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

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00365 – PDF DOWNLOAD

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00365 – PDF DOWNLOAD

Language : English
Pages : 2886
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 UENBM00365 – PDF DOWNLOAD

• Serial Number K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 22
FOREWORD, SAFETY, BASIC INFORMATION . 28
HOW TO READ THE SHOP MANUAL . 28
SAFETY NOTICE FOR OPERATION . 30
PRECAUTIONS TO PREVENT FIRE . 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 42
PRECAUTIONS FOR DEF . 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING . 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 43
THE OTHER PRECAUTIONS . 43
STORE Ad Blue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS . 95
CONTENTS 96
ABBREVIATION LIST . 97
SPECIFICATIONS 103
SPECIFICATION DRAWING . 103
SPECIFICATION DRAWING: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 . 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 . 105
SPECIFICATIONS 106
SPECIFICATIONS: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 106
WEIGHT TABLE 109
WEIGHT TABLE: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 109
TABLE OF FUEL, COOLANT, AND LUBRICANTS 112
10 STRUCTURE AND FUNCTION . 113
CONTENTS 114
ABBREVIATION LIST . 118
UREA SCR SYSTEM . 124
LAYOUT DRAWING OF UREA SCR SYSTEM . 125
UREA SCR SYSTEM DIAGRAM . 130
FUNCTION OF UREA SCR SYSTEM . 131
FUNCTION OF AdBlue/DEF SYSTEM . 131
INDUCEMENT STRATEGY . 133
COMPONENT PARTS OF UREA SCR SYSTEM 141
AdBlue/DEF MIXING TUBE 141
SCR ASSEMBLY 141
AdBlue/DEF TANK . 144
AdBlue/DEF PUMP . 146
AdBlue/DEF INJECTOR . 147
AdBlue/DEF HOSE . 148
AdBlue/DEF TANK HEATING VALVE . 149
BOOT-UP SYSTEM 150
LAYOUT DRAWING OF BOOT-UP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM 152
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 152
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 152
BATTERY DISCONNECT SWITCH . 154
FUNCTION OF BATTERY DISCONNECT SWITCH . 154
ENGINE SYSTEM . 155
LAYOUT DRAWING OF ENGINE SYSTEM . 155
SPECIFICATIONS OF ENGINE SYSTEM . 156
FUNCTION OF ENGINE SYSTEM . 156
ENGINE CONTROL SYSTEM . 157
ENGINE CONTROL SYSTEM DIAGRAM . 157
FUNCTION OF ENGINE CONTROL SYSTEM . 158
AUTO-DECELERATION SYSTEM 160
AUTO-DECELERATION SYSTEM DIAGRAM 160
FUNCTION OF AUTO-DECELERATION SYSTEM 160
OPERATION OF AUTO-DECELERATION SYSTEM . 161
ENGINE AUTOMATIC WARM-UP SYSTEM . 162
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 162
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 163
OVERHEAT PREVENTION SYSTEM 164
OVERHEAT PREVENTION SYSTEM DIAGRAM 164
FUNCTION OF OVERHEAT PREVENTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM 167
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 167
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM 169
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 169
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 169
COMPONENT PARTS OF ENGINE SYSTEM 172
VGT . 172
EGR SYSTEM 176
EGR VALVE . 178
EGR COOLER 180
KCCV SYSTEM . 181
KCCV VENTILATOR . 183
KDPF 185
COOLING SYSTEM 190
LAYOUT DRAWING OF COOLING SYSTEM 190
SPECIFICATIONS OF COOLING SYSTEM 191
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 192
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 192
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 193
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 194
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 194
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 194
COMPONENT PARTS OF COOLING SYSTEM . 196
FAN CLUTCH 196
CONTROL SYSTEM 197
LAYOUT DRAWING OF CONTROL SYSTEM 197
MACHINE MONITOR SYSTEM 200
MACHINE MONITOR SYSTEM DIAGRAM 200
KomVision SYSTEM 201
LAYOUT DRAWING OF KOMVISION SYSTEM 201
KomVision SYSTEM DIAGRAM 203
FUNCTION OF KomVision SYSTEM 203
KomVision CONTROLLER 210
KomVision CAMERA 214
KOMTRAX SYSTEM 215
KOMTRAX SYSTEM DIAGRAM 215
FUNCTION OF KOMTRAX SYSTEM 215
PPC LEVERS 216
LH PPC LEVER 216
RH PPC LEVER 217
AUTOMATIC GREASE SYSTEM . 218
OUTLINE OF AUTO GREASE SYSTEM . 218
COMPONENT PARTS OF CONTROL SYSTEM . 233
MACHINE MONITOR . 233
KomVision CONTROLLER 247
KomVision CAMERA 251
KOMTRAX TERMINAL 251
PUMP CONTROLLER . 254
RESISTOR FOR PC-EPC VALVE . 258
CAN TERMINATING RESISTOR 258
PPC OIL PRESSURE SWITCH . 259
ENGINE CONTROLLER . 260
FUEL CONTROL DIAL . 266
SENSOR 268
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 268
FUNCTION OF ENGINE OIL PRESSURE SWITCH 268
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 268
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 269
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 269
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 270
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 270
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 270
STRUCTURE OF OVERLOAD CAUTION SENSOR 270
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 271
FUNCTION OF OVERLOAD CAUTION SENSOR . 271
HYDRAULIC SYSTEM 272
LAYOUT DRAWING OF HYDRAULIC SYSTEM 272
CLSS 278
STRUCTURE OF CLSS . 278
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 280
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 281
PRESSURE COMPENSATION CONTROL . 294
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 296
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 296
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 297
PUMP AND VALVE CONTROL SYSTEM . 302
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 302
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 303
COMPONENT PARTS OF HYDRAULIC SYSTEM . 305
HYDRAULIC TANK 305
MAIN PUMP . 307
PILOT OIL FILTER 333
CONTROL VALVE . 333
WORK EQUIPMENT SYSTEM . 390
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 390
STRUCTURE OF VALVE CONTROL 395
ONE-TOUCH POWER MAXIMIZING SYSTEM . 397
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 397
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 398
PPC LOCK SYSTEM . 399
PPC LOCK SYSTEM DIAGRAM . 399
FUNCTION OF PPC LOCK SYSTEM . 399
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 400
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 400
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 400
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 401
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 403
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 403
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 405
TOOL CONTROL SYSTEM . 406
TOOL CONTROL SYSTEM DIAGRAM . 406
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 408
WORK EQUIPMENT AND SWING PPC VALVE 408
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 413
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 423
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 425
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 428
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 430
ATTACHMENT BYPASS SOLENOID VALVE 433
ATT EPC VALVE ASSEMBLY 435
PILOT CIRCUIT ACCUMULATOR . 436
ATTACHMENT CIRCUIT ACCUMULATOR 437
SWING SYSTEM 438
LAYOUT DRAWING OF SWING SYSTEM 438
SWING CONTROL SYSTEM DIAGRAM 442
FUNCTION OF SWING CONTROL SYSTEM 442
COMPONENT PARTS OF SWING SYSTEM . 446
SWING MOTOR . 446
SWING MACHINERY . 457
SWING CIRCLE 458
TRAVEL SYSTEM . 460
LAYOUT DRAWING OF TRAVEL SYSTEM . 460
TRAVEL CONTROL SYSTEM DIAGRAM . 464
FUNCTION OF TRAVEL CONTROL SYSTEM . 464
COMPONENT PARTS OF TRAVEL SYSTEM 466
TRAVEL MOTOR 466
FINAL DRIVE . 479
TRAVEL PPC VALVE 480
CENTER SWIVEL JOINT . 485
UNDERCARRIAGE AND FRAME . 487
LAYOUT DRAWING OF UNDERCARRIAGE . 487
SPECIFICATIONS OF UNDERCARRIAGE . 488
WORK EQUIPMENT 489
STRUCTURE OF WORK EQUIPMENT . 489
FUNCTION OF WORK EQUIPMENT 490
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 491
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 491
BUCKET CLEARANCE ADJUSTMENT SHIM 492
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 492
CAB AND ITS ATTACHMENTS . 493
ROPS CAB 493
STRUCTURE OF ROPS CAB . 493
FUNCTION OF ROPS CAB 493
CAB MOUNT . 494
STRUCTURE OF CAB MOUNT 494
FUNCTION OF CAB MOUNT . 494
CAB TIPPING STOPPER . 495
STRUCTURE OF CAB TIPPING STOPPER 495
FUNCTION OF CAB TIPPING STOPPER . 495
20 STANDARD VALUE TABLE . 497
CONTENTS 498
ABBREVIATION LIST . 499
STANDARD VALUE TABLE FOR ENGINE . 505
STANDARD VALUE TABLE FOR ENGINE: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 . 505
STANDARD VALUE TABLE FOR MACHINE 509
STANDARD VALUE TABLE FOR MACHINE: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 509
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 522
STANDARD VALUE TABLE FOR ELECTRICAL . 526
STANDARD VALUE TABLE FOR ELECTRICAL . 526
30 TESTING AND ADJUSTING 537
CONTENTS 538
ABBREVIATION LIST . 541
RELATED INFORMATION ON TESTING AND ADJUSTING 547
TOOLS FOR TESTING AND ADJUSTING . 547
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 554
ENGINE AND COOLING SYSTEM . 556
TEST ENGINE SPEED . 556
METHOD FOR TESTING ENGINE SPEED . 556
TEST BOOST PRESSURE . 559
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 559
METHOD FOR TESTING BOOST PRESSURE . 560
TEST EXHAUST GAS COLOR 561
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 561
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 562
TEST AND ADJUST VALVE CLEARANCE . 564
METHOD FOR TESTING VALVE CLEARANCE 564
METHOD FOR ADJUSTING VALVE CLEARANCE 565
TEST COMPRESSION PRESSURE . 567
METHOD FOR TESTING COMPRESSION PRESSURE . 567
TEST BLOWBY PRESSURE 572
METHOD FOR TESTING BLOWBY PRESSURE 572
TEST ENGINE OIL PRESSURE 574
METHOD FOR TESTING ENGINE OIL PRESSURE 574
TEST EGR VALVE AND VGT OIL PRESSURE . 575
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 575
TEST FUEL PRESSURE 577
METHOD FOR TESTING FUEL PRESSURE 578
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 583
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 584
BLEEDING AIR FROM FUEL SYSTEM . 590
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 590
TEST FUEL CIRCUIT FOR LEAKAGE . 591
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 591
HANDLE CYLINDER CUT-OUT MODE OPERATION 593
HANDLE NO-INJECTION CRANKING OPERATION 594
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 595
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 595
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 595
REPLACING FAN BELT 597
METHOD FOR REPLACING FAN BELT . 597
TEST COOLING FAN SPEED 598
METHOD FOR TESTING COOLING FAN SPEED 598
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 599
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 599
TEST SCR RELATED FUNCTIONS 600
TEST AdBlue/DEF PUMP RAISED PRESSURE 603
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 606
TEST AdBlue/DEF LINE HEATER RELAY 1 . 610
TEST AdBlue/DEF LINE HEATER RELAY 2 . 613
TEST AdBlue/DEF PUMP HEATER RELAY . 615
TEST AdBlue/DEF TANK HEATER VALVE . 618
TEST DENITRATION EFFICIENCY OF SCR 621
CLEAN AdBlue/DEF TANK . 625
METHOD FOR CLEANING AdBlue/DEF TANK . 625
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 629
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 629
POWER TRAIN . 631
TEST SWING CIRCLE BEARING CLEARANCE . 631
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 631
UNDERCARRIAGE AND FRAME . 632
TEST AND ADJUST TRACK TENSION . 632
METHOD FOR TESTING TRACK TENSION 632
METHOD FOR ADJUSTING TRACK TENSION 632
HYDRAULIC SYSTEM 634
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 634
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 634
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 640
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 641
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 647
TEST OIL PRESSURE OF CONTROL CIRCUIT 650
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 650
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 652
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 652
TEST PC-EPC VALVE OUTLET PRESSURE . 653
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 654
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 656
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 656
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 658
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 660
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 661
METHOD FOR ADJUSTING LS VALVE . 662
TEST OUTLET PRESSURE OF SOLENOID VALVE 663
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 663
OPERATING CONDITION OF SOLENOID VALVE . 664
TEST PPC VALVE OUTLET PRESSURE 667
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 667
TEST ATTACHMENT CIRCUIT OIL PRESSURE 669
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 669
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 671
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 671
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 672
TEST PUMP SWASH PLATE SENSOR 674
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 674
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 675
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 675
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 675
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 676
TEST OIL LEAKAGE 677
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 677
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 677
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 678
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 679
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 679
BLEED AIR FROM HYDRAULIC CIRCUIT 680
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 682
CAB AND ITS ATTACHMENTS . 684
TEST CAB TIPPING STOPPER 684
METHOD FOR TESTING CAB TIPPING STOPPER 684
METHOD FOR ADJUSTING MIRRORS 685
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 685
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 686
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 687
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 688
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 689
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 690
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 691
ELECTRICAL SYSTEM . 693
SETTING AND OPERATION OF MACHINE MONITOR 693
OPERATOR MODE . 696
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 697
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 697
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 698
CHECKING FUNCTION OF SERVICE METER 698
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 698
SERVICE MODE 701
SERVICE MODE 701
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 703
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 710
ABNORMALITY RECORD MENU . 720
METHOD FOR CONFIRMING MAINTENANCE RECORD 725
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 726
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 730
DEFAULT MENU 731
DIAGNOSTIC TESTS MENU . 743
ADJUSTMENT MENU . 752
METHOD FOR PERFORMING NO-INJECTION CRANKING . 787
KOMTRAX SETTINGS MENU . 788
METHOD FOR DISPLAYING SERVICE MESSAGE . 791
METHOD FOR STARTING UP KOMTRAX TERMINAL . 792
ADJUST REARVIEW CAMERA ANGLE 797
ADJUST KomVision CAMERA ANGLE . 800
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 801
ADJUST KomVision RELATED ITEMS 805
SETTING OF KomVision (MAIN SETTING) . 805
SETTING OF KomVision (CAMERA SETTING) . 807
SETTING OF KomVision (CAMERA CALIBRATION) . 807
KomVision screen – Check 12 m visibility 821
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 824
HANDLE BATTERY DISCONNECT SWITCH 825
TEST DIODES . 826
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 826
METHOD FOR TESTING DIODE USING ANALOG TESTER 826
Pm CLINIC . 827
Pm CLINIC SERVICE . 827
Pm CLINIC CHECK SHEET . 831
40 TROUBLESHOOTING 843
CONTENTS 844
ABBREVIATION LIST . 855
RELATED INFORMATION ON TROUBLESHOOTING 861
GENERAL TROUBLESHOOTING POINTS 861
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 863
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 875
CHECKS BEFORE TROUBLESHOOTING . 877
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 879
WALK-AROUND CHECK . 879
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 881
CHECK FUEL LEVEL AND TYPE . 881
CHECK IMPURE INGREDIENT IN FUEL . 881
CHECK FUEL PREFILTER 882
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 882
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 883
CHECK MAIN FILTER . 884
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 886
CHECK COOLANT LEVEL (RESERVOIR TANK) 887
CHECK CLOGGING OF AIR CLEANER . 887
OUTER ELEMENT – CLEAN . 888
ELEMENTS – REPLACE 890
CHECK HYDRAULIC OIL LEVEL . 891
CHECK HYDRAULIC OIL STRAINER 892
CHECK HYDRAULIC FILTER 893
CHECK OIL LEVEL IN SWING MACHINERY CASE . 894
CHECK OIL LEVEL IN DAMPER CASE 895
CHECK OIL LEVEL IN FINAL DRIVE CASE . 895
BLEED AIR FROM FUEL SYSTEM 896
BLEED AIR FROM HYDRAULIC SYSTEM . 896
ELECTRICAL EQUIPMENT – CHECK METHOD . 896
AUTOMATIC GREASE SYSTEM . 904
FINDING MALFUNCTIONS 904
MALFUNCTION FINDING PROCEDURES 906
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 908
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 918
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 921
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 925
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 927
CONNECTORS LIST AND LAYOUT 930
CONNECTOR CONTACT IDENTIFICATION 943
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 983
FUSE LOCATION TABLE . 989
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 991
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 995
FAILURE CODES TABLE . 997
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1015
FAILURE CODE [879AKA] .1015
FAILURE CODE [879AKB] .1016
FAILURE CODE [879BKA] .1017
FAILURE CODE [879BKB] .1019
FAILURE CODE [879CKA] .1021
FAILURE CODE [879CKB] .1022
FAILURE CODE [879DKZ] .1023
FAILURE CODE [879EMC] .1025
FAILURE CODE [879FMC] .1026
FAILURE CODE [879GKX] .1027
FAILURE CODE [989L00] .1029
FAILURE CODE [989M00] .1030
FAILURE CODE [989N00] .1031
FAILURE CODE [A1U0N3] .1032
FAILURE CODE [A1U0N4] .1034
FAILURE CODE [A900FR] .1036
FAILURE CODE [A900N6] .1037
FAILURE CODE [A900NY] .1038
FAILURE CODE [AA10NX] .1039
FAILURE CODE [AB00KE] .1041
FAILURE CODE [AQ10N3] .1044
FAILURE CODE [AS00N3] .1046
FAILURE CODE [AS00R2] .1048
FAILURE CODE [AS00R3] .1049
FAILURE CODE [AS00R4] .1050
FAILURE CODE [AS00R5] .1051
FAILURE CODE [AS00R6] .1052
FAILURE CODE [AS00ZK] .1053
FAILURE CODE [AS10KM] .1054
FAILURE CODE [AS10NR] .1055
FAILURE CODE [AS10NT] .1056
FAILURE CODE [B@BAZG] .1057
FAILURE CODE [B@BAZK] .1058
FAILURE CODE [B@BCNS] .1060
FAILURE CODE [B@BCQA] .1061
FAILURE CODE [B@BCZK] .1063
FAILURE CODE [B@HANS] .1065
FAILURE CODE [CA115] 1066
FAILURE CODE [CA122] 1067
FAILURE CODE [CA123] 1069
FAILURE CODE [CA131] 1071
FAILURE CODE [CA132] 1073
FAILURE CODE [CA144] 1075
FAILURE CODE [CA145] 1077
FAILURE CODE [CA153] 1079
FAILURE CODE [CA154] 1082
FAILURE CODE [CA187] 1084
FAILURE CODE [CA221] 1086
FAILURE CODE [CA222] 1088
FAILURE CODE [CA227] 1090
FAILURE CODE [CA234] 1091
FAILURE CODE [CA238] 1092
FAILURE CODE [CA239] 1094
FAILURE CODE [CA249] 1096
FAILURE CODE [CA256] 1098
FAILURE CODE [CA271] 1100
FAILURE CODE [CA272] 1102
FAILURE CODE [CA322] 1104
FAILURE CODE [CA323] 1106
FAILURE CODE [CA324] 1108
FAILURE CODE [CA325] 1110
FAILURE CODE [CA331] 1112
FAILURE CODE [CA332] 1114
FAILURE CODE [CA343] 1116
FAILURE CODE [CA351] 1117
FAILURE CODE [CA352] 1118
FAILURE CODE [CA356] 1121
FAILURE CODE [CA357] 1123
FAILURE CODE [CA386] 1125
FAILURE CODE [CA428] 1126
FAILURE CODE [CA429] 1128
FAILURE CODE [CA435] 1130
FAILURE CODE [CA441] 1132
FAILURE CODE [CA442] 1134
FAILURE CODE [CA449] 1135
FAILURE CODE [CA451] 1136
FAILURE CODE [CA452] 1138
FAILURE CODE [CA488] 1140
FAILURE CODE [CA515] 1141
FAILURE CODE [CA516] 1143
FAILURE CODE [CA553] 1145
FAILURE CODE [CA555] 1146
FAILURE CODE [CA556] 1147
FAILURE CODE [CA559] 1148
FAILURE CODE [CA595] 1151
FAILURE CODE [CA687] 1152
FAILURE CODE [CA689] 1154
FAILURE CODE [CA691] 1157
FAILURE CODE [CA692] 1159
FAILURE CODE [CA697] 1161
FAILURE CODE [CA698] 1162
FAILURE CODE [CA731] 1163
FAILURE CODE [CA778] 1165
FAILURE CODE [CA1117] .1170
FAILURE CODE [CA1664] .1171
FAILURE CODE [CA1669] .1173
FAILURE CODE [CA1673] .1174
FAILURE CODE [CA1677] .1175
FAILURE CODE [CA1678] .1176
FAILURE CODE [CA1682] .1177
FAILURE CODE [CA1683] .1179
FAILURE CODE [CA1684] .1181
FAILURE CODE [CA1686] .1183
FAILURE CODE [CA1691] .1184
FAILURE CODE [CA1694] .1187
FAILURE CODE [CA1695] .1190
FAILURE CODE [CA1696] .1191
FAILURE CODE [CA1712] .1193
FAILURE CODE [CA1713] .1196
FAILURE CODE [CA1714] .1198
FAILURE CODE [CA1715] .1199
FAILURE CODE [CA1776] .1200
FAILURE CODE [CA1777] .1203
FAILURE CODE [CA1843] .1206
FAILURE CODE [CA1844] .1208
FAILURE CODE [CA1879] .1211
FAILURE CODE [CA1881] .1213
FAILURE CODE [CA1883] .1215
FAILURE CODE [CA1885] .1218
FAILURE CODE [CA1887] .1220
FAILURE CODE [CA1921] .1222
FAILURE CODE [CA1922] .1225
FAILURE CODE [CA1942] .1230
FAILURE CODE [CA1993] .1231
FAILURE CODE [CA2185] .1234
FAILURE CODE [CA2186] .1235
FAILURE CODE [CA2249] .1237
FAILURE CODE [CA2271] .1238
FAILURE CODE [CA2272] .1241
FAILURE CODE [CA2288] .1244
FAILURE CODE [CA2311] .1245
FAILURE CODE [CA2349] .1246
FAILURE CODE [CA2353] .1249
FAILURE CODE [CA2357] .1251
FAILURE CODE [CA2381] .1252
FAILURE CODE [CA2382] .1255
FAILURE CODE [CA2383] .1258
FAILURE CODE [CA2386] .1261
FAILURE CODE [CA2387] .1263
FAILURE CODE [CA2555] .1264
FAILURE CODE [CA2556] .1267
FAILURE CODE [CA2637] .1270
FAILURE CODE [CA2639] .1272
FAILURE CODE [CA2771] .1275
FAILURE CODE [CA2777] .1281
FAILURE CODE [CA2976] .1284
FAILURE CODE [CA3133] .1286
FAILURE CODE [CA3134] .1289
FAILURE CODE [CA3135] .1291
FAILURE CODE [CA3142] .1294
FAILURE CODE [CA3143] .1295
FAILURE CODE [CA3144] .1296
FAILURE CODE [CA3146] .1298
FAILURE CODE [CA3147] .1299
FAILURE CODE [CA3148] .1300
FAILURE CODE [CA3151] .1302
FAILURE CODE [CA3165] .1308
FAILURE CODE [CA3229] .1310
FAILURE CODE [CA3231] .1312
FAILURE CODE [CA3232] .1314
FAILURE CODE [CA3235] .1318
FAILURE CODE [CA3239] .1320
FAILURE CODE [CA3241] .1323
FAILURE CODE [CA3242] .1326
FAILURE CODE [CA3251] .1329
FAILURE CODE [CA3253] .1331
FAILURE CODE [CA3254] .1334
FAILURE CODE [CA3255] .1337
FAILURE CODE [CA3256] .1341
FAILURE CODE [CA3311] .1343
FAILURE CODE [CA3312] .1345
FAILURE CODE [CA3313] .1348
FAILURE CODE [CA3314] .1349
FAILURE CODE [CA3315] .1350
FAILURE CODE [CA3316] .1352
FAILURE CODE [CA3317] .1353
FAILURE CODE [CA3318] .1354
FAILURE CODE [CA3319] .1356
FAILURE CODE [CA3321] .1357
FAILURE CODE [CA3322] .1359
FAILURE CODE [CA3419] .1361
FAILURE CODE [CA3421] .1363
FAILURE CODE [CA3497] .1365
FAILURE CODE [CA3498] .1366
FAILURE CODE [CA3543] .1367
FAILURE CODE [CA3545] .1374
FAILURE CODE [CA3547] .1376
FAILURE CODE [CA3558] .1377
FAILURE CODE [CA3559] .1379
FAILURE CODE [CA3562] .1381
FAILURE CODE [CA3563] .1383
FAILURE CODE [CA3567] .1386
FAILURE CODE [CA3568] .1389
FAILURE CODE [CA3571] .1393
FAILURE CODE [CA3572] .1395
FAILURE CODE [CA3574] .1397
FAILURE CODE [CA3575] .1399
FAILURE CODE [CA3577] .1401
FAILURE CODE [CA3578] .1403
FAILURE CODE [CA3582] .1405
FAILURE CODE [CA3583] .1411
FAILURE CODE [CA3596] .1413
FAILURE CODE [CA3649] .1415
FAILURE CODE [CA3681] .1417
FAILURE CODE [CA3682] .1422
FAILURE CODE [CA3713] .1428
FAILURE CODE [CA3717] .1431
FAILURE CODE [CA3718] .1432
FAILURE CODE [CA3725] .1433
FAILURE CODE [CA3741] .1436
FAILURE CODE [CA3748] .1437
FAILURE CODE [CA3751] .1439
FAILURE CODE [CA3755] .1441
FAILURE CODE [CA3866] .1443
FAILURE CODE [CA3867] .1447
FAILURE CODE [CA3868] .1450
FAILURE CODE [CA3899] .1454
FAILURE CODE [CA3911] .1456
FAILURE CODE [CA3912] .1460
FAILURE CODE [CA3932] .1462
FAILURE CODE [CA3933] .1464
FAILURE CODE [CA3934] .1466
FAILURE CODE [CA3935] .1469
FAILURE CODE [CA3936] .1471
FAILURE CODE [CA4151] .1473
FAILURE CODE [CA4152] .1477
FAILURE CODE [CA4155] .1481
FAILURE CODE [CA4156] .1483
FAILURE CODE [CA4157] .1486
FAILURE CODE [CA4158] .1488
FAILURE CODE [CA4159] .1489
FAILURE CODE [CA4161] .1490
FAILURE CODE [CA4162] .1493
FAILURE CODE [CA4163] .1496
FAILURE CODE [CA4164] .1497
FAILURE CODE [CA4165] .1499
FAILURE CODE [CA4166] .1501
FAILURE CODE [CA4168] .1502
FAILURE CODE [CA4169] .1505
FAILURE CODE [CA4171] .1507
FAILURE CODE [CA4249] .1510
FAILURE CODE [CA4251] .1512
FAILURE CODE [CA4259] .1514
FAILURE CODE [CA4261] .1517
FAILURE CODE [CA4277] .1520
FAILURE CODE [CA4281] .1523
FAILURE CODE [CA4459] .1526
FAILURE CODE [CA4461] .1529
FAILURE CODE [CA4658] .1532
FAILURE CODE [CA4731] .1536
FAILURE CODE [CA4732] .1537
FAILURE CODE [CA4739] .1538
FAILURE CODE [CA4768] .1539
FAILURE CODE [CA4769] .1541
FAILURE CODE [CA4842] .1544
FAILURE CODE [CA4952] .1548
FAILURE CODE [CA5115] .1550
FAILURE CODE [CA5179] .1553
FAILURE CODE [CA5181] .1555
FAILURE CODE [CA5383] .1557
FAILURE CODE [D110KB] .1559
FAILURE CODE [D19JKZ] .1561
FAILURE CODE [D811MC] .1564
FAILURE CODE [D862KA] .1565
FAILURE CODE [D8ALKA] .1566
FAILURE CODE [D8ALKB] .1568
FAILURE CODE [D8AQKR] .1570
FAILURE CODE [DA20MC] .1572
FAILURE CODE [DA22KK] .1573
FAILURE CODE [DA25KP] .1576
FAILURE CODE [DA26KP] .1579
FAILURE CODE [DA29KQ] .1582
FAILURE CODE [DA2LKA] .1584
FAILURE CODE [DA2LKB] .1586
FAILURE CODE [DA2QKR] .1588
FAILURE CODE [DA2RKR] .1591
FAILURE CODE [DAF0KM] .1592
FAILURE CODE [DAF0MB] .1593
FAILURE CODE [DAF0MC] .1594
FAILURE CODE [DAF8KB] .1595
FAILURE CODE [DAF9KQ] .1597
FAILURE CODE [DAFGMC] .1598
FAILURE CODE [DAFLKA] .1599
FAILURE CODE [DAFLKB] .1601
FAILURE CODE [DAFQKR] .1603
FAILURE CODE [DAZ9KQ] .1604
FAILURE CODE [DAZQKR] .1605
FAILURE CODE [DB2QKR] .1610
FAILURE CODE [DBP0KM] .1615
FAILURE CODE [DBP0KT] .1616
FAILURE CODE [DB2RKR] .1617
FAILURE CODE [DBP5KB] .1622
FAILURE CODE [DBP5KY] .1625
FAILURE CODE [DBPQKR] .1628
FAILURE CODE [DDNRKA] .1633
FAILURE CODE [DDNRKY] .1635
FAILURE CODE [DDNS00] .1637
FAILURE CODE [DFB1KZ] .1639
FAILURE CODE [DFB2KZ] .1642
FAILURE CODE [DFB3L8] .1645
FAILURE CODE [DFB4L8] .1647
FAILURE CODE [DFB5KZ] .1649
FAILURE CODE [DFB6KZ] .1652
FAILURE CODE [DGH2KA] .1655
FAILURE CODE [DGH2KB] .1657
FAILURE CODE [DHA4KA] .1659
FAILURE CODE [DHAAMA] .1661
FAILURE CODE [DHACMA] .1663
FAILURE CODE [DHPAMA] .1665
FAILURE CODE [DHPBMA] .1668
FAILURE CODE [DHS3MA] .1671
FAILURE CODE [DHS4MA] .1674
FAILURE CODE [DHS8MA] .1677
FAILURE CODE [DHS9MA] .1680
FAILURE CODE [DHSAMA] .1683
FAILURE CODE [DHSBMA] .1686
FAILURE CODE [DHSCMA] .1689
FAILURE CODE [DHSDMA] .1692
FAILURE CODE [DHSFMA] .1695
FAILURE CODE [DHSGMA] .1698
FAILURE CODE [DHSHMA] .1701
FAILURE CODE [DHSJMA] .1704
FAILURE CODE [DHX1MA] .1707
FAILURE CODE [DHZAMA] .1710
FAILURE CODE [DHZCL8] .1714
FAILURE CODE [DKR0MA] .1715
FAILURE CODE [DKR1MA] .1718
FAILURE CODE [DKULKA] .1721
FAILURE CODE [DKULKB] .1723
FAILURE CODE [DKULKY] .1725
FAILURE CODE [DLM5KA] .1727
FAILURE CODE [DLM5MB] .1729
FAILURE CODE [DR10KA] .1731
FAILURE CODE [DR12KA] .1734
FAILURE CODE [DR20KA] .1736
FAILURE CODE [DR21KX] .1738
FAILURE CODE [DR30KA] .1740
FAILURE CODE [DR31KX] .1742
FAILURE CODE [DR40KA] .1744
FAILURE CODE [DUMBKA] .1746
FAILURE CODE [DUMBKB] .1748
FAILURE CODE [DV20KB] .1750
FAILURE CODE [DW43KA] .1752
FAILURE CODE [DW43KB] .1754
FAILURE CODE [DW43KY] .1756
FAILURE CODE [DW45KA] .1758
FAILURE CODE [DW45KB] .1761
FAILURE CODE [DW45KY] .1764
FAILURE CODE [DW4CKY] .1766
FAILURE CODE [DW91KA] .1768
FAILURE CODE [DW91KB] .1770
FAILURE CODE [DW91KY] .1772
FAILURE CODE [DWA2KA] .1774
FAILURE CODE [DWA2KB] .1776
FAILURE CODE [DWA2KY] .1778
FAILURE CODE [DWK0KA] .1780
FAILURE CODE [DWK0KB] .1782
FAILURE CODE [DWK0KY] .1784
FAILURE CODE [DWK2KA] .1786
FAILURE CODE [DWK2KB] .1788
FAILURE CODE [DWK2KY] .1790
FAILURE CODE [DWK8KA] .1792
FAILURE CODE [DWK8KB] .1794
FAILURE CODE [DWK8KY] .1796
FAILURE CODE [DWN5KA] .1798
FAILURE CODE [DWN5KB] .1800
FAILURE CODE [DWN5KY] .1802
FAILURE CODE [DXA8KA] .1804
FAILURE CODE [DXA8KB] .1806
FAILURE CODE [DXA9KA] .1808
FAILURE CODE [DXA9KB] .1810
FAILURE CODE [DXE0KA] .1812
FAILURE CODE [DXE0KB] .1813
FAILURE CODE [DXE4KA] .1815
FAILURE CODE [DXE4KB] .1817
FAILURE CODE [DXE4KY] .1819
FAILURE CODE [DXE5KA] .1821
FAILURE CODE [DXE5KB] .1823
FAILURE CODE [DXE6KA] .1825
FAILURE CODE [DXE6KB] .1827
FAILURE CODE [DXE7KA] .1829
FAILURE CODE [DXE7KB] .1831
FAILURE CODE [DXE7KY] .1833
FAILURE CODE [DXE8KA] .1835
FAILURE CODE [DXE8KB] .1837
FAILURE CODE [DXE8KY] .1839
FAILURE CODE [DXE9KA] .1841
FAILURE CODE [DXE9KB] .1843
FAILURE CODE [DXE9KY] .1845
FAILURE CODE [DXEAKA] .1847
FAILURE CODE [DXEAKB] .1849
FAILURE CODE [DXEAKY] .1851
FAILURE CODE [DY20KA] .1853
FAILURE CODE [DY20MA] .1855
FAILURE CODE [DY2CKB] .1857
FAILURE CODE [DY2DKB] .1860
FAILURE CODE [DY2EKB] .1862
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1864
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1864
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1870
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1873
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1875
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1877
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1880
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1881
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1882
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1883
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1884
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1885
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1886
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1887
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1888
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1889
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1890
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1891
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1893
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1894
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1895
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1896
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1898
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1899
E-24 FUNCTION SWITCH DOES NOT OPERATE .1900
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1901
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1902
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1903
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1904
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1905
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1906
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1907
E-32 ALARM BUZZER CANNOT BE CANCELED 1909
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1910
E-34 SERVICE MODE CANNOT BE SELECTED 1911
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1912
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1915
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1917
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1920
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1922
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1925
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1926
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1928
E-43 HORN DOES NOT SOUND 1929
E-44 HORN DOES NOT STOP SOUNDING 1932
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1934
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1935
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1937
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1938
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1939
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1940
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1941
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1942
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1943
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1944
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1945
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1946
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1948
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1949
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1950
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1950
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1951
FAILURE MODE AND CAUSE TABLE 1953
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1962
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1963
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1966
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1967
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1968
H-6 SPEED OR POWER OF BOOM IS LOW .1970
H-7 ARM SPEED OR POWER IS LOW .1974
H-8 BUCKET SPEED OR POWER IS LOW 1979
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1982
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1983
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1985
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1987
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1988
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1989
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1990
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1991
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1992
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1993
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1994
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1995
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1996
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1998
H-23 TRAVEL SPEED IS LOW 2001
H-24 ONE OF TRACKS DOES NOT RUN .2003
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2004
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2005
H-27 SWINGS ONLY IN ONE DIRECTION .2006
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2007
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2008
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2009
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2010
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2011
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2012
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2013
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2014
H-1 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2015
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .2016
H-38 Quick coupler cylinder will not extend .2017
H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2019
H-40 Buzzer does not sound (but quick coupler cylinder doesretract) .2021
H-41 Quick coupler cylinder extends and retracts slowly .2023
TROUBLESHOOTING OF ENGINE (S-MODE) 2024
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2024
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2025
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2026
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2027
S-4 ENGINE STARTABILITY IS POOR .2029
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2031
S-6 ENGINE STOPS DURING OPERATION .2033
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2035
S-8 ENGINE LACKS POWER 2036
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2038
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2040
S-11 OIL BECOMES CONTAMINATED QUICKLY .2041
S-12 FUEL CONSUMPTION IS EXCESSIVE 2042
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2043
S-14 OIL PRESSURE DROPS .2044
S-15 FUEL MIXES INTO ENGINE OIL .2046
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2047
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2048
S-18 UNUSUAL NOISE IS HEARD .2050
S-19 VIBRATION IS EXCESSIVE .2051
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2052
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2053
S-22 ACTIVE REGENERATION TAKES TIME .2055
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2056
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2057
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2059
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2060
50 DISASSEMBLY AND ASSEMBLY .2061
CONTENTS 2062
ABBREVIATION LIST .2067
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2073
HOW TO READ THIS MANUAL .2073
COATING MATERIALS LIST 2075
SPECIAL TOOLS LIST 2079
SKETCHES OF SPECIAL TOOLS .2091
ENGINE AND COOLING SYSTEM .2097
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2097
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2097
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2100
REMOVE AND INSTALL INJECTOR ASSEMBLY 2103
METHOD FOR REMOVING INJECTOR ASSEMBLY .2103
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2108
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2116
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2117
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2126
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2142
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2142
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2143
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2145
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2145
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2149
REMOVE AND INSTALL STARTER ASSEMBLY .2154
METHOD FOR REMOVING STARTER ASSEMBLY 2154
METHOD FOR INSTALLING STARTER ASSEMBLY 2155
REMOVE AND INSTALL ALTERNATOR BELT 2158
METHOD FOR REMOVING ALTERNATOR BELT .2158
METHOD FOR INSTALLING ALTERNATOR BELT .2160
REMOVE AND INSTALL RADIATOR ASSEMBLY 2163
METHOD FOR REMOVING RADIATOR ASSEMBLY .2163
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2165
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2168
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2168
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2171
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2174
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2174
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2176
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2178
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2178
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2182
REMOVE AND INSTALL FAN 2187
METHOD FOR INSTALLING FAN .2187
METHOD FOR REMOVING FAN .2187
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2188
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2188
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2197
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2209
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2209
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2212
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2216
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2216
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2217
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2220
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2220
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2220
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2222
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2222
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2224
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2229
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2229
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210NLC-11, PC230NHD-11) .2233
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2237
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210NLC-11, PC230NHD-11) .2241
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2245
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2245
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2251
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2257
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2257
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2263
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2268
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2268
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2268
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2270
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2270
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2270
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2271
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2271
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2273
REMOVE AND INSTALL KDPF ASSEMBLY 2276
METHOD FOR REMOVING KDPF ASSEMBLY .2276
METHOD FOR INSTALLING KDPF ASSEMBLY .2278
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2280
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2281
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2284
REMOVE AND INSTALL SCR ASSEMBLY .2289
METHOD FOR REMOVING SCR ASSEMBLY 2289
METHOD FOR INSTALLING SCR ASSEMBLY 2291
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2293
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2293
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2299
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2305
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2305
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (FOR PC210NLC-11, PC230NHD-11) .2312
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2320
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210NLC-11, PC230NHD-11) .2328
REMOVE AND INSTALL KCCV ASSEMBLY 2336
METHOD FOR REMOVING KCCV ASSEMBLY .2336
METHOD FOR INSTALLING KCCV ASSEMBLY .2338
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2343
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2343
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2349
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2355
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2355
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2358
REMOVE AND INSTALL AdBlue/DEF PUMP 2361
METHOD FOR REMOVING AdBlue/DEF PUMP .2361
METHOD FOR INSTALLING AdBlue/DEF PUMP .2364
REMOVE AND INSTALL AdBlue/DEF HOSE 2367
METHOD FOR REMOVING AdBlue/DEF HOSE .2367
METHOD FOR INSTALLING AdBlue/DEF HOSE .2375
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2381
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2381
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2382
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2384
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2384
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2386
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2389
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2389
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2390
POWER TRAIN .2391
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2391
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2391
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2392
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2394
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2394
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2398
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2407
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2407
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2409
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2413
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2413
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2417
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2424
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2424
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2424
UNDERCARRIAGE AND FRAME .2426
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2426
METHOD FOR SEPARATING TRACK ASSEMBLY 2426
METHOD FOR INSTALLING TRACK ASSEMBLY 2428
REMOVE AND INSTALL SPROCKET .2431
METHOD FOR REMOVING SPROCKET 2431
METHOD FOR INSTALLING SPROCKET 2431
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2433
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2433
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2434
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2435
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2435
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2436
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2440
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2441
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2441
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2443
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2444
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2445
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2447
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2447
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2449
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2451
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2451
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2453
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2456
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2456
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210-11, PC210LC-11) .2459
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210NLC-11, PC230NHD-11) .2462
HYDRAULIC SYSTEM 2466
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2466
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2466
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2468
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2471
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2471
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2472
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2474
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2474
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2477
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2480
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2480
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2483
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2486
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2486
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2493
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2501
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2501
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2502
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2506
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2506
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2507
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2509
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2509
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2510
REMOVE AND INSTALL QUICK COUPLER VALVE 2512
WORK EQUIPMENT 2514
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2514
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2514
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2518
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2523
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2523
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2526
CAB AND ITS ATTACHMENTS .2532
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2532
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2532
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2540
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2547
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2549
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2549
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2560
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2560
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2563
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2569
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2569
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2576
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2583
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2583
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2589
REMOVE AND INSTALL OPERATOR’S SEAT 2596
METHOD FOR REMOVING OPERATOR’S SEAT .2596
METHOD FOR INSTALLING OPERATOR’S SEAT .2598
REMOVE AND INSTALL SEAT BELT 2601
METHOD FOR REMOVING SEAT BELT .2601
METHOD FOR INSTALLING SEAT BELT .2602
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2603
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2603
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2608
ELECTRICAL SYSTEM .2617
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2617
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2617
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2618
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2620
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2620
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2624
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2629
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2629
METHOD FOR INSTALLING KomVision CONTROLLER 2630
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2631
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2631
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2634
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2638
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2638
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2639
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2640
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2640
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2641
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2642
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2642
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2643
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2644
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2644
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2646
REMOVE AND INSTALL KomVision CAMERA .2649
METHOD FOR REMOVING KomVision CAMERA 2649
METHOD FOR INSTALLING KomVision CAMERA 2650
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2652
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2652
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2655
60 MAINTENANCE STANDARD .2659
CONTENTS 2660
ABBREVIATION LIST .2661
ENGINE AND COOLING SYSTEM .2667
MAINTENANCE STANDARD OF ENGINE MOUNT 2667
MAINTENANCE STANDARD OF COOLING SYSTEM 2668
POWER TRAIN .2670
MAINTENANCE STANDARD OF SWING CIRCLE 2670
MAINTENANCE STANDARD OF SWING MACHINERY .2671
MAINTENANCE STANDARD OF FINAL DRIVE .2673
MAINTENANCE STANDARD OF SPROCKET 2675
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2676
UNDERCARRIAGE AND FRAME .2678
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2678
MAINTENANCE STANDARD OF IDLER .2680
MAINTENANCE STANDARD OF TRACK ROLLER 2682
MAINTENANCE STANDARD OF CARRIER ROLLER 2683
MAINTENANCE STANDARD OF TRACK SHOE 2684
MAINTENANCE STANDARD OF TRIPLE SHOE .2687
MAINTENANCE STANDARD OF SWAMP SHOE 2688
MAINTENANCE STANDARD OF ROAD LINER 2689
HYDRAULIC SYSTEM 2690
MAINTENANCE STANDARD OF HYDRAULIC TANK 2690
MAINTENANCE STANDARD OF MAIN PUMP .2691
MAINTENANCE STANDARD OF LS-EPC VALVE 2692
MAINTENANCE STANDARD OF PC-EPC VALVE 2693
MAINTENANCE STANDARD OF SWING MOTOR .2694
MAINTENANCE STANDARD OF TRAVEL MOTOR 2697
MAINTENANCE STANDARD OF CONTROL VALVE .2700
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2710
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2713
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2716
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2718
MAINTENANCE STANDARD OF SOLENOID VALVE 2719
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2720
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2722
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2723
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2724
WORK EQUIPMENT 2725
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2725
DIMENSION OF ARM 2730
DIMENSIONS OF BUCKET 2732
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2734
MAINTENANCE STANDARD OF ARM CYLINDER 2735
MAINTENANCE STANDARD OF BUCKET CYLINDER .2736
80 APPENDIX .2737
CONTENTS 2738
ABBREVIATION LIST .2740
AIR CONDITIONER SYSTEM 2746
PRECAUTIONS FOR REFRIGERANT .2746
AIR CONDITIONER COMPONENT .2747
SPECIFICATIONS OF AIR CONDITIONER .2749
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2750
OUTLINE OF REFRIGERATION CYCLE 2751
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2753
AIR CONDITIONER UNIT 2753
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2753
FUNCTION OF AIR CONDITIONER UNIT 2755
COMPONENT PARTS OF AIR CONDITIONER UNIT .2757
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2758
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2758
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2758
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2758
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2759
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2759
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2759
FUNCTION OF DUAL PRESSURE SWITCH 2760
AIR CONDITIONER CONTROLLER 2761
STRUCTURE OF AIR CONDITIONER CONTROLLER .2761
COMPRESSOR 2762
STRUCTURE OF COMPRESSOR .2762
SPECIFICATIONS OF COMPRESSOR 2762
FUNCTION OF COMPRESSOR 2762
CONDENSER .2763
STRUCTURE OF CONDENSER 2763
SPECIFICATIONS OF CONDENSER .2763
FUNCTION OF CONDENSER .2763
SENSORS FOR AIR CONDITIONER SYSTEM 2765
STRUCTURE OF SUNLIGHT SENSOR 2765
FUNCTION OF SUNLIGHT SENSOR .2765
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2765
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2765
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2767
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2769
AIR CONDITIONER SYSTEM DIAGRAM 2771
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2772
FUNCTION OF AIR CONDITIONER CONTROLLER 2773
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2774
TESTING AIR LEAKAGE (DUCT) 2778
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2778
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2780
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2781
TEST VENT (MODE) CHANGEOVER .2782
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2782
TESTING FRESH/RECIRC AIR CHANGEOVER .2784
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2784
TEST SUNLIGHT SENSOR 2785
METHOD FOR TESTING SUNLIGHT SENSOR 2785
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2786
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2786
TEST RELAYS .2788
METHOD FOR TESTING RELAYS .2788
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2789
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2791
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2794
FAILURE CODE [879AKA] .2796
FAILURE CODE [879AKB] .2797
FAILURE CODE [879BKA] .2798
FAILURE CODE [879BKB] .2800
FAILURE CODE [879CKA] .2802
FAILURE CODE [879CKB] .2803
FAILURE CODE [879DKZ] .2804
FAILURE CODE [879EMC] .2806
FAILURE CODE [879FMC] .2807
FAILURE CODE [879GKX] .2808
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2810
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2812
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2815
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2817
TROUBLESHOOTING USING GAUGE PRESSURE 2819
CONNECTION OF SERVICE TOOL 2822
METHOD FOR CONNECTING SERVICE TOOL 2822
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2824
HANDLE COMPRESSOR OIL .2826
METHOD FOR REPLACING DESICCANT 2828
90 CIRCUIT DIAGRAMS .2831
CONTENTS 2832
ABBREVIATION LIST .2833
HYDRAULIC CIRCUIT DIAGRAM .2839
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2839
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2843
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2845
ELECTRICAL CIRCUIT DIAGRAM 2847
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2847
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2851
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2853
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2855
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2857
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2859
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2861
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2863
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2865
INDEX 2867

DESCRIPTION:

Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00365 – PDF DOWNLOAD

• Serial Number K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
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 diagrams.

G.B 31/12/24