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Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Hydraulic Excavator Service & Repair Manual P
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UEN00084-01
HYDRAULIC
EXCAVATOR
PC210-8
PC210LC-8
PC210NLC-8
PC230NHD-8
PC240LC-8
PC240NLC-8
SERIAL NUMBERS
PC210- K50001
and up
PC210LC- K50001
PC210NLC- K50001
PC230NHD-K50001
PC240LC- K50001
PC240NLC- K50001


PC210, 230, 240-8 1
UEN00093-01
HYDRAULIC EXCAVATOR
1SHOP MANUAL
PC210-8
PC210LC-8
PC210NLC-8
PC230NHD-8
PC240LC-8
PC240NLC-8
Machine model Serial number
PC210-8 K50001 and up
PC210LC-8 K50001 and up
PC210NLC-8 K50001 and up
PC230NHD-8 K50001 and up
PC240LC-8 K50001 and up
PC240NLC-8 K50001 and up
00 Index and foreword 1
Index
Organization list of the shop manual .................................................................................................... 2
Table of contents .................................................................................................................................. 4

UEN00093-01 00 Index and foreword
2 PC210, 230, 240-8
Organization list of the shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs UEN00084-01 q
00 Index and foreword
Index UEN00093-01 q
Foreword and general information UEN00094-00
01 Specification
Specification and technical data UEN00095-00
10 Structure, function and maintenance standard
Engine and cooling system UEN00096-00
Power train UEN00097-00
Undercarriage and frame UEN00098-00
Hydraulic system, Part 1 UEN00099-00
Hydraulic system, Part 2 UEN00100-00
Hydraulic system, Part 3 UEN00160-00
Work equipment UEN00101-00
Cab and its attachments UEN00102-00
Electrical system UEN00103-00
20 Standard value table
Standard service value table UEN00227-00
30 Testing and adjusting
Testing and adjusting, Part 1 UEN00228-00
Testing and adjusting, Part 2 UEN00229-00
Testing and adjusting, Part 3 UEN00230-00

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

UEN00093-01 00 Index and foreword
4 PC210, 230, 240-8
Table of contents 1
00 Index and foreword
Index UEN00093-01
Organization list of the shop manual ....................................................................................... 2
Table of contents...................................................................................................................... 4
Foreword and general information UEN00094-00
Foreword and general information .............................................................................................. 2
Safety notice ............................................................................................................................ 2
How to read the shop manual .................................................................................................. 6
Explanation of terms for maintenance standard ...................................................................... 8
Handling electric equipment and hydraulic component ........................................................... 10
How to read electric wire code................................................................................................. 18
Method of disassembling and connecting push-pull type coupler ........................................... 21
Standard tightening torque table .............................................................................................. 24
Conversion table ...................................................................................................................... 28
01 Specification
Specification and technical data UEN00095-00
Specification and technical data .................................................................................................. 2
Specification dimension drawings ............................................................................................ 2
Working range diagram ........................................................................................................... 3
Specifications ........................................................................................................................... 4
Weight table ............................................................................................................................. 8
Table of fuel, coolant and lubricants ........................................................................................ 12
10 Structure, function and maintenance standard
Engine and cooling system UEN00096-00
Engine and cooling system ......................................................................................................... 2
Engine related parts................................................................................................................. 2
Radiator, oil cooler, aftercooler and fuel cooler ........................................................................ 3
Power train UEN00097-00
Power train .................................................................................................................................. 2
Power train............................................................................................................................... 2
Final drive ................................................................................................................................ 4
Swing machinery ..................................................................................................................... 6
Swing circle.............................................................................................................................. 10
Undercarriage and frame UEN00098-00
Undercarriage and frame ............................................................................................................ 2
Track frame and recoil spring .................................................................................................. 2
Idler .......................................................................................................................................... 4
Carrier roller ............................................................................................................................. 6
Track roller ............................................................................................................................... 7
Track shoe ............................................................................................................................... 8
Hydraulic system, Part 1 UEN00099-00
Hydraulic system, Part 1 ............................................................................................................. 2
Hydraulic equipment layout drawing ........................................................................................ 2
Hydraulic tank and filter ........................................................................................................... 4
Hydraulic pump ........................................................................................................................ 5
Pilot oil filter ............................................................................................................................. 29
Hydraulic system, Part 2 UEN00100-00
Hydraulic system, Part 2 ............................................................................................................. 2
Control valve ............................................................................................................................ 2
CLSS ....................................................................................................................................... 15

00 Index and foreword UEN00093-01
PC210, 230, 240-8 5
Functions and operation by valve ............................................................................................ 20
Hydraulic system, Part 3 UEN00160-00
Hydraulic system, Part 3 ............................................................................................................. 3
Swing motor............................................................................................................................. 3
Center swivel joint ................................................................................................................... 12
Travel motor............................................................................................................................. 15
PPC valve ................................................................................................................................ 26
Work equipment and swing PPC valve ................................................................................... 26
Travel PPC valve ..................................................................................................................... 31
Service PPC valve (with EPC valve) ....................................................................................... 40
Service PPC valve ................................................................................................................... 46
Valve control ............................................................................................................................ 48
Solenoid valve ......................................................................................................................... 50
PPC Accumulator .................................................................................................................... 52
Return oil filter ......................................................................................................................... 53
Attachment circuit selector valve ............................................................................................. 54
Hydraulic cylinder .................................................................................................................... 56
Work equipment UEN00101-00
Work equipment .......................................................................................................................... 2
Dimensions of components ..................................................................................................... 2
Cab and its attachments UEN00102-00
Cab and its attachments.............................................................................................................. 2
Air conditioner piping ............................................................................................................... 2
Electrical system UEN00103-00
Electrical system ......................................................................................................................... 2
Engine control .......................................................................................................................... 2
Electrical control system .......................................................................................................... 10
Monitor system ........................................................................................................................ 30
Sensor ..................................................................................................................................... 57
KOMTRAX terminal system..................................................................................................... 60
20 Standard value table
Standard service value table UEN00227-00
Standard service value table ....................................................................................................... 2
Standard value table for engine related parts .......................................................................... 2
Standard value table for chassis related parts ......................................................................... 4
30 Testing and adjusting
Testing and adjusting, Part 1 UEN00228-00
Testing and adjusting, Part 1 ....................................................................................................... 3
Tools for testing, adjusting, and troubleshooting ..................................................................... 3
Measuring engine speed ......................................................................................................... 6
Measuring intake air pressure (boost pressure) ...................................................................... 7
Checking exhaust gas color .................................................................................................... 8
Adjusting valve clearance ........................................................................................................ 9
Measuring compression pressure ........................................................................................... 11
Measuring blow-by pressure ................................................................................................... 13
Measuring engine oil pressure ................................................................................................ 14
Handling fuel system parts ...................................................................................................... 15
Releasing residual pressure from fuel system......................................................................... 15
Measuring fuel pressure .......................................................................................................... 16
Measuring fuel return rate and leakage ................................................................................... 18
Bleeding air from fuel circuit .................................................................................................... 20
Checking fuel circuit for leakage.............................................................................................. 22
Checking and adjusting air conditioner compressor belt tension ............................................ 23
Measuring swing circle bearing clearance............................................................................... 24

UEN00093-01 00 Index and foreword
6 PC210, 230, 240-8
Checking and adjusting track shoe tension ............................................................................. 25
Measuring and adjusting oil pressure in work equipment, swing, and travel circuits............... 27
Measuring control circuit basic pressure ................................................................................. 31
Measuring and adjusting oil pressure in pump PC control circuit ............................................ 32
Measuring and adjusting oil pressure in pump LS control circuit ............................................. 36
Measuring solenoid valve output pressure .............................................................................. 42
Measuring PPC valve output pressure .................................................................................... 45
Adjusting play of work equipment and swing PPC valves ....................................................... 47
Checking parts which cause hydraulic drift of work equipment ............................................... 48
Releasing residual pressure from hydraulic circuit .................................................................. 50
Measuring oil leakage .............................................................................................................. 51
Bleeding air from each part ...................................................................................................... 54
Checking cab tipping stopper .................................................................................................. 57
Adjusting mirrors ...................................................................................................................... 58
Testing and adjusting, Part 2 UEN00229-00
Testing and adjusting, Part 2 ....................................................................................................... 2
Special functions of machine monitor ...................................................................................... 2
Testing and adjusting, Part 3 UEN00230-00
Testing and adjusting, Part 3 ....................................................................................................... 2
Handling high-voltage circuit of engine controller .................................................................... 2
Preparation work for troubleshooting of electrical system ....................................................... 3
Procedure for testing diodes .................................................................................................... 7
Pm Clinic service ..................................................................................................................... 9
40 Troubleshooting
General information on troubleshooting UEN00231-00
Points to remember when troubleshooting .............................................................................. 2
Sequence of events in troubleshooting.................................................................................... 3
Check before troubleshooting .................................................................................................. 4
Classification and procedures for troubleshooting ................................................................... 5
How to read electric wire code................................................................................................. 9
Connection table for connector pin numbers ........................................................................... 12
T-boxes and T-adapters table .................................................................................................. 35
Troubleshooting by failure code (Display of code), Part 1 UEN00240-00
Failure codes table .................................................................................................................. 3
Before carrying out troubleshooting when failure code is displayed ........................................ 8
Information in troubleshooting table......................................................................................... 12
Failure code [989L00] Engine Controller Lock Caution 1 ........................................................ 14
Failure code [989M00] Engine Controller Lock Caution 2 ....................................................... 14
Failure code [989N00] Engine Controller Lock Caution 3........................................................ 15
Failure code [AA10NX] Air Cleaner Clogging .......................................................................... 15
Failure code [AB00KE] Charge Voltage Low ........................................................................... 16
Failure code [B@BAZG] Eng Oil Press. Low........................................................................... 18
Failure code [B@BAZK] Eng Oil Level Low............................................................................. 18
Failure code [B@BCNS] Eng Water Overheat ........................................................................ 19
Failure code [B@BCZK] Eng Water Level Low ....................................................................... 19
Failure code [B@HANS] Hydr Oil Overheat ............................................................................ 20
Failure code [CA111] EMC Critical Internal Failure.................................................................. 20
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ..................................................... 21
Failure code [CA122] Chg Air Press Sensor High Error .......................................................... 22
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................... 24
Failure code [CA131] Throttle Sensor High Error .................................................................... 26
Failure code [CA132] Throttle Sensor Low Error ..................................................................... 28
Failure code [CA144] Coolant Temp Sens High Error ............................................................. 30
Failure code [CA145] Coolant Temp Sens Low Error .............................................................. 32
Failure code [CA153] Chg Air Temp Sensor High Error .......................................................... 34
Failure code [CA154] Chg Air Temp Sensor Low Error ........................................................... 36

00 Index and foreword UEN00093-01
PC210, 230, 240-8 7
Failure code [CA155] Chg Air Temp High Speed Derate......................................................... 38
Failure code [CA187] Sens Supply 2 Volt Low Error ............................................................... 40
Failure code [CA221] Ambient Press Sens High Error ............................................................ 42
Failure code [CA222] Ambient Press Sens Low Error ............................................................. 44
Failure code [CA227] Sens Supply 2 Volt High Error .............................................................. 46
Failure code [CA234] Eng Overspeed ..................................................................................... 47
Failure code [CA238] Ne Speed Sens Supply Volt Error ......................................................... 48
Failure code [CA271] IMV/PCV1 Short Error .......................................................................... 49
Failure code [CA272] IMV/PCV1 Open Error .......................................................................... 50
Failure code [CA322] Inj #1 (L#1) Open/Short Error ............................................................... 52
Failure code [CA323] Inj #5 (L#5) Open/Short Error ............................................................... 54
Failure code [CA324] Inj #3 (L#3) Open/Short Error ............................................................... 56
Failure code [CA325] Inj #6 (L#6) Open/Short Error ............................................................... 58
Failure code [CA331] Inj #2 (L#2) Open/Short Error ............................................................... 60
Failure code [CA332] Inj #4 (L#4) Open/Short Error ............................................................... 62
Troubleshooting by failure code (Display of code), Part 2 UEN00241-00
Failure code [CA342] Calibration Code Incompatibility ........................................................... 3
Failure code [CA351] Injectors Drive Circuit Error ................................................................... 4
Failure code [CA352] Sens Supply 1 Volt Low Error ............................................................... 6
Failure code [CA386] Sens Supply 1 Volt High Error .............................................................. 8
Failure code [CA428] Water in Fuel Sensor High Error ........................................................... 10
Failure code [CA429] Water in Fuel Sensor Low Error............................................................ 12
Failure code [CA435] Eng Oil Press Sw Error ......................................................................... 14
Failure code [CA441] Battery Voltage Low Error ..................................................................... 15
Failure code [CA442] Battery Voltage High Error .................................................................... 18
Failure code [CA449] Rail Press Very High Error .................................................................... 20
Failure code [CA451] Rail Press Sensor High Error ................................................................ 22
Failure code [CA452] Rail Press Sensor Low Error ................................................................ 24
Failure code [CA488] Chg Air Temp High Torque Derate ........................................................ 26
Failure code [CA553] Rail Press High Error ............................................................................ 26
Failure code [CA559] Rail Press Low Error ............................................................................. 27
Failure code [CA689] Eng Ne Speed Sensor Error ................................................................. 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error...................................................... 30
Failure code [CA757] All Continuous Data Lost Error ............................................................. 32
Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................. 34
Failure code [CA1633] KOMNET Datalink Timeout Error ........................................................ 36
Failure code [CA2185] Throt Sens Sup Volt High Error .......................................................... 38
Failure code [CA2186] Throt Sens Sup Volt Low Error ........................................................... 39
Failure code [CA2249] Rail Press Very Low Error ................................................................... 40
Failure code [CA2311] IMV Solenoid Error .............................................................................. 42
Failure code [CA2555] Grid Htr Relay Volt High Error ............................................................. 44
Failure code [CA2556] Grid Htr Relay Volt Low Error ............................................................. 46
Failure code [D19JKZ] Personal Code Relay Abnormality ...................................................... 48
Failure code [D862KA] GPS Antenna Discon ......................................................................... 50
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ........................................................ 51
Failure code [DA29KQ] Model Selection Abnormality ............................................................. 58
Troubleshooting by failure code (Display of code), Part 3 UEN00242-00
Failure code [DA2RMC] CAN Discon (Pump Con Detected) .................................................. 4
Failure code [DAFGMC] GPS Module Error ............................................................................ 6
Failure code [DAFRMC] CAN Discon (Monitor Detected) ....................................................... 8
Failure code [DGH2KB] Hydr Oil Sensor Short ....................................................................... 10
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................... 12
Failure code [DHPBMA] R Pump Press Sensor Abnormality .................................................. 14
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality......................................... 16
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................... 18
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................... 20
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ...................................... 22
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ....................................... 24

UEN00093-01 00 Index and foreword
8 PC210, 230, 240-8
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................. 26
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) ............................................ 28
Failure code [DW43KA] Travel Speed Sol Discon ................................................................... 30
Failure code [DW43KB] Travel Speed Sol Short ..................................................................... 32
Failure code [DW45KA] Swing Brake Sol Discon .................................................................... 34
Failure code [DW45KB] Swing Brake Sol Short ...................................................................... 36
Failure code [DW91KA] Travel Junction Sol Discon ................................................................ 38
Failure code [DW91KB] Travel Junction Sol Short .................................................................. 40
Failure code [DWA2KA] Service Sol Discon ............................................................................ 42
Failure code [DWA2KB] Service Sol Short .............................................................................. 43
Failure code [DWK0KA] 2-stage Relief Sol Discon ................................................................. 44
Failure code [DWK0KB] 2-stage Relief Sol Short .................................................................... 46
Troubleshooting by failure code (Display of code), Part 4 UEN00243-00
Failure code [DXA8KA] PC-EPC (F) Sol Discon ..................................................................... 4
Failure code [DXA8KB] PC-EPC (F) Sol Short ........................................................................ 6
Failure code [DXA9KA] PC-EPC (R) Sol Discon ..................................................................... 8
Failure code [DXA9KB] PC-EPC (R) Sol Short ....................................................................... 10
Failure code [DXE0KA] LS-EPC Sol Discon............................................................................ 12
Failure code [DXE0KB] LS-EPC Sol Short .............................................................................. 14
Failure code [DXE4KA] Service Current EPC Discon ............................................................. 16
Failure code [DXE4KB] Service Current EPC Short ................................................................ 18
Failure code [DXE5KA] Merge-divider Main Sol Discon .......................................................... 20
Failure code [DXE5KB] Merge-divider Main Sol Short ............................................................ 22
Failure code [DXE6KA] Merge-divider LS Sol Discon ............................................................. 24
Failure code [DXE6KB] Merge-divider LS Sol Short ................................................................ 26
Failure code [DY20KA] Wiper Working Abnormality................................................................ 28
Failure code [DY20MA] Wiper Parking Abnormality ................................................................ 30
Failure code [DY2CKA] Washer Drive Discon ......................................................................... 32
Failure code [DY2CKB] Washer Drive Short ........................................................................... 34
Failure code [DY2DKB] Wiper Drive (For) Short ..................................................................... 36
Failure code [DY2EKB] Wiper Drive (Rev) Short ..................................................................... 38
Troubleshooting of electrical system (E-mode) UEN00244-00
Before carrying out troubleshooting of electrical system ......................................................... 3
Information in troubleshooting table......................................................................................... 5
E-1 When starting switch turned ON, machine monitor displays nothing ................................ 6
E-2 When starting switch turned ON (before starting engine), basic check item lights up ...... 8
E-3 Engine does not start (Engine does not turn) .................................................................... 11
E-4 Preheater does not operate .............................................................................................. 14
E-5 Automatic warm-up system does not operate (in cold season) ........................................ 16
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked ...... 18
E-7 Precaution lights up while engine is running ..................................................................... 20
E-8 Emergency stop item lights up while engine is running .................................................... 25
E-9 Engine coolant temperature gauge does not indicate normally ........................................ 26
E-10 Hydraulic oil temperature gauge does not indicate normally .......................................... 27
E-11 Fuel level gauge does not indicate normally ................................................................... 29
E-12 Contents of display by machine monitor are different from applicable machine ............. 31
E-13 Machine monitor does not display some items ............................................................... 31
E-14 Function switch does not work ........................................................................................ 31
E-15 Auto-decelerator does not operate normally ................................................................... 32
E-16 Working mode does not change ..................................................................................... 33
E-17 Travel speed does not change ........................................................................................ 34
E-18 Alarm buzzer cannot be stopped .................................................................................... 35
E-19 Windshield wiper and window washer do not operate .................................................... 36
E-20 Power maximizing function does not operate normally ................................................... 38
E-21 Swing holding brake does not operate normally ............................................................. 40
E-22 Travel alarm does not sound or does not stop sounding ................................................ 42
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 44
E-24 When starting switch is turned OFF, service meter is not displayed ............................... 56
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- This is a comprehensive Factory Service Repair Workshop Manual for the Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Hydraulic Excavator.
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- Professionally written and designed, this manual covers all repairs, servicing, and troubleshooting procedures with detailed photos, diagrams, and step-by-step instructions.
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