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 UENBM00363 – PDF DOWNLOAD

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00363 – PDF DOWNLOAD

Language : English
Pages : 2772
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 UENBM00363 – PDF DOWNLOAD

 SERIAL NUMBERS

• 500007 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC210-11, PC210LC-11, PC210NLC-11 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC210-11, PC210LC-11, PC210NLC-11 102
SPECIFICATIONS 103
SPECIFICATIONS: PC210-11, PC210LC-11, PC210NLC-11 . 103
WEIGHT TABLE 106
WEIGHT TABLE: PC210-11, PC210LC-11, PC210NLC-11 . 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION . 109
CONTENTS 110
ABBREVIATION LIST . 114
UREA SCR SYSTEM . 120
LAYOUT DRAWING OF UREA SCR SYSTEM . 121
UREA SCR SYSTEM DIAGRAM . 126
FUNCTION OF UREA SCR SYSTEM . 127
FUNCTION OF AdBlue/DEF SYSTEM . 127
INDUCEMENT STRATEGY . 129
COMPONENT PARTS OF UREA SCR SYSTEM 137
AdBlue/DEF MIXING TUBE 137
SCR ASSEMBLY 137
AdBlue/DEF TANK . 140
AdBlue/DEF PUMP . 142
AdBlue/DEF INJECTOR . 143
AdBlue/DEF HOSE . 144
AdBlue/DEF TANK HEATING VALVE . 145
BOOT-UP SYSTEM 146
LAYOUT DRAWING OF BOOT-UP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 149
FUNCTION OF BATTERY DISCONNECT SWITCH . 149
ENGINE SYSTEM . 150
LAYOUT DRAWING OF ENGINE SYSTEM . 150
SPECIFICATIONS OF ENGINE SYSTEM . 151
FUNCTION OF ENGINE SYSTEM . 151
ENGINE CONTROL SYSTEM . 152
ENGINE CONTROL SYSTEM DIAGRAM . 152
FUNCTION OF ENGINE CONTROL SYSTEM . 153
AUTO-DECELERATION SYSTEM 155
AUTO-DECELERATION SYSTEM DIAGRAM 155
FUNCTION OF AUTO-DECELERATION SYSTEM 155
OPERATION OF AUTO-DECELERATION SYSTEM . 156
ENGINE AUTOMATIC WARM-UP SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 158
OVERHEAT PREVENTION SYSTEM 159
OVERHEAT PREVENTION SYSTEM DIAGRAM 159
FUNCTION OF OVERHEAT PREVENTION SYSTEM 160
TURBOCHARGER PROTECTION SYSTEM 162
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 162
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 163
AUTOMATIC IDLE STOP SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 164
COMPONENT PARTS OF ENGINE SYSTEM 167
VGT . 167
EGR SYSTEM 170
EGR VALVE . 172
EGR COOLER 174
KCCV SYSTEM . 175
KCCV VENTILATOR . 177
KDPF 179
COOLING SYSTEM 184
LAYOUT DRAWING OF COOLING SYSTEM 184
SPECIFICATIONS OF COOLING SYSTEM 185
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 186
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 186
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 187
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 188
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 188
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 188
COMPONENT PARTS OF COOLING SYSTEM . 190
FAN CLUTCH 190
CONTROL SYSTEM 191
LAYOUT DRAWING OF CONTROL SYSTEM 191
MACHINE MONITOR SYSTEM 194
MACHINE MONITOR SYSTEM DIAGRAM 194
KOMTRAX SYSTEM 195
KOMTRAX SYSTEM DIAGRAM 195
FUNCTION OF KOMTRAX SYSTEM 195
PPC LEVERS 196
LH PPC LEVER 196
RH PPC LEVER 197
AUTOMATIC GREASE SYSTEM . 198
OUTLINE OF AUTO GREASE SYSTEM . 198
COMPONENT PARTS OF CONTROL SYSTEM . 213
MACHINE MONITOR . 213
KOMTRAX TERMINAL 226
PUMP CONTROLLER . 228
RESISTOR FOR PC-EPC VALVE . 232
CAN TERMINATING RESISTOR 233
PPC OIL PRESSURE SWITCH . 233
ENGINE CONTROLLER . 235
FUEL CONTROL DIAL . 241
SENSOR 243
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 243
FUNCTION OF ENGINE OIL PRESSURE SWITCH 243
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 243
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 244
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 244
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 245
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 245
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 245
STRUCTURE OF OVERLOAD CAUTION SENSOR 245
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 246
FUNCTION OF OVERLOAD CAUTION SENSOR . 246
HYDRAULIC SYSTEM 247
LAYOUT DRAWING OF HYDRAULIC SYSTEM 247
CLSS 253
STRUCTURE OF CLSS . 253
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 255
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 256
PRESSURE COMPENSATION CONTROL . 269
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 271
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 271
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 272
PUMP AND VALVE CONTROL SYSTEM . 277
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 277
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 278
COMPONENT PARTS OF HYDRAULIC SYSTEM . 280
HYDRAULIC TANK 280
MAIN PUMP . 282
PILOT OIL FILTER 308
CONTROL VALVE . 308
WORK EQUIPMENT SYSTEM . 365
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 365
STRUCTURE OF VALVE CONTROL 370
ONE-TOUCH POWER MAXIMIZING SYSTEM . 372
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 372
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 373
PPC LOCK SYSTEM . 374
PPC LOCK SYSTEM DIAGRAM . 374
FUNCTION OF PPC LOCK SYSTEM . 374
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 375
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 375
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 375
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 376
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 378
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 378
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 380
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 381
WORK EQUIPMENT AND SWING PPC VALVE 381
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 386
393
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 396
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 398
ATT EPC VALVE ASSEMBLY 401
PILOT CIRCUIT ACCUMULATOR . 402
ATTACHMENT CIRCUIT ACCUMULATOR 403
SWING SYSTEM 404
LAYOUT DRAWING OF SWING SYSTEM 404
SWING CONTROL SYSTEM DIAGRAM 408
FUNCTION OF SWING CONTROL SYSTEM 408
COMPONENT PARTS OF SWING SYSTEM . 412
SWING MOTOR . 412
SWING MACHINERY . 423
SWING CIRCLE 424
TRAVEL SYSTEM . 426
LAYOUT DRAWING OF TRAVEL SYSTEM . 426
TRAVEL CONTROL SYSTEM DIAGRAM . 430
FUNCTION OF TRAVEL CONTROL SYSTEM . 430
COMPONENT PARTS OF TRAVEL SYSTEM 432
TRAVEL MOTOR 432
FINAL DRIVE . 445
TRAVEL PPC VALVE 446
CENTER SWIVEL JOINT . 451
UNDERCARRIAGE AND FRAME . 453
LAYOUT DRAWING OF UNDERCARRIAGE . 453
SPECIFICATIONS OF UNDERCARRIAGE . 454
WORK EQUIPMENT 455
STRUCTURE OF WORK EQUIPMENT . 455
FUNCTION OF WORK EQUIPMENT 456
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
BUCKET CLEARANCE ADJUSTMENT SHIM 458
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 458
CAB AND ITS ATTACHMENTS . 459
ROPS CAB 459
STRUCTURE OF ROPS CAB . 459
FUNCTION OF ROPS CAB 459
CAB MOUNT . 460
STRUCTURE OF CAB MOUNT 460
FUNCTION OF CAB MOUNT . 460
CAB TIPPING STOPPER . 461
STRUCTURE OF CAB TIPPING STOPPER 461
FUNCTION OF CAB TIPPING STOPPER . 461
20 STANDARD VALUE TABLE . 463
CONTENTS 464
ABBREVIATION LIST . 465
STANDARD VALUE TABLE FOR ENGINE . 471
STANDARD VALUE TABLE FOR MACHINE 472
STANDARD VALUE TABLE FOR MACHINE: PC210-11, PC210LC-11 472
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 485
STANDARD VALUE TABLE FOR ELECTRICAL . 489
STANDARD VALUE TABLE FOR ELECTRICAL . 489
30 TESTING AND ADJUSTING 499
CONTENTS 500
ABBREVIATION LIST . 503
RELATED INFORMATION ON TESTING AND ADJUSTING 509
TOOLS FOR TESTING AND ADJUSTING . 509
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 515
ENGINE AND COOLING SYSTEM . 516
TEST ENGINE SPEED . 516
METHOD FOR TESTING ENGINE SPEED . 516
TEST BOOST PRESSURE . 519
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 519
METHOD FOR TESTING BOOST PRESSURE . 520
TEST EXHAUST GAS COLOR 521
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 521
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 522
TEST AND ADJUST VALVE CLEARANCE . 524
METHOD FOR TESTING VALVE CLEARANCE 524
METHOD FOR ADJUSTING VALVE CLEARANCE 525
TEST COMPRESSION PRESSURE . 526
METHOD FOR TESTING COMPRESSION PRESSURE . 526
TEST BLOWBY PRESSURE 531
METHOD FOR TESTING BLOWBY PRESSURE 531
TEST ENGINE OIL PRESSURE 533
METHOD FOR TESTING ENGINE OIL PRESSURE 533
TEST EGR VALVE AND VGT OIL PRESSURE . 534
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 534
TEST FUEL PRESSURE 536
METHOD FOR TESTING FUEL PRESSURE 537
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 542
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 543
BLEEDING AIR FROM FUEL SYSTEM . 549
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 549
TEST FUEL CIRCUIT FOR LEAKAGE . 550
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 550
HANDLE CYLINDER CUT-OUT MODE OPERATION 552
HANDLE NO-INJECTION CRANKING OPERATION 553
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 554
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 554
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 554
REPLACING FAN BELT 556
METHOD FOR REPLACING FAN BELT . 556
TEST COOLING FAN SPEED 557
METHOD FOR TESTING COOLING FAN SPEED 557
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 558
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 558
TEST SCR RELATED FUNCTIONS 559
TEST AdBlue/DEF PUMP RAISED PRESSURE 562
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 565
TEST AdBlue/DEF LINE HEATER RELAY 1 . 569
TEST AdBlue/DEF LINE HEATER RELAY 2 . 572
TEST AdBlue/DEF PUMP HEATER RELAY . 574
TEST AdBlue/DEF TANK HEATER VALVE . 577
TEST DENITRATION EFFICIENCY OF SCR 580
CLEAN AdBlue/DEF TANK . 584
METHOD FOR CLEANING AdBlue/DEF TANK . 584
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 588
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 588
POWER TRAIN . 590
TEST SWING CIRCLE BEARING CLEARANCE . 590
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 590
UNDERCARRIAGE AND FRAME . 591
TEST AND ADJUST TRACK TENSION . 591
METHOD FOR TESTING TRACK TENSION 591
METHOD FOR ADJUSTING TRACK TENSION 591
HYDRAULIC SYSTEM 593
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 593
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 593
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 599
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 600
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 606
TEST OIL PRESSURE OF CONTROL CIRCUIT 609
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 609
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 611
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 611
TEST PC-EPC VALVE OUTLET PRESSURE . 612
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 613
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 614
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 614
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 615
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 618
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 619
METHOD FOR ADJUSTING LS VALVE . 620
TEST OUTLET PRESSURE OF SOLENOID VALVE 621
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 621
OPERATING CONDITION OF SOLENOID VALVE . 622
TEST PPC VALVE OUTLET PRESSURE 625
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 625
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 627
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 627
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 628
TEST PUMP SWASH PLATE SENSOR 630
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 630
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 631
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 631
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 631
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 632
TEST OIL LEAKAGE 633
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 633
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 633
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 634
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 635
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 635
BLEED AIR FROM HYDRAULIC CIRCUIT 636
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 638
CAB AND ITS ATTACHMENTS . 640
TEST CAB TIPPING STOPPER 640
METHOD FOR TESTING CAB TIPPING STOPPER 640
METHOD FOR ADJUSTING MIRRORS 641
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 641
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 642
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 643
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 644
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 645
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 646
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 647
ELECTRICAL SYSTEM . 649
ELECTRICAL SYSTEM . 650
SET AND OPERATE MACHINE MONITOR . 650
OPERATOR MODE . 653
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 654
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 654
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 655
CHECKING FUNCTION OF SERVICE METER 655
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 655
SERVICE MODE 658
METHOD FOR OPERATING SERVICE MODE . 658
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 660
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 667
ABNORMALITY RECORD MENU . 677
METHOD FOR CONFIRMING MAINTENANCE RECORD 682
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 683
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 687
DEFAULT MENU 688
DIAGNOSTIC TESTS MENU . 695
ADJUSTMENT MENU . 704
METHOD FOR PERFORMING NO-INJECTION CRANKING . 726
KOMTRAX SETTINGS MENU . 727
METHOD FOR DISPLAYING SERVICE MESSAGE . 730
METHOD FOR STARTING UP KOMTRAX TERMINAL . 732
ADJUST REARVIEW CAMERA ANGLE 737
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 737
ADJUST KomVision CAMERA ANGLE . 740
741
SETTING OF KomVision (CAMERA CALIBRATION) . 741
KomVision screen – Check 12 m visibility 754
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 757
HANDLE BATTERY DISCONNECT SWITCH 758
TEST DIODES . 759
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 759
METHOD FOR TESTING DIODE USING ANALOG TESTER 759
Pm CLINIC . 760
Pm CLINIC SERVICE . 760
Pm CLINIC CHECK SHEET . 764
40 TROUBLESHOOTING 775
CONTENTS 776
ABBREVIATION LIST . 787
RELATED INFORMATION ON TROUBLESHOOTING 793
GENERAL TROUBLESHOOTING POINTS 793
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 795
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 807
CHECKS BEFORE TROUBLESHOOTING . 809
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 811
WALK-AROUND CHECK . 811
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 813
CHECK FUEL LEVEL AND TYPE . 813
CHECK IMPURE INGREDIENT IN FUEL . 813
CHECK FUEL PREFILTER 814
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 814
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 815
CHECK MAIN FILTER . 816
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 818
CHECK COOLANT LEVEL (RESERVOIR TANK) 819
CHECK CLOGGING OF AIR CLEANER . 819
OUTER ELEMENT – CLEAN . 820
ELEMENTS – REPLACE 822
CHECK HYDRAULIC OIL LEVEL . 823
CHECK HYDRAULIC OIL STRAINER 824
CHECK HYDRAULIC FILTER 825
CHECK OIL LEVEL IN SWING MACHINERY CASE . 826
CHECK OIL LEVEL IN DAMPER CASE 827
CHECK OIL LEVEL IN FINAL DRIVE CASE . 827
BLEED AIR FROM FUEL SYSTEM 828
BLEED AIR FROM HYDRAULIC SYSTEM . 828
ELECTRICAL EQUIPMENT – CHECK METHOD . 828
AUTOMATIC GREASE SYSTEM . 836
FINDING MALFUNCTIONS 836
MALFUNCTION FINDING PROCEDURES 838
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 840
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 850
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 853
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 857
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 859
CONNECTOR LIST AND LAYOUT . 862
CONNECTOR CONTACT IDENTIFICATION 875
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 915
FUSE LOCATION TABLE . 921
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 924
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 928
FAILURE CODES TABLE . 930
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 947
FAILURE CODE [879AKA] . 947
FAILURE CODE [879AKB] . 948
FAILURE CODE [879BKA] . 949
FAILURE CODE [879BKB] . 951
FAILURE CODE [879CKA] . 953
FAILURE CODE [879CKB] . 954
FAILURE CODE [879DKZ] . 955
FAILURE CODE [879EMC] . 957
FAILURE CODE [879FMC] . 958
FAILURE CODE [879GKX] . 959
FAILURE CODE [989L00] . 961
FAILURE CODE [989M00] . 962
FAILURE CODE [989N00] . 963
FAILURE CODE [A1U0N3] . 964
FAILURE CODE [A1U0N4] . 966
FAILURE CODE [A900FR] . 968
FAILURE CODE [A900N6] . 969
FAILURE CODE [A900NY] . 970
FAILURE CODE [AA10NX] . 971
FAILURE CODE [AB00KE] . 973
FAILURE CODE [AQ10N3] . 976
FAILURE CODE [AS00N3] . 978
FAILURE CODE [AS00R2] . 980
FAILURE CODE [AS00R3] . 981
FAILURE CODE [AS00R4] . 982
FAILURE CODE [AS00R5] . 983
FAILURE CODE [AS00R6] . 984
FAILURE CODE [AS00ZK] . 985
FAILURE CODE [AS10KM] . 986
FAILURE CODE [AS10NR] . 987
FAILURE CODE [AS10NT] . 988
FAILURE CODE [B@BAZG] . 989
FAILURE CODE [B@BAZK] . 990
FAILURE CODE [B@BCNS] . 992
FAILURE CODE [B@BCQA] . 993
FAILURE CODE [B@BCZK] . 995
FAILURE CODE [B@HANS] . 997
FAILURE CODE [CA115] 998
FAILURE CODE [CA122] 999
FAILURE CODE [CA123] 1001
FAILURE CODE [CA131] 1003
FAILURE CODE [CA132] 1005
FAILURE CODE [CA144] 1007
FAILURE CODE [CA145] 1009
FAILURE CODE [CA153] 1011
FAILURE CODE [CA154] 1014
FAILURE CODE [CA187] 1016
FAILURE CODE [CA221] 1018
FAILURE CODE [CA222] 1020
FAILURE CODE [CA227] 1022
FAILURE CODE [CA234] 1023
FAILURE CODE [CA238] 1024
FAILURE CODE [CA239] 1026
FAILURE CODE [CA249] 1028
FAILURE CODE [CA256] 1030
FAILURE CODE [CA271] 1032
FAILURE CODE [CA272] 1034
FAILURE CODE [CA322] 1036
FAILURE CODE [CA323] 1038
FAILURE CODE [CA324] 1040
FAILURE CODE [CA325] 1042
FAILURE CODE [CA331] 1044
FAILURE CODE [CA332] 1046
FAILURE CODE [CA343] 1048
FAILURE CODE [CA351] 1049
FAILURE CODE [CA352] 1050
FAILURE CODE [CA356] 1053
FAILURE CODE [CA357] 1055
FAILURE CODE [CA386] 1057
FAILURE CODE [CA428] 1058
FAILURE CODE [CA429] 1060
FAILURE CODE [CA435] 1062
FAILURE CODE [CA441] 1064
FAILURE CODE [CA442] 1066
FAILURE CODE [CA449] 1067
FAILURE CODE [CA451] 1068
FAILURE CODE [CA452] 1070
FAILURE CODE [CA488] 1072
FAILURE CODE [CA515] 1073
FAILURE CODE [CA516] 1075
FAILURE CODE [CA553] 1077
FAILURE CODE [CA555] 1078
FAILURE CODE [CA556] 1079
FAILURE CODE [CA559] 1080
FAILURE CODE [CA595] 1083
FAILURE CODE [CA687] 1084
FAILURE CODE [CA689] 1086
FAILURE CODE [CA691] 1089
FAILURE CODE [CA692] 1091
FAILURE CODE [CA697] 1093
FAILURE CODE [CA698] 1094
FAILURE CODE [CA731] 1095
FAILURE CODE [CA778] 1097
FAILURE CODE [CA1117] .1102
FAILURE CODE [CA1664] .1103
FAILURE CODE [CA1669] .1105
FAILURE CODE [CA1673] .1106
FAILURE CODE [CA1677] .1107
FAILURE CODE [CA1678] .1108
FAILURE CODE [CA1682] .1109
FAILURE CODE [CA1683] .1111
FAILURE CODE [CA1684] .1113
FAILURE CODE [CA1686] .1115
FAILURE CODE [CA1691] .1116
FAILURE CODE [CA1694] .1119
FAILURE CODE [CA1695] .1122
FAILURE CODE [CA1696] .1123
FAILURE CODE [CA1712] .1125
FAILURE CODE [CA1713] .1128
FAILURE CODE [CA1714] .1130
FAILURE CODE [CA1715] .1131
FAILURE CODE [CA1776] .1132
FAILURE CODE [CA1777] .1135
FAILURE CODE [CA1843] .1138
FAILURE CODE [CA1844] .1140
FAILURE CODE [CA1879] .1143
FAILURE CODE [CA1881] .1145
FAILURE CODE [CA1883] .1147
FAILURE CODE [CA1885] .1150
FAILURE CODE [CA1887] .1152
FAILURE CODE [CA1921] .1154
FAILURE CODE [CA1922] .1157
FAILURE CODE [CA1942] .1162
FAILURE CODE [CA1993] .1163
FAILURE CODE [CA2185] .1166
FAILURE CODE [CA2186] .1167
FAILURE CODE [CA2249] .1169
FAILURE CODE [CA2271] .1170
FAILURE CODE [CA2272] .1173
FAILURE CODE [CA2288] .1176
FAILURE CODE [CA2311] .1177
FAILURE CODE [CA2349] .1178
FAILURE CODE [CA2353] .1181
FAILURE CODE [CA2357] .1183
FAILURE CODE [CA2381] .1184
FAILURE CODE [CA2382] .1187
FAILURE CODE [CA2383] .1190
FAILURE CODE [CA2386] .1193
FAILURE CODE [CA2387] .1195
FAILURE CODE [CA2555] .1196
FAILURE CODE [CA2556] .1199
FAILURE CODE [CA2637] .1202
FAILURE CODE [CA2639] .1204
FAILURE CODE [CA2771] .1207
FAILURE CODE [CA2777] .1213
FAILURE CODE [CA2976] .1216
FAILURE CODE [CA3133] .1218
FAILURE CODE [CA3134] .1221
FAILURE CODE [CA3135] .1223
FAILURE CODE [CA3142] .1226
FAILURE CODE [CA3143] .1227
FAILURE CODE [CA3144] .1228
FAILURE CODE [CA3146] .1230
FAILURE CODE [CA3147] .1231
FAILURE CODE [CA3148] .1232
FAILURE CODE [CA3151] .1234
FAILURE CODE [CA3165] .1240
FAILURE CODE [CA3229] .1242
FAILURE CODE [CA3231] .1244
FAILURE CODE [CA3232] .1246
FAILURE CODE [CA3235] .1250
FAILURE CODE [CA3239] .1252
FAILURE CODE [CA3241] .1255
FAILURE CODE [CA3242] .1258
FAILURE CODE [CA3251] .1261
FAILURE CODE [CA3253] .1263
FAILURE CODE [CA3254] .1266
FAILURE CODE [CA3255] .1269
FAILURE CODE [CA3256] .1273
FAILURE CODE [CA3311] .1275
FAILURE CODE [CA3312] .1277
FAILURE CODE [CA3313] .1280
FAILURE CODE [CA3314] .1281
FAILURE CODE [CA3315] .1282
FAILURE CODE [CA3316] .1284
FAILURE CODE [CA3317] .1285
FAILURE CODE [CA3318] .1286
FAILURE CODE [CA3319] .1288
FAILURE CODE [CA3321] .1289
FAILURE CODE [CA3322] .1291
FAILURE CODE [CA3419] .1293
FAILURE CODE [CA3421] .1295
FAILURE CODE [CA3497] .1297
FAILURE CODE [CA3498] .1298
FAILURE CODE [CA3543] .1299
FAILURE CODE [CA3545] .1306
FAILURE CODE [CA3547] .1308
FAILURE CODE [CA3558] .1309
FAILURE CODE [CA3559] .1311
FAILURE CODE [CA3562] .1313
FAILURE CODE [CA3563] .1315
FAILURE CODE [CA3567] .1318
FAILURE CODE [CA3568] .1321
FAILURE CODE [CA3571] .1325
FAILURE CODE [CA3572] .1327
FAILURE CODE [CA3574] .1329
FAILURE CODE [CA3575] .1331
FAILURE CODE [CA3577] .1333
FAILURE CODE [CA3578] .1335
FAILURE CODE [CA3582] .1337
FAILURE CODE [CA3583] .1343
FAILURE CODE [CA3596] .1345
FAILURE CODE [CA3649] .1347
FAILURE CODE [CA3681] .1349
FAILURE CODE [CA3682] .1354
FAILURE CODE [CA3713] .1360
FAILURE CODE [CA3717] .1363
FAILURE CODE [CA3718] .1364
FAILURE CODE [CA3725] .1365
FAILURE CODE [CA3741] .1368
FAILURE CODE [CA3748] .1369
FAILURE CODE [CA3751] .1371
FAILURE CODE [CA3755] .1373
FAILURE CODE [CA3866] .1375
FAILURE CODE [CA3867] .1379
FAILURE CODE [CA3868] .1382
FAILURE CODE [CA3899] .1386
FAILURE CODE [CA3911] .1388
FAILURE CODE [CA3912] .1392
FAILURE CODE [CA3932] .1394
FAILURE CODE [CA3933] .1396
FAILURE CODE [CA3934] .1398
FAILURE CODE [CA3935] .1401
FAILURE CODE [CA3936] .1403
FAILURE CODE [CA4151] .1405
FAILURE CODE [CA4152] .1409
FAILURE CODE [CA4155] .1413
FAILURE CODE [CA4156] .1415
FAILURE CODE [CA4157] .1418
FAILURE CODE [CA4158] .1420
FAILURE CODE [CA4159] .1421
FAILURE CODE [CA4161] .1422
FAILURE CODE [CA4162] .1425
FAILURE CODE [CA4163] .1428
FAILURE CODE [CA4164] .1429
FAILURE CODE [CA4165] .1431
FAILURE CODE [CA4166] .1433
FAILURE CODE [CA4168] .1434
FAILURE CODE [CA4169] .1437
FAILURE CODE [CA4171] .1439
FAILURE CODE [CA4249] .1442
FAILURE CODE [CA4251] .1444
FAILURE CODE [CA4259] .1446
FAILURE CODE [CA4261] .1449
FAILURE CODE [CA4277] .1452
FAILURE CODE [CA4281] .1456
FAILURE CODE [CA4459] .1459
FAILURE CODE [CA4461] .1462
FAILURE CODE [CA4658] .1465
FAILURE CODE [CA4731] .1469
FAILURE CODE [CA4732] .1470
FAILURE CODE [CA4739] .1471
FAILURE CODE [CA4768] .1472
FAILURE CODE [CA4769] .1474
FAILURE CODE [CA4842] .1477
FAILURE CODE [CA4952] .1481
FAILURE CODE [CA5115] .1483
FAILURE CODE [CA5179] .1486
FAILURE CODE [CA5181] .1488
FAILURE CODE [CA5383] .1490
FAILURE CODE [D110KB] .1492
FAILURE CODE [D19JKZ] .1494
FAILURE CODE [D811MC] .1497
FAILURE CODE [D862KA] .1498
FAILURE CODE [D8ALKA] .1499
FAILURE CODE [D8ALKB] .1501
FAILURE CODE [D8AQKR] .1503
FAILURE CODE [DA20MC] .1505
FAILURE CODE [DA22KK] .1506
FAILURE CODE [DA25KP] .1509
FAILURE CODE [DA26KP] .1512
FAILURE CODE [DA29KQ] .1514
FAILURE CODE [DA2LKA] .1516
FAILURE CODE [DA2LKB] .1518
FAILURE CODE [DA2QKR] .1520
FAILURE CODE [DA2RKR] .1523
FAILURE CODE [DAF0MB] .1524
FAILURE CODE [DAF0MC] .1525
FAILURE CODE [DAF8KB] .1526
FAILURE CODE [DAF9KQ] .1528
FAILURE CODE [DAFGMC] .1529
FAILURE CODE [DAFLKA] .1530
FAILURE CODE [DAFLKB] .1532
FAILURE CODE [DAFQKR] .1534
FAILURE CODE [DAZ9KQ] .1535
FAILURE CODE [DAZQKR] .1536
FAILURE CODE [DB2QKR] .1541
FAILURE CODE [DB2RKR] .1546
FAILURE CODE [DDNRKA] .1551
FAILURE CODE [DDNRKY] .1553
FAILURE CODE [DDNS00] .1555
FAILURE CODE [DFB1KZ] .1557
FAILURE CODE [DFB2KZ] .1560
FAILURE CODE [DFB3L8] .1563
FAILURE CODE [DFB4L8] .1565
FAILURE CODE [DFB5KZ] .1567
FAILURE CODE [DFB6KZ] .1570
FAILURE CODE [DGH2KA] .1573
FAILURE CODE [DGH2KB] .1575
FAILURE CODE [DHA4KA] .1577
FAILURE CODE [DHAAMA] .1579
FAILURE CODE [DHACMA] .1581
FAILURE CODE [DHPAMA] .1583
FAILURE CODE [DHPBMA] .1586
FAILURE CODE [DHS3MA] .1589
FAILURE CODE [DHS4MA] .1592
FAILURE CODE [DHS8MA] .1595
FAILURE CODE [DHS9MA] .1598
FAILURE CODE [DHSAMA] .1601
FAILURE CODE [DHSBMA] .1604
FAILURE CODE [DHSCMA] .1607
FAILURE CODE [DHSDMA] .1610
FAILURE CODE [DHSFMA] .1613
FAILURE CODE [DHSGMA] .1616
FAILURE CODE [DHSHMA] .1619
FAILURE CODE [DHSJMA] .1622
FAILURE CODE [DHX1MA] .1625
FAILURE CODE [DKR0MA] .1628
FAILURE CODE [DKR1MA] .1631
FAILURE CODE [DKULKA] .1634
FAILURE CODE [DKULKB] .1636
FAILURE CODE [DKULKY] .1638
FAILURE CODE [DLM5KA] .1640
FAILURE CODE [DLM5MB] .1642
FAILURE CODE [DR21KX] .1644
FAILURE CODE [DR31KX] .1646
FAILURE CODE [DV20KB] .1648
FAILURE CODE [DW43KA] .1650
FAILURE CODE [DW43KB] .1652
FAILURE CODE [DW43KY] .1654
FAILURE CODE [DW45KA] .1656
FAILURE CODE [DW45KB] .1659
FAILURE CODE [DW45KY] .1662
FAILURE CODE [DW4CKY] .1664
FAILURE CODE [DW91KA] .1666
FAILURE CODE [DW91KB] .1668
FAILURE CODE [DW91KY] .1670
FAILURE CODE [DWA2KA] .1672
FAILURE CODE [DWA2KB] .1674
FAILURE CODE [DWA2KY] .1676
FAILURE CODE [DWK0KA] .1678
FAILURE CODE [DWK0KB] .1680
FAILURE CODE [DWK0KY] .1682
FAILURE CODE [DWK2KA] .1684
FAILURE CODE [DWK2KB] .1686
FAILURE CODE [DWK2KY] .1688
FAILURE CODE [DWK8KA] .1690
FAILURE CODE [DWK8KB] .1692
FAILURE CODE [DWK8KY] .1694
FAILURE CODE [DWN5KA] .1696
FAILURE CODE [DWN5KB] .1698
FAILURE CODE [DWN5KY] .1700
FAILURE CODE [DXA8KA] .1702
FAILURE CODE [DXA8KB] .1704
FAILURE CODE [DXA9KA] .1706
FAILURE CODE [DXA9KB] .1708
FAILURE CODE [DXE0KA] .1710
FAILURE CODE [DXE0KB] .1711
FAILURE CODE [DXE4KA] .1713
FAILURE CODE [DXE4KB] .1715
FAILURE CODE [DXE4KY] .1717
FAILURE CODE [DXE5KA] .1719
FAILURE CODE [DXE5KB] .1721
FAILURE CODE [DXE6KA] .1723
FAILURE CODE [DXE6KB] .1725
FAILURE CODE [DXE7KA] .1727
FAILURE CODE [DXE7KB] .1729
FAILURE CODE [DXE7KY] .1731
FAILURE CODE [DXE8KA] .1733
FAILURE CODE [DXE8KB] .1735
FAILURE CODE [DXE8KY] .1737
FAILURE CODE [DXE9KA] .1739
FAILURE CODE [DXE9KB] .1741
FAILURE CODE [DXE9KY] .1743
FAILURE CODE [DXEAKA] .1745
FAILURE CODE [DXEAKB] .1747
FAILURE CODE [DXEAKY] .1749
FAILURE CODE [DY20KA] .1751
FAILURE CODE [DY20MA] .1753
FAILURE CODE [DY2CKB] .1755
FAILURE CODE [DY2DKB] .1758
FAILURE CODE [DY2EKB] .1760
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1762
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1762
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1768
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1771
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1773
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1775
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1778
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1779
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1780
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1781
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1782
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1783
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1784
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1785
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1786
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1787
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1788
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1789
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1791
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1792
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1793
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1794
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1796
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1797
E-24 FUNCTION SWITCH DOES NOT OPERATE .1798
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1799
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1800
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1801
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1802
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1803
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1804
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1805
E-32 ALARM BUZZER CANNOT BE CANCELED 1807
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1808
E-34 SERVICE MODE CANNOT BE SELECTED 1809
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1810
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1813
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1815
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1818
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1820
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1823
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1824
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1826
E-43 HORN DOES NOT SOUND 1827
E-44 HORN DOES NOT STOP SOUNDING 1830
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1832
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1833
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1835
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1836
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1837
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1838
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1839
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1840
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1841
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1842
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1843
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1844
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1846
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1847
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1848
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1848
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1849
FAILURE MODE AND CAUSE TABLE 1851
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1863
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1864
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1867
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1868
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1869
H-6 SPEED OR POWER OF BOOM IS LOW .1871
H-7 ARM SPEED OR POWER IS LOW .1875
H-8 BUCKET SPEED OR POWER IS LOW 1880
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1883
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1884
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1886
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1888
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1889
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1890
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1891
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1892
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1893
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1894
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1895
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1896
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1897
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1899
H-23 TRAVEL SPEED IS LOW 1902
H-24 ONE OF TRACKS DOES NOT RUN .1904
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1905
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1906
H-27 SWINGS ONLY IN ONE DIRECTION .1907
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1908
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1909
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1910
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1911
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1912
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1913
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1914
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1915
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1916
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1917
H-38 Quick coupler cylinder will not extend .1918
H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1920
H-40 Buzzer does not sound (but quick coupler cylinder doesretract) .1922
H-41 Quick coupler cylinder extends and retracts slowly .1924
TROUBLESHOOTING OF ENGINE (S-MODE) 1925
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1925
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1926
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1927
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1928
S-4 ENGINE STARTABILITY IS POOR .1930
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1932
S-6 ENGINE STOPS DURING OPERATION .1934
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1936
S-8 ENGINE LACKS POWER 1937
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1939
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1941
S-11 OIL BECOMES CONTAMINATED QUICKLY .1942
S-12 FUEL CONSUMPTION IS EXCESSIVE 1943
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1944
S-14 OIL PRESSURE DROPS .1945
S-15 FUEL MIXES INTO ENGINE OIL .1947
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1948
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1949
S-18 UNUSUAL NOISE IS HEARD .1951
S-19 VIBRATION IS EXCESSIVE .1952
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1953
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1954
S-22 ACTIVE REGENERATION TAKES TIME .1956
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1957
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1958
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1960
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1961
50 DISASSEMBLY AND ASSEMBLY .1963
CONTENTS 1964
ABBREVIATION LIST .1969
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1975
HOW TO READ THIS MANUAL .1975
COATING MATERIALS LIST 1977
SPECIAL TOOLS LIST 1981
SKETCHES OF SPECIAL TOOLS .1993
ENGINE AND COOLING SYSTEM .1999
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1999
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1999
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2002
REMOVE AND INSTALL INJECTOR ASSEMBLY 2005
METHOD FOR REMOVING INJECTOR ASSEMBLY .2005
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2010
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2018
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2019
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2028
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2044
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2044
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2045
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2047
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2047
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2051
REMOVE AND INSTALL STARTER ASSEMBLY .2056
METHOD FOR REMOVING STARTER ASSEMBLY 2056
METHOD FOR INSTALLING STARTER ASSEMBLY 2057
REMOVE AND INSTALL ALTERNATOR BELT 2060
METHOD FOR REMOVING ALTERNATOR BELT .2060
METHOD FOR INSTALLING ALTERNATOR BELT .2062
REMOVE AND INSTALL RADIATOR ASSEMBLY 2064
METHOD FOR REMOVING RADIATOR ASSEMBLY .2064
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2066
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2069
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2069
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2072
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2075
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2075
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2077
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2079
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2079
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2083
REMOVE AND INSTALL FAN 2087
METHOD FOR INSTALLING FAN .2087
METHOD FOR REMOVING FAN .2087
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2088
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2088
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2097
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2109
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2109
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2112
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2116
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2116
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2117
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2120
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2120
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2120
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2122
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2122
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2124
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2129
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2129
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210NLC-11) 2133
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2136
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210NLC-11) 2140
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2145
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2145
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2151
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2157
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2157
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2163
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2168
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2168
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2168
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2170
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2170
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2170
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2171
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2171
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2173
REMOVE AND INSTALL KDPF ASSEMBLY 2176
METHOD FOR REMOVING KDPF ASSEMBLY .2176
METHOD FOR INSTALLING KDPF ASSEMBLY .2178
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2180
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2181
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2184
REMOVE AND INSTALL SCR ASSEMBLY .2189
METHOD FOR REMOVING SCR ASSEMBLY 2189
METHOD FOR INSTALLING SCR ASSEMBLY 2191
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2193
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2193
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2199
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2205
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2205
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (FOR PC210NLC-11) 2212
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2220
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210NLC-11) 2228
REMOVE AND INSTALL KCCV ASSEMBLY 2236
METHOD FOR REMOVING KCCV ASSEMBLY .2236
METHOD FOR INSTALLING KCCV ASSEMBLY .2238
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2243
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2243
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2249
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2255
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2255
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2258
REMOVE AND INSTALL AdBlue/DEF PUMP 2261
METHOD FOR REMOVING AdBlue/DEF PUMP .2261
METHOD FOR INSTALLING AdBlue/DEF PUMP .2264
REMOVE AND INSTALL AdBlue/DEF HOSE 2267
METHOD FOR REMOVING AdBlue/DEF HOSE .2267
METHOD FOR INSTALLING AdBlue/DEF HOSE .2274
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2280
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2280
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2281
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2283
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2283
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2285
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2288
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2288
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2289
POWER TRAIN .2290
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2290
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2290
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2291
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2293
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2293
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2297
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2306
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2306
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2308
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2312
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2312
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2316
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2323
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2323
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2323
UNDERCARRIAGE AND FRAME .2325
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2325
METHOD FOR SEPARATING TRACK ASSEMBLY 2325
METHOD FOR INSTALLING TRACK ASSEMBLY 2327
REMOVE AND INSTALL SPROCKET .2330
METHOD FOR REMOVING SPROCKET 2330
METHOD FOR INSTALLING SPROCKET 2330
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2332
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2332
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2333
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2334
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2334
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2335
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2339
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2339
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2340
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2342
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2343
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2344
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2346
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2346
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2348
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2350
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2350
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2352
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2355
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2355
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210-11, PC210LC-11) .2358
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210NLC-11) 2361
HYDRAULIC SYSTEM 2365
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2365
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2365
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2367
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2370
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2370
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2371
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2373
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2373
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2375
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2378
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2378
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2381
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2384
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2384
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2391
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2399
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2399
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2400
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2404
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2404
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2405
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2407
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2407
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2408
REMOVE AND INSTALL QUICK COUPLER VALVE 2410
WORK EQUIPMENT 2412
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2412
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2412
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2416
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2421
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2421
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2424
CAB AND ITS ATTACHMENTS .2430
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2430
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2430
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2436
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2443
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2445
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2445
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2456
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2456
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2459
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2465
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2465
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2472
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2479
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2479
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2484
REMOVE AND INSTALL OPERATOR’S SEAT 2490
METHOD FOR REMOVING OPERATOR’S SEAT .2490
METHOD FOR INSTALLING OPERATOR’S SEAT .2492
REMOVE AND INSTALL SEAT BELT 2495
METHOD FOR REMOVING SEAT BELT .2495
METHOD FOR INSTALLING SEAT BELT .2496
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2497
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2497
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2502
ELECTRICAL SYSTEM .2511
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2511
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2511
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2512
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2514
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2514
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2518
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2523
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2523
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2526
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2530
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2530
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2531
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2532
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2532
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2533
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2534
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2534
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2535
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2536
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2536
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2538
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2540
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2540
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2543
60 MAINTENANCE STANDARD .2547
CONTENTS 2548
ABBREVIATION LIST .2549
ENGINE AND COOLING SYSTEM .2555
MAINTENANCE STANDARD OF ENGINE MOUNT 2555
MAINTENANCE STANDARD OF COOLING SYSTEM 2556
POWER TRAIN .2558
MAINTENANCE STANDARD OF SWING CIRCLE 2558
MAINTENANCE STANDARD OF SWING MACHINERY .2559
MAINTENANCE STANDARD OF FINAL DRIVE .2561
MAINTENANCE STANDARD OF SPROCKET 2563
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2564
UNDERCARRIAGE AND FRAME .2566
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2566
MAINTENANCE STANDARD OF IDLER .2568
MAINTENANCE STANDARD OF TRACK ROLLER 2570
MAINTENANCE STANDARD OF CARRIER ROLLER 2571
MAINTENANCE STANDARD OF TRACK SHOE 2572
MAINTENANCE STANDARD OF TRIPLE SHOE .2575
MAINTENANCE STANDARD OF SWAMP SHOE 2576
MAINTENANCE STANDARD OF ROAD LINER 2577
HYDRAULIC SYSTEM 2578
MAINTENANCE STANDARD OF HYDRAULIC TANK 2578
MAINTENANCE STANDARD OF MAIN PUMP .2579
MAINTENANCE STANDARD OF LS-EPC VALVE 2580
MAINTENANCE STANDARD OF PC-EPC VALVE 2581
MAINTENANCE STANDARD OF SWING MOTOR .2582
MAINTENANCE STANDARD OF TRAVEL MOTOR 2585
MAINTENANCE STANDARD OF CONTROL VALVE .2588
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2598
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2601
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2604
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2605
MAINTENANCE STANDARD OF SOLENOID VALVE 2607
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2608
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2610
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2611
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2612
WORK EQUIPMENT 2613
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2613
DIMENSION OF ARM 2618
DIMENSIONS OF BUCKET 2620
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2622
MAINTENANCE STANDARD OF ARM CYLINDER 2623
MAINTENANCE STANDARD OF BUCKET CYLINDER .2624
80 APPENDIX .2625
CONTENTS 2626
ABBREVIATION LIST .2628
AIR CONDITIONER SYSTEM 2634
PRECAUTIONS FOR REFRIGERANT .2634
AIR CONDITIONER COMPONENT .2635
SPECIFICATIONS OF AIR CONDITIONER .2637
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2638
OUTLINE OF REFRIGERATION CYCLE 2639
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2641
AIR CONDITIONER UNIT 2641
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2641
FUNCTION OF AIR CONDITIONER UNIT 2643
COMPONENT PARTS OF AIR CONDITIONER UNIT .2645
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2646
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2646
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2646
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2646
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2647
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2647
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2647
FUNCTION OF DUAL PRESSURE SWITCH 2648
AIR CONDITIONER CONTROLLER 2649
STRUCTURE OF AIR CONDITIONER CONTROLLER .2649
COMPRESSOR 2650
STRUCTURE OF COMPRESSOR .2650
SPECIFICATIONS OF COMPRESSOR 2650
FUNCTION OF COMPRESSOR 2650
CONDENSER .2651
STRUCTURE OF CONDENSER 2651
SPECIFICATIONS OF CONDENSER .2651
FUNCTION OF CONDENSER .2651
SENSORS FOR AIR CONDITIONER SYSTEM 2653
STRUCTURE OF SUNLIGHT SENSOR 2653
FUNCTION OF SUNLIGHT SENSOR .2653
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2653
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2653
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2655
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2657
AIR CONDITIONER SYSTEM DIAGRAM 2659
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2660
FUNCTION OF AIR CONDITIONER CONTROLLER 2661
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2662
TESTING AIR LEAKAGE (DUCT) 2666
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2666
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2668
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2669
TEST VENT (MODE) CHANGEOVER .2670
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2670
TESTING FRESH/RECIRC AIR CHANGEOVER .2672
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2672
TEST SUNLIGHT SENSOR 2673
METHOD FOR TESTING SUNLIGHT SENSOR 2673
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2674
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2674
TEST RELAYS .2676
METHOD FOR TESTING RELAYS .2676
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2677
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2679
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2682
FAILURE CODE [879AKA] .2684
FAILURE CODE [879AKB] .2685
FAILURE CODE [879BKA] .2686
FAILURE CODE [879BKB] .2688
FAILURE CODE [879CKA] .2690
FAILURE CODE [879CKB] .2691
FAILURE CODE [879DKZ] .2692
FAILURE CODE [879EMC] .2694
FAILURE CODE [879FMC] .2695
FAILURE CODE [879GKX] .2696
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2698
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2700
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2703
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2705
TROUBLESHOOTING USING GAUGE PRESSURE 2707
CONNECTION OF SERVICE TOOL 2710
METHOD FOR CONNECTING SERVICE TOOL 2710
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2712
HANDLE COMPRESSOR OIL .2714
METHOD FOR REPLACING DESICCANT 2716
90 CIRCUIT DIAGRAMS .2719
CONTENTS 2720
ABBREVIATION LIST .2721
HYDRAULIC CIRCUIT DIAGRAM .2727
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2727
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2731
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2733
ELECTRICAL CIRCUIT DIAGRAM 2735
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2735
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2739
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2741
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2743
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2745
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2747
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2749
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2751
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2753
INDEX 2755
Front Cover (UENBM00363).pdf . 0
Blank Page . 2

DESCRIPTION:

Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00363 – PDF DOWNLOAD

 SERIAL NUMBERS

• 500007 and up
• 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 29/12/24