Standard value table for engine related parts...2482
        Standard value table for chassis related parts...2484
  30 Testing and adjusting...2503
    Testing and adjusting, Part 1...2503
      Testing and adjusting, Part 1...2505
        Tools for testing, adjusting, and troubleshooting...2505
        Measuring engine speed...2508
        Measuring intake air pressure (boost pressure)...2509
        Checking exhaust gas colour...2510
        Adjusting valve clearance...2511
        Measuring compression pressure...2513
        Measuring blow-by pressure...2515
        Measuring engine oil pressure...2516
        Handling fuel system parts...2517
        Releasing residual pressure from fuel system...2517
        Measuring fuel pressure...2518
        Measuring fuel return rate and leakage...2520
        Bleeding air from fuel circuit...2522
        Checking fuel circuit for leakage...2524
        Checking and adjusting air conditioner compressor belt tension...2525
        Measuring swing circle bearing clearance...2526
        Checking and adjusting track shoe tension...2527
        Measuring and adjusting oil pressure in work equipment, swing, and travel circuits...2529
        Measuring control circuit basic pressure...2533
        Measuring and adjusting oil pressure in pump PC control circuit...2534
        Measuring and adjusting oil pressure in pump LS control circuit...2538
        Measuring solenoid valve output pressure...2544
        Measuring PPC valve output pressure...2547
        Adjusting play of work equipment and swing PPC valves...2549
        Measuring and adjusting quick coupler control valve output pressure - For PC210 K50001 - K53423, PC230 K50001 - K50286 and PC240 K50001 - K51093...2550
        Measuring and adjusting quick coupler control valve output pressure - For PC210 K53424 and up, PC230 K50287 and up and PC240 K51094 and up...2551
        Checking parts which cause hydraulic drift of work equipment...2552
        Releasing residual pressure from hydraulic circuit...2554
        Measuring oil leakage...2555
        Bleeding air from each part...2558
        Checking cab tipping stopper...2561
        Adjusting mirrors...2562
        Adjusting mirrors...2564
  30 Testing and adjusting...2567
    Testing and adjusting, Part 2...2567
      Testing and adjusting, Part 2...2568
        Special functions of machine monitor...2568
  30 Testing and adjusting...2633
    Testing and adjusting, Part 3...2633
      Testing and adjusting, Part 3...2634
        Handling high-voltage circuit of engine controller...2634
        Preparation work for troubleshooting of electrical system...2635
        Procedure for testing diodes...2639
        Pm Clinic service...2641
        Warning...2643
        Pm Clinic service...2647
  40 Troubleshooting...2655
    General information on troubleshooting...2655
      General information on troubleshooting...2656
        Points to remember when troubleshooting...2656
        Sequence of events in troubleshooting...2657
        Check before troubleshooting...2658
        Classification and procedures for troubleshooting...2659
        How to read electric wire code...2663
        Connection table for connector pin numbers...2666
        T-boxes and T-adapters table...2697
  40 Troubleshooting...2703
    Troubleshooting by failure code (Display of code), Part 1...2703
      Troubleshooting by failure code (Display of code), Part 1...2705
        Failure codes table...2705
        Before carrying out troubleshooting when failure code is displayed...2710
        Before carrying out troubleshooting when failure code is displayed...2711
        Information in troubleshooting table...2716
        Failure code [989L00] Engine Controller Lock Caution 1...2718
        Failure code [989M00] Engine Controller Lock Caution 2...2718
        Failure code [989N00] Engine Controller Lock Caution 3...2719
        Failure code [AA10NX] Air Cleaner Clogging...2719
        Failure code [AB00KE] Charge Voltage Low...2720
        Failure code [B@BAZG] Eng Oil Press. Low...2722
        Failure code [B@BAZK] Eng Oil Level Low...2722
        Failure code [B@BCNS] Eng Water Overheat...2723
        Failure code [B@BCZK] Eng Water Level Low...2723
        Failure code [B@HANS] Hydr Oil Overheat...2724
        Failure code [CA111] EMC Critical Internal Failure...2724
        Failure code [CA115] Eng Ne and Bkup Speed Sens Error...2725
        Failure code [CA122] Chg Air Press Sensor High Error...2726
        Failure code [CA123] Chg Air Press Sensor Low Error...2728
        Failure code [CA131] Throttle Sensor High Error...2730
        Failure code [CA132] Throttle Sensor Low Error...2732
        Failure code [CA144] Coolant Temp Sens High Error...2734
        Failure code [CA145] Coolant Temp Sens Low Error...2736
        Failure code [CA153] Chg Air Temp Sensor High Error...2738
        Failure code [CA154] Chg Air Temp Sensor Low Error...2740
        Failure code [CA155] Chg Air Temp High Speed Derate...2742
        Failure code [CA187] Sens Supply 2 Volt Low Error...2744
        Failure code [CA221] Ambient Press Sens High Error...2746
        Failure code [CA222] Ambient Press Sens Low Error...2748
        Failure code [CA227] Sens Supply 2 Volt High Error...2750
        Failure code [CA234] Eng Overspeed...2751
        Failure code [CA238] Ne Speed Sens Supply Volt Error...2752
        Failure code [CA271] IMV/PCV1 Short Error...2753
        Failure code [CA272] IMV/PCV1 Open Error...2754
        Failure code [CA322] Inj #1 (L#1) Open/Short Error...2756
        Failure code [CA323] Inj #5 (L#5) Open/Short Error...2758
        Failure code [CA324] Inj #3 (L#3) Open/Short Error...2760
        Failure code [CA325] Inj #6 (L#6) Open/Short Error...2762
        Failure code [CA331] Inj #2 (L#2) Open/Short Error...2764
        Failure code [CA332] Inj #4 (L#4) Open/Short Error...2766
  40 Troubleshooting...2769
    Troubleshooting by failure code (Display of code), Part 2...2769
      Troubleshooting by failure code (Display of code), Part 2...2771
        Failure code [CA342] Calibration Code Incompatibility...2771
        Failure code [CA351] Injectors Drive Circuit Error...2772
        Failure code [CA352] Sens Supply 1 Volt Low Error...2774
        Failure code [CA386] Sens Supply 1 Volt High Error...2776
        Failure code [CA428] Water in Fuel Sensor High Error...2778
        Failure code [CA429] Water in Fuel Sensor Low Error...2780
        Failure code [CA435] Eng Oil Press Sw Error...2782
        Failure code [CA441] Battery Voltage Low Error...2783
        Failure code [CA442] Battery Voltage High Error...2786
        Failure code [CA449] Rail Press Very High Error...2788
        Failure code [CA451] Rail Press Sensor High Error...2790
        Failure code [CA452] Rail Press Sensor Low Error...2792
        Failure code [CA488] Chg Air Temp High Torque Derate...2794
        Failure code [CA553] Rail Press High Error...2794
        Failure code [CA559] Rail Press Low Error...2795
        Failure code [CA689] Eng Ne Speed Sensor Error...2796
        Failure code [CA731] Eng Bkup Speed Sens Phase Error...2798
        Failure code [CA757] All Continuous Data Lost Error...2800
        Failure code [CA778] Eng Bkup Speed Sensor Error...2802
        Failure code [CA1633] KOMNET Datalink Timeout Error...2804
        Failure code [CA2185] Throt Sens Sup Volt High Error...2806
        Failure code [CA2186] Throt Sens Sup Volt Low Error...2807
        Failure code [CA2249] Rail Press Very Low Error...2808
        Failure code [CA2311] IMV Solenoid Error...2810
        Failure code [CA2555] Grid Htr Relay Volt High Error...2812
        Failure code [CA2556] Grid Htr Relay Volt Low Error...2814
        Failure code [D19JKZ] Personal Code Relay Abnormality...2816
        Failure code [D862KA] GPS Antenna Discon...2818
        Failure code [DA25KP] 5V Sensor 1 Power Abnormality...2819
        Failure code [DA29KQ] Model Selection Abnormality...2826
  40 Troubleshooting...2831
    Troubleshooting by failure code (Display of code), Part 3...2831
      Troubleshooting by failure code (Display of code), Part 3...2834
        Failure code [DA2RMC] CAN Discon (Pump Con Detected)...2834
        Failure code [DAFGMC] GPS Module Error...2836
        Failure code [DAFRMC] CAN Discon (Monitor Detected)...2838
        Failure code [DGH2KB] Hydr Oil Sensor Short...2840
        Failure code [DHPAMA] F Pump Press Sensor Abnormality...2842
        Failure code [DHPBMA] R Pump Press Sensor Abnormality...2844
        Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality...2846
        Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...2848
        Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality...2850
        Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality...2852
        Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality...2854
        Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...2856
        Failure code [DHX1MA] Overload Sensor Abnormality (Analog)...2858
        Failure code [DW43KA] Travel Speed Sol Discon...2860
        Failure code [DW43KB] Travel Speed Sol Short...2862
        Failure code [DW45KA] Swing Brake Sol Discon...2864
        Failure code [DW45KB] Swing Brake Sol Short...2866
        Failure code [DW91KA] Travel Junction Sol Discon...2868
        Failure code [DW91KB] Travel Junction Sol Short...2870
        Failure code [DWA2KA] Service Sol Discon...2872
        Failure code [DWA2KB] Service Sol Short...2873
        Failure code [DWK0KA] 2-stage Relief Sol Discon...2874
        Failure code [DWK0KB] 2-stage Relief Sol Short...2876
  40 Troubleshooting...2879
    Troubleshooting by failure code (Display of code), Part 4...2879
      Troubleshooting by failure code (Display of code), Part 4...2881
        Failure code [DXA8KA] PC-EPC (F) Sol Discon...2881
        Failure code [DXA8KB] PC-EPC (F) Sol Short...2883
        Failure code [DXA9KA] PC-EPC (R) Sol Discon...2885
        Failure code [DXA9KB] PC-EPC (R) Sol Short...2887
        Failure code [DXE0KA] LS-EPC Sol Discon...2889
        Failure code [DXE0KB] LS-EPC Sol Short...2891
        Failure code [DXE4KA] Service Current EPC Discon...2893
        Failure code [DXE4KB] Service Current EPC Short...2895
        Failure code [DXE5KA] Merge-divider Main Sol Discon...2897
        Failure code [DXE5KB] Merge-divider Main Sol Short...2899
        Failure code [DXE6KA] Merge-divider LS Sol Discon...2901
        Failure code [DXE6KB] Merge-divider LS Sol Short...2903
        Failure code [DY20KA] Wiper Working Abnormality...2905
        Failure code [DY20MA] Wiper Parking Abnormality...2907
        Failure code [DY2CKA] Washer Drive Discon...2909
        Failure code [DY2CKB] Washer Drive Short...2911
        Failure code [DY2DKB] Wiper Drive (For) Short...2913
        Failure code [DY2EKB] Wiper Drive (Rev) Short...2915
        Failure code [DXEAKA] Service Current EPC1 Discon...2917
        Failure code [DXEAKB] Service Current EPC1 Short...2918
        Failure code [DXE7KA] Service Current EPC2 Discon...2919
        Failure code [DXE7KB] Service Current EPC2 Short...2920
        Failure code [DXE8KA] Service Current EPC3 Discon...2921
        Failure code [DXE8KB] Service Current EPC3 Short...2922
        Failure code [DXE9KA] Service Current EPC4 Discon...2923
        Failure code [DXE9KB] Service Current EPC4 Short...2924
        Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality...2927
        Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality...2929
        Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality...2931
        Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality...2933
        Failure code [DFB3L8] Service Lever 1 Potentio Error...2935
        Failure code [DFB4L8] Service Lever 2 Potentio Error...2936
  40 Troubleshooting...2939
    Troubleshooting of electrical system (E-mode)...2939
      Troubleshooting of electrical system (E-mode)...2941
      Before carrying out troubleshooting of electrical system...2941
      Troubleshooting of electrical system (E-mode)...2942
      Information in troubleshooting table...2945
      E-1 When starting switch turned ON, machine monitor displays nothing...2946
      E-2 When starting switch turned ON (before starting engine), basic check item lights up...2948
      E-3 Engine does not start (Engine does not turn)...2951
      E-4 Preheater does not operate...2954
      E-5 Automatic warm-up system does not operate (in cold season)...2956
      E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked...2958
      E-7 Precaution lights up while engine is running...2960
      E-8 Emergency stop item lights up while engine is running...2965
      E-9 Engine coolant temperature gauge does not indicate normally...2966
      E-10 Hydraulic oil temperature gauge does not indicate normally...2967
      E-11 Fuel level gauge does not indicate normally...2969
      E-12 Contents of display by machine monitor are different from applicable machine...2971
      E-13 Machine monitor does not display some items...2971
      E-14 Function switch does not work...2971
      E-15 Auto-decelerator does not operate normally...2972
      E-16 Working mode does not change...2973
      E-17 Travel speed does not change...2974
      E-18 Alarm buzzer cannot be stopped...2975
      E-18 Alarm buzzer cannot be stopped...2976
      E-19 Windshield wiper and window washer do not operate...2978
      E-20 Power maximising function does not operate normally...2980
      E-20 Power maximising function does not operate normally...2982
      E-21 Swing holding brake does not operate normally...2984
      E-22 Travel alarm does not sound or does not stop sounding...2986
      E-23 Air conditioner does not operate normally (including air conditioner abnormality record)...2988
      E-24 When starting switch is turned OFF, service meter is not displayed...3000
      E-25 Machine monitor cannot be set in service mode...3000
      E-26 Monitoring function does not display lever control signal normally...3001
      E-27 KOMTRAX system does not operate normally...3010
  40 Troubleshooting...3013
    Troubleshooting of hydraulic and mechanical system (H-mode)...3013
      Troubleshooting of hydraulic and mechanical system (H-mode)...3016
        System diagram of hydraulic and mechanical system...3016
        Information in troubleshooting table...3018
        H-1 Speed or power of whole work equipment, swing, and travel is low...3019
        H-2 Engine speed lowers extremely or engine stalls...3021
        H-3 Work equipment, swing, and travel systems do not work...3022
        H-4 Abnormal sound comes out from around hydraulic pump...3022
        H-5 Auto-decelerator does not operate...3023
        H-6 Fine control performance or response is low...3023
        H-7 Speed or power of boom is low...3024
        H-8 Speed or power of arm is low...3025
        H-9 Speed or power of bucket is low...3026
        H-10 Work equipment does not move singly...3026
        H-11 Hydraulic drift of work equipment is large...3027
        H-12 Time lag of work equipment is large...3029
        H-13 When part of work equipment is relieved singly, other parts of work equipment move...3029
        H-14 Power maximizing function does not work...3030
        H-15 In compound operation of work equipment, speed of part loaded more is low...3030
        H-16 When machine swings and raises boom simultaneously, boom rising speed is low...3031
        H-17 When machine swings and travels simultaneously, travel speed lowers largely...3031
        H-18 Machine deviates during travel...3032
        H-19 Travel speed is low...3033
        H-20 Machine is not steered well or steering power is low...3034
        H-21 Travel speed does not change or travel speed is low/high...3035
        H-22 Travel system does not move (only one side)...3036
        H-23 Upper structure does not swing...3037
        H-24 Swing acceleration or swing speed is low...3039
        H-25 Upper structure overruns remarkably when it stops swinging...3040
        H-26 Large shock is made when upper structure stops swinging...3041
        H-27 Large sound is made when upper structure stops swinging...3041
        H-28 Hydraulic drift of swing is large...3042
        H-29 Attachment circuit is not changed...3043
        H-30 Oil flow in attachment circuit cannot be controlled...3043
        Quick coupler...3044
        Quick coupler...3046
        Quick coupler...3048
  40 Troubleshooting...3053
    Troubleshooting of engine (S-mode)...3053
      Troubleshooting of engine (S-mode)...3055
        Method of using troubleshooting chart...3055
        S-1 Starting performance is poor...3058
        S-2 Engine does not start...3059
        S-3 Engine does not pick up smoothly...3062
        S-4 Engine stops during operations...3063
        S-5 Engine does not rotate smoothly...3064
        S-6 Engine lack output (or lacks power)...3065
        S-7 Exhaust smoke is black (incomplete combustion)...3067
        S-8 Oil consumption is excessive (or exhaust smoke is blue)...3068
        S-9 Oil becomes contaminated quickly...3069
        S-10 Fuel consumption is excessive...3070
        S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)...3071
        S-12 Oil pressure drops...3072
        S-13 Oil level rises (Entry of coolant/fuel)...3073
        S-14 Coolant temperature becomes too high (overheating)...3074
        S-15 Abnormal noise is made...3075
        S-16 Vibration is excessive...3076
        S-17 Diesel Particulate Filter System...3077
  40 Troubleshooting...3079
    Troubleshooting of Auto Grease system...3079
  50 Disassembly and assembly...3087
    Disassembly and assembly related information...3087
      Disassembly and assembly related information...3088
        How to read this manual...3088
        List of adhesives...3090
        Special tool list...3093
        Sketches of special tools...3098
  50 Disassembly and assembly...3103
    Engine cooling related...3103
      Engine cooling related...3104
        Removal and installation of fuel supply pump assembly...3104
        Removal and installation of fuel injector assembly...3106
        Removal and installation of engine front seal...3113
        Removal and installation of engine rear seal...3116
        Removal and installation of cylinder head assembly...3119
        Removal and installation of radiator assembly...3131
        Removal and installation of assembly hydraulic oil cooler assembly...3134
        Removal and installation of aftercooler assembly...3136
        Removal and installation of fuel cooler assembly...3138
        Removal and installation of engine and hydraulic pump assemblies...3139
  50 Disassembly and assembly...3151
    Power train...3151
      Power train...3152
        Removal and installation of final drive assembly...3152
        Disassembly and assembly of final drive assembly...3154
        Removal and installation of swing motor and swing machinery assembly...3170
        Disassembly and assembly of swing motor and swing machinery assembly...3172
        Removal and installation of swing circle assembly...3182
  50 Disassembly and assembly...3185
    Under carriage and frame...3185
      Under carriage and frame...3186
        Disassembly and assembly of carrier roller...3186
        Disassembly and assembly of track roller assembly...3189
        Disassembly and assembly of idler assembly...3191
        Disassembly and assembly of recoil spring...3194
        Removal and installation of sprocket...3196
        Expansion and installation of track shoe assembly...3197
        Removal and installation of revolving frame assembly...3199
        Removal and installation of counterweight assembly...3201
  50 Disassembly and assembly...3203
    Hydraulic system...3203
      Hydraulic system...3204
        Removal and installation of center swivel joint assembly...3204
        Disassembly and assembly of center swivel joint assembly...3206
        Removal and installation of hydraulic tank assembly...3207
        Removal and installation of control valve assembly...3210
        Disassembly and assembly of control valve assembly...3215
        Removal and installation of hydraulic pump assembly...3219
        Removal and installation of oil seal in hydraulic pump input shaft...3224
        Disassembly and assembly of work equipment PPC valve assembly...3225
        Disassembly and assembly of travel PPC valve assembly...3226
        Disassembly and assembly of hydraulic cylinder assembly...3227
        Disassembly and Assembly of Quick Coupler Valve - For PC210 K50001 - K53423, PC230 K50001 - K50286 and PC240 K50001 - K51093...3233
        Disassembly and Assembly of Quick Coupler Valve - For PC210 K53424 and up, PC230 K50287 and up and PC240 K51094 and up...3234
  50 Disassembly and assembly...3237
    Work equipment...3237
      Work equipment...3238
        Removal and installation of the work equipment assembly...3238
  50 Disassembly and assembly...3243
    Cab related...3243
      Cab related...3244
        Removal and installation of operator's cab assembly...3244
        Removal and installation of operator cab glass (stuck glass)...3247
        Removal and installation of front window assembly...3257
        Removal and installation of floor frame assembly...3264
  50 Disassembly and assembly...3269
    Electric components...3269
      Electric components...3270
        Removal and installation of air conditioner unit assembly...3270
        Removal and installation of KOMTRAX communication modem assembly...3273
        Removal and installation of monitor assembly...3274
        Removal and installation of pump controller assembly...3276
        Removal and installation of engine controller assembly...3277
  90 Diagrams and drawings...3281
    Hydraulic diagrams and drawings...3281
      Hydraulic diagrams and drawings (for PC210 K50001~K51094, PC230 K50001~K50113 and PC240 K50001~K50303)...3283
        Hydraulic circuit diagram 1/2...3283
        Hydraulic circuit diagram 2/2...3285
      Hydraulic diagrams and drawings (For PC210 K51095 and up, PC230 K50114 and up and PC240 K50304 and up)...3287
        Hydraulic circuit diagram 1/2...3287
        Hydraulic circuit diagram 2/2...3289
  90 Diagrams and drawings...3293
    Electrical diagrams and drawings...3293
      Electrical diagrams and drawings (for PC210 K50001~K51094, PC230 K50001~K50113 and PC240 K50001~K50303)...3295
        Electrical circuit diagram (1/5)...3295
        Electrical circuit diagram (2/5)...3297
        Electrical circuit diagram (3/5)...3299
        Electrical circuit diagram (4/5)...3301
        Electrical circuit diagram (5/5)...3303
      Electrical diagrams and drawings (For PC210 K51095 ~ K52292, PC230 K50114 ~ K50200 and PC240 K50304 ~ K50595)...3305
        Electrical circuit diagram (1/5)...3305
        Electrical circuit diagram (2/5)...3307
        Electrical circuit diagram (3/5)...3309
        Electrical circuit diagram (4/5)...3311
        Electrical circuit diagram (5/5)...3313
      Electrical diagrams and drawings (for PC210 K52293 and up, PC230 K50201 and up and PC240 K50596 and up)...3315
        Electrical circuit diagram (1/5)...3315
        Electrical circuit diagram (2/5)...3317
        Electrical circuit diagram (3/5)...3319
        Electrical circuit diagram (4/5)...3321
        Electrical circuit diagram (5/5)...3323
        Connector arrangement diagram...3325
        Electrical circuit diagram for air conditioner...3327

Komatsu Hydraulic Excavator PC210, PC210LC, PC210NLC, PC230NHD, PC240LC, PC240NLC Repair Service Manuals