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 UENBM00366 – PDF DOWNLOAD

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Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00366 – PDF DOWNLOAD

Language : English
Pages : 2872
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 UENBM00366 – PDF DOWNLOAD

• SERIAL NUMBERS K70001 and up

UENBM00366_PC210_LC_NLC_PC230NHD-11_2122.pdf . 0
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 AdBlue/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 111
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 269
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 270
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 270
STRUCTURE OF OVERLOAD CAUTION SENSOR 270
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 270
FUNCTION OF OVERLOAD CAUTION SENSOR . 270
HYDRAULIC SYSTEM 271
LAYOUT DRAWING OF HYDRAULIC SYSTEM 271
CLSS 277
STRUCTURE OF CLSS . 277
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 279
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 280
PRESSURE COMPENSATION CONTROL . 293
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 295
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 295
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 296
PUMP AND VALVE CONTROL SYSTEM . 301
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 301
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 302
COMPONENT PARTS OF HYDRAULIC SYSTEM . 304
HYDRAULIC TANK 304
MAIN PUMP . 306
PILOT OIL FILTER 332
CONTROL VALVE . 332
WORK EQUIPMENT SYSTEM . 389
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 389
STRUCTURE OF VALVE CONTROL 394
ONE-TOUCH POWER MAXIMIZING SYSTEM . 396
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 396
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 397
PPC LOCK SYSTEM . 398
PPC LOCK SYSTEM DIAGRAM . 398
FUNCTION OF PPC LOCK SYSTEM . 398
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 399
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 399
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 399
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 400
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 401
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 401
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 403
TOOL CONTROL SYSTEM . 404
TOOL CONTROL SYSTEM DIAGRAM . 404
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 406
WORK EQUIPMENT AND SWING PPC VALVE 406
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 411
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 420
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 422
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 425
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 427
ATTACHMENT BYPASS SOLENOID VALVE 430
ATT EPC VALVE ASSEMBLY 432
PILOT CIRCUIT ACCUMULATOR . 433
ATTACHMENT CIRCUIT ACCUMULATOR 434
SWING SYSTEM 435
LAYOUT DRAWING OF SWING SYSTEM 435
SWING CONTROL SYSTEM DIAGRAM 439
FUNCTION OF SWING CONTROL SYSTEM 439
COMPONENT PARTS OF SWING SYSTEM . 443
SWING MOTOR . 443
SWING MACHINERY . 454
SWING CIRCLE 455
TRAVEL SYSTEM . 457
LAYOUT DRAWING OF TRAVEL SYSTEM . 457
TRAVEL CONTROL SYSTEM DIAGRAM . 461
FUNCTION OF TRAVEL CONTROL SYSTEM . 461
COMPONENT PARTS OF TRAVEL SYSTEM 463
TRAVEL MOTOR 463
FINAL DRIVE . 475
TRAVEL PPC VALVE 477
CENTER SWIVEL JOINT . 482
UNDERCARRIAGE AND FRAME . 484
LAYOUT DRAWING OF UNDERCARRIAGE . 484
SPECIFICATIONS OF UNDERCARRIAGE . 485
WORK EQUIPMENT 486
STRUCTURE OF WORK EQUIPMENT . 486
FUNCTION OF WORK EQUIPMENT 487
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 488
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 488
BUCKET CLEARANCE ADJUSTMENT SHIM 489
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 489
CAB AND ITS ATTACHMENTS . 490
ROPS CAB 490
STRUCTURE OF ROPS CAB . 490
FUNCTION OF ROPS CAB 490
CAB MOUNT . 491
STRUCTURE OF CAB MOUNT 491
FUNCTION OF CAB MOUNT . 491
CAB TIPPING STOPPER . 492
STRUCTURE OF CAB TIPPING STOPPER 492
FUNCTION OF CAB TIPPING STOPPER . 492
20 STANDARD VALUE TABLE . 493
CONTENTS 494
ABBREVIATION LIST . 495
STANDARD VALUE TABLE FOR ENGINE . 501
STANDARD VALUE TABLE FOR ENGINE: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 . 501
STANDARD VALUE TABLE FOR MACHINE 505
STANDARD VALUE TABLE FOR MACHINE: PC210-11, PC210LC-11, PC210NLC-11, PC230NHD-11 505
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 518
STANDARD VALUE TABLE FOR ELECTRICAL . 522
STANDARD VALUE TABLE FOR ELECTRICAL . 522
30 TESTING AND ADJUSTING 533
CONTENTS 534
ABBREVIATION LIST . 537
RELATED INFORMATION ON TESTING AND ADJUSTING 543
TOOLS FOR TESTING AND ADJUSTING . 543
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 550
ENGINE AND COOLING SYSTEM . 552
TEST ENGINE SPEED . 552
METHOD FOR TESTING ENGINE SPEED . 552
TEST BOOST PRESSURE . 555
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 555
METHOD FOR TESTING BOOST PRESSURE . 556
TEST EXHAUST GAS COLOR 557
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 557
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 558
TEST AND ADJUST VALVE CLEARANCE . 560
METHOD FOR TESTING VALVE CLEARANCE 560
METHOD FOR ADJUSTING VALVE CLEARANCE 561
TEST COMPRESSION PRESSURE . 563
METHOD FOR TESTING COMPRESSION PRESSURE . 563
TEST BLOWBY PRESSURE 568
METHOD FOR TESTING BLOWBY PRESSURE 568
TEST ENGINE OIL PRESSURE 570
METHOD FOR TESTING ENGINE OIL PRESSURE 570
TEST EGR VALVE AND VGT OIL PRESSURE . 571
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 571
TEST FUEL PRESSURE 573
METHOD FOR TESTING FUEL PRESSURE 574
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 579
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 580
BLEEDING AIR FROM FUEL SYSTEM . 586
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 586
TEST FUEL CIRCUIT FOR LEAKAGE . 587
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 587
HANDLE CYLINDER CUT-OUT MODE OPERATION 589
HANDLE NO-INJECTION CRANKING OPERATION 590
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 591
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 591
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 591
REPLACING FAN BELT 593
METHOD FOR REPLACING FAN BELT . 593
TEST COOLING FAN SPEED 594
METHOD FOR TESTING COOLING FAN SPEED 594
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 595
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 595
TEST SCR RELATED FUNCTIONS 596
TEST AdBlue/DEF PUMP RAISED PRESSURE 599
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 602
TEST AdBlue/DEF LINE HEATER RELAY 1 . 606
TEST AdBlue/DEF LINE HEATER RELAY 2 . 609
TEST AdBlue/DEF PUMP HEATER RELAY . 611
TEST AdBlue/DEF TANK HEATER VALVE . 614
TEST DENITRATION EFFICIENCY OF SCR 617
CLEAN AdBlue/DEF TANK . 621
METHOD FOR CLEANING AdBlue/DEF TANK . 621
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 625
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 625
POWER TRAIN . 627
TEST SWING CIRCLE BEARING CLEARANCE . 627
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 627
UNDERCARRIAGE AND FRAME . 628
TEST AND ADJUST TRACK TENSION . 628
METHOD FOR TESTING TRACK TENSION 628
METHOD FOR ADJUSTING TRACK TENSION 628
HYDRAULIC SYSTEM 630
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 630
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 630
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 634
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 636
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 637
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 643
TEST OIL PRESSURE OF CONTROL CIRCUIT 646
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 646
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 648
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 648
TEST PC-EPC VALVE OUTLET PRESSURE . 649
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 650
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 652
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 652
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 653
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 656
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 657
METHOD FOR ADJUSTING LS VALVE . 658
TEST OUTLET PRESSURE OF SOLENOID VALVE 659
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 659
OPERATING CONDITION OF SOLENOID VALVE . 660
TEST PPC VALVE OUTLET PRESSURE 663
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 663
TEST ATTACHMENT CIRCUIT OIL PRESSURE 665
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 665
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 667
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 667
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 668
TEST PUMP SWASH PLATE SENSOR 670
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 670
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 671
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 671
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 671
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 672
TEST OIL LEAKAGE 673
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 673
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 673
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 674
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 675
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 675
BLEED AIR FROM HYDRAULIC CIRCUIT 676
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 678
CAB AND ITS ATTACHMENTS . 680
TEST CAB TIPPING STOPPER 680
METHOD FOR TESTING CAB TIPPING STOPPER 680
METHOD FOR ADJUSTING MIRRORS 681
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 681
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 682
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 683
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 684
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210-11, PC210LC-11) . 685
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) (PC210NLC-11, PC230NHD-11) . 686
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 687
ELECTRICAL SYSTEM . 689
SETTING AND OPERATION OF MACHINE MONITOR 689
OPERATOR MODE . 692
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 693
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 693
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 694
CHECKING FUNCTION OF SERVICE METER 694
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 694
SERVICE MODE 697
SERVICE MODE 697
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 699
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 706
ABNORMALITY RECORD MENU . 716
METHOD FOR CONFIRMING MAINTENANCE RECORD 721
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 722
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 726
DEFAULT MENU 727
DIAGNOSTIC TESTS MENU . 739
ADJUSTMENT MENU . 748
METHOD FOR PERFORMING NO-INJECTION CRANKING . 783
KOMTRAX SETTINGS MENU . 784
METHOD FOR DISPLAYING SERVICE MESSAGE . 786
METHOD FOR STARTING UP KOMTRAX TERMINAL . 787
ADJUST REARVIEW CAMERA ANGLE 793
ADJUST KomVision CAMERA ANGLE . 796
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 797
ADJUST KomVision RELATED ITEMS 801
SETTING OF KomVision (MAIN SETTING) . 801
SETTING OF KomVision (CAMERA SETTING) . 803
SETTING OF KomVision (CAMERA CALIBRATION) . 803
KomVision screen – Check 12 m visibility 817
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 820
HANDLE BATTERY DISCONNECT SWITCH 821
TEST DIODES . 822
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 822
METHOD FOR TESTING DIODE USING ANALOG TESTER 822
Pm CLINIC . 823
Pm CLINIC SERVICE . 823
Pm CLINIC CHECK SHEET . 827
40 TROUBLESHOOTING 839
CONTENTS 840
ABBREVIATION LIST . 851
RELATED INFORMATION ON TROUBLESHOOTING 857
GENERAL TROUBLESHOOTING POINTS 857
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 858
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 870
CHECKS BEFORE TROUBLESHOOTING . 872
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 874
WALK-AROUND CHECK . 874
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 876
CHECK FUEL LEVEL AND TYPE . 876
CHECK IMPURE INGREDIENT IN FUEL . 876
CHECK FUEL PREFILTER 877
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 877
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 878
CHECK MAIN FILTER . 879
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 881
CHECK COOLANT LEVEL (RESERVOIR TANK) 882
CHECK CLOGGING OF AIR CLEANER . 882
OUTER ELEMENT – CLEAN . 883
ELEMENTS – REPLACE 885
CHECK HYDRAULIC OIL LEVEL . 886
CHECK HYDRAULIC OIL STRAINER 887
CHECK HYDRAULIC FILTER 888
CHECK OIL LEVEL IN SWING MACHINERY CASE . 889
CHECK OIL LEVEL IN DAMPER CASE 890
CHECK OIL LEVEL IN FINAL DRIVE CASE . 890
BLEED AIR FROM FUEL SYSTEM 891
BLEED AIR FROM HYDRAULIC SYSTEM . 891
ELECTRICAL EQUIPMENT – CHECK METHOD . 891
AUTOMATIC GREASE SYSTEM . 899
FINDING MALFUNCTIONS 899
MALFUNCTION FINDING PROCEDURES 901
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 903
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 913
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 916
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 920
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 922
CONNECTORS LIST AND LAYOUT 925
CONNECTOR CONTACT IDENTIFICATION 938
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 978
FUSE LOCATION TABLE . 984
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 986
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 990
FAILURE CODES TABLE . 992
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1010
FAILURE CODE [879AKA] .1010
FAILURE CODE [879AKB] .1011
FAILURE CODE [879BKA] .1012
FAILURE CODE [879BKB] .1014
FAILURE CODE [879CKA] .1016
FAILURE CODE [879CKB] .1017
FAILURE CODE [879DKZ] .1018
FAILURE CODE [879EMC] .1020
FAILURE CODE [879FMC] .1021
FAILURE CODE [879GKX] .1022
FAILURE CODE [989L00] .1024
FAILURE CODE [989M00] .1025
FAILURE CODE [989N00] .1026
FAILURE CODE [A1U0N3] .1027
FAILURE CODE [A1U0N4] .1029
FAILURE CODE [A900FR] .1031
FAILURE CODE [A900N6] .1032
FAILURE CODE [A900NY] .1033
FAILURE CODE [AA10NX] .1034
FAILURE CODE [AB00KE] .1036
FAILURE CODE [AQ10N3] .1039
FAILURE CODE [AS00N3] .1041
FAILURE CODE [AS00R2] .1043
FAILURE CODE [AS00R3] .1044
FAILURE CODE [AS00R4] .1045
FAILURE CODE [AS00R5] .1046
FAILURE CODE [AS00R6] .1047
FAILURE CODE [AS00ZK] .1048
FAILURE CODE [AS10KM] .1049
FAILURE CODE [AS10NR] .1050
FAILURE CODE [AS10NT] .1051
FAILURE CODE [B@BAZG] .1052
FAILURE CODE [B@BAZK] .1053
FAILURE CODE [B@BCNS] .1055
FAILURE CODE [B@BCQA] .1056
FAILURE CODE [B@BCZK] .1058
FAILURE CODE [B@HANS] .1060
FAILURE CODE [CA115] 1061
FAILURE CODE [CA122] 1062
FAILURE CODE [CA123] 1064
FAILURE CODE [CA131] 1066
FAILURE CODE [CA132] 1068
FAILURE CODE [CA144] 1070
FAILURE CODE [CA145] 1072
FAILURE CODE [CA153] 1074
FAILURE CODE [CA154] 1077
FAILURE CODE [CA187] 1079
FAILURE CODE [CA221] 1081
FAILURE CODE [CA222] 1083
FAILURE CODE [CA227] 1085
FAILURE CODE [CA234] 1086
FAILURE CODE [CA238] 1087
FAILURE CODE [CA239] 1089
FAILURE CODE [CA249] 1091
FAILURE CODE [CA256] 1093
FAILURE CODE [CA271] 1095
FAILURE CODE [CA272] 1097
FAILURE CODE [CA322] 1099
FAILURE CODE [CA323] 1101
FAILURE CODE [CA324] 1103
FAILURE CODE [CA325] 1105
FAILURE CODE [CA331] 1107
FAILURE CODE [CA332] 1109
FAILURE CODE [CA343] 1111
FAILURE CODE [CA351] 1112
FAILURE CODE [CA352] 1113
FAILURE CODE [CA356] 1116
FAILURE CODE [CA357] 1118
FAILURE CODE [CA386] 1120
FAILURE CODE [CA428] 1121
FAILURE CODE [CA429] 1123
FAILURE CODE [CA435] 1125
FAILURE CODE [CA441] 1127
FAILURE CODE [CA442] 1129
FAILURE CODE [CA449] 1130
FAILURE CODE [CA451] 1131
FAILURE CODE [CA452] 1133
FAILURE CODE [CA488] 1135
FAILURE CODE [CA515] 1136
FAILURE CODE [CA516] 1138
FAILURE CODE [CA553] 1140
FAILURE CODE [CA555] 1141
FAILURE CODE [CA556] 1142
FAILURE CODE [CA559] 1143
FAILURE CODE [CA595] 1146
FAILURE CODE [CA687] 1147
FAILURE CODE [CA689] 1149
FAILURE CODE [CA691] 1152
FAILURE CODE [CA692] 1154
FAILURE CODE [CA697] 1156
FAILURE CODE [CA698] 1157
FAILURE CODE [CA731] 1158
FAILURE CODE [CA778] 1160
FAILURE CODE [CA1117] .1165
FAILURE CODE [CA1664] .1166
FAILURE CODE [CA1669] .1168
FAILURE CODE [CA1673] .1169
FAILURE CODE [CA1677] .1170
FAILURE CODE [CA1678] .1171
FAILURE CODE [CA1682] .1172
FAILURE CODE [CA1683] .1174
FAILURE CODE [CA1684] .1176
FAILURE CODE [CA1686] .1178
FAILURE CODE [CA1691] .1179
FAILURE CODE [CA1694] .1182
FAILURE CODE [CA1695] .1185
FAILURE CODE [CA1696] .1186
FAILURE CODE [CA1712] .1188
FAILURE CODE [CA1713] .1191
FAILURE CODE [CA1714] .1193
FAILURE CODE [CA1715] .1194
FAILURE CODE [CA1776] .1195
FAILURE CODE [CA1777] .1198
FAILURE CODE [CA1843] .1201
FAILURE CODE [CA1844] .1203
FAILURE CODE [CA1879] .1206
FAILURE CODE [CA1881] .1208
FAILURE CODE [CA1883] .1210
FAILURE CODE [CA1885] .1213
FAILURE CODE [CA1887] .1215
FAILURE CODE [CA1921] .1217
FAILURE CODE [CA1922] .1220
FAILURE CODE [CA1942] .1225
FAILURE CODE [CA1993] .1226
FAILURE CODE [CA2185] .1229
FAILURE CODE [CA2186] .1230
FAILURE CODE [CA2249] .1232
FAILURE CODE [CA2271] .1233
FAILURE CODE [CA2272] .1236
FAILURE CODE [CA2288] .1239
FAILURE CODE [CA2311] .1240
FAILURE CODE [CA2349] .1241
FAILURE CODE [CA2353] .1244
FAILURE CODE [CA2357] .1246
FAILURE CODE [CA2381] .1247
FAILURE CODE [CA2382] .1250
FAILURE CODE [CA2383] .1253
FAILURE CODE [CA2386] .1256
FAILURE CODE [CA2387] .1258
FAILURE CODE [CA2555] .1259
FAILURE CODE [CA2556] .1262
FAILURE CODE [CA2637] .1265
FAILURE CODE [CA2639] .1267
FAILURE CODE [CA2771] .1270
FAILURE CODE [CA2777] .1276
FAILURE CODE [CA2976] .1279
FAILURE CODE [CA3133] .1281
FAILURE CODE [CA3134] .1284
FAILURE CODE [CA3135] .1286
FAILURE CODE [CA3142] .1289
FAILURE CODE [CA3143] .1290
FAILURE CODE [CA3144] .1291
FAILURE CODE [CA3146] .1293
FAILURE CODE [CA3147] .1294
FAILURE CODE [CA3148] .1295
FAILURE CODE [CA3151] .1297
FAILURE CODE [CA3165] .1303
FAILURE CODE [CA3229] .1305
FAILURE CODE [CA3231] .1307
FAILURE CODE [CA3232] .1309
FAILURE CODE [CA3235] .1313
FAILURE CODE [CA3239] .1315
FAILURE CODE [CA3241] .1318
FAILURE CODE [CA3242] .1321
FAILURE CODE [CA3251] .1324
FAILURE CODE [CA3253] .1326
FAILURE CODE [CA3254] .1329
FAILURE CODE [CA3255] .1332
FAILURE CODE [CA3256] .1336
FAILURE CODE [CA3311] .1338
FAILURE CODE [CA3312] .1340
FAILURE CODE [CA3313] .1343
FAILURE CODE [CA3314] .1344
FAILURE CODE [CA3315] .1345
FAILURE CODE [CA3316] .1347
FAILURE CODE [CA3317] .1348
FAILURE CODE [CA3318] .1349
FAILURE CODE [CA3319] .1351
FAILURE CODE [CA3321] .1352
FAILURE CODE [CA3322] .1354
FAILURE CODE [CA3419] .1356
FAILURE CODE [CA3421] .1358
FAILURE CODE [CA3497] .1360
FAILURE CODE [CA3498] .1361
FAILURE CODE [CA3543] .1362
FAILURE CODE [CA3545] .1369
FAILURE CODE [CA3547] .1371
FAILURE CODE [CA3558] .1372
FAILURE CODE [CA3559] .1374
FAILURE CODE [CA3562] .1376
FAILURE CODE [CA3563] .1378
FAILURE CODE [CA3567] .1381
FAILURE CODE [CA3568] .1384
FAILURE CODE [CA3571] .1388
FAILURE CODE [CA3572] .1390
FAILURE CODE [CA3574] .1392
FAILURE CODE [CA3575] .1394
FAILURE CODE [CA3577] .1396
FAILURE CODE [CA3578] .1398
FAILURE CODE [CA3582] .1400
FAILURE CODE [CA3583] .1406
FAILURE CODE [CA3596] .1408
FAILURE CODE [CA3649] .1410
FAILURE CODE [CA3681] .1412
FAILURE CODE [CA3682] .1417
FAILURE CODE [CA3713] .1423
FAILURE CODE [CA3717] .1426
FAILURE CODE [CA3718] .1427
FAILURE CODE [CA3725] .1428
FAILURE CODE [CA3741] .1431
FAILURE CODE [CA3748] .1432
FAILURE CODE [CA3751] .1434
FAILURE CODE [CA3755] .1436
FAILURE CODE [CA3866] .1438
FAILURE CODE [CA3867] .1442
FAILURE CODE [CA3868] .1445
FAILURE CODE [CA3899] .1449
FAILURE CODE [CA3911] .1451
FAILURE CODE [CA3912] .1455
FAILURE CODE [CA3932] .1457
FAILURE CODE [CA3933] .1459
FAILURE CODE [CA3934] .1461
FAILURE CODE [CA3935] .1464
FAILURE CODE [CA3936] .1466
FAILURE CODE [CA4151] .1468
FAILURE CODE [CA4152] .1472
FAILURE CODE [CA4155] .1476
FAILURE CODE [CA4156] .1478
FAILURE CODE [CA4157] .1481
FAILURE CODE [CA4158] .1483
FAILURE CODE [CA4159] .1484
FAILURE CODE [CA4161] .1485
FAILURE CODE [CA4162] .1488
FAILURE CODE [CA4163] .1491
FAILURE CODE [CA4164] .1492
FAILURE CODE [CA4165] .1494
FAILURE CODE [CA4166] .1496
FAILURE CODE [CA4168] .1497
FAILURE CODE [CA4169] .1500
FAILURE CODE [CA4171] .1502
FAILURE CODE [CA4249] .1505
FAILURE CODE [CA4251] .1507
FAILURE CODE [CA4259] .1509
FAILURE CODE [CA4261] .1512
FAILURE CODE [CA4277] .1515
FAILURE CODE [CA4281] .1518
FAILURE CODE [CA4459] .1521
FAILURE CODE [CA4461] .1524
FAILURE CODE [CA4658] .1527
FAILURE CODE [CA4731] .1531
FAILURE CODE [CA4732] .1532
FAILURE CODE [CA4739] .1533
FAILURE CODE [CA4768] .1534
FAILURE CODE [CA4769] .1536
FAILURE CODE [CA4842] .1539
FAILURE CODE [CA4952] .1543
FAILURE CODE [CA5115] .1545
FAILURE CODE [CA5179] .1548
FAILURE CODE [CA5181] .1550
FAILURE CODE [CA5383] .1552
FAILURE CODE [D110KB] .1554
FAILURE CODE [D19JKZ] .1556
FAILURE CODE [D811MC] .1559
FAILURE CODE [D862KA] .1560
FAILURE CODE [D8ALKA] .1561
FAILURE CODE [D8ALKB] .1563
FAILURE CODE [D8AQKR] .1565
FAILURE CODE [DA20MC] .1567
FAILURE CODE [DA22KK] .1568
FAILURE CODE [DA25KP] .1571
FAILURE CODE [DA26KP] .1574
FAILURE CODE [DA29KQ] .1577
FAILURE CODE [DA2LKA] .1579
FAILURE CODE [DA2LKB] .1581
FAILURE CODE [DA2QKR] .1583
FAILURE CODE [DA2RKR] .1586
FAILURE CODE [DAF0KM] .1587
FAILURE CODE [DAF0MB] .1588
FAILURE CODE [DAF0MC] .1589
FAILURE CODE [DAF8KB] .1590
FAILURE CODE [DAF9KQ] .1592
FAILURE CODE [DAFGMC] .1593
FAILURE CODE [DAFLKA] .1594
FAILURE CODE [DAFLKB] .1596
FAILURE CODE [DAFQKR] .1598
FAILURE CODE [DAZ9KQ] .1599
FAILURE CODE [DAZQKR] .1600
FAILURE CODE [DB2QKR] .1605
FAILURE CODE [DBP0KM] .1610
FAILURE CODE [DBP0KT] .1611
FAILURE CODE [DB2RKR] .1612
FAILURE CODE [DBP5KB] .1617
FAILURE CODE [DBP5KY] .1620
FAILURE CODE [DBPQKR] .1623
FAILURE CODE [DDNRKA] .1628
FAILURE CODE [DDNRKY] .1630
FAILURE CODE [DDNS00] .1632
FAILURE CODE [DFB1KZ] .1634
FAILURE CODE [DFB2KZ] .1636
FAILURE CODE [DFB3L8] .1638
FAILURE CODE [DFB4L8] .1640
FAILURE CODE [DFB5KZ] .1642
FAILURE CODE [DFB6KZ] .1644
FAILURE CODE [DGH2KA] .1646
FAILURE CODE [DGH2KB] .1648
FAILURE CODE [DHA4KA] .1650
FAILURE CODE [DHAAMA] .1652
FAILURE CODE [DHACMA] .1654
FAILURE CODE [DHPAMA] .1656
FAILURE CODE [DHPBMA] .1659
FAILURE CODE [DHS3MA] .1662
FAILURE CODE [DHS4MA] .1665
FAILURE CODE [DHS8MA] .1668
FAILURE CODE [DHS9MA] .1671
FAILURE CODE [DHSAMA] .1674
FAILURE CODE [DHSBMA] .1677
FAILURE CODE [DHSCMA] .1680
FAILURE CODE [DHSDMA] .1683
FAILURE CODE [DHSFMA] .1686
FAILURE CODE [DHSGMA] .1689
FAILURE CODE [DHSHMA] .1692
FAILURE CODE [DHSJMA] .1695
FAILURE CODE [DHX1MA] .1698
FAILURE CODE [DHZAMA] .1701
FAILURE CODE [DHZCL8] .1705
FAILURE CODE [DKR0MA] .1706
FAILURE CODE [DKR1MA] .1709
FAILURE CODE [DKULKA] .1712
FAILURE CODE [DKULKB] .1714
FAILURE CODE [DKULKY] .1716
FAILURE CODE [DLM5KA] .1718
FAILURE CODE [DLM5MB] .1720
FAILURE CODE [DR10KA] .1722
FAILURE CODE [DR12KA] .1725
FAILURE CODE [DR20KA] .1727
FAILURE CODE [DR21KX] .1729
FAILURE CODE [DR30KA] .1731
FAILURE CODE [DR31KX] .1733
FAILURE CODE [DR40KA] .1735
FAILURE CODE [DUMBKA] .1737
FAILURE CODE [DUMBKB] .1739
FAILURE CODE [DV20KB] .1741
FAILURE CODE [DW43KA] .1743
FAILURE CODE [DW43KB] .1745
FAILURE CODE [DW43KY] .1747
FAILURE CODE [DW45KA] .1749
FAILURE CODE [DW45KB] .1752
FAILURE CODE [DW45KY] .1755
FAILURE CODE [DW4CKY] .1757
FAILURE CODE [DW91KA] .1759
FAILURE CODE [DW91KB] .1761
FAILURE CODE [DW91KY] .1763
FAILURE CODE [DWA2KA] .1765
FAILURE CODE [DWA2KB] .1767
FAILURE CODE [DWA2KY] .1769
FAILURE CODE [DWK0KA] .1771
FAILURE CODE [DWK0KB] .1773
FAILURE CODE [DWK0KY] .1775
FAILURE CODE [DWK2KA] .1777
FAILURE CODE [DWK2KB] .1779
FAILURE CODE [DWK2KY] .1781
FAILURE CODE [DWK8KA] .1783
FAILURE CODE [DWK8KB] .1785
FAILURE CODE [DWK8KY] .1787
FAILURE CODE [DWN5KA] .1789
FAILURE CODE [DWN5KB] .1791
FAILURE CODE [DWN5KY] .1793
FAILURE CODE [DXA8KA] .1795
FAILURE CODE [DXA8KB] .1797
FAILURE CODE [DXA9KA] .1799
FAILURE CODE [DXA9KB] .1801
FAILURE CODE [DXE0KA] .1803
FAILURE CODE [DXE0KB] .1804
FAILURE CODE [DXE4KA] .1806
FAILURE CODE [DXE4KB] .1808
FAILURE CODE [DXE4KY] .1810
FAILURE CODE [DXE5KA] .1812
FAILURE CODE [DXE5KB] .1814
FAILURE CODE [DXE6KA] .1816
FAILURE CODE [DXE6KB] .1818
FAILURE CODE [DXE7KA] .1820
FAILURE CODE [DXE7KB] .1822
FAILURE CODE [DXE7KY] .1824
FAILURE CODE [DXE8KA] .1826
FAILURE CODE [DXE8KB] .1828
FAILURE CODE [DXE8KY] .1830
FAILURE CODE [DXE9KA] .1832
FAILURE CODE [DXE9KB] .1834
FAILURE CODE [DXE9KY] .1836
FAILURE CODE [DXEAKA] .1838
FAILURE CODE [DXEAKB] .1840
FAILURE CODE [DXEAKY] .1842
FAILURE CODE [DY20KA] .1844
FAILURE CODE [DY20MA] .1846
FAILURE CODE [DY2CKB] .1848
FAILURE CODE [DY2DKB] .1851
FAILURE CODE [DY2EKB] .1853
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1855
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1855
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1861
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1864
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1866
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1868
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1871
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1872
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1873
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1874
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1875
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1876
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1877
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1878
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1879
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1880
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1881
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1882
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1884
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1885
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1886
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1887
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1889
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1890
E-24 FUNCTION SWITCH DOES NOT OPERATE .1891
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1892
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1893
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1894
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1895
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1896
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1897
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1898
E-32 ALARM BUZZER CANNOT BE CANCELED 1900
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1901
E-34 SERVICE MODE CANNOT BE SELECTED 1902
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1903
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1906
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1908
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1911
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1913
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1916
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1917
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1919
E-43 HORN DOES NOT SOUND 1920
E-44 HORN DOES NOT STOP SOUNDING 1923
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1925
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1926
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1928
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1929
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1930
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1931
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1932
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1933
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1934
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1935
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1936
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1937
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1939
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1940
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1941
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1941
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1942
FAILURE MODE AND CAUSE TABLE 1944
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1953
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1954
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1957
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1958
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1959
H-6 SPEED OR POWER OF BOOM IS LOW .1961
H-7 ARM SPEED OR POWER IS LOW .1965
H-8 BUCKET SPEED OR POWER IS LOW 1970
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1973
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1974
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1976
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1978
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1979
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1980
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1981
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1982
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1983
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1984
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1985
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1986
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1987
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1989
H-23 TRAVEL SPEED IS LOW 1992
H-24 ONE OF TRACKS DOES NOT RUN .1994
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1995
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1996
H-27 SWINGS ONLY IN ONE DIRECTION .1997
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1998
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1999
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2000
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2001
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2002
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2003
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2004
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2005
H-1 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2006
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .2007
H-38 Quick coupler cylinder will not extend .2008
H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2010
H-40 Buzzer does not sound (but quick coupler cylinder doesretract) .2012
H-41 Quick coupler cylinder extends and retracts slowly .2014
TROUBLESHOOTING OF ENGINE (S-MODE) 2015
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2015
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2016
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2017
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2018
S-4 ENGINE STARTABILITY IS POOR .2020
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2022
S-6 ENGINE STOPS DURING OPERATION .2024
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2026
S-8 ENGINE LACKS POWER 2027
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2029
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2031
S-11 OIL BECOMES CONTAMINATED QUICKLY .2032
S-12 FUEL CONSUMPTION IS EXCESSIVE 2033
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2034
S-14 OIL PRESSURE DROPS .2035
S-15 FUEL MIXES INTO ENGINE OIL .2037
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2038
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2039
S-18 UNUSUAL NOISE IS HEARD .2040
S-19 VIBRATION IS EXCESSIVE .2041
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2042
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2043
S-22 ACTIVE REGENERATION TAKES TIME .2045
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2046
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2047
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2049
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2050
50 DISASSEMBLY AND ASSEMBLY .2051
CONTENTS 2052
ABBREVIATION LIST .2057
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2063
HOW TO READ THIS MANUAL .2063
COATING MATERIALS LIST 2065
SPECIAL TOOLS LIST 2069
SKETCHES OF SPECIAL TOOLS .2081
ENGINE AND COOLING SYSTEM .2087
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2087
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2087
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2090
REMOVE AND INSTALL INJECTOR ASSEMBLY 2093
METHOD FOR REMOVING INJECTOR ASSEMBLY .2093
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2098
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2106
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2107
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2116
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2132
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2132
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2133
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2135
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2135
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2139
REMOVE AND INSTALL STARTER ASSEMBLY .2144
METHOD FOR REMOVING STARTER ASSEMBLY 2144
METHOD FOR INSTALLING STARTER ASSEMBLY 2145
REMOVE AND INSTALL ALTERNATOR BELT 2148
METHOD FOR REMOVING ALTERNATOR BELT .2148
METHOD FOR INSTALLING ALTERNATOR BELT .2150
REMOVE AND INSTALL RADIATOR ASSEMBLY 2153
METHOD FOR REMOVING RADIATOR ASSEMBLY .2153
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2155
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2158
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2158
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2161
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2164
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2164
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2166
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2168
REMOVE FAN CLUTCH ASSEMBLY 2168
INSTALL FAN CLUTCH ASSEMBLY .2173
REMOVE AND INSTALL FAN 2177
METHOD FOR INSTALLING FAN .2177
METHOD FOR REMOVING FAN .2177
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2178
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2178
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2187
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2199
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2199
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2202
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2206
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2206
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2207
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2210
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2210
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2210
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2212
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2212
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2214
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2219
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2219
METHOD FOR REMOVING FUEL TANK ASSEMBLY (PC210NLC-11, PC230NHD-11) .2223
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210-11, PC210LC-11) .2227
METHOD FOR INSTALLING FUEL TANK ASSEMBLY (PC210NLC-11, PC230NHD-11) .2231
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2235
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2235
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2241
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2247
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2247
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2253
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2258
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2258
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2258
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2260
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2260
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2260
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2261
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2261
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2263
REMOVE AND INSTALL KDPF ASSEMBLY 2266
METHOD FOR REMOVING KDPF ASSEMBLY .2266
METHOD FOR INSTALLING KDPF ASSEMBLY .2268
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2270
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2271
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2274
REMOVE AND INSTALL SCR ASSEMBLY .2279
METHOD FOR REMOVING SCR ASSEMBLY 2279
METHOD FOR INSTALLING SCR ASSEMBLY 2281
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2283
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2283
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2289
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2295
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2295
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET (FOR PC210NLC-11, PC230NHD-11) .2302
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210-11, PC210LC-11) .2310
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET (PC210NLC-11, PC230NHD-11) .2318
REMOVE AND INSTALL KCCV ASSEMBLY 2326
METHOD FOR REMOVING KCCV ASSEMBLY .2326
METHOD FOR INSTALLING KCCV ASSEMBLY .2328
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2333
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2333
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2339
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2345
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2345
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2348
REMOVE AND INSTALL AdBlue/DEF PUMP 2351
METHOD FOR REMOVING AdBlue/DEF PUMP .2351
METHOD FOR INSTALLING AdBlue/DEF PUMP .2354
REMOVE AND INSTALL AdBlue/DEF HOSE 2357
METHOD FOR REMOVING AdBlue/DEF HOSE .2357
METHOD FOR INSTALLING AdBlue/DEF HOSE .2365
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2371
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2371
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2372
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2374
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2374
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2376
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2379
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2379
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2380
POWER TRAIN .2381
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2381
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2381
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2382
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2384
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2384
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2388
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2397
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2397
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2399
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2403
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2403
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2407
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2414
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2414
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2414
UNDERCARRIAGE AND FRAME .2416
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2416
METHOD FOR SEPARATING TRACK ASSEMBLY 2416
METHOD FOR INSTALLING TRACK ASSEMBLY 2418
REMOVE AND INSTALL SPROCKET .2421
METHOD FOR REMOVING SPROCKET 2421
METHOD FOR INSTALLING SPROCKET 2421
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2423
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2423
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2424
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2425
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2425
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2426
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2430
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2431
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2431
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2433
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2434
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2435
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2437
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2437
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2439
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2441
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2441
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2443
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2446
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2446
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210-11, PC210LC-11) .2449
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY (PC210NLC-11, PC230NHD-11) .2452
HYDRAULIC SYSTEM 2456
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2456
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2456
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2458
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2461
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2461
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2462
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2464
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2464
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2467
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2470
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2470
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2473
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2476
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2476
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2483
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2491
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2491
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2492
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2496
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2496
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2496
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2498
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2498
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2499
REMOVE AND INSTALL QUICK COUPLER VALVE 2501
WORK EQUIPMENT 2503
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2503
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2503
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2507
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2512
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2512
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2515
CAB AND ITS ATTACHMENTS .2521
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2521
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2521
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2529
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2536
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2538
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2538
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2548
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2548
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2551
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2557
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2557
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2564
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2571
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2571
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2577
REMOVE AND INSTALL OPERATOR’S SEAT 2584
METHOD FOR REMOVING OPERATOR’S SEAT .2584
METHOD FOR INSTALLING OPERATOR’S SEAT .2586
REMOVE AND INSTALL SEAT BELT 2589
METHOD FOR REMOVING SEAT BELT .2589
METHOD FOR INSTALLING SEAT BELT .2590
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2591
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2591
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2596
ELECTRICAL SYSTEM .2605
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2605
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2605
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2606
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2608
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2608
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2612
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2617
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2617
METHOD FOR INSTALLING KomVision CONTROLLER 2618
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2619
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2619
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2622
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2626
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2626
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2627
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2628
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2628
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2628
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2630
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2630
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2631
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2632
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2632
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2634
REMOVE AND INSTALL KomVision CAMERA .2637
METHOD FOR REMOVING KomVision CAMERA 2637
METHOD FOR INSTALLING KomVision CAMERA 2638
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2640
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2640
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2643
60 MAINTENANCE STANDARD .2647
CONTENTS 2648
ABBREVIATION LIST .2649
ENGINE AND COOLING SYSTEM .2655
MAINTENANCE STANDARD OF ENGINE MOUNT 2655
MAINTENANCE STANDARD OF COOLING SYSTEM 2656
POWER TRAIN .2658
MAINTENANCE STANDARD OF SWING CIRCLE 2658
MAINTENANCE STANDARD OF SWING MACHINERY .2659
MAINTENANCE STANDARD OF FINAL DRIVE .2661
MAINTENANCE STANDARD OF SPROCKET 2663
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2664
UNDERCARRIAGE AND FRAME .2666
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2666
MAINTENANCE STANDARD OF IDLER .2668
MAINTENANCE STANDARD OF TRACK ROLLER 2670
MAINTENANCE STANDARD OF CARRIER ROLLER 2671
MAINTENANCE STANDARD OF TRACK SHOE 2672
MAINTENANCE STANDARD OF TRIPLE SHOE .2675
MAINTENANCE STANDARD OF SWAMP SHOE 2676
MAINTENANCE STANDARD OF ROAD LINER 2677
HYDRAULIC SYSTEM 2678
MAINTENANCE STANDARD OF HYDRAULIC TANK 2678
MAINTENANCE STANDARD OF MAIN PUMP .2679
MAINTENANCE STANDARD OF LS-EPC VALVE 2680
MAINTENANCE STANDARD OF PC-EPC VALVE 2681
MAINTENANCE STANDARD OF SWING MOTOR .2682
MAINTENANCE STANDARD OF TRAVEL MOTOR 2685
MAINTENANCE STANDARD OF CONTROL VALVE .2688
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2698
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2701
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2704
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2706
MAINTENANCE STANDARD OF SOLENOID VALVE 2707
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2708
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2710
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2711
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2712
WORK EQUIPMENT 2713
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2713
DIMENSION OF ARM 2718
DIMENSIONS OF BUCKET 2720
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2722
MAINTENANCE STANDARD OF ARM CYLINDER 2723
MAINTENANCE STANDARD OF BUCKET CYLINDER .2724
80 APPENDIX .2725
CONTENTS 2726
ABBREVIATION LIST .2728
AIR CONDITIONER SYSTEM 2734
PRECAUTIONS FOR REFRIGERANT .2734
AIR CONDITIONER COMPONENT .2735
SPECIFICATIONS OF AIR CONDITIONER .2737
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2738
OUTLINE OF REFRIGERATION CYCLE 2739
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2741
AIR CONDITIONER UNIT 2741
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2741
FUNCTION OF AIR CONDITIONER UNIT 2743
COMPONENT PARTS OF AIR CONDITIONER UNIT .2745
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2746
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2746
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2746
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2746
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2747
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2747
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2747
FUNCTION OF DUAL PRESSURE SWITCH 2748
AIR CONDITIONER CONTROLLER 2749
STRUCTURE OF AIR CONDITIONER CONTROLLER .2749
COMPRESSOR 2750
STRUCTURE OF COMPRESSOR .2750
SPECIFICATIONS OF COMPRESSOR 2750
FUNCTION OF COMPRESSOR 2750
CONDENSER .2751
STRUCTURE OF CONDENSER 2751
SPECIFICATIONS OF CONDENSER .2751
FUNCTION OF CONDENSER .2751
SENSORS FOR AIR CONDITIONER SYSTEM 2753
STRUCTURE OF SUNLIGHT SENSOR 2753
FUNCTION OF SUNLIGHT SENSOR .2753
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2753
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2753
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2755
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2757
AIR CONDITIONER SYSTEM DIAGRAM 2759
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2760
FUNCTION OF AIR CONDITIONER CONTROLLER 2761
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2762
TESTING AIR LEAKAGE (DUCT) 2766
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2766
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2768
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2769
TEST VENT (MODE) CHANGEOVER .2770
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2770
TESTING FRESH/RECIRC AIR CHANGEOVER .2772
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2772
TEST SUNLIGHT SENSOR 2773
METHOD FOR TESTING SUNLIGHT SENSOR 2773
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2774
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2774
TEST RELAYS .2775
METHOD FOR TESTING RELAYS .2775
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2776
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2777
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2780
FAILURE CODE [879AKA] .2782
FAILURE CODE [879AKB] .2783
FAILURE CODE [879BKA] .2784
FAILURE CODE [879BKB] .2786
FAILURE CODE [879CKA] .2788
FAILURE CODE [879CKB] .2789
FAILURE CODE [879DKZ] .2790
FAILURE CODE [879EMC] .2792
FAILURE CODE [879FMC] .2793
FAILURE CODE [879GKX] .2794
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2796
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2798
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2801
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2803
TROUBLESHOOTING USING GAUGE PRESSURE 2805
CONNECTION OF SERVICE TOOL 2808
METHOD FOR CONNECTING SERVICE TOOL 2808
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2810
HANDLE COMPRESSOR OIL .2812
METHOD FOR REPLACING DESICCANT 2814
90 CIRCUIT DIAGRAMS .2817
CONTENTS 2818
ABBREVIATION LIST .2819
HYDRAULIC CIRCUIT DIAGRAM .2825
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2825
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2829
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2831
ELECTRICAL CIRCUIT DIAGRAM 2833
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2833
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2837
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2839
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2841
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2843
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2845
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2847
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2849
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2851
INDEX 2853

DESCRIPTION:

Komatsu PC210-11,PC210LC-11,PC210NLC-11,PC230NHD-11 Hydraulic Excavator Shop Manual UENBM00366 – PDF DOWNLOAD

• SERIAL NUMBERS 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