Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Hydraulic Excavator Service Manual
1,205 pages · Publication UEN00084-07
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- Models
- PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8
- Serial coverage
- K50001 and up
- Manual type
- Service Manual
- Pages
- 1,205
- Publication
- UEN00084-07
- Condition
- Brand new
What's inside
From the manual's own table of contents: 191 sections, 388 entries. See sample pages (PDF, 1067 KB)
Organization list of the shop manual
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling electric equipment and hydraulic component
How to read electric wire code
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
Specification and technical data
Specification dimension drawings
Working range diagram
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine and cooling system
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
Diesel Particulate Filter
Diesel Particulate Filter - Component Parts
System Description
Regeneration
Power train
Show all 191 sections
Final drive
Swing machinery
Swing circle
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system, Part 1
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Pilot oil filter37 topics
- Hydraulic system, Part 2
- Control valve
- CLSS
- Functions and operation by valve
- Hydraulic system, Part 3
- Swing motor
- Centre swivel joint
- Travel motor
- PPC valve
- Valve control
- ATT EPC Valve Assembly
- Solenoid valve
- PPC Accumulator
- Return oil filter
- Attachment circuit selector valve
- Hydraulic cylinder
- Work equipment
- Dimensions of components
- Cab and its attachments
- Air conditioner piping
- Electrical system
- Engine control
- Electrical control system
- Monitor system
- Sensor
- PPC Levers
- KOMTRAX terminal system
- Outline of Auto Grease System
- Assembly
- Components
- The Greasing Cycle
- Introduction
- Standard service value table
- Standard value table for engine related parts
- Standard value table for chassis related parts
- Testing and adjusting, Part 1
- Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Checking exhaust gas colour
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Measuring fuel pressure
Measuring fuel return rate and leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Checking and adjusting air conditioner compressor belt tension
Measuring swing circle bearing clearance
Checking and adjusting track shoe tension
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits
Measuring control circuit basic pressure
Measuring and adjusting oil pressure in pump PC control circuit
Measuring and adjusting oil pressure in pump LS control circuit
Measuring solenoid valve output pressure
Measuring PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Checking parts which cause hydraulic drift of work equipment
Releasing residual pressure from hydraulic circuit
Measuring oil leakage
Bleeding air from each part
Checking cab tipping stopper
Adjusting mirrors
Testing and adjusting, Part 2
Special functions of machine monitor
Testing and adjusting, Part 3
Handling high-voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service
Points to remember when troubleshooting
Sequence of events in troubleshooting
Check before troubleshooting
Classification and procedures for troubleshooting
Connection table for connector pin numbers
T-boxes and T-adapters table
Failure codes table
Before carrying out troubleshooting when failure code is displayed
Information in troubleshooting table
Failure code [989L00] Engine Controller Lock Caution 157 topics
- Failure code [989M00] Engine Controller Lock Caution 2
- Failure code [989N00] Engine Controller Lock Caution 3
- Failure code [AA10NX] Air Cleaner Clogging
- Failure code [AB00KE] Charge Voltage Low
- Failure code [B@BAZG] Eng Oil Press. Low
- Failure code [B@BAZK] Eng Oil Level Low
- Failure code [B@BCNS] Eng Water Overheat
- Failure code [B@BCZK] Eng Water Level Low
- Failure code [B@HANS] Hydr Oil Overheat
- Failure code [CA111] EMC Critical Internal Failure
- Failure code [CA115] Eng Ne and Bkup Speed Sens Error
- Failure code [CA122] Chg Air Press Sensor High Error
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA155] Chg Air Temp High Speed Derate
- Failure code [CA187] Sens Supply 2 Volt Low Error
- Failure code [CA221] Ambient Press Sens High Error
- Failure code [CA222] Ambient Press Sens Low Error
- Failure code [CA227] Sens Supply 2 Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sens Supply Volt Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA322] Inj #1 (L#1) Open/Short Error
- Failure code [CA323] Inj #5 (L#5) Open/Short Error
- Failure code [CA324] Inj #3 (L#3) Open/Short Error
- Failure code [CA325] Inj #6 (L#6) Open/Short Error
- Failure code [CA331] Inj #2 (L#2) Open/Short Error
- Failure code [CA332] Inj #4 (L#4) Open/Short Error
- Failure code [CA342] Calibration Code Incompatibility
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sens Supply 1 Volt Low Error
- Failure code [CA386] Sens Supply 1 Volt High Error
- Failure code [CA428] Water in Fuel Sensor High Error
- Failure code [CA429] Water in Fuel Sensor Low Error
- Failure code [CA435] Eng Oil Press Sw Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA488] Chg Air Temp High Torque Derate
- Failure code [CA553] Rail Press High Error
- Failure code [CA559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA757] All Continuous Data Lost Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1633] KOMNET Datalink Timeout Error
- Failure code [CA2185] Throt Sens Sup Volt High Error
- Failure code [CA2186] Throt Sens Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2556] Grid Htr Relay Volt Low Error
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D862KA] GPS Antenna Discon
Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA2RMC] CAN Discon (Pump Con Detected)
Failure code [DAFGMC] GPS Module Error
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DGH2KB] Hydr Oil Sensor Short
Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHX1MA] Overload Sensor Abnormality (Analog)
Failure code [DW43KA] Travel Speed Sol Discon
Failure code [DW43KB] Travel Speed Sol Short
Failure code [DW45KA] Swing Brake Sol Discon
Failure code [DW45KB] Swing Brake Sol Short
Failure code [DW91KA] Travel Junction Sol Discon
Failure code [DW91KB] Travel Junction Sol Short
Failure code [DWA2KA] Service Sol Discon
Failure code [DWA2KB] Service Sol Short
Failure code [DWK0KA] 2-stage Relief Sol Discon
Failure code [DWK0KB] 2-stage Relief Sol Short
Failure code [DXA8KA] PC-EPC (F) Sol Discon
Failure code [DXA8KB] PC-EPC (F) Sol Short
Failure code [DXA9KA] PC-EPC (R) Sol Discon
Failure code [DXA9KB] PC-EPC (R) Sol Short
Failure code [DXE0KA] LS-EPC Sol Discon
Failure code [DXE0KB] LS-EPC Sol Short
Failure code [DXE4KA] Service Current EPC Discon
Failure code [DXE4KB] Service Current EPC Short
Failure code [DXE5KA] Merge-divider Main Sol Discon
Failure code [DXE5KB] Merge-divider Main Sol Short
Failure code [DXE6KA] Merge-divider LS Sol Discon
Failure code [DXE6KB] Merge-divider LS Sol Short
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKA] Washer Drive Discon
Failure code [DY2CKB] Washer Drive Short
Failure code [DY2DKB] Wiper Drive (For) Short
Failure code [DY2EKB] Wiper Drive (Rev) Short
Failure code [DXEAKA] Service Current EPC1 Discon
Failure code [DXEAKB] Service Current EPC1 Short
Failure code [DXE7KA] Service Current EPC2 Discon
Failure code [DXE7KB] Service Current EPC2 Short
Failure code [DXE8KA] Service Current EPC3 Discon
Failure code [DXE8KB] Service Current EPC3 Short
Failure code [DXE9KA] Service Current EPC4 Discon
Failure code [DXE9KB] Service Current EPC4 Short53 topics
- Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality
- Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality
- Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality
- Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality
- Failure code [DFB3L8] Service Lever 1 Potentio Error
- Failure code [DFB4L8] Service Lever 2 Potentio Error
- Troubleshooting of electrical system (E-mode)
- Before carrying out troubleshooting of electrical system
- Information in troubleshooting table
- When starting switch turned ON, machine monitor displays nothing
- When starting switch turned ON (before starting engine), basic check item lights up
- Engine does not start (Engine does not turn)
- Preheater does not operate
- Automatic warm-up system does not operate (in cold season)
- All work equipment, swing, and travel mechanism do not move or cannot be locked
- Precaution lights up while engine is running
- Emergency stop item lights up while engine is running
- Engine coolant temperature gauge does not indicate normally
- Hydraulic oil temperature gauge does not indicate normally
- Fuel level gauge does not indicate normally
- Contents of display by machine monitor are different from applicable machine
- Machine monitor does not display some items
- Function switch does not work
- Auto-decelerator does not operate normally
- Working mode does not change
- Travel speed does not change
- Alarm buzzer cannot be stopped
- Windshield wiper and window washer do not operate
- Power maximising function does not operate normally
- Swing holding brake does not operate normally
- Travel alarm does not sound or does not stop sounding
- When starting switch is turned OFF, service meter is not displayed
- Machine monitor cannot be set in service mode
- Monitoring function does not display lever control signal normally
- KOMTRAX system does not operate normally
- System diagram of hydraulic and mechanical system
- Speed or power of whole work equipment, swing, and travel is low
- Engine speed lowers extremely or engine stalls
- Work equipment, swing, and travel systems do not work
- Abnormal sound comes out from around hydraulic pump
- Auto-decelerator does not operate
- Fine control performance or response is low
- Speed or power of boom is low
- Speed or power of arm is low
- Speed or power of bucket is low
- Work equipment does not move singly
- Hydraulic drift of work equipment is large
- Time lag of work equipment is large
- When part of work equipment is relieved singly, other parts of work equipment move
- Power maximizing function does not work
- In compound operation of work equipment, speed of part loaded more is low
- When machine swings and raises boom simultaneously, boom rising speed is low
- When machine swings and travels simultaneously, travel speed lowers largely
Machine deviates during travel
Travel speed is low
Machine is not steered well or steering power is low
Travel speed does not change or travel speed is low/high
Travel system does not move (only one side)
Upper structure does not swing
Swing acceleration or swing speed is low
Upper structure overruns remarkably when it stops swinging
Large shock is made when upper structure stops swinging
Large sound is made when upper structure stops swinging
Hydraulic drift of swing is large
Attachment circuit is not changed
Oil flow in attachment circuit cannot be controlled
Quick coupler
Method of using troubleshooting chart
Starting performance is poor
Engine does not start
Engine does not pick up smoothly
Engine stops during operations
Engine does not rotate smoothly
Engine lack output (or lacks power)
Exhaust smoke is black (incomplete combustion)
Oil consumption is excessive (or exhaust smoke is blue)
Oil becomes contaminated quickly
Fuel consumption is excessive
Oil is in coolant (or coolant spurts back or coolant level goes down)
Oil pressure drops
Oil level rises (Entry of coolant/fuel)
Coolant temperature becomes too high (overheating)
Abnormal noise is made
Vibration is excessive
Diesel Particulate Filter System
Finding malfunctions
Malfunction reports of the display
General
Malfunction finding procedures
Procedure to check the correct working of the grease pressure switch and cable
Procedure to check the working of the pump and the 5/2-magnetic valve
Procedure when an internal system leak is suspected
Disassembly and assembly related information
How to read this manual
List of adhesives
Special tool list
Sketches of special tools
Engine cooling related
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly50 topics
- Removal and installation of assembly hydraulic oil cooler assembly
- Removal and installation of aftercooler assembly
- Removal and installation of fuel cooler assembly
- Removal and installation of engine and hydraulic pump assemblies
- Removal and installation of final drive assembly
- Disassembly and assembly of final drive assembly
- Removal and installation of swing motor and swing machinery assembly
- Disassembly and assembly of swing motor and swing machinery assembly
- Removal and installation of swing circle assembly
- Under carriage and frame
- Disassembly and assembly of carrier roller
- Disassembly and assembly of track roller assembly
- Disassembly and assembly of idler assembly
- Disassembly and assembly of recoil spring
- Removal and installation of sprocket
- Expansion and installation of track shoe assembly
- Removal and installation of revolving frame assembly
- Removal and installation of counterweight assembly
- Hydraulic system
- Removal and installation of center swivel joint assembly
- Disassembly and assembly of center swivel joint assembly
- Removal and installation of hydraulic tank assembly
- Removal and installation of control valve assembly
- Disassembly and assembly of control valve assembly
- Removal and installation of hydraulic pump assembly
- Removal and installation of oil seal in hydraulic pump input shaft
- Disassembly and assembly of work equipment PPC valve assembly
- Disassembly and assembly of travel PPC valve assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Removal and installation of the work equipment assembly
- Cab related
- Removal and installation of operator's cab assembly
- Removal and installation of operator cab glass (stuck glass)
- Removal and installation of front window assembly
- Removal and installation of floor frame assembly
- Electric components
- Removal and installation of air conditioner unit assembly
- Removal and installation of KOMTRAX communication modem assembly
- Removal and installation of monitor assembly
- Removal and installation of pump controller assembly
- Removal and installation of engine controller assembly
- Hydraulic circuit diagram 1/2
- Hydraulic circuit diagram 2/2
- Electrical circuit diagram (1/5)
- Electrical circuit diagram (2/5)
- Electrical circuit diagram (3/5)
- Electrical circuit diagram (4/5)
- Electrical circuit diagram (5/5)
- Connector arrangement diagram
- Electrical circuit diagram for air conditioner
Inside this manual
Real pages from this service manual (1,205 pages). Open the sample pages (PDF, 1066 KB)
- Troubleshooting, page 591: Information in troubleshooting table
- Diagram, page 681: Failure code [CA2185] Throt Sens Sup Volt High Error
- Specifications, page 987: 50 Disassembly and assembly
- Color page, page 425: 30 Testing and adjusting
- Color page, page 1,018: 50 Disassembly and assembly
- Foldout diagram, page 1,180: Electrical circuit diagram (1/5)
Other manuals for this machine
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This is a service manual
Here's how it compares to the other manual types.
This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 1,205 pages
Quantity one is the manual described above.
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Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
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