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KOMATSU PC210i-10i PC210LCi-10i HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00340 – PDF DOWNLOAD
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KOMATSU PC210i-10i PC210LCi-10i HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00340 – PDF DOWNLOAD
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KOMATSU PC210i-10i PC210LCi-10i HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00340 – PDF DOWNLOAD
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KOMATSU PC210i-10i PC210LCi-10i HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00340 – PDF DOWNLOAD
Language : English
Pages : 2308
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File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC210i-10i PC210LCi-10i HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00340 – PDF DOWNLOAD
00 Index and foreword ..................................................................................................................... 3 Index ................................................................................................................................. 4 Foreword, safety and general information .............................................................................................. 18 Important safety notice ........................................................................................................... 18 How to read the shop manual ....................................................................................................... 25 Explanation of terms for maintenance standard ..................................................................................... 27 Handling equipment of fuel system devices ......................................................................................... 29 Handling of intake system parts ................................................................................................... 30 Handling of hydraulic equipment ................................................................................................... 31 Method of disconnecting and connecting of push-pull type coupler .................................................................. 33 Handling of electrical equipment .................................................................................................. 36 How to read electric wire code .................................................................................................... 44 Precautions when performing operation ............................................................................................. 47 Practical use of KOMTRAX .......................................................................................................... 52 Standard tightening torque table .................................................................................................. 53 List of abbreviation .............................................................................................................. 59 Conversion table .................................................................................................................. 64 01 Specification .......................................................................................................................... 69 Table of contents ..................................................................................................................... 70 Specifications ........................................................................................................................ 71 Specification drawing ............................................................................................................. 71 Working range drawings ............................................................................................................ 73 Specifications .................................................................................................................... 75 Weight table ...................................................................................................................... 81 Table of fuel, coolant, and lubricants ............................................................................................ 85 10 Structure and function ................................................................................................................. 87 Table of contents ..................................................................................................................... 88 Engine and cooling system ............................................................................................................. 89 Engine related parts .............................................................................................................. 89 KVGT .............................................................................................................................. 91 EGR system piping drawing ......................................................................................................... 98 EGR system circuit diagram ........................................................................................................ 100 EGR valve ......................................................................................................................... 102 EGR cooler ........................................................................................................................ 104 KCCV layout drawing ............................................................................................................... 105 KCCV ventilator ................................................................................................................... 107 KDPF .............................................................................................................................. 109 Cooling system .................................................................................................................... 113 Power train ........................................................................................................................... 115 Power train system ................................................................................................................ 115 Swing circle ...................................................................................................................... 117 Swing machinery ................................................................................................................... 118 Final drive ....................................................................................................................... 120 Undercarriage and frame ............................................................................................................... 122 Track frame and idler cushion ..................................................................................................... 122 Hydraulic system ...................................................................................................................... 124 Hydraulic component layout ........................................................................................................ 124 Valve control ..................................................................................................................... 126 Hydraulic tank .................................................................................................................... 128 CLSS .............................................................................................................................. 130 Main pump ......................................................................................................................... 135 Control valve ..................................................................................................................... 160 Swing motor ....................................................................................................................... 215 Travel motor ...................................................................................................................... 226 PPC valve ......................................................................................................................... 239 Solenoid valve .................................................................................................................... 260 Attachment circuit selector valve (for high pressure circuit) ..................................................................... 263 Attachment circuit selector valve (for low pressure circuit) ...................................................................... 265 Anti-drop valve ................................................................................................................... 268 Center swivel joint ............................................................................................................... 272 Accumulator ....................................................................................................................... 274 ATT EPC valve assembly ............................................................................................................ 275 Return oil filter ................................................................................................................. 277 Quick coupler control valve ....................................................................................................... 278 EPC valve for intelligent Machine Control ......................................................................................... 281 Work equipment ........................................................................................................................ 286 Work equipment .................................................................................................................... 286 Work equipment shim ............................................................................................................... 287 Bucket play adjustment shim ....................................................................................................... 288 Cab and its attachments ............................................................................................................... 289 Cab mount and cab tipping stopper ................................................................................................. 289 ROPS cab .......................................................................................................................... 290 Electrical system ..................................................................................................................... 291 Electrical control system ......................................................................................................... 291 Machine monitor system ............................................................................................................ 352 KOMTRAX system .................................................................................................................... 373 Sensor ............................................................................................................................ 375 Auto grease system ................................................................................................................ 406 20 Standard value tables .................................................................................................................. 419 Table of contents ..................................................................................................................... 420 Standard service value table .......................................................................................................... 421 Standard value table for engine ................................................................................................... 421 Standard value table for machine .................................................................................................. 423 Standard value table for electrical system ........................................................................................ 441 30 Testing and adjusting .................................................................................................................. 451 Table of contents ..................................................................................................................... 452 Related information on testing and adjusting .......................................................................................... 453 Tools for testing and adjusting ................................................................................................... 453 Sketch of tools for testing and adjusting ......................................................................................... 458 Engine and cooling system ............................................................................................................. 459 Testing engine speed .............................................................................................................. 459 Testing boost pressure ............................................................................................................ 460 Testing exhaust gas color ......................................................................................................... 462 Testing and adjusting valve clearance ............................................................................................. 464 Testing compression pressure ...................................................................................................... 467 Testing blowby pressure ........................................................................................................... 471 Testing engine oil pressure ....................................................................................................... 472 Testing EGR valve and KVGT oil pressures .......................................................................................... 473 Measuring fuel pressure ........................................................................................................... 474 Measuring fuel delivery, return and leakage ....................................................................................... 480 Bleeding air from fuel system ..................................................................................................... 485 Testing fuel circuit for leakage .................................................................................................. 487 Handling cylinder cutout mode operation ........................................................................................... 488 Handling no-injection cranking operation .......................................................................................... 489 Testing and adjusting air conditioner compressor belt tension ..................................................................... 490 Replacing fan belt ................................................................................................................ 492 Power train ........................................................................................................................... 493 Testing swing circle bearing clearance ............................................................................................ 493 Undercarriage and frame ............................................................................................................... 494 Testing and adjusting track tension ............................................................................................... 494 Hydraulic system ...................................................................................................................... 495 Releasing remaining pressure from hydraulic circuit ............................................................................... 495 Testing and adjusting oil pressure in work equipment, swing, and travel circuits .................................................. 499 Testing oil pressure of control circuit ........................................................................................... 503 Testing and adjusting oil pressure in pump PC control circuit ..................................................................... 506 Testing and adjusting oil pressure in pump LS control circuit ..................................................................... 509 Testing output pressure of solenoid valve ......................................................................................... 514 Testing PPC valve output pressure ................................................................................................. 518 Adjusting play of work equipment and swing PPC valves ............................................................................. 520 Testing pump swash plate sensor ................................................................................................... 521 Isolating the parts causing hydraulic drift in work equipment ..................................................................... 522 Testing oil leakage ............................................................................................................... 524 Bleeding air from hydraulic circuit ............................................................................................... 527 Cab and its attachments ............................................................................................................... 529 Testing cab tipping stopper ....................................................................................................... 529 Adjusting mirrors ................................................................................................................. 530 Electrical system ..................................................................................................................... 532 Special functions of machine monitor .............................................................................................. 532 Special function of control box ................................................................................................... 815 KOMTRAX terminal start-up procedure ............................................................................................... 873 Adjusting rearview camera angle ................................................................................................... 876 Handling voltage circuit of engine controller ..................................................................................... 878 Handling battery disconnect switch ................................................................................................ 879 Testing diodes .................................................................................................................... 880 Pm clinic ............................................................................................................................. 881 Pm Clinic service ................................................................................................................. 881 40 Troubleshooting ........................................................................................................................ 891 Table of contents ..................................................................................................................... 892 Related information on troubleshooting ................................................................................................ 901 Troubleshooting points ............................................................................................................ 901 Sequence of events in troubleshooting ............................................................................................. 903 Testing before troubleshooting .................................................................................................... 905 Inspection procedure before troubleshooting ....................................................................................... 907 Preparation for troubleshooting of electrical system .............................................................................. 926 Classification and procedure for troubleshooting .................................................................................. 934 Symptom of probable failure and troubleshooting No. ............................................................................... 937 Information in troubleshooting table .............................................................................................. 940 Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................................................... 942 Connector list and layout ......................................................................................................... 944 Connector contact identification .................................................................................................. 956 T-branch box and T-branch adapter table ........................................................................................... 994 Fuse location table ............................................................................................................... 999 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement .....................................................................1002 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ...................................................1005 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .......................................1006 Failure codes table ...............................................................................................................1007 Troubleshooting by failure code (Display of code) .....................................................................................1019 Failure code [879AKA] A/C Inner Sensor Open Circuit ...............................................................................1019 Failure code [879AKB] A/C Inner Sensor Short Circuit ..............................................................................1020 Failure code [879BKA] A/C Outer Sensor Open Circuit ...............................................................................1021 Failure code [879BKB] A/C Outer Sensor Short Circuit ..............................................................................1022 Failure code [879CKA] Ventilating Sensor Open Circuit .............................................................................1023 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................1024 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .......................................................................1025 Failure code [879EMC] Ventilation Damper Abnormality ..............................................................................1026 Failure code [879FMC] Air Mix Damper Abnormality ..................................................................................1027 Failure code [879GKX] Refrigerant Abnormality .....................................................................................1028 Failure code [989L00] Engine Controller Lock Caution1 .............................................................................1029 Failure code [989M00] Engine Controller Lock Caution2 .............................................................................1030 Failure code [989N00] Engine Controller Lock Caution3 .............................................................................1031 Failure code [A1U0N3] HC Desorb Request 1 .........................................................................................1032 Failure code [A1U0N4] HC Desorb Request 2 .........................................................................................1034 Failure code [AA10NX] Air Cleaner Clogging ........................................................................................1036 Failure code [AB00KE] Charge Voltage Low ..........................................................................................1038 Failure code [B@BAZG] Engine Oil Pressure Low .....................................................................................1040 Failure code [B@BAZK] Eng Oil Level Low ...........................................................................................1041 Failure code [B@BCNS] Engine Coolant Overheat .....................................................................................1042 Failure code [B@BCZK] Radiator Coolant Level Low ..................................................................................1043 Failure code [B@HANS] Hyd Oil Overheat ............................................................................................1045 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .............................................................................1046 Failure code [CA122] Chg Air Press Sensor High Error ..............................................................................1047 Failure code [CA123] Chg Air Press Sensor Low Error ...............................................................................1049 Failure code [CA131] Throttle Sensor High Error ...................................................................................1051 Failure code [CA132] Throttle Sensor Low Error ....................................................................................1053 Failure code [CA144] Coolant Temp Sens High Error .................................................................................1055 Failure code [CA145] Coolant Temp Sens Low Error ..................................................................................1057 Failure code [CA153] Chg Air Temp Sensor High Error ...............................................................................1059 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................1061 Failure code [CA187] Sensor 2 Supply Volt Low Error ...............................................................................1063 Failure code [CA221] Ambient Press Sensor High Error ..............................................................................1065 Failure code [CA222] Ambient Press Sensor Low Error ...............................................................................1067 Failure code [CA227] Sensor 2 Supply Volt High Error ..............................................................................1069 Failure code [CA234] Eng Overspeed ................................................................................................1070 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................1071 Failure code [CA239] Ne Speed Sens Supply Volt High Error .........................................................................1072 Failure code [CA271] IMV/PCV1 Short Error .........................................................................................1073 Failure code [CA272] IMV/PCV1 Open Error ..........................................................................................1075 Failure code [CA295] Ambient Press Sens In Range Error ............................................................................1077 Failure code [CA322] Inj #1(L#1) Open/Short Error .................................................................................1078 Failure code [CA323] Inj #5(L#5) Open/Short Error .................................................................................1080 Failure code [CA324] Inj #3(L#3) Open/Short Error .................................................................................1082 Failure code [CA325] Inj #6(L#6) Open/Short Error .................................................................................1084 Failure code [CA331] Inj #2(L#2) Open/Short Error .................................................................................1086 Failure code [CA332] Inj #4(L#4) Open/Short Error .................................................................................1088 Failure code [CA343] ECM Critical Internal Failure ................................................................................1090 Failure code [CA351] Injectors Drive Circuit Error ................................................................................1091 Failure code [CA352] Sensor 1 Supply Volt Low Error ...............................................................................1092 Failure code [CA356] Mass Air Flow Sensor High Error ..............................................................................1094 Failure code [CA357] Mass Air Flow Sensor Low Error ...............................................................................1096 Failure code [CA386] Sensor 1 Supply Volt High Error ..............................................................................1098 Failure code [CA428] Water in Fuel Sensor High Error ..............................................................................1099 Failure code [CA429] Water in Fuel Sensor Low Error ...............................................................................1101 Failure code [CA435] Eng Oil Press Sw Error .......................................................................................1103 Failure code [CA441] Battery Voltage Low Error ....................................................................................1104 Failure code [CA442] Battery Voltage High Error ...................................................................................1106 Failure code [CA449] Rail Press Very High Error ...................................................................................1107 Failure code [CA451] Rail Press Sensor High Error .................................................................................1108 Failure code [CA452] Rail Press Sensor Low Error ..................................................................................1110 Failure code [CA488] Chg Air Temp High Torque Derate ..............................................................................1112 Failure code [CA515] Rail Press Sens Sup Volt High Error ..........................................................................1113 Failure code [CA516] Rail Press Sens Sup Volt Low Error ...........................................................................1115 Failure code [CA553] Rail Press High Error ........................................................................................1117 Failure code [CA555] Crankcase Press High Error 1 .................................................................................1118 Failure code [CA556] Crankcase Press High Error 2 .................................................................................1119 Failure code [CA559] Rail Press Low Error .........................................................................................1120 Failure code [CA595] Turbo Speed High Error 2 .....................................................................................1122 Failure code [CA687] Turbo Speed Low Error ........................................................................................1123 Failure code [CA689] Eng Ne Speed Sensor Error ....................................................................................1125 Failure code [CA691] Intake Air Temp Sens High Error ..............................................................................1127 Failure code [CA692] Intake Air Temp Sens Low Error ...............................................................................1129 Failure code [CA697] ECM Int Temp Sensor High Error ...............................................................................1131 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................1132 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..............................................................................1133 Failure code [CA778] Eng Bkup Speed Sensor Error ..................................................................................1135 Failure code [CA1117] Persistent Data Lost Error ..................................................................................1140 Failure code [CA1664] KDOC Malfunction ............................................................................................1141 Failure code [CA1691] Regeneration Ineffective ....................................................................................1143 Failure code [CA1695] Sensor 5 Supply Volt High Error .............................................................................1146 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..............................................................................1147 Failure code [CA1843] Crankcase Press Sens High Error .............................................................................1148 Failure code [CA1844] Crankcase Press Sens Low Error ..............................................................................1150 Failure code [CA1879] KDPF Delta P Sensor High Error ..............................................................................1152 Failure code [CA1881] KDPF Delta P Sensor Low Error ...............................................................................1154 Failure code [CA1883] KDPF Delta P Sens In Range Error ............................................................................1156 Failure code [CA1921] KDPF Soot Load High Error 1 .................................................................................1159 Failure code [CA1922] KDPF Soot Load High Error 2 .................................................................................1162 Failure code [CA1942] Crankcase Press Sens In Range Error .........................................................................1167 Failure code [CA1993] KDPF Delta Pressure Low Error ...............................................................................1168 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................1171 Failure code [CA2186] Throt Sensor Sup Volt Low Error .............................................................................1173 Failure code [CA2249] Rail Press Very Low Error ...................................................................................1175 Failure code [CA2271] EGR Valve Pos Sens High Error ...............................................................................1176 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................1178 Failure code [CA2288] Turbo Speed High Error 1 ....................................................................................1181 Failure code [CA2311] IMV Solenoid Error ..........................................................................................1182 Failure code [CA2349] EGR Valve Solenoid Open Error ...............................................................................1183 Failure code [CA2353] EGR Valve Solenoid Short Error ..............................................................................1185 Failure code [CA2357] EGR Valve Servo Error .......................................................................................1187 Failure code [CA2373] Exhaust Manifold Press Sens High error ......................................................................1188 Failure code [CA2374] Exhaust Manifold Press Sens Low error .......................................................................1190 Failure code [CA2375] EGR Orifice Temp Sens High Error ............................................................................1192 Failure code [CA2376] EGR Orifice Temp Sens Low Error .............................................................................1194 Failure code [CA2381] KVGT Pos Sens High Error ....................................................................................1196 Failure code [CA2382] KVGT Pos Sens Low Error .....................................................................................1198 Failure code [CA2383] KVGT Solenoid Open Error ....................................................................................1201 Failure code [CA2386] KVGT Solenoid Short Error ...................................................................................1203 Failure code [CA2387] KVGT Servo Error ............................................................................................1205 Failure code [CA2554] Exh Manifold Press Sens In Range Error ......................................................................1206 Failure code [CA2555] Grid Htr Relay Volt Low Error ...............................................................................1207 Failure code [CA2556] Grid Htr Relay Volt High Error ..............................................................................1209 Failure code [CA2637] KDOC Face Plugging ..........................................................................................1211 Failure code [CA2639] Manual Stationary Regeneration Request ......................................................................1213 Failure code [CA2961] EGR Orifice Temp High Error 1 ...............................................................................1216 Failure code [CA2973] Chg Air Press Sensor In Range Error .........................................................................1217 Failure code [CA3133] KDPF Outlet Press Sens High Error ...........................................................................1218 Failure code [CA3134] KDPF Outlet Press Sens Low Error ............................................................................1220 Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................................................1222 Failure code [CA3251] KDOC Inlet Temp High Error ..................................................................................1226 Failure code [CA3253] KDOC Temp Error - Non Regeneration ..........................................................................1229 Failure code [CA3254] KDOC Outlet Temp High Error 1 ...............................................................................1232 Failure code [CA3255] KDPF Temp Error - Non Regeneration ..........................................................................1235 Failure code [CA3256] KDPF Outlet Temp High Error 1 ...............................................................................1238 Failure code [CA3311] KDOC Outlet Temp High Error 2 ...............................................................................1241 Failure code [CA3312] KDPF Outlet Temp High Error 2 ...............................................................................1244 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ............................................................................1247 Failure code [CA3314] KDOC Inlet Temp Sens High Error .............................................................................1250 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .........................................................................1254 Failure code [CA3316] KDOC Outlet Temp Sens Low Error .............................................................................1258 Failure code [CA3317] KDOC Outlet Temp Sens High Error ............................................................................1261 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ........................................................................1265 Failure code [CA3319] KDPF Outlet Temp Sens High Error ............................................................................1269 Failure code [CA3321] KDPF Outlet Temp Sens Low Error .............................................................................1273 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ........................................................................1276 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ....................................................................1280 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error .....................................................................1282 Failure code [CA3741] Rail Press Valve Trip Error .................................................................................1284 Failure code [D110KB] Battery Relay Output Voltage ................................................................................1285 Failure code [D19JKZ] Personal Code Relay Abnormality .............................................................................1287 Failure code [D811MC] KOMTRAX Error ...............................................................................................1290 Failure code [D862KA] GPS Antenna Open Circuit ....................................................................................1291 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .......................................................................1292 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ......................................................................1294 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .......................................................................................1295 Failure code [DA20MC] Pump Controller .............................................................................................1296 Failure code [DA22KK] Pump Solenoid Power Low Error ...............................................................................1297 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ...............................................................................1299 Failure code [DA29KQ] Model Selection Abnormality .................................................................................1301 Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ......................................................................1303 Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) .....................................................................1305 Failure code [DA2QKR] CAN2 Discon (Pump Con) ......................................................................................1306 Failure code [DA2RKR] CAN1 Discon (Pump Con) ......................................................................................1308 Failure code [DAF0MB] Monitor ROM Abnormality .....................................................................................1309 Failure code [DAF0MC] Monitor Error ...............................................................................................1310 Failure code [DAF8KB] Camera Power Supply Short Circuit ...........................................................................1311 Failure code [DAF9KQ] Model Selection Abnormality .................................................................................1313 Failure code [DAFGMC] GPS Module Error ............................................................................................1314 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) .......................................................................1315 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ......................................................................1317 Failure code [DAFQKR] CAN2 Discon (Monitor) .......................................................................................1318 Failure code [DAZ9KQ] A/C Model Selection Abnormality .............................................................................1319 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ....................................................................................1320 Failure code [DB2QKR] CAN2 Discon (Engine Con) ....................................................................................1325 Failure code [DB2RKR] CAN1 Discon (Engine Con) ....................................................................................1331 Failure code [DB90KT] W/E Controller Internal Failure .............................................................................1338 Failure code [DB90MC] W/E Controller Reset ........................................................................................1339 Failure code [DB92KK] W/E CON Solenoid Power Voltage Low Error ....................................................................1340 Failure code [DB95KP] W/E CON 5V Sensor 0 Power Volt Low Error ....................................................................1342 Failure code [DB96KP] W/E CON 5V Sensor 1 Power Volt Low Error ....................................................................1345 Failure code [DB99KQ] Model Selection Signal Mismatch (W/E Con) ...................................................................1349 Failure code [DB9LKA] Operating Lamp Open Circuit (W/E CON) .......................................................................1352 Failure code [DB9LKB] Operating Lamp Hot Short Circuit (W/E CON) ..................................................................1354 Failure code [DB9QKR] CAN2 Defective Communication (W/E CON) ......................................................................1356 Failure code [DB9RKR] CAN1 Defective Communication (W/E CON) ......................................................................1358 Failure code [DBR0KT] ICT Sensor Controller Internal Failure ......................................................................1360 Failure code [DBR0MC] ICT Sensor Controller Reset .................................................................................1361 Failure code [DBR2KK] ICT Sensor Con Solenoid Power Low Error .....................................................................1362 Failure code [DBR5KP] ICT Sensor Con 5V Sensor 0 Power Low Error ..................................................................1364 Failure code [DBR6KP] ICT Sensor Con 5V Sensor 1 Power Low Error ..................................................................1366 Failure code [DBR9KQ] Model Selection Signal Mismatch (ICT Sens) ..................................................................1368 Failure code [DBRLKA] Operating Lamp Open Circuit (ICT Sens Con) ..................................................................1371 Failure code [DBRLKB] Operating Lamp Hot Short (ICT Sensor Con) ...................................................................1373 Failure code [DBRQKR] CAN 2 Defective Communication (ICT Sensor) ..................................................................1375 Failure code [DBRRKR] CAN 1 Defective Communication (ICT Sensor) ..................................................................1378 Failure code [DBRSKB] Battery Relay Short Circuit (ICT Sensor) ....................................................................1381 Failure code [DD20MA] Auto/Manual Selector Switch Error ...........................................................................1383 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ................................................................................1385 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ........................................................................1387 Failure code [DHPAMA] F Pump Press Sensor Abnormality .............................................................................1388 Failure code [DHPBMA] R Pump Press Sensor Abnormality .............................................................................1391 Failure code [DHS3MA] Arm IN PPC Press Sens Defective Function ....................................................................1394 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Def Function ...................................................................1396 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Def Function ....................................................................1398 Failure code [DHS9MA] Boom LOWER PPC Press Sensor Def Function ....................................................................1400 Failure code [DHSAMA] Swing Right PPC Press Sens Def Function .....................................................................1402 Failure code [DHSBMA] Swing Left PPC Press Sens Def Function ......................................................................1404 Failure code [DHSCMA] Arm OUT PPC Press Sens Defective Function ...................................................................1406 Failure code [DHSDMA] Bucket DUMP PPC Press Sensor Def Function ...................................................................1408 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ..................................................................1410 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality ..................................................................1413 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ..................................................................1416 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ..................................................................1419 Failure code [DK80KM] IMU Calibration Not Complete ................................................................................1422 Failure code [DK80KR] IMU Defective Communication .................................................................................1423 Failure code [DK80KT] IMU Error ...................................................................................................1424 Failure code [DKG1KM] Bucket Cylinder Calibration Not Complete ....................................................................1425 Failure code [DKG1L8] Bucket Cyl Stroke Sensor Inrange Error ......................................................................1426 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality .......................................................................1427 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality .......................................................................1429 Failure code [DKT0KM] Boom Cylinder Calibration Not Complete ......................................................................1431 Failure code [DKT0L8] Boom Cyl Stroke Sensor Inrange Error ........................................................................1432 Failure code [DKT1KA] Boom Cyl Stroke Sens A Phase Open Circuit ...................................................................1433 Failure code [DKT1KB] Boom Cyl Stroke Sens A Phase Hot Short ......................................................................1435 Failure code [DKT2KA] Boom Cyl Stroke Sens B Phase Open Circuit ...................................................................1436 Failure code [DKT2KB] Boom Cyl Stroke Sensor B Phase Hot Short ....................................................................1438 Failure code [DKT4KM] Arm Cylinder Calibration Not Complete .......................................................................1439 Failure code [DKT4L8] Arm Cylinder Stroke Sensor Inrange Error ....................................................................1440 Failure code [DKT5KA] Arm Cyl Stroke Sensor A Phase Open Circuit ..................................................................1441 Failure code [DKT5KB] Arm Cyl Stroke Sensor A Phase Hot Short .....................................................................1443 Failure code [DKT6KA] Arm Cyl Stroke Sensor B Phase Open Circuit ..................................................................1445 Failure code [DKT6KB] Arm Cyl Stroke Sensor B Phase Hot Short .....................................................................1447 Failure code [DKT8KA] Bucket Cyl Stroke Sensor A Open Circuit .....................................................................1449 Failure code [DKT8KB] Bucket Cyl Stroke Sensor A Phase Hot Short ..................................................................1451 Failure code [DKT9KA] Bucket Cyl Stroke Sensor B Open Circuit .....................................................................1453 Failure code [DKT9KB] Bucket Cyl Stroke Sensor B Phase Hot Short ..................................................................1455 Failure code [DKTAKA] Bucket Cyl Stroke Reset Sens Open Circuit ...................................................................1457 Failure code [DKTAKB] Bucket Cyl Stroke Reset Sensor Hot Short ....................................................................1459 Failure code [DKTAMB] Bucket Cyl Stroke Reset Sens InRange Error ..................................................................1461 Failure code [DKTBKX] Boom Cyl Stroke Reset Encoder A,B Error .....................................................................1462 Failure code [DKTBMC] Boom Cylinder Stroke Reset Encoder Error ....................................................................1464 Failure code [DKTEMB] Boom Cylinder Stroke Reset Encoder Z Error ..................................................................1465 Failure code [DKTFKX] Arm Cyl Stroke Reset Encoder A,B Error ......................................................................1467 Failure code [DKTFMC] Arm Cyl Stroke Reset Enc Error ..............................................................................1469 Failure code [DKTJMB] Arm Cyl Stroke Reset Encoder Z Phase Error ..................................................................1470 Failure code [DKU1MA] Boom Spool Stroke Sensor In Range Error .....................................................................1472 Failure code [DKU2MA] Arm Spool Storke Sensor In Range Error ......................................................................1473 Failure code [DKUGKA] Arm IN PPC Reduce Press EPC Open Circuit ....................................................................1474 Failure code [DKUGKB] Arm IN PPC Reduce Press EPC Ground Fault ....................................................................1476 Failure code [DKUGKY] Arm IN PPC Reduce Pressure EPC Hot Short ....................................................................1477 Failure code [DKUHKA] Arm OUT PPC Reduce Press EPC Open Circuit ...................................................................1479 Failure code [DKUHKB] Arm OUT PPC Reduce Press EPC Ground Fault ...................................................................1481 Failure code [DKUHKY] Arm OUT PPC Reduce Pressure EPC Hot Short ...................................................................1482 Failure code [DKV0KA] Boom Spool Stroke Sensor 1 Open Circuit .....................................................................1484 Failure code [DKV0KY] Boom Spool Stroke Sensor 1 Hot Short Cir ....................................................................1486 Failure code [DKV1KA] Arm Spool Stroke Sensor 1 Open Circuit ......................................................................1488 Failure code [DKV1KY] Arm Spool Stroke Sensor 1 Hot Short Cir .....................................................................1490 Failure code [DKV2KA] Boom Spool Stroke Sensor 2 Open Circuit .....................................................................1492 Failure code [DKV2KY] Boom Spool Stroke Sensor 2 Hot Short Cir ....................................................................1494 Failure code [DKV3KA] Arm Spool Stroke Sensor 2 Open Circuit ......................................................................1496 Failure code [DKV3KY] Arm Spool Stroke Sensor 2 Hot Short Cir .....................................................................1498 Failure code [DKV4MA] Boom RAISE PPC Press Sensor 2 Def Function ..................................................................1500 Failure code [DKV5MA] Boom LOWER PPC Press Sensor 2 Def Function ..................................................................1502 Failure code [DKV6MA] Arm OUT PPC Press Sensor 2 Def Function .....................................................................1505 Failure code [DKV7MA] Arm IN PPC Press Sens 2 Defective Function ..................................................................1508 Failure code [DKV8MA] Bucket DUMP PPC Press Sens 2 Def Function ...................................................................1511 Failure code [DKV9MA] Bucket CURL PPC Press Sens 2 Def Function ...................................................................1513 Failure code [DKVAMA] PPC Source Press Sensor Error ...............................................................................1515 Failure code [DKVBKA] Bucket CURL PPC Reduce Press EPC Open Cir ...................................................................1517 Failure code [DKVBKB] Bucket CURL PPC Reduce Press EPC Grd Fault ..................................................................1519 Failure code [DKVBKY] Bucket CURL PPC Reduce Press EPC Hot Short ..................................................................1520 Failure code [DKVCKA] Boom RAISE PPC Intervention EPC Open Cir ....................................................................1522 Failure code [DKVCKB] Boom RAISE PPC Intervention EPC Grnd Fault ..................................................................1524 Failure code [DKVCKY] Boom RAISE PPC Intervention EPC Hot Short ...................................................................1526 Failure code [DKVDKA] Boom RAISE EPC Cut Relay Open Circuit .......................................................................1529 Failure code [DKVDKB] Boom RAISE EPC Cut Relay Ground Fault .......................................................................1530 Failure code [DKVDKY] Boom RAISE EPC Cut Relay Hot Short Circuit ..................................................................1532 Failure code [DKVDMA] Boom RAISE EPC Cut Relay Error ..............................................................................1533 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .....................................................................1534 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .....................................................................1536 Failure code [DV20KB] Travel Alarm Short Circuit ..................................................................................1538 Failure code [DW43KA] Travel Speed Sol Open Circuit ...............................................................................1540 Failure code [DW43KB] Travel Speed Sol Short Circuit ..............................................................................1542 Failure code [DW45KA] Swing holding brake Sol Open Circuit ........................................................................1544 Failure code [DW45KB] Swing holding brake Sol Short Circuit .......................................................................1547 Failure code [DW4FKA] Boom LOWER PPC Reduce Press EPC Open Cir ....................................................................1549 Failure code [DW4FKB] Boom LOWER PPC Reduce Press EPC Grnd Fault ..................................................................1551 Failure code [DW4FKY] Boom LOWER PPC Reduce Press EPC Hot Short ...................................................................1553 Failure code [DW4GKA] Boom RAISE PPC Reduce Press EPC Open Cir. ...................................................................1555 Failure code [DW4GKB] Boom RAISE PPC Reduce Press EPC Grnd Fault ..................................................................1557 Failure code [DW4GKY] Boom RAISE PPC Reduce Press EPC Hot Short ...................................................................1559 Failure code [DW4SKA] Bucket DUMP PPC Reduce Press EPC Open Cir ...................................................................1561 Failure code [DW4SKB] Bucket DUMP PPC Reduce Press EPC Grd Fault ..................................................................1563 Failure code [DW4SKY] Bucket DUMP PPC Reduce Press EPC Hot Short ..................................................................1564 Failure code [DW91KA] Travel Junction Sol Open Circuit ............................................................................1566 Failure code [DW91KB] Travel Junction Sol Short Circuit ...........................................................................1568 Failure code [DWA2KA] Attachment Sol Open Circuit .................................................................................1570 Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................1572 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .............................................................................1574 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ............................................................................1576 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ........................................................................1578 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .......................................................................1580 Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ............................................................................1582 Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ...........................................................................1584 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .................................................................................1586 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ................................................................................1588 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .................................................................................1590 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ................................................................................1592 Failure code [DXE0KA] LS-EPC Sol Open Circuit .....................................................................................1594 Failure code [DXE0KB] LS-EPC Sol Short Circuit ....................................................................................1596 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ............................................................................1598 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...........................................................................1600 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..........................................................................1602 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .........................................................................1604 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ............................................................................1606 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ...........................................................................1608 Failure code [DY20KA] Wiper Working Abnormality ...................................................................................1610 Failure code [DY20MA] Wiper Parking Abnormality ...................................................................................1612 Failure code [DY2CKB] Washer Drive Short Circuit ..................................................................................1614 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................1616 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .............................................................................1618 Troubleshooting of electrical system (E-mode) .........................................................................................1620 E-1 Engine does not start (Engine does not crank) .................................................................................1620 E-2 Manual preheating system does not work ........................................................................................1626 E-3 Automatic preheating system does not work .....................................................................................1629 E-4 Preheating monitor does not light up when preheater is operated ...............................................................1631 E-5 When starting switch is turned to ON position, machine monitor displays nothing ...............................................1633 E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow ..........1636 E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow ....1637 E-8 Coolant temperature monitor lights up in white while engine is running ........................................................1638 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................................................1639 E-10 Charge level monitor lights up while engine is running .......................................................................1640 E-11 Fuel level monitor lights up in red while engine is running ..................................................................1641 E-12 Air cleaner clogging monitor lights up in yellow while engine is running .....................................................1642 E-13 Water separator monitor lights up while engine is running ....................................................................1643 E-14 Coolant temperature monitor lights up in red while engine is running .........................................................1644 E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................................................1645 E-16 Engine oil pressure monitor lights up in red while engine is running .........................................................1646 E-17 Fuel gauge indicates either full or empty and does not move ..................................................................1647 E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .....................................................1648 E-19 Coolant temperature gauge indicates either Min. or Max. and does not move ....................................................1649 E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) ..................................1650 E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not move ..............................................1651 E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) ............................1653 E-23 Content of display on machine monitor is different from that of actual machine ...............................................1654 E-24 Machine monitor does not display some items ..................................................................................1655 E-25 Function switch does not work ................................................................................................1656 E-26 Automatic preheating system does not work (In cold season) ...................................................................1657 E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated .....................1658 E-28 Auto-deceleration is not actuated or canceled when lever is operated .........................................................1659 E-29 Working mode selection screen is not diplayed when working mode switch is operated ...........................................1660 E-30 Engine or hydraulic pump setting does not change when working mode is changed ................................................1661 E-31 Travel speed monitor does not change when travel speed switch is operated ....................................................1662 E-32 Travel speed does not change while travel speed selection is changed .........................................................1663 E-33 Alarm buzzer does not stop sounding ..........................................................................................1664 E-34 When starting switch is turned to OFF position, service meter is not displayed ...............................................1665 E-35 Service mode cannot be selected ..............................................................................................1666 E-36 Any of work equipment, swing and travel does not work ........................................................................1667 E-37 Any of work equipment, swing and travel cannot be locked .....................................................................1669 E-38 Machine cannot swing while swing brake cancel switch is canceled .............................................................1670 E-39 Swing brake does not operate while swing brake cancel switch is locked .......................................................1672 E-40 One-touch power maximizing function does not work or monitor is not displayed ................................................1674 E-41 One-touch power maximizing function cannot be canceled .......................................................................1676 E-42 Travel alarm does not sound when machine travels .............................................................................1677 E-43 Alarm does not stop sounding while machine is stopped ........................................................................1678 E-44 Horn does not sound ..........................................................................................................1679 E-45 Horn does not stop sounding ..................................................................................................1681 E-46 Wiper monitor does not light up or go out when wiper switch is operated ......................................................1682 E-47 Wiper does not operate when wiper switch is operated .........................................................................1683 E-48 Window washer does not operate when window washer switch is operated .........................................................1685 E-49 BOOM LOWER indication is not displayed properly with monitoring function .....................................................1686 E-50 ARM DUMP indication is not displayed properly with monitoring function .......................................................1687 E-51 ARM IN indication is not displayed properly with monitoring function .........................................................1688 E-52 BOOM RAISE indication is not displayed properly with monitoring function .....................................................1689 E-53 BUCKET CURL indication is not displayed properly with monitoring function ....................................................1690 E-54 BUCKET DUMP indication is not displayed properly with monitoring function ....................................................1691 E-55 SWING indication is not displayed properly with monitoring function ..........................................................1692 E-56 TRAVEL indication is not displayed properly with monitoring function .........................................................1693 E-57 Service is not displayed properly with monitoring function ...................................................................1694 E-58 Attachment hydraulic circuit cannot be changed ...............................................................................1697 E-59 KOMTRAX system does not operate normally .....................................................................................1698 E-60 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] .........1700 E-61 Control box displays the message [GPS receiver not connected!] ...............................................................1705 E-62 Control box displays the message [Waiting for radio link...] .................................................................1708 E-63 Control box displays the message [Tilt Bucket Sensor Offline!] ...............................................................1709 E-64 Control box displays the message [Waiting for satellites...] .................................................................1710 E-65 Control box displays the message [Komatsu controller not connected!] .........................................................1711 E-66 Control box displays the message [Sensors are invalid] .......................................................................1714 E-67 Control box displays the message [Waiting to initialize...] ..................................................................1716 E-68 Control box displays the message [Initializing...] ...........................................................................1717 E-69 Control box displays the message [No GPS Localization...] ....................................................................1718 E-70 Control box displays the message [Low precisions...] .........................................................................1719 E-71 Control box displays [Out of design area...] .................................................................................1720 E-72 Control box displays [Avoidance Area Breach] .................................................................................1721 E-73 Control box can not be turned on .............................................................................................1722 E-74 Control box does not display intelligent Machine Control screen ..............................................................1723 E-75 Control box does not display hydraulic excavator image .......................................................................1724 E-76 Control box does not display design surface ..................................................................................1725 E-77 Control box touch panel does not respond .....................................................................................1726 E-78 Control box touch panel is inaccurate ........................................................................................1727 E-79 When checking and adjusting the bucket edge position, the value is different from actual machine .............................1728 E-80 When pressing auto／manual switch, Semi-auto limited digging mode is not displayed. ...........................................1730 E-81 Automatic leveling assist function does not work while Semi-auto limited digging mode is displayed ...........................1731 E-82 Automatic stop control function does not work while Semi-auto limited digging mode is displayed ..............................1732 E-83 Blade edge position on design surface is not accurate when automatic leveling assist function is on. .........................1733 E-84 Blade edge stop position is not accurate for design surface when automatic stop control function is on .......................1735 E-85 Opposite direction compass does not show the opposite direction ..............................................................1737 E-86 NG occurs very often in IMU calibration diagnosis ............................................................................1738 Troubleshooting of hydraulic and mechanical system (H-mode) ...........................................................................1739 Information described in troubleshooting table (H-mode) ...........................................................................1739 System chart for hydraulic system .................................................................................................1740 Failure mode and cause table ......................................................................................................1742 H-1 All of work equipment, swing and travel operation lacks speed or power ........................................................1750 H-2 Engine speed drops significantly or engine stalls .............................................................................1753 H-3 All work equipment, swing and travel does not work ............................................................................1756 H-4 Unusual sound is heard from around hydraulic pump .............................................................................1757 H-5 Fine control performance or response is poor ..................................................................................1758 H-6 Boom speed or power is low ....................................................................................................1760 H-7 Arm speed or power is low .....................................................................................................1764 H-8 Bucket speed or power is low ..................................................................................................1769 H-9 Work equipment does not move in single operation ..............................................................................1772 H-10 Hydraulic drift of boom is large .............................................................................................1773 H-11 Hydraulic drift of arm is large ..............................................................................................1774 H-12 Hydraulic drift of bucket is large ...........................................................................................1775 H-13 Time lag of work equipment is large ..........................................................................................1776 H-14 When part of work equipment is relieved singly, other parts of work equipment move ...........................................1778 H-15 One-touch power maximizing function does not operate .........................................................................1779 H-16 In combined operation of work equipment, equipment having heavier load moves slower ..........................................1780 H-17 In combined operations of swing and boom RAISE, boom rising speed is low .....................................................1781 H-18 In combined operations of swing and travel, travel speed drops largely .......................................................1782 H-19 Machine does not travel straight .............................................................................................1783 H-20 Travel speed is slow .........................................................................................................1786 H-21 Machine is hard to steer or travel power is low ..............................................................................1788 H-22 Travel speed does not change, or travel speed is too slow or fast ............................................................1791 H-23 One of tracks does not run ...................................................................................................1792 H-24 Upper structure does not swing to the right or left ..........................................................................1794 H-25 Upper structure swing only to the right or left ..............................................................................1795 H-26 Swing acceleration or swing speed is low in both directions (right and left) .................................................1796 H-27 Swing acceleration performance is poor or swing speed is slow in only one direction ..........................................1797 H-28 Upper structure overruns excessively when it stops swinging (both right and left) ............................................1798 H-29 Upper structure overruns excessively when it stops swinging (either right or left) ...........................................1799 H-30 Shock is large when upper structure stops swinging ...........................................................................1800 H-31 Large unusual noise is heard when upper structure stops swinging .............................................................1801 H-32 Swing drift on a slope is large while swing holding brake is applied .........................................................1802 H-33 Swing drift on a slope is large while swing holding brake is released ........................................................1803 H-34 Attachment hydraulic circuit cannot be changed while attachment is installed .................................................1804 H-35 Oil flow in attachment circuit cannot be controlled ..........................................................................1805 Troubleshooting of engine (S-mode) ....................................................................................................1806 Information mentioned in troubleshooting table (S mode) ...........................................................................1806 S-1 When starting switch is turned to START position, engine does not crank .......................................................1807 S-2 Engine cranks but no exhaust smoke comes out ..................................................................................1808 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ................................1809 S-4 Engine startability is poor ...................................................................................................1810 S-5 Engine does not pick up smoothly ..............................................................................................1812 S-6 Engine stops during operation .................................................................................................1814 S-7 Engine runs rough or is unstable ..............................................................................................1816 S-8 Engine lacks power ............................................................................................................1817 S-9 Exhaust smoke is black (KDPF clogs up early) ..................................................................................1819 S-10 Engine oil consumption is excessive ..........................................................................................1821 S-11 Engine oil becomes contaminated early ........................................................................................1822 S-12 Fuel consumption is excessive ................................................................................................1823 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .............................................................1824 S-14 Engine oil pressure drops ....................................................................................................1825 S-15 Fuel is contaminated in engine oil ...........................................................................................1826 S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .............................................................1827 S-17 Coolant temperature rises too high (overheating) .............................................................................1828 S-18 Unusual noise is heard .......................................................................................................1829 S-19 Vibration is excessive .......................................................................................................1830 S-20 Air cannot be bled from fuel circuit .........................................................................................1831 S-21 Active regeneration is executed frequently ...................................................................................1832 S-22 Active regeneration takes time ...............................................................................................1833 S-23 White smoke is exhausted during active regeneration ..........................................................................1834 50 Disassembly and assembly ...............................................................................................................1835 Table of contents .....................................................................................................................1836 Related information on disassembly and assembly .......................................................................................1838 How to read this manual ...........................................................................................................1838 Coating materials list ............................................................................................................1840 Special tools list ................................................................................................................1844 Sketches of special tools .........................................................................................................1849 Engine and cooling system .............................................................................................................1853 Removal and installation of supply pump assembly ..................................................................................1853 Removal and installation of injector assembly .....................................................................................1858 Removal and installation of cylinder head assembly ................................................................................1867 Removal and installation of radiator assembly .....................................................................................1887 Removal and installation of hydraulic oil cooler assembly .........................................................................1889 Removal and installation of aftercooler assembly ..................................................................................1892 Removal and installation of engine and main pump assembly .........................................................................1894 Removal and installation of engine front oil seal .................................................................................1906 Removal and installation of engine rear oil seal ..................................................................................1910 Removal and installation of fuel cooler assembly ..................................................................................1913 Removal and installation of fuel tank assembly ....................................................................................1914 Removal and installation of engine hood assembly ..................................................................................1917 Removal and installation of KDPF assembly .........................................................................................1920 Disassembly and assembly of KDPF assembly .........................................................................................1928 Removal and installation of KCCV assembly .........................................................................................1936 Removal and installation of air cleaner assembly ..................................................................................1940 Power train ...........................................................................................................................1943 Removal and installation of travel motor and final drive assembly .................................................................1943 Disassembly and assembly of final drive ...........................................................................................1944 Removal and installation of swing motor and swing machinery assembly ..............................................................1952 Disassembly and assembly of swing machinery .......................................................................................1955 Removal and installation of swing circle assembly .................................................................................1962 Undercarriage and frame ...............................................................................................................1963 Separation and connection of track shoe assembly ..................................................................................1963 Removal and installation of sprocket ..............................................................................................1966 Removal and installation of idler and idler cushion assembly ......................................................................1967 Disassembly and assembly of idler assembly ........................................................................................1968 Disassembly and assembly of idler cushion .........................................................................................1971 Disassembly and assembly of track roller assembly .................................................................................1973 Disassembly and assembly of carrier roller ........................................................................................1975 Removal and installation of revolving frame assembly ..............................................................................1978 Removal and installation of counterweight assembly ................................................................................1980 Hydraulic system ......................................................................................................................1983 Removal and installation of center swivel joint assembly ..........................................................................1983 Disassembly and assembly of center swivel joint ...................................................................................1986 Removal and installation of hydraulic tank assembly ...............................................................................1987 Removal and installation of main pump assembly ....................................................................................1991 Removal and installation of control valve assembly ................................................................................1995 Disassembly and assembly of control valve .........................................................................................2002 Removal and installation of junction block assembly for Intelligent Machine Control ...............................................2007 Removal and installation of pressure sensor for Intelligent Machine Control .......................................................2010 Removal and installation of boom spool stroke sensor ..............................................................................2012 Removal and installation of arm spool stroke sensor ...............................................................................2013 Disassembly and assembly of work equipment PPC valve ..............................................................................2014 Disassembly and assembly of travel PPC valve ......................................................................................2016 Work equipment ........................................................................................................................2019 Removal and installation of work equipment assembly ...............................................................................2019 Disassembly and assembly of work equipment cylinder assembly ......................................................................2023 Cab and its attachments ...............................................................................................................2035 Removal and installation of operator's cab assembly ...............................................................................2035 Removal and installation of operator cab glass (adhered glass) ....................................................................2041 Removal and installation of front window assembly .................................................................................2051 Removal and installation of floor frame assembly ..................................................................................2057 Removal and installation of air conditioner unit assembly .........................................................................2063 Removal and installation of operator's seat .......................................................................................2069 Removal and installation of seat belt .............................................................................................2072 Removal and installation of front wiper assembly ..................................................................................2074 Electrical system .....................................................................................................................2081 Removal and installation of air conditioner compressor assembly ...................................................................2081 Removal and installation of air conditioner condenser assembly ....................................................................2084 Removal and installation of engine controller assembly ............................................................................2086 Removal and installation of pump controller assembly ..............................................................................2088 Removal and installation of machine monitor assembly ..............................................................................2092 Removal and installation of pump swash plate sensor ...............................................................................2095 Removal and installation of mass air flow and temperature sensor ..................................................................2096 Removal and installation of KOMTRAX terminal assembly .............................................................................2097 Removal and installation of ICT sensor controller assembly ........................................................................2099 Removal and installation of junction harness of control box .......................................................................2101 Removal and installation of control box harness ...................................................................................2103 Removal and installation of work equipment controller assembly ....................................................................2104 Removal and installation of GNSS receiver .........................................................................................2106 Removal and installation of radio device and site link ............................................................................2108 Removal and installation of GNSS antenna ..........................................................................................2110 Removal and installation of IMU sensor ............................................................................................2112 60 Maintenance standard ...................................................................................................................2113 Table of contents .....................................................................................................................2114 Engine and cooling system .............................................................................................................2115 Engine mount ......................................................................................................................2115 Cooling system ....................................................................................................................2116 Power train ...........................................................................................................................2117 Swing circle ......................................................................................................................2117 Swing machinery ...................................................................................................................2118 Final drive .......................................................................................................................2120 Sprocket ..........................................................................................................................2122 Undercarriage and frame ...............................................................................................................2124 Track frame and idler cushion .....................................................................................................2124 Idler .............................................................................................................................2126 Track roller ......................................................................................................................2128 Carrier roller ....................................................................................................................2129 Track shoe ........................................................................................................................2130 Hydraulic system ......................................................................................................................2136 Hydraulic tank ....................................................................................................................2136 Main pump .........................................................................................................................2137 Control valve .....................................................................................................................2138 Swing motor .......................................................................................................................2148 Travel motor ......................................................................................................................2150 Work equipment and swing PPC valve ................................................................................................2153 Travel PPC valve ..................................................................................................................2156 1st-line attachment PPC valve (with EPC valve) ....................................................................................2158 2nd-line attachment PPC valve .....................................................................................................2161 Solenoid valve ....................................................................................................................2163 Attachment circuit selector valve (for high-pressure circuit) .....................................................................2164 Attachment circuit selector valve (for low-pressure circuit) ......................................................................2165 Center swivel joint ...............................................................................................................2166 Work equipment ........................................................................................................................2167 Work equipment ....................................................................................................................2167 Boom cylinder .....................................................................................................................2176 Stroke sensing boom cylinder ......................................................................................................2177 Stroke sensing arm cylinder .......................................................................................................2178 Stroke sensing bucket cylinder ....................................................................................................2179 80 Appendix ...............................................................................................................................2183 Table of contents .....................................................................................................................2184 Air conditioner components ............................................................................................................2185 Precautions for refrigerant .......................................................................................................2185 Air conditioner component .........................................................................................................2186 Configuration and function of refrigeration cycle .................................................................................2189 Outline of refrigeration cycle ....................................................................................................2190 Air conditioner unit ..............................................................................................................2192 Dual pressure switch ..............................................................................................................2199 Air conditioner controller ........................................................................................................2200 Compressor ........................................................................................................................2201 Air conditioner condenser .........................................................................................................2202 Sunlight sensor ...................................................................................................................2204 Outer temperature sensor (outside air temperature sensor) .........................................................................2205 Procedure for testing and troubleshooting .........................................................................................2206 Circuit diagram and arrangement of connector pins .................................................................................2208 System diagram ....................................................................................................................2210 Input and output signals of the air conditioner controller ........................................................................2211 Parts and connectors layout .......................................................................................................2213 Testing air leakage (duct) ........................................................................................................2217 Testing with self-diagnosis function ..............................................................................................2221 Testing vent (mode) changeover ....................................................................................................2224 Testing FRESH/RECIRC air changeover ...............................................................................................2227 Testing sunlight sensor ...........................................................................................................2228 Testing (dual) pressure switch for refrigerant ....................................................................................2229 Testing relays ....................................................................................................................2230 Troubleshooting chart 1 ...........................................................................................................2231 Troubleshooting chart 2 ...........................................................................................................2232 Information in troubleshooting table ..............................................................................................2235 Failure code list related to air conditioner ......................................................................................2236 Failure code [879AKA] A/C Inner Sensor Open Circuit ...............................................................................2237 Failure code [879AKB] A/C Inner Sensor Short Circuit ..............................................................................2238 Failure code [879BKA] A/C Outer sensor Open Circuit ...............................................................................2239 Failure code [879BKB] A/C Outer sensor Short Circuit ..............................................................................2241 Failure code [879CKA] Ventilating Sensor Open Circuit .............................................................................2243 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................2244 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .......................................................................2245 Failure code [879EMC] Ventilation Damper Abnormality ..............................................................................2247 Failure code [879FMC] Air Mix Damper Abnormality ..................................................................................2248 Failure code [879GKX] Refrigerant Abnormality .....................................................................................2249 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ....................................................2250 A-2 Troubleshooting of compressor system (Air is not cooled) ......................................................................2252 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............................................2255 A-4 Troubleshooting for FRESH/RECIRC air changeover ...............................................................................2257 Troubleshooting with gauge pressure ...............................................................................................2259 Connection of service tool ........................................................................................................2262 Precautions for disconnecting and connecting air conditioner piping ...............................................................2264 Handling of compressor oil ........................................................................................................2266 Desiccant replacement .............................................................................................................2268 90 Diagrams and drawings ..................................................................................................................2271 Table of contents .....................................................................................................................2272 Hydraulic circuit diagram .............................................................................................................2273 Symbols in hydraulic circuit diagram ..............................................................................................2273 Hydraulic circuit diagram ......................................................................................................... 0 Electric circuit diagram ..............................................................................................................2279 Symbols in electric circuit diagram ...............................................................................................2279 Electrical circuit diagram ........................................................................................................ 0 Electric circuit diagram of air conditioner unit .................................................................................. 0 SEN06499-01-MA2_1.pdf...................................................................................................................... 0 Hydraulic circuit diagram (1/2)........................................................................................................2277 Hydraulic circuit diagram (2/2)........................................................................................................2278 Electrical circuit diagram (1/11)...................................................................................................... 0 Electrical circuit diagram (2/11)...................................................................................................... 0 Electrical circuit diagram (3/11)...................................................................................................... 0 Electrical circuit diagram (4/11)...................................................................................................... 0 Electrical circuit diagram (5/11)...................................................................................................... 0 Electrical circuit diagram (6/11)...................................................................................................... 0 Electrical circuit diagram (7/11)...................................................................................................... 0 Electrical circuit diagram (8/11)...................................................................................................... 0 Electrical circuit diagram (9/11)...................................................................................................... 0 Electrical circuit diagram (10/11)..................................................................................................... 0 Electrical circuit diagram (11/11)..................................................................................................... 0 Electrical circuit diagram of air conditioner unit..................................................................................... 0 SEN06499-01-MA2_2.pdf...................................................................................................................... 0 Hydraulic circuit diagram (1/2)........................................................................................................ 0 Hydraulic circuit diagram (2/2)........................................................................................................ 0 Electrical circuit diagram (1/11)......................................................................................................2283 Electrical circuit diagram (2/11)......................................................................................................2284 Electrical circuit diagram (3/11)......................................................................................................2285 Electrical circuit diagram (4/11)......................................................................................................2286 Electrical circuit diagram (5/11)......................................................................................................2287 Electrical circuit diagram (6/11)......................................................................................................2288 Electrical circuit diagram (7/11)......................................................................................................2289 Electrical circuit diagram (8/11)......................................................................................................2290 Electrical circuit diagram (9/11)......................................................................................................2291 Electrical circuit diagram (10/11).....................................................................................................2292 Electrical circuit diagram (11/11).....................................................................................................2293 Electrical circuit diagram of air conditioner unit.....................................................................................2294
DESCRIPTION:
KOMATSU PC210i-10i PC210LCi-10i HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00340 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
1. Always wear the protective eyeglasses when hitting parts with a hammer.
2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with 2 or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
S.S 24/12/24
