Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Shop Manual PDF

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00362 – PDF DOWNLOAD

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00362 – PDF DOWNLOAD

Language : English
Pages :2734
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 UENBM00362 – PDF DOWNLOAD

SERIAL NUMBERS

• 500007 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 26
HOW TO READ THE SHOP MANUAL . 26
SAFETY NOTICE FOR OPERATION . 28
PRECAUTIONS TO PREVENT FIRE . 36
ACTIONS IF FIRE OCCURS 38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 39
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 40
PRECAUTIONS FOR DEF . 41
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 41
PRECAUTIONS FOR ADDING 41
PRECAUTIONS FOR STORING . 41
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 41
THE OTHER PRECAUTIONS . 41
STORE AdBlue/DEF 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 52
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 54
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 55
PRACTICAL USE OF KOMTRAX 56
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 59
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 61
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 65
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 71
HOW TO READ ELECTRICAL WIRE CODE 72
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 76
STANDARD TIGHTENING TORQUE TABLE 79
CONVERSION TABLE 86
01 SPECIFICATIONS . 91
CONTENTS 92
ABBREVIATION LIST . 93
SPECIFICATIONS 98
SPECIFICATION DRAWING . 98
SPECIFICATION DRAWING: PC210-11, PC210LC-11, PC210NLC-11 98
WORKING RANGE DRAWINGS 99
WORKING RANGE: PC210-11, PC210LC-11, PC210NLC-11 99
SPECIFICATIONS 100
SPECIFICATIONS: PC210-11, PC210LC-11, PC210NLC-11 . 100
WEIGHT TABLE 103
WEIGHT TABLE: PC210-11, PC210LC-11, PC210NLC-11 . 103
TABLE OF FUEL, COOLANT, AND LUBRICANTS 105
10 STRUCTURE AND FUNCTION . 107
CONTENTS 108
ABBREVIATION LIST . 112
UREA SCR SYSTEM . 117
LAYOUT DRAWING OF UREA SCR SYSTEM . 118
UREA SCR SYSTEM DIAGRAM . 123
FUNCTION OF UREA SCR SYSTEM . 124
FUNCTION OF AdBlue/DEF SYSTEM . 124
INDUCEMENT STRATEGY . 126
COMPONENT PARTS OF UREA SCR SYSTEM 134
AdBlue/DEF MIXING TUBE 134
SCR ASSEMBLY 134
AdBlue/DEF TANK . 137
AdBlue/DEF PUMP . 139
AdBlue/DEF INJECTOR . 140
AdBlue/DEF HOSE . 141
AdBlue/DEF TANK HEATING VALVE . 142
BOOT-UP SYSTEM 143
LAYOUT DRAWING OF BOOT-UP SYSTEM 143
SYSTEM OPERATING LAMP SYSTEM 145
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 145
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 145
BATTERY DISCONNECT SWITCH . 146
FUNCTION OF BATTERY DISCONNECT SWITCH . 146
ENGINE SYSTEM . 147
LAYOUT DRAWING OF ENGINE SYSTEM . 147
SPECIFICATIONS OF ENGINE SYSTEM . 148
FUNCTION OF ENGINE SYSTEM . 148
ENGINE CONTROL SYSTEM . 149
ENGINE CONTROL SYSTEM DIAGRAM . 149
FUNCTION OF ENGINE CONTROL SYSTEM . 150
AUTO-DECELERATION SYSTEM 152
AUTO-DECELERATION SYSTEM DIAGRAM 152
FUNCTION OF AUTO-DECELERATION SYSTEM 152
OPERATION OF AUTO-DECELERATION SYSTEM . 153
ENGINE AUTOMATIC WARM-UP SYSTEM . 154
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 154
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 155
OVERHEAT PREVENTION SYSTEM 156
OVERHEAT PREVENTION SYSTEM DIAGRAM 156
FUNCTION OF OVERHEAT PREVENTION SYSTEM 157
TURBOCHARGER PROTECTION SYSTEM 159
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 159
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 160
AUTOMATIC IDLE STOP SYSTEM 161
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 161
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 161
COMPONENT PARTS OF ENGINE SYSTEM 164
VGT . 164
EGR SYSTEM 167
EGR VALVE . 169
EGR COOLER 171
KCCV SYSTEM . 172
KCCV VENTILATOR . 174
KDPF 176
COOLING SYSTEM 181
LAYOUT DRAWING OF COOLING SYSTEM 181
SPECIFICATIONS OF COOLING SYSTEM 182
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 183
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 183
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 184
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 185
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 185
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 185
COMPONENT PARTS OF COOLING SYSTEM . 187
FAN CLUTCH 187
CONTROL SYSTEM 188
LAYOUT DRAWING OF CONTROL SYSTEM 188
MACHINE MONITOR SYSTEM 191
MACHINE MONITOR SYSTEM DIAGRAM 191
KOMTRAX SYSTEM 192
KOMTRAX SYSTEM DIAGRAM 192
FUNCTION OF KOMTRAX SYSTEM 192
PPC LEVERS 193
LH PPC LEVER 193
RH PPC LEVER 194
AUTOMATIC GREASE SYSTEM . 195
OUTLINE OF AUTO GREASE SYSTEM . 195
COMPONENT PARTS OF CONTROL SYSTEM . 210
MACHINE MONITOR . 210
KOMTRAX TERMINAL 223
PUMP CONTROLLER . 225
RESISTOR FOR PC-EPC VALVE . 229
CAN TERMINATING RESISTOR 230
PPC OIL PRESSURE SWITCH . 230
ENGINE CONTROLLER . 232
FUEL CONTROL DIAL . 238
SENSOR 240
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 240
FUNCTION OF ENGINE OIL PRESSURE SWITCH 240
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 240
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 241
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 241
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 241
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 241
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 241
STRUCTURE OF OVERLOAD CAUTION SENSOR 241
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 242
FUNCTION OF OVERLOAD CAUTION SENSOR . 242
HYDRAULIC SYSTEM 243
LAYOUT DRAWING OF HYDRAULIC SYSTEM 243
CLSS 249
STRUCTURE OF CLSS . 249
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 251
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 252
PRESSURE COMPENSATION CONTROL . 265
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 267
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 267
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 268
PUMP AND VALVE CONTROL SYSTEM . 273
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 273
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 274
COMPONENT PARTS OF HYDRAULIC SYSTEM . 276
HYDRAULIC TANK 276
MAIN PUMP . 277
PILOT OIL FILTER 304
CONTROL VALVE . 304
WORK EQUIPMENT SYSTEM . 360
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 360
STRUCTURE OF VALVE CONTROL 365
ONE-TOUCH POWER MAXIMIZING SYSTEM . 367
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 367
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 368
PPC LOCK SYSTEM . 369
PPC LOCK SYSTEM DIAGRAM . 369
FUNCTION OF PPC LOCK SYSTEM . 369
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 370
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 370
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 370
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 371
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 372
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 372
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 374
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 375
WORK EQUIPMENT AND SWING PPC VALVE 375
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 380
386
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 389
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 391
ATT EPC VALVE ASSEMBLY 394
RETURN OIL FILTER . 395
QUICK COUPLER CONTROL VALVE . 397
PILOT CIRCUIT ACCUMULATOR . 399
ATTACHMENT CIRCUIT ACCUMULATOR 400
SWING SYSTEM 401
LAYOUT DRAWING OF SWING SYSTEM 401
SWING CONTROL SYSTEM DIAGRAM 405
FUNCTION OF SWING CONTROL SYSTEM 405
COMPONENT PARTS OF SWING SYSTEM . 409
SWING MOTOR . 409
SWING MACHINERY . 420
SWING CIRCLE 421
TRAVEL SYSTEM . 423
LAYOUT DRAWING OF TRAVEL SYSTEM . 423
TRAVEL CONTROL SYSTEM DIAGRAM . 427
FUNCTION OF TRAVEL CONTROL SYSTEM . 427
COMPONENT PARTS OF TRAVEL SYSTEM 429
TRAVEL MOTOR 429
FINAL DRIVE . 442
TRAVEL PPC VALVE 443
CENTER SWIVEL JOINT . 448
UNDERCARRIAGE AND FRAME . 450
LAYOUT DRAWING OF UNDERCARRIAGE . 450
SPECIFICATIONS OF UNDERCARRIAGE . 451
WORK EQUIPMENT 452
STRUCTURE OF WORK EQUIPMENT . 452
FUNCTION OF WORK EQUIPMENT 453
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 454
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 454
BUCKET CLEARANCE ADJUSTMENT SHIM 455
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 455
CAB AND ITS ATTACHMENTS . 456
ROPS CAB 456
STRUCTURE OF ROPS CAB . 456
FUNCTION OF ROPS CAB 456
CAB MOUNT . 457
STRUCTURE OF CAB MOUNT 457
FUNCTION OF CAB MOUNT . 457
CAB TIPPING STOPPER . 458
STRUCTURE OF CAB TIPPING STOPPER 458
FUNCTION OF CAB TIPPING STOPPER . 458
20 STANDARD VALUE TABLE . 459
CONTENTS 460
ABBREVIATION LIST . 461
STANDARD VALUE TABLE FOR ENGINE . 466
STANDARD VALUE TABLE FOR MACHINE 467
STANDARD VALUE TABLE FOR MACHINE: PC210-11, PC210LC-11 467
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 480
STANDARD VALUE TABLE FOR ELECTRICAL . 484
STANDARD VALUE TABLE FOR ELECTRICAL . 484
30 TESTING AND ADJUSTING 495
CONTENTS 496
ABBREVIATION LIST . 499
RELATED INFORMATION ON TESTING AND ADJUSTING 504
TOOLS FOR TESTING AND ADJUSTING . 504
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 510
ENGINE AND COOLING SYSTEM . 511
TEST ENGINE SPEED . 511
METHOD FOR TESTING ENGINE SPEED . 511
TEST BOOST PRESSURE . 514
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 514
METHOD FOR TESTING BOOST PRESSURE . 515
TEST EXHAUST GAS COLOR 516
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 516
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 517
TEST AND ADJUST VALVE CLEARANCE . 519
METHOD FOR TESTING VALVE CLEARANCE 519
METHOD FOR ADJUSTING VALVE CLEARANCE 520
TEST COMPRESSION PRESSURE . 521
METHOD FOR TESTING COMPRESSION PRESSURE . 521
TEST BLOWBY PRESSURE 526
METHOD FOR TESTING BLOWBY PRESSURE 526
TEST ENGINE OIL PRESSURE 528
METHOD FOR TESTING ENGINE OIL PRESSURE 528
TEST EGR VALVE AND KVGT OIL PRESSURE 529
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE 529
TEST FUEL PRESSURE 531
METHOD FOR TESTING FUEL PRESSURE 532
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 537
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 538
BLEEDING AIR FROM FUEL SYSTEM . 543
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 543
TEST FUEL CIRCUIT FOR LEAKAGE . 544
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 544
HANDLE CYLINDER CUT-OUT MODE OPERATION 546
HANDLE NO-INJECTION CRANKING OPERATION 547
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 548
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 548
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 548
REPLACING FAN BELT 550
METHOD FOR REPLACING FAN BELT . 550
TEST COOLING FAN SPEED 551
METHOD FOR TESTING COOLING FAN SPEED 551
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 552
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 552
TEST SCR RELATED FUNCTIONS 553
TEST AdBlue/DEF PUMP RAISED PRESSURE 556
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 559
TEST AdBlue/DEF LINE HEATER RELAY 1 . 562
TEST AdBlue/DEF LINE HEATER RELAY 2 . 565
TEST AdBlue/DEF PUMP HEATER RELAY . 567
TEST AdBlue/DEF TANK HEATER VALVE . 570
TEST DENITRATION EFFICIENCY OF SCR 573
CLEAN AdBlue/DEF TANK . 577
METHOD FOR CLEANING AdBlue/DEF TANK . 577
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 581
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 581
POWER TRAIN . 583
TEST SWING CIRCLE BEARING CLEARANCE . 583
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 583
UNDERCARRIAGE AND FRAME . 584
TEST AND ADJUST TRACK TENSION . 584
METHOD FOR TESTING TRACK TENSION 584
METHOD FOR ADJUSTING TRACK TENSION 584
HYDRAULIC SYSTEM 586
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 586
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 586
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 592
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 593
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 599
TEST OIL PRESSURE OF CONTROL CIRCUIT 602
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 602
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 604
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 604
TEST PC-EPC VALVE OUTLET PRESSURE . 605
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 606
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 607
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 607
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 608
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 611
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 612
METHOD FOR ADJUSTING LS VALVE . 613
TEST OUTLET PRESSURE OF SOLENOID VALVE 614
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 614
OPERATING CONDITION OF SOLENOID VALVE . 615
TEST PPC VALVE OUTLET PRESSURE 618
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 618
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 620
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 620
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 621
TEST PUMP SWASH PLATE SENSOR 623
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 623
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 624
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 624
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 624
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 625
TEST OIL LEAKAGE 626
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 626
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 626
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 627
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 627
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 627
BLEED AIR FROM HYDRAULIC CIRCUIT 629
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 631
CAB AND ITS ATTACHMENTS . 633
TEST CAB TIPPING STOPPER 633
METHOD FOR TESTING CAB TIPPING STOPPER 633
METHOD FOR ADJUSTING MIRRORS 634
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 634
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 635
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 636
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 637
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 638
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 639
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 640
ELECTRICAL SYSTEM . 642
ELECTRICAL SYSTEM . 643
SET AND OPERATE MACHINE MONITOR . 643
OPERATOR MODE . 646
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 647
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 647
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 648
CHECKING FUNCTION OF SERVICE METER 648
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 648
SERVICE MODE 651
METHOD FOR OPERATING SERVICE MODE . 651
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 653
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 659
ABNORMALITY RECORD MENU . 670
METHOD FOR CONFIRMING MAINTENANCE RECORD 675
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 676
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 680
DEFAULT MENU 681
DIAGNOSTIC TESTS MENU . 688
ADJUSTMENT MENU . 697
METHOD FOR PERFORMING NO-INJECTION CRANKING . 719
KOMTRAX SETTINGS MENU . 720
METHOD FOR DISPLAYING SERVICE MESSAGE . 723
METHOD FOR STARTING UP KOMTRAX TERMINAL . 725
ADJUST REARVIEW CAMERA ANGLE 730
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 730
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 733
HANDLE BATTERY DISCONNECT SWITCH 734
TEST DIODES . 735
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 735
METHOD FOR TESTING DIODE USING ANALOG TESTER 735
Pm CLINIC . 736
Pm CLINIC SERVICE . 736
Pm CLINIC CHECK SHEET . 740
40 TROUBLESHOOTING 751
CONTENTS 752
ABBREVIATION LIST . 763
RELATED INFORMATION ON TROUBLESHOOTING 768
GENERAL TROUBLESHOOTING POINTS 768
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 769
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 781
CHECKS BEFORE TROUBLESHOOTING . 783
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 785
WALK-AROUND CHECK . 785
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 787
CHECK FUEL LEVEL AND TYPE . 787
CHECK IMPURE INGREDIENT IN FUEL . 787
CHECK FUEL PREFILTER 788
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 788
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 789
CHECK MAIN FILTER . 790
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 792
CHECK COOLANT LEVEL (RESERVOIR TANK) 793
CHECK CLOGGING OF AIR CLEANER . 793
OUTER ELEMENT – CLEAN . 794
ELEMENTS – REPLACE 796
CHECK HYDRAULIC OIL LEVEL . 797
CHECK HYDRAULIC OIL STRAINER 798
CHECK HYDRAULIC FILTER 799
CHECK OIL LEVEL IN SWING MACHINERY CASE . 800
CHECK OIL LEVEL IN DAMPER CASE 801
CHECK OIL LEVEL IN FINAL DRIVE CASE . 801
BLEED AIR FROM FUEL SYSTEM 802
BLEED AIR FROM HYDRAULIC SYSTEM . 802
ELECTRICAL EQUIPMENT – CHECK METHOD . 802
AUTOMATIC GREASE SYSTEM . 810
FINDING MALFUNCTIONS 810
MALFUNCTION FINDING PROCEDURES 812
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 814
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 824
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 827
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 831
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 833
CONNECTOR LIST AND LAYOUT . 836
CONNECTOR CONTACT IDENTIFICATION 849
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 889
FUSE LOCATION TABLE . 895
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 898
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 902
FAILURE CODES TABLE . 904
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 921
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit . 921
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 922
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit . 923
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 925
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit . 927
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 928
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit . 929
FAILURE CODE [879EMC] Ventilation Damper Malfunction 931
FAILURE CODE [879FMC] Air Mix Damper Malfunction 932
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 933
FAILURE CODE [989L00] Engine Controller Lock Caution 1 935
FAILURE CODE [989M00] Engine Controller Lock Caution 2 936
FAILURE CODE [989N00] Engine Controller Lock Caution 3 937
FAILURE CODE [A1U0N3] HC Desorb Request 1 . 938
FAILURE CODE [A1U0N4] HC Desorb Request 2 . 940
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3 942
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1 943
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2 944
FAILURE CODE [AA10NX] Air Cleaner Clogging 945
FAILURE CODE [AB00KE] Charge Voltage Low 947
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) . 950
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) 952
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) 954
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) . 955
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality) . 956
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) . 957
FAILURE CODE [AS00R6] Temporary Recovery of Inducement 958
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5 959
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning 960
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning 961
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution 962
FAILURE CODE [B@BAZG] Engine Oil Pressure Low . 963
FAILURE CODE [B@BAZK] Eng Oil Level Low . 964
FAILURE CODE [B@BCNS] Eng Water Overheat 966
FAILURE CODE [B@BCZK] Eng Water Level Low . 967
FAILURE CODE [B@HANS] Hyd Oil Overheat 969
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error 970
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error 971
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error . 973
FAILURE CODE [CA131] Throttle Sensor High Error . 975
FAILURE CODE [CA132] Throttle Sensor Low Error 977
FAILURE CODE [CA144] Coolant Temperature Sensor High Error 979
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error . 981
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error . 983
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error 986
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error 988
FAILURE CODE [CA221] Ambient Pressure Sensor High Error . 990
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error 992
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error . 994
FAILURE CODE [CA234] Engine Overspeed . 995
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error . 996
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error 998
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error .1000
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error 1002
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error .1004
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error 1006
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error 1008
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error 1010
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error 1012
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error 1014
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error 1016
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error 1018
FAILURE CODE [CA343] Engine Controller Internal Failure .1020
FAILURE CODE [CA351] Injectors Drive Circuit Error 1021
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error 1022
FAILURE CODE [CA356] MAF Sensor High Error 1025
FAILURE CODE [CA357] MAF Sensor Low Error .1027
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error .1029
FAILURE CODE [CA428] Water in Fuel Sensor High Error 1030
FAILURE CODE [CA429] Water in Fuel Sensor Low Error .1032
FAILURE CODE [CA435] Engine Oil Pressure SW Error .1034
FAILURE CODE [CA441] Battery Voltage Low Error 1036
FAILURE CODE [CA442] Battery Voltage High Error .1038
FAILURE CODE [CA449] Common Rail Pressure High Error 2 1039
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error .1040
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error 1042
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate 1044
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error 1045
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error .1047
FAILURE CODE [CA553] Common Rail Pressure High Error 1 1049
FAILURE CODE [CA555] Crankcase Pressure High Error 1 1050
FAILURE CODE [CA556] Crankcase Pressure High Error 2 1051
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 .1052
FAILURE CODE [CA595] Turbocharger Speed High Error 2 1055
FAILURE CODE [CA687] Turbocharger Speed Low Error .1056
FAILURE CODE [CA689] Engine NE Speed Sensor Error .1058
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error .1061
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error 1063
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error .1065
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error 1066
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error .1067
FAILURE CODE [CA778] Engine Backup Speed Sensor Error .1069
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error .1074
FAILURE CODE [CA1664] KDOC Abnormality 1075
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error 1077
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 1078
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error .1079
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error 1080
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error .1081
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error 1083
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error .1085
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error 1087
FAILURE CODE [CA1691] Defective Regeneration 1088
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error 1091
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error 1094
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error .1095
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error .1097
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error .1100
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error 1102
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error 1103
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error 1104
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error .1107
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error 1110
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error .1112
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error 1115
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error .1117
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error 1119
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error .1122
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error .1124
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 .1126
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 .1129
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error 1134
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error 1135
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .1138
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error 1139
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 1141
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error 1142
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error .1145
FAILURE CODE [CA2288] Turbocharger Speed High Error 1 .1148
FAILURE CODE [CA2311] lMV Solenoid Error 1149
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error .1150
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error 1153
FAILURE CODE [CA2357] EGR Valve Servo Error .1155
FAILURE CODE [CA2381] KVGT Position Sensor High Error .1156
FAILURE CODE [CA2382] KVGT Position Sensor Low Error 1159
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error 1162
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error .1165
FAILURE CODE [CA2387] KVGT Servo Error 1167
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error 1168
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error .1171
FAILURE CODE [CA2637] KDOC Face Plugging 1174
FAILURE CODE [CA2639] Manual Stationary Regeneration Request 1176
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error 1179
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable 1185
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error .1188
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error 1190
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error .1193
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error 1195
FAILURE CODE [CA3142] SCR Temperature Sensor High Error .1198
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error 1199
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error .1200
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error 1202
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error .1203
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error 1204
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2 .1206
FAILURE CODE [CA3165] SCR Outlet Temperature High Error .1212
FAILURE CODE [CA3229] SCR Temperature High Error 1214
FAILURE CODE [CA3231] SCR Temperature High Error – Non Regeneration .1216
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error 1218
FAILURE CODE [CA3235] SCR Outlet Temperature High Error – Non Regeneration 1222
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error .1224
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error 1227
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error .1230
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error .1233
FAILURE CODE [CA3253] KDOC Temperature Error – Non Regeneration .1235
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1 1238
FAILURE CODE [CA3255] KDPF Temperature Error – Non Regeneration .1241
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 1245
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 1247
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 1249
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error .1252
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error 1254
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error 1255
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error 1257
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error .1259
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error .1260
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error .1262
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error 1263
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error .1265
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error 1267
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error .1269
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1 1271
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2 1272
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) 1273
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error 1279
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4 1281
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error 1282
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error .1284
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error 1286
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error .1288
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error .1291
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction .1294
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error 1298
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error .1300
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error 1302
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error .1304
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error .1306
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error 1308
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1 .1310
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error .1316
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error .1318
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error .1320
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error .1322
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error .1327
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error .1333
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error 1336
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error 1337
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error 1338
FAILURE CODE [CA3741] Rail Press Valve Trip Error .1341
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error 1342
FAILURE CODE [CA3751] SCR Catalyst Degradation Error 1344
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error .1346
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 1348
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 1351
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error .1354
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error 1358
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error .1360
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error 1364
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error 1366
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error .1368
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error 1370
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error 1373
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error .1375
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error .1377
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error .1381
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error .1385
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error 1388
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction 1391
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error .1393
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error .1394
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error .1395
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error 1398
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error .1401
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error .1403
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error 1405
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error .1407
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error .1409
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error 1412
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error .1414
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error .1417
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error .1419
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error 1421
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error 1424
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error .1427
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error .1430
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error 1433
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error .1436
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error .1439
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error .1443
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error .1444
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error 1445
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error .1446
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible .1448
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error .1451
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) .1454
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error 1456
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error .1459
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error 1461
FAILURE CODE [CA5383] Ash Accumulation High Error .1463
FAILURE CODE [D110KB] Battery Relay Output Short Circuit 1465
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit .1467
FAILURE CODE [D811MC] KOMTRAX Malfunction .1470
FAILURE CODE [D862KA] GPS Antenna Open Circuit 1471
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX) 1472
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .1474
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) .1476
FAILURE CODE [DA20MC] Pump Controller Malfunction .1478
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error 1479
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error .1482
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller) .1485
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller) 1487
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller) .1489
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller) .1491
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller) .1494
FAILURE CODE [DAF0MB] Monitor ROM Abnormality .1495
FAILURE CODE [DAF0MC] Monitor Malfunction .1496
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit .1497
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor) .1499
FAILURE CODE [DAFGMC] GPS Module Malfunction 1500
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) 1501
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) .1503
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) .1505
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) .1506
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU) .1507
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) .1512
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) .1517
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit 1522
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit .1524
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On 1526
FAILURE CODE [DFB1KZ] Service Lever Potentio 1 Open or Short Circuit 1528
FAILURE CODE [DFB2KZ] Service Lever Potentio 2 Open or Short Circuit 1531
FAILURE CODE [DFB3L8] Service Lever 1 Potentiometer Error .1534
FAILURE CODE [DFB4L8] Service Lever 2 Potentiometer Error .1536
FAILURE CODE [DFB5KZ] Service Lever Sub Potentio 1 Open or Short Circuit 1538
FAILURE CODE [DFB6KZ] Service Lever Sub Potentio 2 Open or Short Circuit 1541
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit .1544
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault .1546
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1548
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen 1550
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen 1552
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function .1554
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function 1557
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function .1560
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function 1563
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function .1566
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function .1569
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function 1572
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function .1575
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function 1578
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function 1581
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function 1584
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function .1587
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function 1590
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function .1593
FAILURE CODE [DHX1MA] Overload Sensor Abnormality (Analog) 1596
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function 1599
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function .1602
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit .1605
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit 1607
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit 1609
FAILURE CODE [DLM5KA] Fan Speed Sensor Open Circuit .1611
FAILURE CODE [DLM5MB] Fan control:Mismatch 1613
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range .1615
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range .1617
FAILURE CODE [DV20KB] Travel Alarm Short Circuit 1619
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit 1621
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit .1623
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit .1625
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit 1627
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit 1630
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit 1633
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit .1635
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit .1637
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit 1639
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit 1641
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit .1643
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit 1645
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit 1647
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit 1649
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit 1651
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .1653
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit 1655
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit .1657
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit .1659
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit .1661
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit 1663
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit 1665
FAILURE CODE [DWN5KA] Fan Clutch Solenoid Open Circuit 1667
FAILURE CODE [DWN5KB] Fan Clutch Solenoid short Circuit .1669
FAILURE CODE [DWN5KY] Fan Clutch Solenoid Hot Short Circuit .1671
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit .1673
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit 1675
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit 1677
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit .1679
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit 1681
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit .1682
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit 1684
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit .1686
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit .1688
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit 1690
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit .1692
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit 1694
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit .1696
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit 1698
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit .1700
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit 1702
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit 1704
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit .1706
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit 1708
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit 1710
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit .1712
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit 1714
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit 1716
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit .1718
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 5 Hot Short Circuit 1720
FAILURE CODE [DY20KA]Wiper Motor Open Circuit .1722
FAILURE CODE [DY20MA] Wiper Motor Defective Function 1724
FAILURE CODE [DY2CKB] Washer Motor Short Circuit 1726
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit .1729
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit 1731
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1733
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1733
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1739
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1742
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1744
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1746
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1749
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1750
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1751
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1752
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1753
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1754
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1755
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1756
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1757
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1758
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1759
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1760
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1762
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1763
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1764
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1765
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1767
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1768
E-24 FUNCTION SWITCH DOES NOT OPERATE .1769
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1770
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1771
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1772
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1773
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1774
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1775
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1776
E-32 ALARM BUZZER CANNOT BE CANCELED 1778
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1779
E-34 SERVICE MODE CANNOT BE SELECTED 1780
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1781
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1784
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1786
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1789
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1791
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1794
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1795
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1797
E-43 HORN DOES NOT SOUND 1798
E-44 HORN DOES NOT STOP SOUNDING 1801
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1803
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1804
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1806
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1807
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1808
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1809
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1810
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1811
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1812
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1813
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1814
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1815
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1817
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1818
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1819
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1819
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1820
FAILURE MODE AND CAUSE TABLE 1822
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1834
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1835
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1838
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1839
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1840
H-6 SPEED OR POWER OF BOOM IS LOW .1842
H-7 ARM SPEED OR POWER IS LOW .1846
H-8 BUCKET SPEED OR POWER IS LOW 1851
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1854
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1855
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1857
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1859
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1860
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1861
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1862
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1863
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1864
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1865
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1866
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1867
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1868
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1870
H-23 TRAVEL SPEED IS LOW 1873
H-24 ONE OF TRACKS DOES NOT RUN .1875
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1876
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1877
H-27 SWINGS ONLY IN ONE DIRECTION .1878
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1879
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1880
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1881
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1882
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1883
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1884
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1885
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1886
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1887
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1888
H-38 Quick coupler cylinder will not extend .1889
H-39 Quick coupler cylinder will not retract (but buzzer does not sound) 1891
H-40 Buzzer does not sound (but quick coupler cylinder does retract) 1893
H-41 Quick coupler cylinder extends and retracts slowly .1895
TROUBLESHOOTING OF ENGINE (S-MODE) 1896
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1896
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1897
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1898
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1899
S-4 ENGINE STARTABILITY IS POOR .1901
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1903
S-6 ENGINE STOPS DURING OPERATION .1905
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1907
S-8 ENGINE LACKS POWER 1908
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1910
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1912
S-11 OIL BECOMES CONTAMINATED QUICKLY .1913
S-12 FUEL CONSUMPTION IS EXCESSIVE 1914
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1915
S-14 OIL PRESSURE DROPS .1916
S-15 FUEL MIXES INTO ENGINE OIL .1918
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1919
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1920
S-18 UNUSUAL NOISE IS HEARD .1921
S-19 VIBRATION IS EXCESSIVE .1922
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1923
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1924
S-22 ACTIVE REGENERATION TAKES TIME .1926
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1927
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1928
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1930
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1931
50 DISASSEMBLY AND ASSEMBLY .1933
CONTENTS 1934
ABBREVIATION LIST .1939
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1944
HOW TO READ THIS MANUAL .1944
COATING MATERIALS LIST 1946
SPECIAL TOOLS LIST 1951
SKETCHES OF SPECIAL TOOLS .1963
ENGINE AND COOLING SYSTEM .1969
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1969
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1969
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1972
REMOVE AND INSTALL INJECTOR ASSEMBLY 1975
METHOD FOR REMOVING INJECTOR ASSEMBLY .1975
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1980
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1988
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1989
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1998
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2014
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2014
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2015
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2017
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2017
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2021
REMOVE AND INSTALL STARTER ASSEMBLY .2026
METHOD FOR REMOVING STARTER ASSEMBLY 2026
METHOD FOR INSTALLING STARTER ASSEMBLY 2027
REMOVE AND INSTALL ALTERNATOR BELT 2030
METHOD FOR REMOVING ALTERNATOR BELT .2030
METHOD FOR INSTALLING ALTERNATOR BELT .2032
REMOVE AND INSTALL RADIATOR ASSEMBLY 2034
METHOD FOR REMOVING RADIATOR ASSEMBLY .2034
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2036
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2039
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2039
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2042
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2045
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2045
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2047
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2049
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2049
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2053
REMOVE AND INSTALL FAN 2057
METHOD FOR INSTALLING FAN .2057
METHOD FOR REMOVING FAN .2057
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2058
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2058
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2067
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2079
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2079
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2082
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2086
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2086
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2087
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2090
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2090
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2090
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2092
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2092
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2094
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2099
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2099
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210NLC-11) 2103
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2106
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210NLC-11) 2110
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2115
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2115
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2121
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2127
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2127
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2133
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2138
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2138
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2138
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2140
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2140
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2140
REMOVE AND INSTALL KDPF ASSEMBLY 2141
METHOD FOR REMOVING KDPF ASSEMBLY .2141
METHOD FOR INSTALLING KDPF ASSEMBLY .2143
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2145
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2146
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2149
REMOVE AND INSTALL SCR ASSEMBLY .2154
METHOD FOR REMOVING SCR ASSEMBLY 2154
METHOD FOR INSTALLING SCR ASSEMBLY 2156
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2158
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2158
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2164
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2170
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2170
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (FOR PC210NLC-11) 2177
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2185
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210NLC-11) 2193
REMOVE AND INSTALL KCCV ASSEMBLY 2201
METHOD FOR REMOVING KCCV ASSEMBLY .2201
METHOD FOR INSTALLING KCCV ASSEMBLY .2203
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2208
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2208
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2214
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2220
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2220
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2223
REMOVE AND INSTALL AdBlue/DEF PUMP 2226
METHOD FOR REMOVING AdBlue/DEF PUMP .2226
METHOD FOR INSTALLING AdBlue/DEF PUMP .2229
REMOVE AND INSTALL AdBlue/DEF HOSE 2232
METHOD FOR REMOVING AdBlue/DEF HOSE .2232
METHOD FOR INSTALLING AdBlue/DEF HOSE .2239
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2245
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2245
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2246
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2248
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2248
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2250
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2253
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2253
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2254
POWER TRAIN .2255
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2255
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2255
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2256
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2258
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2258
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2262
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2271
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2271
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2273
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2277
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2277
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2281
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2288
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2288
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2288
UNDERCARRIAGE AND FRAME .2290
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2290
METHOD FOR SEPARATING TRACK ASSEMBLY 2290
METHOD FOR INSTALLING TRACK ASSEMBLY 2292
REMOVE AND INSTALL SPROCKET .2295
METHOD FOR REMOVING SPROCKET 2295
METHOD FOR INSTALLING SPROCKET 2295
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2297
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2297
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2298
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2299
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2299
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2300
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2304
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2304
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2305
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2307
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2308
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2309
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2311
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2311
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2312
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2315
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2315
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2317
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2320
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2320
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210-11, PC210LC-11) .2323
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210NLC-11) 2326
HYDRAULIC SYSTEM 2330
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2330
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2330
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2332
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2335
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2335
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2336
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2338
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2338
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2340
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2343
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2343
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2346
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2349
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2349
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2356
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2364
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2364
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2365
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2369
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2369
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2369
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2371
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2371
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2372
REMOVE AND INSTALL QUICK COUPLER VALVE 2374
WORK EQUIPMENT 2376
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2376
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2376
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2380
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2385
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2385
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2388
CAB AND ITS ATTACHMENTS .2394
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2394
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2394
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2400
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2407
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2409
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2409
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2419
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2419
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2422
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2428
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2428
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2435
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2442
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2442
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2447
REMOVE AND INSTALL OPERATOR’S SEAT 2453
METHOD FOR REMOVING OPERATOR’S SEAT .2453
METHOD FOR INSTALLING OPERATOR’S SEAT .2455
REMOVE AND INSTALL SEAT BELT 2458
METHOD FOR REMOVING SEAT BELT .2458
METHOD FOR INSTALLING SEAT BELT .2459
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2460
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2460
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2465
ELECTRICAL SYSTEM .2473
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2473
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2473
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2474
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2476
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2476
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2480
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2485
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2485
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2488
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2492
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2492
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2493
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2494
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2494
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2494
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2496
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2496
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2497
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2498
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2498
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2500
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2502
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2502
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2505
60 MAINTENANCE STANDARD .2509
CONTENTS 2510
ABBREVIATION LIST .2511
ENGINE AND COOLING SYSTEM .2516
MAINTENANCE STANDARD OF ENGINE MOUNT 2516
MAINTENANCE STANDARD OF COOLING SYSTEM 2517
POWER TRAIN .2519
MAINTENANCE STANDARD OF SWING CIRCLE 2519
MAINTENANCE STANDARD OF SWING MACHINERY .2520
MAINTENANCE STANDARD OF FINAL DRIVE .2522
MAINTENANCE STANDARD OF SPROCKET 2524
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2525
UNDERCARRIAGE AND FRAME .2527
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2527
MAINTENANCE STANDARD OF IDLER .2529
MAINTENANCE STANDARD OF TRACK ROLLER 2531
MAINTENANCE STANDARD OF CARRIER ROLLER 2532
MAINTENANCE STANDARD OF TRACK SHOE 2533
MAINTENANCE STANDARD OF TRIPLE SHOE .2536
MAINTENANCE STANDARD OF SWAMP SHOE 2537
MAINTENANCE STANDARD OF ROAD LINER 2538
HYDRAULIC SYSTEM 2539
MAINTENANCE STANDARD OF HYDRAULIC TANK 2539
MAINTENANCE STANDARD OF MAIN PUMP .2540
MAINTENANCE STANDARD OF LS-EPC VALVE 2541
MAINTENANCE STANDARD OF PC-EPC VALVE 2542
MAINTENANCE STANDARD OF SWING MOTOR .2543
MAINTENANCE STANDARD OF TRAVEL MOTOR 2546
MAINTENANCE STANDARD OF CONTROL VALVE .2549
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2559
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2562
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2565
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2567
MAINTENANCE STANDARD OF SOLENOID VALVE 2568
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2569
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2571
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2572
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2573
WORK EQUIPMENT 2574
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2574
DIMENSION OF ARM 2579
DIMENSIONS OF BUCKET 2581
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2583
MAINTENANCE STANDARD OF ARM CYLINDER 2584
MAINTENANCE STANDARD OF BUCKET CYLINDER .2585
80 APPENDIX .2587
CONTENTS 2588
ABBREVIATION LIST .2590
AIR CONDITIONER SYSTEM 2595
PRECAUTIONS FOR REFRIGERANT .2595
AIR CONDITIONER COMPONENT .2596
SPECIFICATIONS OF AIR CONDITIONER .2598
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2599
OUTLINE OF REFRIGERATION CYCLE 2600
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2602
AIR CONDITIONER UNIT 2602
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2602
FUNCTION OF AIR CONDITIONER UNIT 2604
COMPONENT PARTS OF AIR CONDITIONER UNIT .2606
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2607
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2607
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2607
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2607
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2608
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2608
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2608
FUNCTION OF DUAL PRESSURE SWITCH 2609
AIR CONDITIONER CONTROLLER 2610
STRUCTURE OF AIR CONDITIONER CONTROLLER .2610
COMPRESSOR 2611
STRUCTURE OF COMPRESSOR .2611
SPECIFICATIONS OF COMPRESSOR 2611
FUNCTION OF COMPRESSOR 2611
CONDENSER .2612
STRUCTURE OF CONDENSER 2612
SPECIFICATIONS OF CONDENSER .2612
FUNCTION OF CONDENSER .2612
SENSORS FOR AIR CONDITIONER SYSTEM 2614
STRUCTURE OF SUNLIGHT SENSOR 2614
FUNCTION OF SUNLIGHT SENSOR .2614
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2614
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2614
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2616
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2618
AIR CONDITIONER SYSTEM DIAGRAM 2620
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2621
FUNCTION OF AIR CONDITIONER CONTROLLER 2622
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2623
TESTING AIR LEAKAGE (DUCT) 2627
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2627
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2629
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2630
TEST VENT (MODE) CHANGEOVER .2631
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2631
TESTING FRESH/RECIRC AIR CHANGEOVER .2633
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2633
TEST SUNLIGHT SENSOR 2634
METHOD FOR TESTING SUNLIGHT SENSOR 2634
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2635
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2635
TEST RELAYS .2636
METHOD FOR TESTING RELAYS .2636
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2637
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2638
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2641
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit .2643
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 2644
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit .2645
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 2647
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit .2649
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 2650
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit .2651
FAILURE CODE [879EMC] Ventilation Damper Malfunction 2653
FAILURE CODE [879FMC] Air Mix Damper Malfunction 2654
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 2655
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2657
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2659
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2662
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2664
TROUBLESHOOTING USING GAUGE PRESSURE 2666
CONNECTION OF SERVICE TOOL 2669
METHOD FOR CONNECTING SERVICE TOOL 2669
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2671
HANDLE COMPRESSOR OIL .2673
METHOD FOR REPLACING DESICCANT 2675
90 CIRCUIT DIAGRAMS .2677
CONTENTS 2678
ABBREVIATION LIST .2679
HYDRAULIC CIRCUIT DIAGRAM .2684
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2684
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2689
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2691
ELECTRICAL CIRCUIT DIAGRAM 2693
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2693
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2697
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2699
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2701
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2703
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2705
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2707
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2709
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2711
INDEX .2713
Front Cover (new NLC).pdf . 0
Blank Page 2

DESCRIPTION:

Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00362 – PDF DOWNLOAD

SERIAL NUMBERS

• 500007 and up
• K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
REMARK
• 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 diagrams.+

G.B 29/12/24