KOMATSU PC230NHD-8 Hydraulic Excavator Service Manual
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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
The KOMATSU PC230NHD-8 HYDRAULIC EXCAVATOR SN K50001 and up service manual is an essential resource for both professional mechanics and DIY enthusiasts. It provides accurate technical information and repair instructions for the product, covering various aspects of repair and maintenance.
The manual includes the following sections:
01 GENERAL
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
90 OTHERS
Key features of the manual:
Ability to print specific pages or the entire manual
Detailed substeps for repair procedures
Important notes, cautions, and warnings throughout each chapter
Numbered instructions for easy guidance
Bold figure numbers for quick reference to illustrations
Detailed illustrations, drawings, and photos for visual guidance
Enlarged inset for detailed parts examination
Numbered table of contents for quick information retrieval
The KOMATSU PC230NHD-8 HYDRAULIC EXCAVATOR SN K50001 AND UP manual is available in .PDF format and is compatible with all versions of Windows and Mac. It can be saved to the hard drive or burned to a CD-ROM, offering the convenience of accessibility without shipping delays.
With its comprehensive coverage and user-friendly format, this manual is an indispensable tool for anyone involved in the repair and maintenance of the KOMATSU PC230NHD-8 HYDRAULIC EXCAVATOR SN K50001 and up.
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KOMATSU PC230NHD-8 Hydraulic Excavator Service Manual