Komatsu PC210-11 PC230NHD-11 Series Excavator Repair Manual PDF

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00364 – PDF DOWNLOAD

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00364 – PDF DOWNLOAD

Language : English
Pages :2804
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00364 – PDF DOWNLOAD

SERIAL NUMBERS

• 500007 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC210-11, PC210LC-11, PC210NLC-11 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC210-11, PC210LC-11, PC210NLC-11 102
SPECIFICATIONS 103
SPECIFICATIONS: PC210-11, PC210LC-11, PC210NLC-11 . 103
WEIGHT TABLE 106
WEIGHT TABLE: PC210-11, PC210LC-11, PC210NLC-11 . 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION . 109
CONTENTS 110
ABBREVIATION LIST . 114
UREA SCR SYSTEM . 120
LAYOUT DRAWING OF UREA SCR SYSTEM . 121
UREA SCR SYSTEM DIAGRAM . 126
FUNCTION OF UREA SCR SYSTEM . 127
FUNCTION OF AdBlue/DEF SYSTEM . 127
INDUCEMENT STRATEGY . 129
COMPONENT PARTS OF UREA SCR SYSTEM 137
AdBlue/DEF MIXING TUBE 137
SCR ASSEMBLY 137
AdBlue/DEF TANK . 140
AdBlue/DEF PUMP . 142
AdBlue/DEF INJECTOR . 143
AdBlue/DEF HOSE . 144
AdBlue/DEF TANK HEATING VALVE . 145
BOOT-UP SYSTEM 146
LAYOUT DRAWING OF BOOT-UP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 149
FUNCTION OF BATTERY DISCONNECT SWITCH . 149
ENGINE SYSTEM . 150
LAYOUT DRAWING OF ENGINE SYSTEM . 150
SPECIFICATIONS OF ENGINE SYSTEM . 151
FUNCTION OF ENGINE SYSTEM . 151
ENGINE CONTROL SYSTEM . 152
ENGINE CONTROL SYSTEM DIAGRAM . 152
FUNCTION OF ENGINE CONTROL SYSTEM . 153
AUTO-DECELERATION SYSTEM 155
AUTO-DECELERATION SYSTEM DIAGRAM 155
FUNCTION OF AUTO-DECELERATION SYSTEM 155
OPERATION OF AUTO-DECELERATION SYSTEM . 156
ENGINE AUTOMATIC WARM-UP SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 158
OVERHEAT PREVENTION SYSTEM 159
OVERHEAT PREVENTION SYSTEM DIAGRAM 159
FUNCTION OF OVERHEAT PREVENTION SYSTEM 160
TURBOCHARGER PROTECTION SYSTEM 162
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 162
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 163
AUTOMATIC IDLE STOP SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 164
COMPONENT PARTS OF ENGINE SYSTEM 167
VGT . 167
EGR SYSTEM 170
EGR VALVE . 172
EGR COOLER 174
KCCV SYSTEM . 175
KCCV VENTILATOR . 177
KDPF 179
COOLING SYSTEM 184
LAYOUT DRAWING OF COOLING SYSTEM 184
SPECIFICATIONS OF COOLING SYSTEM 185
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 186
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 186
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 187
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 188
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 188
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 188
COMPONENT PARTS OF COOLING SYSTEM . 190
FAN CLUTCH 190
CONTROL SYSTEM 191
LAYOUT DRAWING OF CONTROL SYSTEM 191
MACHINE MONITOR SYSTEM 194
MACHINE MONITOR SYSTEM DIAGRAM 194
KomVision SYSTEM 195
LAYOUT DRAWING OF KOMVISION SYSTEM 195
KomVision SYSTEM DIAGRAM 196
FUNCTION OF KomVision SYSTEM 197
KOMTRAX SYSTEM 199
KOMTRAX SYSTEM DIAGRAM 199
FUNCTION OF KOMTRAX SYSTEM 199
PPC LEVERS 200
LH PPC LEVER 200
RH PPC LEVER 201
AUTOMATIC GREASE SYSTEM . 202
OUTLINE OF AUTO GREASE SYSTEM . 202
COMPONENT PARTS OF CONTROL SYSTEM . 217
MACHINE MONITOR . 217
KomVision CONTROLLER 231
KomVision CAMERA 235
KOMTRAX TERMINAL 235
PUMP CONTROLLER . 237
RESISTOR FOR PC-EPC VALVE . 241
CAN TERMINATING RESISTOR 242
PPC OIL PRESSURE SWITCH . 242
ENGINE CONTROLLER . 244
FUEL CONTROL DIAL . 250
SENSOR 252
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 252
FUNCTION OF ENGINE OIL PRESSURE SWITCH 252
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 252
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 253
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 253
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 254
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 254
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 254
STRUCTURE OF OVERLOAD CAUTION SENSOR 254
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 255
FUNCTION OF OVERLOAD CAUTION SENSOR . 255
HYDRAULIC SYSTEM 256
LAYOUT DRAWING OF HYDRAULIC SYSTEM 256
CLSS 262
STRUCTURE OF CLSS . 262
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 264
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 265
PRESSURE COMPENSATION CONTROL . 278
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 280
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 280
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 281
PUMP AND VALVE CONTROL SYSTEM . 286
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 286
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 287
COMPONENT PARTS OF HYDRAULIC SYSTEM . 289
HYDRAULIC TANK 289
MAIN PUMP . 291
PILOT OIL FILTER 317
CONTROL VALVE . 317
WORK EQUIPMENT SYSTEM . 374
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 374
STRUCTURE OF VALVE CONTROL 379
ONE-TOUCH POWER MAXIMIZING SYSTEM . 381
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 381
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 382
PPC LOCK SYSTEM . 383
PPC LOCK SYSTEM DIAGRAM . 383
FUNCTION OF PPC LOCK SYSTEM . 383
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 384
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 384
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 384
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 385
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 387
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 387
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 389
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 390
WORK EQUIPMENT AND SWING PPC VALVE 390
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 395
402
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 405
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 407
ATT EPC VALVE ASSEMBLY 410
PILOT CIRCUIT ACCUMULATOR . 411
ATTACHMENT CIRCUIT ACCUMULATOR 412
SWING SYSTEM 413
LAYOUT DRAWING OF SWING SYSTEM 413
SWING CONTROL SYSTEM DIAGRAM 417
FUNCTION OF SWING CONTROL SYSTEM 417
COMPONENT PARTS OF SWING SYSTEM . 421
SWING MOTOR . 421
SWING MACHINERY . 432
SWING CIRCLE 433
TRAVEL SYSTEM . 435
LAYOUT DRAWING OF TRAVEL SYSTEM . 435
TRAVEL CONTROL SYSTEM DIAGRAM . 439
FUNCTION OF TRAVEL CONTROL SYSTEM . 439
COMPONENT PARTS OF TRAVEL SYSTEM 441
TRAVEL MOTOR 441
FINAL DRIVE . 454
TRAVEL PPC VALVE 455
CENTER SWIVEL JOINT . 460
UNDERCARRIAGE AND FRAME . 462
LAYOUT DRAWING OF UNDERCARRIAGE . 462
SPECIFICATIONS OF UNDERCARRIAGE . 463
WORK EQUIPMENT 464
STRUCTURE OF WORK EQUIPMENT . 464
FUNCTION OF WORK EQUIPMENT 465
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 466
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 466
BUCKET CLEARANCE ADJUSTMENT SHIM 467
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 467
CAB AND ITS ATTACHMENTS . 468
ROPS CAB 468
STRUCTURE OF ROPS CAB . 468
FUNCTION OF ROPS CAB 468
CAB MOUNT . 469
STRUCTURE OF CAB MOUNT 469
FUNCTION OF CAB MOUNT . 469
CAB TIPPING STOPPER . 470
STRUCTURE OF CAB TIPPING STOPPER 470
FUNCTION OF CAB TIPPING STOPPER . 470
20 STANDARD VALUE TABLE . 471
CONTENTS 472
ABBREVIATION LIST . 473
STANDARD VALUE TABLE FOR ENGINE . 479
STANDARD VALUE TABLE FOR ENGINE: PC210LC-11 . 479
STANDARD VALUE TABLE FOR MACHINE 483
STANDARD VALUE TABLE FOR MACHINE: PC210-11, PC210LC-11 483
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 496
STANDARD VALUE TABLE FOR ELECTRICAL . 500
STANDARD VALUE TABLE FOR ELECTRICAL . 500
30 TESTING AND ADJUSTING 511
CONTENTS 512
ABBREVIATION LIST . 515
RELATED INFORMATION ON TESTING AND ADJUSTING 521
TOOLS FOR TESTING AND ADJUSTING . 521
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 528
ENGINE AND COOLING SYSTEM . 530
TEST ENGINE SPEED . 530
METHOD FOR TESTING ENGINE SPEED . 530
TEST BOOST PRESSURE . 533
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 533
METHOD FOR TESTING BOOST PRESSURE . 534
TEST EXHAUST GAS COLOR 535
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 535
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 536
TEST AND ADJUST VALVE CLEARANCE . 538
METHOD FOR TESTING VALVE CLEARANCE 538
METHOD FOR ADJUSTING VALVE CLEARANCE 539
TEST COMPRESSION PRESSURE . 540
METHOD FOR TESTING COMPRESSION PRESSURE . 540
TEST BLOWBY PRESSURE 545
METHOD FOR TESTING BLOWBY PRESSURE 545
TEST ENGINE OIL PRESSURE 547
METHOD FOR TESTING ENGINE OIL PRESSURE 547
TEST EGR VALVE AND VGT OIL PRESSURE . 548
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 548
TEST FUEL PRESSURE 550
METHOD FOR TESTING FUEL PRESSURE 551
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 556
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 557
BLEEDING AIR FROM FUEL SYSTEM . 563
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 563
TEST FUEL CIRCUIT FOR LEAKAGE . 564
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 564
HANDLE CYLINDER CUT-OUT MODE OPERATION 566
HANDLE NO-INJECTION CRANKING OPERATION 567
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 568
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 568
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 568
REPLACING FAN BELT 570
METHOD FOR REPLACING FAN BELT . 570
TEST COOLING FAN SPEED 571
METHOD FOR TESTING COOLING FAN SPEED 571
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 572
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 572
TEST SCR RELATED FUNCTIONS 573
TEST AdBlue/DEF PUMP RAISED PRESSURE 576
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 579
TEST AdBlue/DEF LINE HEATER RELAY 1 . 583
TEST AdBlue/DEF LINE HEATER RELAY 2 . 586
TEST AdBlue/DEF PUMP HEATER RELAY . 588
TEST AdBlue/DEF TANK HEATER VALVE . 591
TEST DENITRATION EFFICIENCY OF SCR 594
CLEAN AdBlue/DEF TANK . 598
METHOD FOR CLEANING AdBlue/DEF TANK . 598
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 602
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 602
POWER TRAIN . 604
TEST SWING CIRCLE BEARING CLEARANCE . 604
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 604
UNDERCARRIAGE AND FRAME . 605
TEST AND ADJUST TRACK TENSION . 605
METHOD FOR TESTING TRACK TENSION 605
METHOD FOR ADJUSTING TRACK TENSION 605
HYDRAULIC SYSTEM 607
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 607
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 607
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 613
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 614
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 620
TEST OIL PRESSURE OF CONTROL CIRCUIT 623
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 623
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 625
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 625
TEST PC-EPC VALVE OUTLET PRESSURE . 626
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 627
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 628
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 628
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 629
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 632
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 633
METHOD FOR ADJUSTING LS VALVE . 634
TEST OUTLET PRESSURE OF SOLENOID VALVE 635
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 635
OPERATING CONDITION OF SOLENOID VALVE . 636
TEST PPC VALVE OUTLET PRESSURE 639
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 639
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 641
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 641
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 642
TEST PUMP SWASH PLATE SENSOR 644
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 644
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 645
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 645
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 645
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 646
TEST OIL LEAKAGE 647
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 647
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 647
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 648
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 649
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 649
BLEED AIR FROM HYDRAULIC CIRCUIT 650
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 652
CAB AND ITS ATTACHMENTS . 654
TEST CAB TIPPING STOPPER 654
METHOD FOR TESTING CAB TIPPING STOPPER 654
METHOD FOR ADJUSTING MIRRORS 655
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 655
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 656
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 657
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 658
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 659
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 660
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 661
ELECTRICAL SYSTEM . 663
ELECTRICAL SYSTEM . 664
SET AND OPERATE MACHINE MONITOR . 664
OPERATOR MODE . 667
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 668
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 668
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 669
CHECKING FUNCTION OF SERVICE METER 669
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 669
SERVICE MODE 672
METHOD FOR OPERATING SERVICE MODE . 672
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 674
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 681
ABNORMALITY RECORD MENU . 691
METHOD FOR CONFIRMING MAINTENANCE RECORD 696
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 697
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 701
DEFAULT MENU 702
DIAGNOSTIC TESTS MENU . 709
ADJUSTMENT MENU . 718
METHOD FOR PERFORMING NO-INJECTION CRANKING . 740
KOMTRAX SETTINGS MENU . 741
METHOD FOR DISPLAYING SERVICE MESSAGE . 744
METHOD FOR STARTING UP KOMTRAX TERMINAL . 746
ADJUST REARVIEW CAMERA ANGLE 751
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 751
ADJUST KomVision CAMERA ANGLE . 754
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 755
ADJUST KomVision RELATED ITEMS 759
SETTING OF KomVision (MAIN SETTING) . 759
SETTING OF KomVision (CAMERA SETTING) . 761
SETTING OF KomVision (CAMERA CALIBRATION) . 761
KomVision screen – Check 12 m visibility 775
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 778
HANDLE BATTERY DISCONNECT SWITCH 779
TEST DIODES . 780
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 780
METHOD FOR TESTING DIODE USING ANALOG TESTER 780
Pm CLINIC . 781
Pm CLINIC SERVICE . 781
Pm CLINIC CHECK SHEET . 785
40 TROUBLESHOOTING 797
CONTENTS 798
ABBREVIATION LIST . 809
RELATED INFORMATION ON TROUBLESHOOTING 815
GENERAL TROUBLESHOOTING POINTS 815
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 817
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 829
CHECKS BEFORE TROUBLESHOOTING . 831
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 833
WALK-AROUND CHECK . 833
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 835
CHECK FUEL LEVEL AND TYPE . 835
CHECK IMPURE INGREDIENT IN FUEL . 835
CHECK FUEL PREFILTER 836
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 836
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 837
CHECK MAIN FILTER . 838
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 840
CHECK COOLANT LEVEL (RESERVOIR TANK) 841
CHECK CLOGGING OF AIR CLEANER . 841
OUTER ELEMENT – CLEAN . 842
ELEMENTS – REPLACE 844
CHECK HYDRAULIC OIL LEVEL . 845
CHECK HYDRAULIC OIL STRAINER 846
CHECK HYDRAULIC FILTER 847
CHECK OIL LEVEL IN SWING MACHINERY CASE . 848
CHECK OIL LEVEL IN DAMPER CASE 849
CHECK OIL LEVEL IN FINAL DRIVE CASE . 849
BLEED AIR FROM FUEL SYSTEM 850
BLEED AIR FROM HYDRAULIC SYSTEM . 850
ELECTRICAL EQUIPMENT – CHECK METHOD . 850
AUTOMATIC GREASE SYSTEM . 858
FINDING MALFUNCTIONS 858
MALFUNCTION FINDING PROCEDURES 860
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 862
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 872
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 875
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 879
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 881
CONNECTOR LIST AND LAYOUT . 884
CONNECTOR CONTACT IDENTIFICATION 897
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 937
FUSE LOCATION TABLE . 943
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 946
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 950
FAILURE CODES TABLE . 952
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 970
FAILURE CODE [879AKA] . 970
FAILURE CODE [879AKB] . 971
FAILURE CODE [879BKA] . 972
FAILURE CODE [879BKB] . 974
FAILURE CODE [879CKA] . 976
FAILURE CODE [879CKB] . 977
FAILURE CODE [879DKZ] . 978
FAILURE CODE [879EMC] . 980
FAILURE CODE [879FMC] . 981
FAILURE CODE [879GKX] . 982
FAILURE CODE [989L00] . 984
FAILURE CODE [989M00] . 985
FAILURE CODE [989N00] . 986
FAILURE CODE [A1U0N3] . 987
FAILURE CODE [A1U0N4] . 989
FAILURE CODE [A900FR] . 991
FAILURE CODE [A900N6] . 992
FAILURE CODE [A900NY] . 993
FAILURE CODE [AA10NX] . 994
FAILURE CODE [AB00KE] . 996
FAILURE CODE [AQ10N3] . 999
FAILURE CODE [AS00N3] .1001
FAILURE CODE [AS00R2] .1003
FAILURE CODE [AS00R3] .1004
FAILURE CODE [AS00R4] .1005
FAILURE CODE [AS00R5] .1006
FAILURE CODE [AS00R6] .1007
FAILURE CODE [AS00ZK] .1008
FAILURE CODE [AS10KM] .1009
FAILURE CODE [AS10NR] .1010
FAILURE CODE [AS10NT] .1011
FAILURE CODE [B@BAZG] .1012
FAILURE CODE [B@BAZK] .1013
FAILURE CODE [B@BCNS] .1015
FAILURE CODE [B@BCQA] .1016
FAILURE CODE [B@BCZK] .1018
FAILURE CODE [B@HANS] .1020
FAILURE CODE [CA115] 1021
FAILURE CODE [CA122] 1022
FAILURE CODE [CA123] 1024
FAILURE CODE [CA131] 1026
FAILURE CODE [CA132] 1028
FAILURE CODE [CA144] 1030
FAILURE CODE [CA145] 1032
FAILURE CODE [CA153] 1034
FAILURE CODE [CA154] 1037
FAILURE CODE [CA187] 1039
FAILURE CODE [CA221] 1041
FAILURE CODE [CA222] 1043
FAILURE CODE [CA227] 1045
FAILURE CODE [CA234] 1046
FAILURE CODE [CA238] 1047
FAILURE CODE [CA239] 1049
FAILURE CODE [CA249] 1051
FAILURE CODE [CA256] 1053
FAILURE CODE [CA271] 1055
FAILURE CODE [CA272] 1057
FAILURE CODE [CA322] 1059
FAILURE CODE [CA323] 1061
FAILURE CODE [CA324] 1063
FAILURE CODE [CA325] 1065
FAILURE CODE [CA331] 1067
FAILURE CODE [CA332] 1069
FAILURE CODE [CA343] 1071
FAILURE CODE [CA351] 1072
FAILURE CODE [CA352] 1073
FAILURE CODE [CA356] 1076
FAILURE CODE [CA357] 1078
FAILURE CODE [CA386] 1080
FAILURE CODE [CA428] 1081
FAILURE CODE [CA429] 1083
FAILURE CODE [CA435] 1085
FAILURE CODE [CA441] 1087
FAILURE CODE [CA442] 1089
FAILURE CODE [CA449] 1090
FAILURE CODE [CA451] 1091
FAILURE CODE [CA452] 1093
FAILURE CODE [CA488] 1095
FAILURE CODE [CA515] 1096
FAILURE CODE [CA516] 1098
FAILURE CODE [CA553] 1100
FAILURE CODE [CA555] 1101
FAILURE CODE [CA556] 1102
FAILURE CODE [CA559] 1103
FAILURE CODE [CA595] 1106
FAILURE CODE [CA687] 1107
FAILURE CODE [CA689] 1109
FAILURE CODE [CA691] 1112
FAILURE CODE [CA692] 1114
FAILURE CODE [CA697] 1116
FAILURE CODE [CA698] 1117
FAILURE CODE [CA731] 1118
FAILURE CODE [CA778] 1120
FAILURE CODE [CA1117] .1125
FAILURE CODE [CA1664] .1126
FAILURE CODE [CA1669] .1128
FAILURE CODE [CA1673] .1129
FAILURE CODE [CA1677] .1130
FAILURE CODE [CA1678] .1131
FAILURE CODE [CA1682] .1132
FAILURE CODE [CA1683] .1134
FAILURE CODE [CA1684] .1136
FAILURE CODE [CA1686] .1138
FAILURE CODE [CA1691] .1139
FAILURE CODE [CA1694] .1142
FAILURE CODE [CA1695] .1145
FAILURE CODE [CA1696] .1146
FAILURE CODE [CA1712] .1148
FAILURE CODE [CA1713] .1151
FAILURE CODE [CA1714] .1153
FAILURE CODE [CA1715] .1154
FAILURE CODE [CA1776] .1155
FAILURE CODE [CA1777] .1158
FAILURE CODE [CA1843] .1161
FAILURE CODE [CA1844] .1163
FAILURE CODE [CA1879] .1166
FAILURE CODE [CA1881] .1168
FAILURE CODE [CA1883] .1170
FAILURE CODE [CA1885] .1173
FAILURE CODE [CA1887] .1175
FAILURE CODE [CA1921] .1177
FAILURE CODE [CA1922] .1180
FAILURE CODE [CA1942] .1185
FAILURE CODE [CA1993] .1186
FAILURE CODE [CA2185] .1189
FAILURE CODE [CA2186] .1190
FAILURE CODE [CA2249] .1192
FAILURE CODE [CA2271] .1193
FAILURE CODE [CA2272] .1196
FAILURE CODE [CA2288] .1199
FAILURE CODE [CA2311] .1200
FAILURE CODE [CA2349] .1201
FAILURE CODE [CA2353] .1204
FAILURE CODE [CA2357] .1206
FAILURE CODE [CA2381] .1207
FAILURE CODE [CA2382] .1210
FAILURE CODE [CA2383] .1213
FAILURE CODE [CA2386] .1216
FAILURE CODE [CA2387] .1218
FAILURE CODE [CA2555] .1219
FAILURE CODE [CA2556] .1222
FAILURE CODE [CA2637] .1225
FAILURE CODE [CA2639] .1227
FAILURE CODE [CA2771] .1230
FAILURE CODE [CA2777] .1236
FAILURE CODE [CA2976] .1239
FAILURE CODE [CA3133] .1241
FAILURE CODE [CA3134] .1244
FAILURE CODE [CA3135] .1246
FAILURE CODE [CA3142] .1249
FAILURE CODE [CA3143] .1250
FAILURE CODE [CA3144] .1251
FAILURE CODE [CA3146] .1253
FAILURE CODE [CA3147] .1254
FAILURE CODE [CA3148] .1255
FAILURE CODE [CA3151] .1257
FAILURE CODE [CA3165] .1263
FAILURE CODE [CA3229] .1265
FAILURE CODE [CA3231] .1267
FAILURE CODE [CA3232] .1269
FAILURE CODE [CA3235] .1273
FAILURE CODE [CA3239] .1275
FAILURE CODE [CA3241] .1278
FAILURE CODE [CA3242] .1281
FAILURE CODE [CA3251] .1284
FAILURE CODE [CA3253] .1286
FAILURE CODE [CA3254] .1289
FAILURE CODE [CA3255] .1292
FAILURE CODE [CA3256] .1296
FAILURE CODE [CA3311] .1298
FAILURE CODE [CA3312] .1300
FAILURE CODE [CA3313] .1303
FAILURE CODE [CA3314] .1304
FAILURE CODE [CA3315] .1305
FAILURE CODE [CA3316] .1307
FAILURE CODE [CA3317] .1308
FAILURE CODE [CA3318] .1309
FAILURE CODE [CA3319] .1311
FAILURE CODE [CA3321] .1312
FAILURE CODE [CA3322] .1314
FAILURE CODE [CA3419] .1316
FAILURE CODE [CA3421] .1318
FAILURE CODE [CA3497] .1320
FAILURE CODE [CA3498] .1321
FAILURE CODE [CA3543] .1322
FAILURE CODE [CA3545] .1329
FAILURE CODE [CA3547] .1331
FAILURE CODE [CA3558] .1332
FAILURE CODE [CA3559] .1334
FAILURE CODE [CA3562] .1336
FAILURE CODE [CA3563] .1338
FAILURE CODE [CA3567] .1341
FAILURE CODE [CA3568] .1344
FAILURE CODE [CA3571] .1348
FAILURE CODE [CA3572] .1350
FAILURE CODE [CA3574] .1352
FAILURE CODE [CA3575] .1354
FAILURE CODE [CA3577] .1356
FAILURE CODE [CA3578] .1358
FAILURE CODE [CA3582] .1360
FAILURE CODE [CA3583] .1366
FAILURE CODE [CA3596] .1368
FAILURE CODE [CA3649] .1370
FAILURE CODE [CA3681] .1372
FAILURE CODE [CA3682] .1377
FAILURE CODE [CA3713] .1383
FAILURE CODE [CA3717] .1386
FAILURE CODE [CA3718] .1387
FAILURE CODE [CA3725] .1388
FAILURE CODE [CA3741] .1391
FAILURE CODE [CA3748] .1392
FAILURE CODE [CA3751] .1394
FAILURE CODE [CA3755] .1396
FAILURE CODE [CA3866] .1398
FAILURE CODE [CA3867] .1402
FAILURE CODE [CA3868] .1405
FAILURE CODE [CA3899] .1409
FAILURE CODE [CA3911] .1411
FAILURE CODE [CA3912] .1415
FAILURE CODE [CA3932] .1417
FAILURE CODE [CA3933] .1419
FAILURE CODE [CA3934] .1421
FAILURE CODE [CA3935] .1424
FAILURE CODE [CA3936] .1426
FAILURE CODE [CA4151] .1428
FAILURE CODE [CA4152] .1432
FAILURE CODE [CA4155] .1436
FAILURE CODE [CA4156] .1438
FAILURE CODE [CA4157] .1441
FAILURE CODE [CA4158] .1443
FAILURE CODE [CA4159] .1444
FAILURE CODE [CA4161] .1445
FAILURE CODE [CA4162] .1448
FAILURE CODE [CA4163] .1451
FAILURE CODE [CA4164] .1452
FAILURE CODE [CA4165] .1454
FAILURE CODE [CA4166] .1456
FAILURE CODE [CA4168] .1457
FAILURE CODE [CA4169] .1460
FAILURE CODE [CA4171] .1462
FAILURE CODE [CA4249] .1465
FAILURE CODE [CA4251] .1467
FAILURE CODE [CA4259] .1469
FAILURE CODE [CA4261] .1472
FAILURE CODE [CA4277] .1475
FAILURE CODE [CA4281] .1479
FAILURE CODE [CA4459] .1482
FAILURE CODE [CA4461] .1485
FAILURE CODE [CA4658] .1488
FAILURE CODE [CA4731] .1492
FAILURE CODE [CA4732] .1493
FAILURE CODE [CA4739] .1494
FAILURE CODE [CA4768] .1495
FAILURE CODE [CA4769] .1497
FAILURE CODE [CA4842] .1500
FAILURE CODE [CA4952] .1504
FAILURE CODE [CA5115] .1506
FAILURE CODE [CA5179] .1509
FAILURE CODE [CA5181] .1511
FAILURE CODE [CA5383] .1513
FAILURE CODE [D110KB] .1515
FAILURE CODE [D19JKZ] .1517
FAILURE CODE [D811MC] .1520
FAILURE CODE [D862KA] .1521
FAILURE CODE [D8ALKA] .1522
FAILURE CODE [D8ALKB] .1524
FAILURE CODE [D8AQKR] .1526
FAILURE CODE [DA20MC] .1528
FAILURE CODE [DA22KK] .1529
FAILURE CODE [DA25KP] .1532
FAILURE CODE [DA26KP] .1535
FAILURE CODE [DA29KQ] .1537
FAILURE CODE [DA2LKA] .1539
FAILURE CODE [DA2LKB] .1541
FAILURE CODE [DA2QKR] .1543
FAILURE CODE [DA2RKR] .1546
FAILURE CODE [DAF0MB] .1547
FAILURE CODE [DAF0MC] .1548
FAILURE CODE [DAF8KB] .1549
FAILURE CODE [DAF9KQ] .1551
FAILURE CODE [DAFGMC] .1552
FAILURE CODE [DAFLKA] .1553
FAILURE CODE [DAFLKB] .1555
FAILURE CODE [DAFQKR] .1557
FAILURE CODE [DAZ9KQ] .1558
FAILURE CODE [DAZQKR] .1559
FAILURE CODE [DB2QKR] .1564
FAILURE CODE [DB2RKR] .1569
FAILURE CODE [DDNRKA] .1574
FAILURE CODE [DDNRKY] .1576
FAILURE CODE [DDNS00] .1578
FAILURE CODE [DFB1KZ] .1580
FAILURE CODE [DFB2KZ] .1583
FAILURE CODE [DFB3L8] .1586
FAILURE CODE [DFB4L8] .1588
FAILURE CODE [DFB5KZ] .1590
FAILURE CODE [DFB6KZ] .1593
FAILURE CODE [DGH2KA] .1596
FAILURE CODE [DGH2KB] .1598
FAILURE CODE [DHA4KA] .1600
FAILURE CODE [DHAAMA] .1602
FAILURE CODE [DHACMA] .1604
FAILURE CODE [DHPAMA] .1606
FAILURE CODE [DHPBMA] .1609
FAILURE CODE [DHS3MA] .1612
FAILURE CODE [DHS4MA] .1615
FAILURE CODE [DHS8MA] .1618
FAILURE CODE [DHS9MA] .1621
FAILURE CODE [DHSAMA] .1624
FAILURE CODE [DHSBMA] .1627
FAILURE CODE [DHSCMA] .1630
FAILURE CODE [DHSDMA] .1633
FAILURE CODE [DHSFMA] .1636
FAILURE CODE [DHSGMA] .1639
FAILURE CODE [DHSHMA] .1642
FAILURE CODE [DHSJMA] .1645
FAILURE CODE [DHX1MA] .1648
FAILURE CODE [DKR0MA] .1651
FAILURE CODE [DKR1MA] .1654
FAILURE CODE [DKULKA] .1657
FAILURE CODE [DKULKB] .1659
FAILURE CODE [DKULKY] .1661
FAILURE CODE [DLM5KA] .1663
FAILURE CODE [DLM5MB] .1665
FAILURE CODE [DR21KX] .1667
FAILURE CODE [DR31KX] .1669
FAILURE CODE [DV20KB] .1671
FAILURE CODE [DW43KA] .1673
FAILURE CODE [DW43KB] .1675
FAILURE CODE [DW43KY] .1677
FAILURE CODE [DW45KA] .1679
FAILURE CODE [DW45KB] .1682
FAILURE CODE [DW45KY] .1685
FAILURE CODE [DW4CKY] .1687
FAILURE CODE [DW91KA] .1689
FAILURE CODE [DW91KB] .1691
FAILURE CODE [DW91KY] .1693
FAILURE CODE [DWA2KA] .1695
FAILURE CODE [DWA2KB] .1697
FAILURE CODE [DWA2KY] .1699
FAILURE CODE [DWK0KA] .1701
FAILURE CODE [DWK0KB] .1703
FAILURE CODE [DWK0KY] .1705
FAILURE CODE [DWK2KA] .1707
FAILURE CODE [DWK2KB] .1709
FAILURE CODE [DWK2KY] .1711
FAILURE CODE [DWK8KA] .1713
FAILURE CODE [DWK8KB] .1715
FAILURE CODE [DWK8KY] .1717
FAILURE CODE [DWN5KA] .1719
FAILURE CODE [DWN5KB] .1721
FAILURE CODE [DWN5KY] .1723
FAILURE CODE [DXA8KA] .1725
FAILURE CODE [DXA8KB] .1727
FAILURE CODE [DXA9KA] .1729
FAILURE CODE [DXA9KB] .1731
FAILURE CODE [DXE0KA] .1733
FAILURE CODE [DXE0KB] .1734
FAILURE CODE [DXE4KA] .1736
FAILURE CODE [DXE4KB] .1738
FAILURE CODE [DXE4KY] .1740
FAILURE CODE [DXE5KA] .1742
FAILURE CODE [DXE5KB] .1744
FAILURE CODE [DXE6KA] .1746
FAILURE CODE [DXE6KB] .1748
FAILURE CODE [DXE7KA] .1750
FAILURE CODE [DXE7KB] .1752
FAILURE CODE [DXE7KY] .1754
FAILURE CODE [DXE8KA] .1756
FAILURE CODE [DXE8KB] .1758
FAILURE CODE [DXE8KY] .1760
FAILURE CODE [DXE9KA] .1762
FAILURE CODE [DXE9KB] .1764
FAILURE CODE [DXE9KY] .1766
FAILURE CODE [DXEAKA] .1768
FAILURE CODE [DXEAKB] .1770
FAILURE CODE [DXEAKY] .1772
FAILURE CODE [DY20KA] .1774
FAILURE CODE [DY20MA] .1776
FAILURE CODE [DY2CKB] .1778
FAILURE CODE [DY2DKB] .1781
FAILURE CODE [DY2EKB] .1783
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1785
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1785
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1791
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1794
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1796
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1798
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1801
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1802
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1803
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1804
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1805
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1806
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1807
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1808
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1809
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1810
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1811
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1812
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1814
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1815
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1816
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1817
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1819
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1820
E-24 FUNCTION SWITCH DOES NOT OPERATE .1821
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1822
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1823
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1824
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1825
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1826
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1827
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1828
E-32 ALARM BUZZER CANNOT BE CANCELED 1830
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1831
E-34 SERVICE MODE CANNOT BE SELECTED 1832
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1833
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1836
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1838
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1841
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1843
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1846
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1847
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1849
E-43 HORN DOES NOT SOUND 1850
E-44 HORN DOES NOT STOP SOUNDING 1853
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1855
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1856
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1858
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1859
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1860
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1861
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1862
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1863
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1864
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1865
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1866
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1867
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1869
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1870
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1871
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1871
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1872
FAILURE MODE AND CAUSE TABLE 1874
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1886
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1887
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1890
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1891
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1892
H-6 SPEED OR POWER OF BOOM IS LOW .1894
H-7 ARM SPEED OR POWER IS LOW .1898
H-8 BUCKET SPEED OR POWER IS LOW 1903
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1906
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1907
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1909
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1911
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1912
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1913
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1914
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1915
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1916
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1917
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1918
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1919
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1920
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1922
H-23 TRAVEL SPEED IS LOW 1925
H-24 ONE OF TRACKS DOES NOT RUN .1927
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1928
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1929
H-27 SWINGS ONLY IN ONE DIRECTION .1930
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1931
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1932
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1933
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1934
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1935
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1936
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1937
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1938
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1939
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1940
H-38 Quick coupler cylinder will not extend .1941
H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1943
H-40 Buzzer does not sound (but quick coupler cylinder doesretract) .1945
H-41 Quick coupler cylinder extends and retracts slowly .1947
TROUBLESHOOTING OF ENGINE (S-MODE) 1948
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1948
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1949
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1950
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1951
S-4 ENGINE STARTABILITY IS POOR .1953
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1955
S-6 ENGINE STOPS DURING OPERATION .1957
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1959
S-8 ENGINE LACKS POWER 1960
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1962
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1964
S-11 OIL BECOMES CONTAMINATED QUICKLY .1965
S-12 FUEL CONSUMPTION IS EXCESSIVE 1966
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1967
S-14 OIL PRESSURE DROPS .1968
S-15 FUEL MIXES INTO ENGINE OIL .1970
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1971
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1972
S-18 UNUSUAL NOISE IS HEARD .1974
S-19 VIBRATION IS EXCESSIVE .1975
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1976
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1977
S-22 ACTIVE REGENERATION TAKES TIME .1979
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1980
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1981
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1983
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1984
50 DISASSEMBLY AND ASSEMBLY .1985
CONTENTS 1986
ABBREVIATION LIST .1991
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1997
HOW TO READ THIS MANUAL .1997
COATING MATERIALS LIST 1999
SPECIAL TOOLS LIST 2003
SKETCHES OF SPECIAL TOOLS .2015
ENGINE AND COOLING SYSTEM .2021
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2021
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2021
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2024
REMOVE AND INSTALL INJECTOR ASSEMBLY 2027
METHOD FOR REMOVING INJECTOR ASSEMBLY .2027
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2032
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2040
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2041
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2050
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2066
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2066
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2067
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2069
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2069
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2073
REMOVE AND INSTALL STARTER ASSEMBLY .2078
METHOD FOR REMOVING STARTER ASSEMBLY 2078
METHOD FOR INSTALLING STARTER ASSEMBLY 2079
REMOVE AND INSTALL ALTERNATOR BELT 2082
METHOD FOR REMOVING ALTERNATOR BELT .2082
METHOD FOR INSTALLING ALTERNATOR BELT .2084
REMOVE AND INSTALL RADIATOR ASSEMBLY 2086
METHOD FOR REMOVING RADIATOR ASSEMBLY .2086
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2088
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2091
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2091
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2094
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2097
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2097
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2099
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2101
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2101
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2105
REMOVE AND INSTALL FAN 2109
METHOD FOR INSTALLING FAN .2109
METHOD FOR REMOVING FAN .2109
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2110
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2110
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2119
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2131
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2131
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2134
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2138
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2138
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2139
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2142
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2142
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2142
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2144
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2144
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2146
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2151
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2151
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210NLC-11) 2155
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2158
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210NLC-11) 2162
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2167
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2167
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2173
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2179
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2179
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2185
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2190
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2190
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2190
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2192
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2192
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2192
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2193
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2193
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2195
REMOVE AND INSTALL KDPF ASSEMBLY 2198
METHOD FOR REMOVING KDPF ASSEMBLY .2198
METHOD FOR INSTALLING KDPF ASSEMBLY .2200
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2202
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2203
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2206
REMOVE AND INSTALL SCR ASSEMBLY .2211
METHOD FOR REMOVING SCR ASSEMBLY 2211
METHOD FOR INSTALLING SCR ASSEMBLY 2213
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2215
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2215
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2221
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2227
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2227
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (FOR PC210NLC-11) 2234
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2242
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210NLC-11) 2250
REMOVE AND INSTALL KCCV ASSEMBLY 2258
METHOD FOR REMOVING KCCV ASSEMBLY .2258
METHOD FOR INSTALLING KCCV ASSEMBLY .2260
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2265
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2265
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2271
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2277
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2277
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2280
REMOVE AND INSTALL AdBlue/DEF PUMP 2283
METHOD FOR REMOVING AdBlue/DEF PUMP .2283
METHOD FOR INSTALLING AdBlue/DEF PUMP .2286
REMOVE AND INSTALL AdBlue/DEF HOSE 2289
METHOD FOR REMOVING AdBlue/DEF HOSE .2289
METHOD FOR INSTALLING AdBlue/DEF HOSE .2296
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2302
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2302
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2303
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2305
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2305
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2307
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2310
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2310
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2311
POWER TRAIN .2312
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2312
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2312
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2313
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2315
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2315
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2319
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2328
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2328
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2330
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2334
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2334
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2338
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2345
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2345
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2345
UNDERCARRIAGE AND FRAME .2347
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2347
METHOD FOR SEPARATING TRACK ASSEMBLY 2347
METHOD FOR INSTALLING TRACK ASSEMBLY 2349
REMOVE AND INSTALL SPROCKET .2352
METHOD FOR REMOVING SPROCKET 2352
METHOD FOR INSTALLING SPROCKET 2352
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2354
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2354
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2355
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2356
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2356
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2357
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2361
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2361
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2362
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2364
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2365
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2366
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2368
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2368
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2370
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2372
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2372
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2374
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2377
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2377
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210-11, PC210LC-11) .2380
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210NLC-11) 2383
HYDRAULIC SYSTEM 2387
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2387
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2387
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2389
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2392
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2392
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2393
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2395
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2395
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2397
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2400
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2400
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2403
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2406
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2406
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2413
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2421
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2421
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2422
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2426
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2426
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2427
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2429
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2429
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2430
REMOVE AND INSTALL QUICK COUPLER VALVE 2432
WORK EQUIPMENT 2434
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2434
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2434
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2438
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2443
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2443
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2446
CAB AND ITS ATTACHMENTS .2452
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2452
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2452
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2458
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2465
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2467
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2467
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2478
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2478
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2481
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2487
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2487
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2494
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2501
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2501
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2506
REMOVE AND INSTALL OPERATOR’S SEAT 2512
METHOD FOR REMOVING OPERATOR’S SEAT .2512
METHOD FOR INSTALLING OPERATOR’S SEAT .2514
REMOVE AND INSTALL SEAT BELT 2517
METHOD FOR REMOVING SEAT BELT .2517
METHOD FOR INSTALLING SEAT BELT .2518
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2519
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2519
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2524
ELECTRICAL SYSTEM .2533
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2533
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2533
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2534
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2536
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2536
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2540
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2545
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2545
METHOD FOR INSTALLING KomVision CONTROLLER 2546
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2547
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2547
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2550
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2554
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2554
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2555
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2556
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2556
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2557
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2558
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2558
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2559
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2560
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2560
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2562
REMOVE AND INSTALL KomVision CAMERA .2564
METHOD FOR REMOVING KomVision CAMERA 2564
METHOD FOR INSTALLING KomVision CAMERA 2567
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2570
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2570
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2573
60 MAINTENANCE STANDARD .2577
CONTENTS 2578
ABBREVIATION LIST .2579
ENGINE AND COOLING SYSTEM .2585
MAINTENANCE STANDARD OF ENGINE MOUNT 2585
MAINTENANCE STANDARD OF COOLING SYSTEM 2586
POWER TRAIN .2588
MAINTENANCE STANDARD OF SWING CIRCLE 2588
MAINTENANCE STANDARD OF SWING MACHINERY .2589
MAINTENANCE STANDARD OF FINAL DRIVE .2591
MAINTENANCE STANDARD OF SPROCKET 2593
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2594
UNDERCARRIAGE AND FRAME .2596
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2596
MAINTENANCE STANDARD OF IDLER .2598
MAINTENANCE STANDARD OF TRACK ROLLER 2600
MAINTENANCE STANDARD OF CARRIER ROLLER 2601
MAINTENANCE STANDARD OF TRACK SHOE 2602
MAINTENANCE STANDARD OF TRIPLE SHOE .2605
MAINTENANCE STANDARD OF SWAMP SHOE 2606
MAINTENANCE STANDARD OF ROAD LINER 2607
HYDRAULIC SYSTEM 2608
MAINTENANCE STANDARD OF HYDRAULIC TANK 2608
MAINTENANCE STANDARD OF MAIN PUMP .2609
MAINTENANCE STANDARD OF LS-EPC VALVE 2610
MAINTENANCE STANDARD OF PC-EPC VALVE 2611
MAINTENANCE STANDARD OF SWING MOTOR .2612
MAINTENANCE STANDARD OF TRAVEL MOTOR 2615
MAINTENANCE STANDARD OF CONTROL VALVE .2618
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2628
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2631
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2634
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2635
MAINTENANCE STANDARD OF SOLENOID VALVE 2637
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2638
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2640
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2641
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2642
WORK EQUIPMENT 2643
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2643
DIMENSION OF ARM 2648
DIMENSIONS OF BUCKET 2650
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2652
MAINTENANCE STANDARD OF ARM CYLINDER 2653
MAINTENANCE STANDARD OF BUCKET CYLINDER .2654
80 APPENDIX .2655
CONTENTS 2656
ABBREVIATION LIST .2658
AIR CONDITIONER SYSTEM 2664
PRECAUTIONS FOR REFRIGERANT .2664
AIR CONDITIONER COMPONENT .2665
SPECIFICATIONS OF AIR CONDITIONER .2667
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2668
OUTLINE OF REFRIGERATION CYCLE 2669
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2671
AIR CONDITIONER UNIT 2671
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2671
FUNCTION OF AIR CONDITIONER UNIT 2673
COMPONENT PARTS OF AIR CONDITIONER UNIT .2675
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2676
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2676
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2676
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2676
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2677
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2677
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2677
FUNCTION OF DUAL PRESSURE SWITCH 2678
AIR CONDITIONER CONTROLLER 2679
STRUCTURE OF AIR CONDITIONER CONTROLLER .2679
COMPRESSOR 2680
STRUCTURE OF COMPRESSOR .2680
SPECIFICATIONS OF COMPRESSOR 2680
FUNCTION OF COMPRESSOR 2680
CONDENSER .2681
STRUCTURE OF CONDENSER 2681
SPECIFICATIONS OF CONDENSER .2681
FUNCTION OF CONDENSER .2681
SENSORS FOR AIR CONDITIONER SYSTEM 2683
STRUCTURE OF SUNLIGHT SENSOR 2683
FUNCTION OF SUNLIGHT SENSOR .2683
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2683
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2683
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2685
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2687
AIR CONDITIONER SYSTEM DIAGRAM 2689
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2690
FUNCTION OF AIR CONDITIONER CONTROLLER 2691
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2692
TESTING AIR LEAKAGE (DUCT) 2696
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2696
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2698
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2699
TEST VENT (MODE) CHANGEOVER .2700
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2700
TESTING FRESH/RECIRC AIR CHANGEOVER .2702
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2702
TEST SUNLIGHT SENSOR 2703
METHOD FOR TESTING SUNLIGHT SENSOR 2703
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2704
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2704
TEST RELAYS .2706
METHOD FOR TESTING RELAYS .2706
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2707
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2709
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2712
FAILURE CODE [879AKA] .2714
FAILURE CODE [879AKB] .2715
FAILURE CODE [879BKA] .2716
FAILURE CODE [879BKB] .2718
FAILURE CODE [879CKA] .2720
FAILURE CODE [879CKB] .2721
FAILURE CODE [879DKZ] .2722
FAILURE CODE [879EMC] .2724
FAILURE CODE [879FMC] .2725
FAILURE CODE [879GKX] .2726
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2728
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2730
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2733
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2735
TROUBLESHOOTING USING GAUGE PRESSURE 2737
CONNECTION OF SERVICE TOOL 2740
METHOD FOR CONNECTING SERVICE TOOL 2740
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2742
HANDLE COMPRESSOR OIL .2744
METHOD FOR REPLACING DESICCANT 2746
90 CIRCUIT DIAGRAMS .2749
CONTENTS 2750
ABBREVIATION LIST .2751
HYDRAULIC CIRCUIT DIAGRAM .2757
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2757
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2761
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2763
ELECTRICAL CIRCUIT DIAGRAM 2765
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2765
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2769
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2771
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2773
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2775
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2777
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2779
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2781
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2783
INDEX 2785
Front Cover (UENBM00364).pdf . 0
Blank Page . 2

DESCRIPTION:

Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00364 – PDF DOWNLOAD

SERIAL NUMBERS

• 500007 and up
• K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION (ALL-A-0370-001-00-B)
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagram

G.B 29/12/24