SEN06616-03

HYDRAULIC PC210LCI -11

EXCAVATOR SERIAL NUMBERS 500470 and up
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 00 INDEX AND FOREWORD

PC210LCI-11 00-1

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INDEX 00 INDEX AND FOREWORD

INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ........................................................................................................................... 00-23
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-29
HOW TO READ THE SHOP MANUAL........................................................................................... 00-29
SAFETY NOTICE FOR OPERATION............................................................................................. 00-31
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-39
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-43
PRECAUTIONS FOR DEF............................................................................................................. 00-44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-57
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-59
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-73
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-78
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-81
CONVERSION TABLE ................................................................................................................... 00-88
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
SPECIFICATION DRAWING............................................................................................................ 01-9
WORKING RANGE DRAWINGS ....................................................................................................01-11
SPECIFICATIONS ......................................................................................................................... 01-12
WEIGHT TABLE ............................................................................................................................ 01-15
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-17
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
ABBREVIATION LIST ............................................................................................................................. 10-6
UREA SCR SYSTEM............................................................................................................................ 10-12
LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-13
UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-18
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-19
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-36
BOOT-UP SYSTEM .............................................................................................................................. 10-45
LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-45
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-47
BATTERY DISCONNECT SWITCH ............................................................................................... 10-49
ENGINE SYSTEM ................................................................................................................................ 10-50
LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-50
ENGINE CONTROL SYSTEM ....................................................................................................... 10-52
AUTO-DECELERATION SYSTEM ................................................................................................. 10-55
ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-57
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-59
TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-62

00-2 PC210LCI-11

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00 INDEX AND FOREWORD INDEX

AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-64

COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-67
COOLING SYSTEM.............................................................................................................................. 10-86
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-86
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH .................................................................... 10-88
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH........................................................... 10-90
COMPONENT PARTS OF COOLING SYSTEM............................................................................. 10-92
CONTROL SYSTEM............................................................................................................................. 10-93
LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-93
MACHINE MONITOR SYSTEM ..................................................................................................... 10-96
KomVision SYSTEM ...................................................................................................................... 10-98
KOMTRAX SYSTEM.....................................................................................................................10-102
COMPONENT PARTS OF CONTROL SYSTEM...........................................................................10-103
HYDRAULIC SYSTEM.........................................................................................................................10-144
LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-144
CLSS ............................................................................................................................................10-150
ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-169
PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-175
COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-178
WORK EQUIPMENT SYSTEM ............................................................................................................10-266
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-266
STRUCTURE OF VALVE CONTROL............................................................................................10-271
ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-273
PPC LOCK SYSTEM ....................................................................................................................10-275
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-276
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-278
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-280
ICT SYSTEM .......................................................................................................................................10-305
LAYOUT DRAWING OF ICT SYSTEM..........................................................................................10-305
ICT CONTROL SYSTEM DIAGRAM.............................................................................................10-309
BUCKET EDGE POSITION DETECTION SYSTEM......................................................................10-310
THE INTELLIGENT MACHINE CONTROL SYSTEM....................................................................10-312
CUSHION SYSTEM FOR ARM IN END........................................................................................10-333
BOOM SECONDARY DRIVE SWITCH.........................................................................................10-335
COMPONENT PARTS OF ICT SYSTEM ......................................................................................10-336
SWING SYSTEM .................................................................................................................................10-370
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-370
SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-374
COMPONENT PARTS OF SWING SYSTEM................................................................................10-378
TRAVEL SYSTEM................................................................................................................................10-392
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-392
TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-396
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-398
UNDERCARRIAGE AND FRAME........................................................................................................10-419
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-419
WORK EQUIPMENT............................................................................................................................10-421
STRUCTURE OF WORK EQUIPMENT ........................................................................................10-421
FUNCTION OF WORK EQUIPMENT ...........................................................................................10-422
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-423
BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-424
CAB AND ITS ATTACHMENTS ...........................................................................................................10-425
ROPS CAB ...................................................................................................................................10-425
CAB MOUNT ................................................................................................................................10-426
CAB TIPPING STOPPER .............................................................................................................10-427
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
ABBREVIATION LIST ............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9

PC210LCI-11 00-3

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INDEX 00 INDEX AND FOREWORD

STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11 ............................................................... 20-9

STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-13
STANDARD VALUE TABLE FOR MACHINE: PC210LCI-11 .......................................................... 20-13
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-36
STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-40
STANDARD VALUE TABLE FOR ELECTRICAL ............................................................................ 20-40
30 TESTING AND ADJUSTING ..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
ABBREVIATION LIST ............................................................................................................................. 30-6
RELATED INFORMATION ON TESTING AND ADJUSTING ................................................................ 30-12
TOOLS FOR TESTING AND ADJUSTING..................................................................................... 30-12
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-22
ENGINE AND COOLING SYSTEM....................................................................................................... 30-23
TEST ENGINE SPEED .................................................................................................................. 30-23
TEST BOOST PRESSURE............................................................................................................ 30-26
TEST EXHAUST GAS COLOR ...................................................................................................... 30-28
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-31
TEST COMPRESSION PRESSURE.............................................................................................. 30-33
TEST BLOWBY PRESSURE ......................................................................................................... 30-38
TEST ENGINE OIL PRESSURE .................................................................................................... 30-40
TEST EGR VALVE AND VGT OIL PRESSURE ............................................................................. 30-41
TEST FUEL PRESSURE ............................................................................................................... 30-43
TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-49
BLEEDING AIR FROM FUEL SYSTEM ......................................................................................... 30-55
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-56
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-58
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-59
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-60
TEST COOLING FAN SPEED ...................................................................................................... 30-62
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-63
TEST SCR RELATED FUNCTIONS............................................................................................... 30-64
CLEAN AdBlue/DEF TANK ............................................................................................................ 30-91
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK ................................................... 30-95
POWER TRAIN..................................................................................................................................... 30-97
TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-97
UNDERCARRIAGE AND FRAME......................................................................................................... 30-98
TEST AND ADJUST TRACK TENSION......................................................................................... 30-98
HYDRAULIC SYSTEM.........................................................................................................................30-100
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................30-100
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........
..................................................................................................................................................30-101
TEST OIL PRESSURE OF CONTROL CIRCUIT .......................................................................... 30-111
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ...................................30-113
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT....................................30-116
TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-123
TEST PPC VALVE OUTLET PRESSURE .....................................................................................30-127
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-129
TEST PUMP SWASH PLATE SENSOR........................................................................................30-130
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-131
TEST OIL LEAKAGE ....................................................................................................................30-133
BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-136
CAB AND ITS ATTACHMENTS ...........................................................................................................30-140
TEST CAB TIPPING STOPPER ...................................................................................................30-140
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-141
ELECTRICAL SYSTEM .......................................................................................................................30-147
SET AND OPERATE MACHINE MONITOR..................................................................................30-147
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-254
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-259

00-4 PC210LCI-11

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00 INDEX AND FOREWORD INDEX

ADJUST KomVision CAMERA ANGLE .........................................................................................30-262

ADJUST KomVision RELATED ITEMS .........................................................................................30-267
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-283
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-284
TEST DIODES ..............................................................................................................................30-285
ICT SYSTEM .......................................................................................................................................30-286
SET AND OPERATE CONTROL BOX ..........................................................................................30-286
CALIBRATE INTELLIGENT MACHINE CONTROL .......................................................................30-295
Pm CLINIC...........................................................................................................................................30-733
Pm CLINIC SERVICE ...................................................................................................................30-733
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
ABBREVIATION LIST ........................................................................................................................... 40-15
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-21
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-21
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-22
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-34
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-36
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-38
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-40
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM..................................... 40-60
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-69
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-72
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-77
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM............................................................................................................................ 40-79
CONNECTOR LIST AND LAYOUT ................................................................................................ 40-82
CONNECTOR CONTACT IDENTIFICATION ................................................................................40-105
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-145
FUSE LOCATION TABLE .............................................................................................................40-151
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..........................40-155
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135])..........................................................................................................................40-159
FAILURE CODES TABLE .............................................................................................................40-161
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-183
FAILURE CODE [879AKA]............................................................................................................40-183
FAILURE CODE [879AKB]............................................................................................................40-184
FAILURE CODE [879BKA]............................................................................................................40-185
FAILURE CODE [879BKB]............................................................................................................40-187
FAILURE CODE [879CKA]............................................................................................................40-189
FAILURE CODE [879CKB]............................................................................................................40-190
FAILURE CODE [879DKZ]............................................................................................................40-191
FAILURE CODE [879EMC] ...........................................................................................................40-193
FAILURE CODE [879FMC] ...........................................................................................................40-194
FAILURE CODE [879GKX] ...........................................................................................................40-195
FAILURE CODE [989L00] .............................................................................................................40-197
FAILURE CODE [989M00] ............................................................................................................40-198
FAILURE CODE [989N00] ............................................................................................................40-199
FAILURE CODE [A1U0N3] ...........................................................................................................40-200
FAILURE CODE [A1U0N4] ...........................................................................................................40-202
FAILURE CODE [A900FR]............................................................................................................40-204
FAILURE CODE [A900N6] ............................................................................................................40-205
FAILURE CODE [A900NY]............................................................................................................40-206
FAILURE CODE [AA10NX] ...........................................................................................................40-207
FAILURE CODE [AB00KE] ...........................................................................................................40-209
FAILURE CODE [AQ10N3] ...........................................................................................................40-212
FAILURE CODE [AS00N3]............................................................................................................40-214
FAILURE CODE [AS00R2]............................................................................................................40-216

PC210LCI-11 00-5

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INDEX 00 INDEX AND FOREWORD

FAILURE CODE [AS00R3]............................................................................................................40-217

FAILURE CODE [AS00R4]............................................................................................................40-218
FAILURE CODE [AS00R5]............................................................................................................40-219
FAILURE CODE [AS00R6]............................................................................................................40-220
FAILURE CODE [AS00ZK]............................................................................................................40-221
FAILURE CODE [AS10KM]...........................................................................................................40-222
FAILURE CODE [AS10NR] ...........................................................................................................40-223
FAILURE CODE [AS10NT] ...........................................................................................................40-224
FAILURE CODE [B@BAZG] .........................................................................................................40-225
FAILURE CODE [B@BAZK]..........................................................................................................40-226
FAILURE CODE [B@BCNS] .........................................................................................................40-228
FAILURE CODE [B@BCZK] .........................................................................................................40-229
FAILURE CODE [B@HANS] .........................................................................................................40-231
FAILURE CODE [CA115] ..............................................................................................................40-232
FAILURE CODE [CA122] ..............................................................................................................40-233
FAILURE CODE [CA123] ..............................................................................................................40-235
FAILURE CODE [CA131] ..............................................................................................................40-237
FAILURE CODE [CA132] ..............................................................................................................40-239
FAILURE CODE [CA144] ..............................................................................................................40-241
FAILURE CODE [CA145] ..............................................................................................................40-243
FAILURE CODE [CA153] ..............................................................................................................40-245
FAILURE CODE [CA154] ..............................................................................................................40-248
FAILURE CODE [CA187] ..............................................................................................................40-250
FAILURE CODE [CA221] ..............................................................................................................40-252
FAILURE CODE [CA222] ..............................................................................................................40-254
FAILURE CODE [CA227] ..............................................................................................................40-256
FAILURE CODE [CA234] ..............................................................................................................40-257
FAILURE CODE [CA238] ..............................................................................................................40-258
FAILURE CODE [CA239] ..............................................................................................................40-260
FAILURE CODE [CA249] ..............................................................................................................40-262
FAILURE CODE [CA256] ..............................................................................................................40-264
FAILURE CODE [CA271] ..............................................................................................................40-266
FAILURE CODE [CA272] ..............................................................................................................40-268
FAILURE CODE [CA322] ..............................................................................................................40-270
FAILURE CODE [CA323] ..............................................................................................................40-272
FAILURE CODE [CA324] ..............................................................................................................40-274
FAILURE CODE [CA325] ..............................................................................................................40-276
FAILURE CODE [CA331] ..............................................................................................................40-278
FAILURE CODE [CA332] ..............................................................................................................40-280
FAILURE CODE [CA343] ..............................................................................................................40-282
FAILURE CODE [CA351] ..............................................................................................................40-283
FAILURE CODE [CA352] ..............................................................................................................40-284
FAILURE CODE [CA356] ..............................................................................................................40-287
FAILURE CODE [CA357] ..............................................................................................................40-289
FAILURE CODE [CA386] ..............................................................................................................40-291
FAILURE CODE [CA428] ..............................................................................................................40-292
FAILURE CODE [CA429] ..............................................................................................................40-294
FAILURE CODE [CA435] ..............................................................................................................40-296
FAILURE CODE [CA441] ..............................................................................................................40-298
FAILURE CODE [CA442] ..............................................................................................................40-300
FAILURE CODE [CA449] ..............................................................................................................40-301
FAILURE CODE [CA451] ..............................................................................................................40-302
FAILURE CODE [CA452] ..............................................................................................................40-304
FAILURE CODE [CA488] ..............................................................................................................40-306
FAILURE CODE [CA515] ..............................................................................................................40-307
FAILURE CODE [CA516] ..............................................................................................................40-309
FAILURE CODE [CA553] ..............................................................................................................40-311
FAILURE CODE [CA555] ..............................................................................................................40-312

00-6 PC210LCI-11

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00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA556] ..............................................................................................................40-313

FAILURE CODE [CA559] ..............................................................................................................40-314
FAILURE CODE [CA595] ..............................................................................................................40-317
FAILURE CODE [CA687] ..............................................................................................................40-318
FAILURE CODE [CA689] ..............................................................................................................40-320
FAILURE CODE [CA691] ..............................................................................................................40-323
FAILURE CODE [CA692] ..............................................................................................................40-325
FAILURE CODE [CA697] ..............................................................................................................40-327
FAILURE CODE [CA698] ..............................................................................................................40-328
FAILURE CODE [CA731] ..............................................................................................................40-329
FAILURE CODE [CA778] ..............................................................................................................40-331
FAILURE CODE [CA1117] ............................................................................................................40-336
FAILURE CODE [CA1664] ............................................................................................................40-337
FAILURE CODE [CA1669] ............................................................................................................40-339
FAILURE CODE [CA1673] ............................................................................................................40-340
FAILURE CODE [CA1677] ............................................................................................................40-341
FAILURE CODE [CA1678] ............................................................................................................40-342
FAILURE CODE [CA1682] ............................................................................................................40-343
FAILURE CODE [CA1683] ............................................................................................................40-345
FAILURE CODE [CA1684] ............................................................................................................40-347
FAILURE CODE [CA1686] ............................................................................................................40-349
FAILURE CODE [CA1691] ............................................................................................................40-350
FAILURE CODE [CA1694] ............................................................................................................40-353
FAILURE CODE [CA1695] ............................................................................................................40-356
FAILURE CODE [CA1696] ............................................................................................................40-357
FAILURE CODE [CA1712] ............................................................................................................40-359
FAILURE CODE [CA1713] ............................................................................................................40-362
FAILURE CODE [CA1714] ............................................................................................................40-364
FAILURE CODE [CA1715] ............................................................................................................40-365
FAILURE CODE [CA1776] ............................................................................................................40-366
FAILURE CODE [CA1777] ............................................................................................................40-369
FAILURE CODE [CA1843] ............................................................................................................40-372
FAILURE CODE [CA1844] ............................................................................................................40-374
FAILURE CODE [CA1879] ............................................................................................................40-377
FAILURE CODE [CA1881] ............................................................................................................40-379
FAILURE CODE [CA1883] ............................................................................................................40-381
FAILURE CODE [CA1885] ............................................................................................................40-384
FAILURE CODE [CA1887] ............................................................................................................40-386
FAILURE CODE [CA1921] ............................................................................................................40-388
FAILURE CODE [CA1922] ............................................................................................................40-391
FAILURE CODE [CA1942] ............................................................................................................40-396
FAILURE CODE [CA1993] ............................................................................................................40-397
FAILURE CODE [CA2185] ............................................................................................................40-400
FAILURE CODE [CA2186] ............................................................................................................40-401
FAILURE CODE [CA2249] ............................................................................................................40-403
FAILURE CODE [CA2271] ............................................................................................................40-404
FAILURE CODE [CA2272] ............................................................................................................40-407
FAILURE CODE [CA2288] ............................................................................................................40-410
FAILURE CODE [CA2311] ............................................................................................................40-411
FAILURE CODE [CA2349] ............................................................................................................40-412
FAILURE CODE [CA2353] ............................................................................................................40-415
FAILURE CODE [CA2357] ............................................................................................................40-417
FAILURE CODE [CA2381] ............................................................................................................40-418
FAILURE CODE [CA2382] ............................................................................................................40-421
FAILURE CODE [CA2383] ............................................................................................................40-424
FAILURE CODE [CA2386] ............................................................................................................40-427
FAILURE CODE [CA2387] ............................................................................................................40-429
FAILURE CODE [CA2555] ............................................................................................................40-430

PC210LCI-11 00-7

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INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA2556] ............................................................................................................40-433

FAILURE CODE [CA2637] ............................................................................................................40-436
FAILURE CODE [CA2639] ............................................................................................................40-438
FAILURE CODE [CA2771] ............................................................................................................40-441
FAILURE CODE [CA2777] ............................................................................................................40-447
FAILURE CODE [CA2976] ............................................................................................................40-450
FAILURE CODE [CA3133] ............................................................................................................40-452
FAILURE CODE [CA3134] ............................................................................................................40-455
FAILURE CODE [CA3135] ............................................................................................................40-457
FAILURE CODE [CA3142] ............................................................................................................40-460
FAILURE CODE [CA3143] ............................................................................................................40-461
FAILURE CODE [CA3144] ............................................................................................................40-462
FAILURE CODE [CA3146] ............................................................................................................40-464
FAILURE CODE [CA3147] ............................................................................................................40-465
FAILURE CODE [CA3148] ............................................................................................................40-466
FAILURE CODE [CA3151] ............................................................................................................40-468
FAILURE CODE [CA3165] ............................................................................................................40-474
FAILURE CODE [CA3229] ............................................................................................................40-476
FAILURE CODE [CA3231] ............................................................................................................40-478
FAILURE CODE [CA3232] ............................................................................................................40-480
FAILURE CODE [CA3235] ............................................................................................................40-484
FAILURE CODE [CA3239] ............................................................................................................40-486
FAILURE CODE [CA3241] ............................................................................................................40-489
FAILURE CODE [CA3242] ............................................................................................................40-492
FAILURE CODE [CA3251] ............................................................................................................40-495
FAILURE CODE [CA3253] ............................................................................................................40-497
FAILURE CODE [CA3254] ............................................................................................................40-500
FAILURE CODE [CA3255] ............................................................................................................40-503
FAILURE CODE [CA3256] ............................................................................................................40-507
FAILURE CODE [CA3311] ............................................................................................................40-509
FAILURE CODE [CA3312] ............................................................................................................40-511
FAILURE CODE [CA3313] ............................................................................................................40-514
FAILURE CODE [CA3314] ............................................................................................................40-516
FAILURE CODE [CA3315] ............................................................................................................40-517
FAILURE CODE [CA3316] ............................................................................................................40-519
FAILURE CODE [CA3317] ............................................................................................................40-521
FAILURE CODE [CA3318] ............................................................................................................40-522
FAILURE CODE [CA3319] ............................................................................................................40-524
FAILURE CODE [CA3321] ............................................................................................................40-525
FAILURE CODE [CA3322] ............................................................................................................40-527
FAILURE CODE [CA3419] ............................................................................................................40-529
FAILURE CODE [CA3421] ............................................................................................................40-531
FAILURE CODE [CA3497] ............................................................................................................40-533
FAILURE CODE [CA3498] ............................................................................................................40-534
FAILURE CODE [CA3543] ............................................................................................................40-535
FAILURE CODE [CA3545] ............................................................................................................40-541
FAILURE CODE [CA3547] ............................................................................................................40-543
FAILURE CODE [CA3558] ............................................................................................................40-544
FAILURE CODE [CA3559] ............................................................................................................40-546
FAILURE CODE [CA3562] ............................................................................................................40-548
FAILURE CODE [CA3563] ............................................................................................................40-550
FAILURE CODE [CA3567] ............................................................................................................40-553
FAILURE CODE [CA3568] ............................................................................................................40-556
FAILURE CODE [CA3571] ............................................................................................................40-560
FAILURE CODE [CA3572] ............................................................................................................40-562
FAILURE CODE [CA3574] ............................................................................................................40-564
FAILURE CODE [CA3575] ............................................................................................................40-566
FAILURE CODE [CA3577] ............................................................................................................40-568

00-8 PC210LCI-11

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00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA3578] ............................................................................................................40-570

FAILURE CODE [CA3582] ............................................................................................................40-572
FAILURE CODE [CA3583] ............................................................................................................40-578
FAILURE CODE [CA3596] ............................................................................................................40-580
FAILURE CODE [CA3649] ............................................................................................................40-582
FAILURE CODE [CA3681] ............................................................................................................40-584
FAILURE CODE [CA3682] ............................................................................................................40-589
FAILURE CODE [CA3713] ............................................................................................................40-595
FAILURE CODE [CA3717] ............................................................................................................40-598
FAILURE CODE [CA3718] ............................................................................................................40-599
FAILURE CODE [CA3725] ............................................................................................................40-600
FAILURE CODE [CA3741] ............................................................................................................40-603
FAILURE CODE [CA3748] ............................................................................................................40-604
FAILURE CODE [CA3751] ............................................................................................................40-606
FAILURE CODE [CA3755] ............................................................................................................40-608
FAILURE CODE [CA3866] ............................................................................................................40-610
FAILURE CODE [CA3867] ............................................................................................................40-613
FAILURE CODE [CA3868] ............................................................................................................40-616
FAILURE CODE [CA3899] ............................................................................................................40-620
FAILURE CODE [CA3911] ............................................................................................................40-622
FAILURE CODE [CA3912] ............................................................................................................40-626
FAILURE CODE [CA3932] ............................................................................................................40-628
FAILURE CODE [CA3933] ............................................................................................................40-630
FAILURE CODE [CA3934] ............................................................................................................40-632
FAILURE CODE [CA3935] ............................................................................................................40-635
FAILURE CODE [CA3936] ............................................................................................................40-637
FAILURE CODE [CA4151] ............................................................................................................40-639
FAILURE CODE [CA4152] ............................................................................................................40-643
FAILURE CODE [CA4155] ............................................................................................................40-647
FAILURE CODE [CA4156] ............................................................................................................40-650
FAILURE CODE [CA4157] ............................................................................................................40-653
FAILURE CODE [CA4158] ............................................................................................................40-655
FAILURE CODE [CA4159] ............................................................................................................40-656
FAILURE CODE [CA4161] ............................................................................................................40-657
FAILURE CODE [CA4162] ............................................................................................................40-660
FAILURE CODE [CA4163] ............................................................................................................40-663
FAILURE CODE [CA4164] ............................................................................................................40-664
FAILURE CODE [CA4165] ............................................................................................................40-666
FAILURE CODE [CA4166] ............................................................................................................40-668
FAILURE CODE [CA4168] ............................................................................................................40-669
FAILURE CODE [CA4169] ............................................................................................................40-672
FAILURE CODE [CA4171] ............................................................................................................40-674
FAILURE CODE [CA4249] ............................................................................................................40-677
FAILURE CODE [CA4251] ............................................................................................................40-679
FAILURE CODE [CA4259] ............................................................................................................40-681
FAILURE CODE [CA4261] ............................................................................................................40-684
FAILURE CODE [CA4277] ............................................................................................................40-687
FAILURE CODE [CA4281] ............................................................................................................40-690
FAILURE CODE [CA4459] ............................................................................................................40-693
FAILURE CODE [CA4461] ............................................................................................................40-696
FAILURE CODE [CA4658] ............................................................................................................40-699
FAILURE CODE [CA4731] ............................................................................................................40-703
FAILURE CODE [CA4732] ............................................................................................................40-704
FAILURE CODE [CA4739] ............................................................................................................40-705
FAILURE CODE [CA4768] ............................................................................................................40-706
FAILURE CODE [CA4769] ............................................................................................................40-708
FAILURE CODE [CA4842] ............................................................................................................40-711
FAILURE CODE [CA4952] ............................................................................................................40-714

PC210LCI-11 00-9
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA5115] ............................................................................................................40-716

FAILURE CODE [CA5179] ............................................................................................................40-719
FAILURE CODE [CA5181] ............................................................................................................40-721
FAILURE CODE [CA5383] ............................................................................................................40-723
FAILURE CODE [D110KB]............................................................................................................40-725
FAILURE CODE [D19JKZ] ............................................................................................................40-727
FAILURE CODE [D811MC] ...........................................................................................................40-730
FAILURE CODE [D862KA]............................................................................................................40-731
FAILURE CODE [D8ALKA] ...........................................................................................................40-732
FAILURE CODE [D8ALKB] ...........................................................................................................40-734
FAILURE CODE [D8AQKR] ..........................................................................................................40-736
FAILURE CODE [DA20MC] ..........................................................................................................40-738
FAILURE CODE [DA22KK] ...........................................................................................................40-739
FAILURE CODE [DA25KP] ...........................................................................................................40-742
FAILURE CODE [DA26KP] ...........................................................................................................40-745
FAILURE CODE [DA29KQ]...........................................................................................................40-747
FAILURE CODE [DA2LKA] ...........................................................................................................40-750
FAILURE CODE [DA2LKB] ...........................................................................................................40-752
FAILURE CODE [DA2QKR] ..........................................................................................................40-754
FAILURE CODE [DA2RKR] ..........................................................................................................40-757
FAILURE CODE [DAF0MB] ..........................................................................................................40-759
FAILURE CODE [DAF0MC] ..........................................................................................................40-760
FAILURE CODE [DAF8KB] ...........................................................................................................40-761
FAILURE CODE [DAF9KQ]...........................................................................................................40-763
FAILURE CODE [DAFGMC] .........................................................................................................40-764
FAILURE CODE [DAFLKA] ...........................................................................................................40-765
FAILURE CODE [DAFLKB] ...........................................................................................................40-767
FAILURE CODE [DAFQKR] ..........................................................................................................40-769
FAILURE CODE [DAZ9KQ]...........................................................................................................40-770
FAILURE CODE [DAZQKR] ..........................................................................................................40-771
FAILURE CODE [DB2QKR] ..........................................................................................................40-776
FAILURE CODE [DB2RKR] ..........................................................................................................40-781
FAILURE CODE [DB90MC] ..........................................................................................................40-786
FAILURE CODE [DB92KK] ...........................................................................................................40-787
FAILURE CODE [DB95KP] ...........................................................................................................40-789
FAILURE CODE [DB96KP] ...........................................................................................................40-793
FAILURE CODE [DB99KQ]...........................................................................................................40-797
FAILURE CODE [DB9LKA] ...........................................................................................................40-800
FAILURE CODE [DB9LKB] ...........................................................................................................40-802
FAILURE CODE [DB9QKR] ..........................................................................................................40-804
FAILURE CODE [DB9RKR] ..........................................................................................................40-811
FAILURE CODE [DBP0KM] ..........................................................................................................40-817
FAILURE CODE [DBP0KT] ...........................................................................................................40-818
FAILURE CODE [DBPQKR]..........................................................................................................40-819
FAILURE CODE [DBR0MC]..........................................................................................................40-824
FAILURE CODE [DBR2KK]...........................................................................................................40-825
FAILURE CODE [DBR5KP]...........................................................................................................40-828
FAILURE CODE [DBR6KP]...........................................................................................................40-830
FAILURE CODE [DBR9KQ] ..........................................................................................................40-832
FAILURE CODE [DBRLKA]...........................................................................................................40-835
FAILURE CODE [DBRLKB]...........................................................................................................40-837
FAILURE CODE [DBRQKR]..........................................................................................................40-839
FAILURE CODE [DBRRKR]..........................................................................................................40-846
FAILURE CODE [DBRSKB] ..........................................................................................................40-852
FAILURE CODE [DBRTKB] ..........................................................................................................40-854
FAILURE CODE [DBUSKR] ..........................................................................................................40-856
FAILURE CODE [DD20MA] ..........................................................................................................40-860
FAILURE CODE [DDNRKA]..........................................................................................................40-863

00-10 PC210LCI-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [DDNRKY]..........................................................................................................40-865

FAILURE CODE [DDNS00]...........................................................................................................40-867
FAILURE CODE [DFB1KZ] ...........................................................................................................40-869
FAILURE CODE [DFB2KZ] ...........................................................................................................40-871
FAILURE CODE [DFB3L8]............................................................................................................40-873
FAILURE CODE [DFB4L8]............................................................................................................40-875
FAILURE CODE [DFB5KZ] ...........................................................................................................40-877
FAILURE CODE [DFB6KZ] ...........................................................................................................40-879
FAILURE CODE [DGH2KA] ..........................................................................................................40-881
FAILURE CODE [DGH2KB] ..........................................................................................................40-883
FAILURE CODE [DHA4KA]...........................................................................................................40-885
FAILURE CODE [DHAAMA]..........................................................................................................40-887
FAILURE CODE [DHACMA] .........................................................................................................40-889
FAILURE CODE [DHPAMA] ..........................................................................................................40-891
FAILURE CODE [DHPBMA]..........................................................................................................40-893
FAILURE CODE [DHS3MA] ..........................................................................................................40-895
FAILURE CODE [DHS4MA] ..........................................................................................................40-898
FAILURE CODE [DHS8MA] ..........................................................................................................40-901
FAILURE CODE [DHS9MA] ..........................................................................................................40-904
FAILURE CODE [DHSAMA]..........................................................................................................40-907
FAILURE CODE [DHSBMA]..........................................................................................................40-910
FAILURE CODE [DHSCMA] .........................................................................................................40-913
FAILURE CODE [DHSDMA] .........................................................................................................40-916
FAILURE CODE [DHSFMA]..........................................................................................................40-919
FAILURE CODE [DHSGMA] .........................................................................................................40-922
FAILURE CODE [DHSHMA] .........................................................................................................40-925
FAILURE CODE [DHSJMA] ..........................................................................................................40-928
FAILURE CODE [DHUXMA] .........................................................................................................40-931
FAILURE CODE [DHUYMA] .........................................................................................................40-933
FAILURE CODE [DK80KM]...........................................................................................................40-935
FAILURE CODE [DK80KR] ...........................................................................................................40-936
FAILURE CODE [DK80KT] ...........................................................................................................40-942
FAILURE CODE [DKG1KM]..........................................................................................................40-943
FAILURE CODE [DKG1L8] ...........................................................................................................40-944
FAILURE CODE [DKR0MA] ..........................................................................................................40-945
FAILURE CODE [DKR1MA] ..........................................................................................................40-947
FAILURE CODE [DKT0KM] ..........................................................................................................40-949
FAILURE CODE [DKT0L8]............................................................................................................40-950
FAILURE CODE [DKT1KA] ...........................................................................................................40-951
FAILURE CODE [DKT1KB] ...........................................................................................................40-953
FAILURE CODE [DKT2KA] ...........................................................................................................40-955
FAILURE CODE [DKT2KB] ...........................................................................................................40-957
FAILURE CODE [DKT4KM] ..........................................................................................................40-959
FAILURE CODE [DKT4L8]............................................................................................................40-960
FAILURE CODE [DKT5KA] ...........................................................................................................40-961
FAILURE CODE [DKT5KB] ...........................................................................................................40-963
FAILURE CODE [DKT6KA] ...........................................................................................................40-965
FAILURE CODE [DKT6KB] ...........................................................................................................40-967
FAILURE CODE [DKT8KA] ...........................................................................................................40-969
FAILURE CODE [DKT8KB] ...........................................................................................................40-971
FAILURE CODE [DKT9KA] ...........................................................................................................40-973
FAILURE CODE [DKT9KB] ...........................................................................................................40-975
FAILURE CODE [DKTAKA]...........................................................................................................40-977
FAILURE CODE [DKTAKB]...........................................................................................................40-979
FAILURE CODE [DKTAMB] ..........................................................................................................40-981
FAILURE CODE [DKTBKX]...........................................................................................................40-982
FAILURE CODE [DKTBMC]..........................................................................................................40-984
FAILURE CODE [DKTEMB] ..........................................................................................................40-985

PC210LCI-11 00-11
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [DKTFKX]...........................................................................................................40-987

FAILURE CODE [DKTFMC] ..........................................................................................................40-989
FAILURE CODE [DKTJMB]...........................................................................................................40-990
FAILURE CODE [DKTUL8] ...........................................................................................................40-992
FAILURE CODE [DKTVKA]...........................................................................................................40-993
FAILURE CODE [DKTVKB]...........................................................................................................40-995
FAILURE CODE [DKTWKA]..........................................................................................................40-996
FAILURE CODE [DKTWKB]..........................................................................................................40-998
FAILURE CODE [DKU1MA] ..........................................................................................................40-999
FAILURE CODE [DKU2MA] ........................................................................................................40-1000
FAILURE CODE [DKUGKA]........................................................................................................40-1001
FAILURE CODE [DKUGKB]........................................................................................................40-1003
FAILURE CODE [DKUGKY]........................................................................................................40-1005
FAILURE CODE [DKUHKA] ........................................................................................................40-1007
FAILURE CODE [DKUHKB] ........................................................................................................40-1009
FAILURE CODE [DKUHKY] ........................................................................................................40-1011
FAILURE CODE [DKULKA].........................................................................................................40-1013
FAILURE CODE [DKULKB].........................................................................................................40-1015
FAILURE CODE [DKULKY].........................................................................................................40-1017
FAILURE CODE [DKV0KA].........................................................................................................40-1019
FAILURE CODE [DKV0KY].........................................................................................................40-1022
FAILURE CODE [DKV1KA].........................................................................................................40-1024
FAILURE CODE [DKV1KY].........................................................................................................40-1026
FAILURE CODE [DKV2KA].........................................................................................................40-1028
FAILURE CODE [DKV2KY].........................................................................................................40-1030
FAILURE CODE [DKV3KA].........................................................................................................40-1032
FAILURE CODE [DKV3KY].........................................................................................................40-1034
FAILURE CODE [DKV4MA] ........................................................................................................40-1036
FAILURE CODE [DKV5MA] ........................................................................................................40-1039
FAILURE CODE [DKV6MA] ........................................................................................................40-1042
FAILURE CODE [DKV7MA] ........................................................................................................40-1045
FAILURE CODE [DKV8MA] ........................................................................................................40-1048
FAILURE CODE [DKV9MA] ........................................................................................................40-1051
FAILURE CODE [DKVAMA] ........................................................................................................40-1054
FAILURE CODE [DKVBKA] ........................................................................................................40-1057
FAILURE CODE [DKVBKB] ........................................................................................................40-1059
FAILURE CODE [DKVBKY] ........................................................................................................40-1061
FAILURE CODE [DKVCKA] ........................................................................................................40-1063
FAILURE CODE [DKVCKB] ........................................................................................................40-1065
FAILURE CODE [DKVCKY] ........................................................................................................40-1067
FAILURE CODE [DKVDKA] ........................................................................................................40-1069
FAILURE CODE [DKVDKB] ........................................................................................................40-1071
FAILURE CODE [DKVDKY] ........................................................................................................40-1073
FAILURE CODE [DKVDMA]........................................................................................................40-1075
FAILURE CODE [DLM5KA].........................................................................................................40-1077
FAILURE CODE [DLM5MB] ........................................................................................................40-1079
FAILURE CODE [DR10KA] .........................................................................................................40-1081
FAILURE CODE [DR21KX] .........................................................................................................40-1084
FAILURE CODE [DR31KX] .........................................................................................................40-1086
FAILURE CODE [DUMBKA]........................................................................................................40-1088
FAILURE CODE [DUMBKB]........................................................................................................40-1090
FAILURE CODE [DV20KB] .........................................................................................................40-1092
FAILURE CODE [DW43KA] ........................................................................................................40-1094
FAILURE CODE [DW43KB] ........................................................................................................40-1096
FAILURE CODE [DW43KY] ........................................................................................................40-1098
FAILURE CODE [DW45KA] ........................................................................................................40-1100
FAILURE CODE [DW45KB] ........................................................................................................40-1103
FAILURE CODE [DW45KY] ........................................................................................................40-1106

00-12 PC210LCI-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [DW4CKY]........................................................................................................40-1108

FAILURE CODE [DW4FKA] ........................................................................................................ 40-1110
FAILURE CODE [DW4FKB] ........................................................................................................ 40-1113
FAILURE CODE [DW4FKY] ........................................................................................................ 40-1115
FAILURE CODE [DW4GKA] ....................................................................................................... 40-1117
FAILURE CODE [DW4GKB] .......................................................................................................40-1120
FAILURE CODE [DW4GKY] .......................................................................................................40-1122
FAILURE CODE [DW4SKA]........................................................................................................40-1124
FAILURE CODE [DW4SKB]........................................................................................................40-1126
FAILURE CODE [DW4SKY]........................................................................................................40-1128
FAILURE CODE [DW91KA] ........................................................................................................40-1130
FAILURE CODE [DW91KB] ........................................................................................................40-1132
FAILURE CODE [DW91KY] ........................................................................................................40-1134
FAILURE CODE [DWA2KA] ........................................................................................................40-1136
FAILURE CODE [DWA2KB] ........................................................................................................40-1138
FAILURE CODE [DWA2KY] ........................................................................................................40-1140
FAILURE CODE [DWK0KA]........................................................................................................40-1142
FAILURE CODE [DWK0KB]........................................................................................................40-1144
FAILURE CODE [DWK0KY]........................................................................................................40-1146
FAILURE CODE [DWK2KA]........................................................................................................40-1148
FAILURE CODE [DWK2KB]........................................................................................................40-1150
FAILURE CODE [DWK2KY]........................................................................................................40-1152
FAILURE CODE [DWK8KA]........................................................................................................40-1154
FAILURE CODE [DWK8KB]........................................................................................................40-1156
FAILURE CODE [DWK8KY]........................................................................................................40-1158
FAILURE CODE [DWN5KA]........................................................................................................40-1160
FAILURE CODE [DWN5KB]........................................................................................................40-1162
FAILURE CODE [DWN5KY]........................................................................................................40-1164
FAILURE CODE [DXA8KA].........................................................................................................40-1166
FAILURE CODE [DXA8KB].........................................................................................................40-1168
FAILURE CODE [DXA9KA].........................................................................................................40-1170
FAILURE CODE [DXA9KB].........................................................................................................40-1172
FAILURE CODE [DXE0KA].........................................................................................................40-1174
FAILURE CODE [DXE0KB].........................................................................................................40-1175
FAILURE CODE [DXE4KA].........................................................................................................40-1177
FAILURE CODE [DXE4KB].........................................................................................................40-1179
FAILURE CODE [DXE4KY].........................................................................................................40-1181
FAILURE CODE [DXE5KA].........................................................................................................40-1183
FAILURE CODE [DXE5KB].........................................................................................................40-1185
FAILURE CODE [DXE6KA].........................................................................................................40-1187
FAILURE CODE [DXE6KB].........................................................................................................40-1189
FAILURE CODE [DXE7KA].........................................................................................................40-1191
FAILURE CODE [DXE7KB].........................................................................................................40-1193
FAILURE CODE [DXE7KY].........................................................................................................40-1195
FAILURE CODE [DXE8KA].........................................................................................................40-1197
FAILURE CODE [DXE8KB].........................................................................................................40-1199
FAILURE CODE [DXE8KY].........................................................................................................40-1201
FAILURE CODE [DXE9KA].........................................................................................................40-1203
FAILURE CODE [DXE9KB].........................................................................................................40-1205
FAILURE CODE [DXE9KY].........................................................................................................40-1207
FAILURE CODE [DXEAKA] ........................................................................................................40-1209
FAILURE CODE [DXEAKB] ........................................................................................................40-1211
FAILURE CODE [DXEAKY] ........................................................................................................40-1213
FAILURE CODE [DY20KA] .........................................................................................................40-1215
FAILURE CODE [DY20MA].........................................................................................................40-1217
FAILURE CODE [DY2CKB].........................................................................................................40-1219
FAILURE CODE [DY2DKB].........................................................................................................40-1222
FAILURE CODE [DY2EKB].........................................................................................................40-1224

PC210LCI-11 00-13
INDEX 00 INDEX AND FOREWORD

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1226

E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1226
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1232
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1235
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.....40-1237
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING................................................................................................................................40-1239
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), EN-
GINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW ...........................................................40-1242
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIA-
TOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .................................................40-1243
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1244
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1245
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...
................................................................................................................................................40-1246
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............40-1247
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................40-1248
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......40-1249
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1250
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1251
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1252
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .................40-1253
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...............................40-1255
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM.........................................................................................................................40-1256
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL-
ANT TEMPERATURE..............................................................................................................40-1257
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM ...............................................................................................................................40-1258
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM-
PERATURE .............................................................................................................................40-1260
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ......................40-1261
E-24 FUNCTION SWITCH DOES NOT OPERATE .....................................................................40-1262
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)..................40-1263
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF ....................................................................40-1264
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ....................40-1265
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ....................................................................................................................40-1266
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED ......................................................................................................................40-1267
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE .................................................................................................................................40-1268
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE .................................................................................................................................40-1269
E-32 ALARM BUZZER CANNOT BE CANCELED ......................................................................40-1271
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
................................................................................................................................................40-1272
E-34 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1273
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ....40-1274
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK........40-1277
E-37 BUCKET DOES NOT MOVE WITH AUTO TILT FUNCTION .............................................40-1279
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ....................................................................................................................................40-1280

00-14 PC210LCI-11
00 INDEX AND FOREWORD INDEX

E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE ...............................................................................................40-1283
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDI-
CATOR NOT DISPLAYED ON MONITOR ...............................................................................40-1285
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ...........................40-1288
E-42 ALARM DOES NOT SOUND DURING TRAVEL ................................................................40-1289
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................40-1291
E-44 HORN DOES NOT SOUND................................................................................................40-1292
E-45 HORN DOES NOT STOP SOUNDING...............................................................................40-1295
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .
................................................................................................................................................40-1297
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...40-1298
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPER-
ATE .........................................................................................................................................40-1300
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ...
................................................................................................................................................40-1301
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1302
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..........
................................................................................................................................................40-1303
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1304
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
................................................................................................................................................40-1305
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1306
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.40-1307
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1308
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
................................................................................................................................................40-1309
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.......................................40-1311
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1312
E-60 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not con-
nected !] AND [Slope sensor not connected !] .........................................................................40-1313
E-61 CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected!] .....................40-1318
E-62 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link...] ...............................40-1322
E-63 CONTROL BOX DISPLAYS THE MESSAGE [Tilt Bucket Sensor Offline!] .........................40-1323
E-64 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites...]................................40-1324
E-65 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] ............40-1325
E-66 CONTROL BOX DISPLAYS THE MESSAGE [Sensors are invalid] ....................................40-1328
E-67 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize....] .................................40-1331
E-68 CONTROL BOX DISPLAYS THE MESSAGE [Initializing....]...............................................40-1332
E-69 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization...]...............................40-1333
E-70 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions...]........................................40-1334
E-71 CONTROL BOX DISPLAYS [Out of design area...].............................................................40-1335
E-72 CONTROL BOX DISPLAYS THE MESSAGE [Avoidance Area Breach!] ............................40-1336
E-73 CONTROL BOX CAN NOT BE TURNED ON .....................................................................40-1337
E-74 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN ...40-1338
E-75 CONTROL BOX DOES NOT DISPLAY HYDRAULIC EXCAVATOR IMAGE.......................40-1339
E-76 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE ..............................................40-1340
E-77 CONTROL BOX TOUCH PANEL DOES NOT RESPOND..................................................40-1341
E-78 CONTROL BOX TOUCH PANEL IS INACCURATE............................................................40-1342
E-79 WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE VALUE IS DIFFER-
ENT FROM ACTUAL MACHINE .............................................................................................40-1343
E-80 SEMI-AUTO MODE IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED40-1345
E-81 AUTO GRADE ASSIST CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DIS-
PLAYED ..................................................................................................................................40-1346
E-82 AUTO STOP CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED........
................................................................................................................................................40-1347

PC210LCI-11 00-15
INDEX 00 INDEX AND FOREWORD

E-83 BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN AUTO GRADE
ASSIST FUNCTION IS ON......................................................................................................40-1348
E-84 BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE WHEN AUTO
STOP CONTROL FUNCTION IS ON ......................................................................................40-1350
E-85 FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TARGET .......40-1352
E-86 NG OCCURS VERY OFTEN IN IMU CALIBRATION DIAGNOSIS .....................................40-1353
E-87 CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK .............................40-1354
E-88 CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK .......................................40-1355
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1358
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1358
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1359
FAILURE MODE AND CAUSE TABLE........................................................................................40-1361
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK......................................40-1373
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER ..................40-1374
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR............................................40-1377
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ..................................40-1378
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..................................................40-1379
H-6 SPEED OR POWER OF BOOM IS LOW .............................................................................40-1381
H-7 ARM SPEED OR POWER IS LOW ......................................................................................40-1385
H-8 BUCKET SPEED OR POWER IS LOW................................................................................40-1390
H-9 BUCKET DOES NOT MOVE IN SINGLE OPERATION WITH AUTO TILT FUNCTION ........40-1393
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION ...................................40-1394
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1395
H-12 HYDRAULIC DRIFT OF ARM IS LARGE ...........................................................................40-1397
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1399
H-14 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIP-
MENT MOVES ........................................................................................................................40-1400
H-15 TIME LAG OF WORK EQUIPMENT IS LARGE .................................................................40-1401
H-16 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .........................40-1402
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................40-1403
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................40-1404
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER ...................................................................................................................40-1405
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY ......
................................................................................................................................................40-1406
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW ....
................................................................................................................................................40-1407
H-22 MACHINE DOES NOT TRAVEL STRAIGHT ......................................................................40-1408
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................40-1410
H-24 TRAVEL SPEED IS LOW ...................................................................................................40-1413
H-25 ONE OF TRACKS DOES NOT RUN ..................................................................................40-1415
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ..40-1416
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .................40-1417
H-28 SWINGS ONLY IN ONE DIRECTION.................................................................................40-1418
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) ......................................................................................................................................40-1419
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION ....................................................................................................................40-1420
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT)..................................................................................................................40-1421
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT)..................................................................................40-1422
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .............................40-1423
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING40-1424
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)40-1425
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) ........
................................................................................................................................................40-1426
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ............................40-1427

00-16 PC210LCI-11
00 INDEX AND FOREWORD INDEX

H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1428

TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1429
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1429
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
................................................................................................................................................40-1430
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1431
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ........................................................................................................40-1432
S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1434
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1436
S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1438
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1440
S-8 ENGINE LACKS POWER.....................................................................................................40-1441
S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1443
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1445
S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1446
S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1447
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
................................................................................................................................................40-1448
S-14 OIL PRESSURE DROPS ...................................................................................................40-1449
S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1451
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1452
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1453
S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1454
S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1455
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1456
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1457
S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1459
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1460
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1461
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1463
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1464
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
ABBREVIATION LIST ............................................................................................................................. 50-8
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ........................................................ 50-14
HOW TO READ THIS MANUAL..................................................................................................... 50-14
COATING MATERIALS LIST.......................................................................................................... 50-16
SPECIAL TOOLS LIST .................................................................................................................. 50-21
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-33
ENGINE AND COOLING SYSTEM....................................................................................................... 50-39
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-39
REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-45
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-58
REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................ 50-84
REMOVE AND INSTALL EGR COOLER ASSEMBLY.................................................................... 50-87
REMOVE AND INSTALL STARTER ASSEMBLY ........................................................................... 50-96
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-100
REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-104
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-109
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-115
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY ....................................................................50-119
REMOVE AND INSTALL FAN .......................................................................................................50-127
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-128
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-149
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-156
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .................................................................50-160
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-162

PC210LCI-11 00-17
INDEX 00 INDEX AND FOREWORD

REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-169

REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-177
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-189
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-201
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-203
REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-204
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-208
REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-217
REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-221
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-233
REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-249
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-256
REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-268
REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-274
REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-280
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-293
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-296
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-301
POWER TRAIN....................................................................................................................................50-303
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-303
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-306
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-319
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-325
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-336
UNDERCARRIAGE AND FRAME........................................................................................................50-338
SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-338
REMOVE AND INSTALL SPROCKET ..........................................................................................50-343
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-345
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-347
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-352
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-355
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-359
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-363
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-368
HYDRAULIC SYSTEM.........................................................................................................................50-375
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-375
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-380
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-383
REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-388
REMOVE AND INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL...
..................................................................................................................................................50-394
REMOVE AND INSTALL PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL .......50-401
REMOVE AND INSTALL BOOM SPOOL STROKE SENSOR ......................................................50-404
REMOVE AND INSTALL ARM SPOOL STROKE SENSOR .........................................................50-406
REMOVE AND INSTALL JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE
CONTROL.................................................................................................................................50-408
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-412
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-428
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-433
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-435
WORK EQUIPMENT............................................................................................................................50-438
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-438
DISASSEMBLE AND ASSEMBLE STROKE SENSING BOOM CYLINDER ASSEMBLY..............50-450
DISASSEMBLE AND ASSEMBLE STROKE SENSING ARM CYLINDER ASSEMBLY ................50-463
DISASSEMBLE AND ASSEMBLE STROKE SENSING BUCKET CYLINDER ASSEMBLY ..........50-477
CAB AND ITS ATTACHMENTS ...........................................................................................................50-494
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-494
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-512

00-18 PC210LCI-11
00 INDEX AND FOREWORD INDEX

REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-524

REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-533
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-549
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-564
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-570
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-572
ELECTRICAL SYSTEM .......................................................................................................................50-586
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-586
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-589
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY ................................50-599
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY ................................................50-603
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-605
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-612
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-614
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-616
REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-618
REMOVE AND INSTALL KomVision CAMERA .............................................................................50-622
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-628
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY ...........................................50-635
REMOVE AND INSTALL JUNCTION HARNESS OF CONTROL BOX .........................................50-641
REMOVE AND INSTALL CONTROL BOX HARNESS ..................................................................50-647
REMOVE AND INSTALL GNSS RECEIVER.................................................................................50-650
REMOVE AND INSTALL NETWORK MODEM .............................................................................50-652
REMOVE AND INSTALL GNSS RECEIVER ANTENNA ...............................................................50-653
REMOVE AND INSTALL NETWORK MODEM ANTENNA ...........................................................50-655
REMOVE AND INSTALL GNSS ANTENNA ..................................................................................50-657
REMOVE AND INSTALL IMU SENSOR .......................................................................................50-659
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ABBREVIATION LIST ............................................................................................................................. 60-3
ENGINE AND COOLING SYSTEM......................................................................................................... 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-9
MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................. 60-10
POWER TRAIN..................................................................................................................................... 60-12
MAINTENANCE STANDARD OF SWING CIRCLE ........................................................................ 60-12
MAINTENANCE STANDARD OF SWING MACHINERY................................................................ 60-13
MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-15
MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-17
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING......... 60-18
UNDERCARRIAGE AND FRAME......................................................................................................... 60-20
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-20
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-22
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-24
MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-25
MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-26
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-29
MAINTENANCE STANDARD OF SWAMP SHOE.......................................................................... 60-30
MAINTENANCE STANDARD OF ROAD LINER ............................................................................ 60-31
HYDRAULIC SYSTEM.......................................................................................................................... 60-32
MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-32
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-33
MAINTENANCE STANDARD OF LS-EPC VALVE ......................................................................... 60-34
MAINTENANCE STANDARD OF PC-EPC VALVE......................................................................... 60-35
MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-36
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-39
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-42
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-52
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-55

PC210LCI-11 00-19
INDEX 00 INDEX AND FOREWORD

MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-58
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE ..................................... 60-61
MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-63
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRES-
SURE) ........................................................................................................................................ 60-64
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRES-
SURE) ........................................................................................................................................ 60-65
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-66
WORK EQUIPMENT............................................................................................................................. 60-67
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-67
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-76
MAINTENANCE STANDARD OF STROKE SENSING BOOM CYLINDER .................................... 60-77
MAINTENANCE STANDARD OF STROKE SENSING ARM CYLINDER....................................... 60-79
MAINTENANCE STANDARD OF STROKE SENSING BUCKET CYLINDER ................................ 60-81
MAINTENANCE STANDARD OF STROKE SENSOR FOR BOOM CYLINDER ............................ 60-83
MAINTENANCE STANDARD OF STROKE SENSOR FOR ARM CYLINDER ............................... 60-84
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER.... 60-85
80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
ABBREVIATION LIST ............................................................................................................................. 80-4
AIR CONDITIONER SYSTEM .............................................................................................................. 80-10
PRECAUTIONS FOR REFRIGERANT .......................................................................................... 80-10
AIR CONDITIONER COMPONENT ................................................................................................80-11
SPECIFICATIONS OF AIR CONDITIONER ................................................................................... 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................. 80-14
OUTLINE OF REFRIGERATION CYCLE ....................................................................................... 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-17
AIR CONDITIONER UNIT.............................................................................................................. 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-21
AIR CONDITIONER CONTROLLER .............................................................................................. 80-25
COMPRESSOR ............................................................................................................................. 80-26
CONDENSER ................................................................................................................................ 80-27
SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-29
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......
.......................................................................................................................................................... 80-31
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-33
AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-36
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.......................................................................................................................................................... 80-38
TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-42
METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-42
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-44
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR .......................................................................................................... 80-45
TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-46
METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-46
TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-48
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-48
TEST SUNLIGHT SENSOR.................................................................................................................. 80-49
METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-49
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-50
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-50
TEST RELAYS...................................................................................................................................... 80-51
METHOD FOR TESTING RELAYS ................................................................................................ 80-51
AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-53
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-56

00-20 PC210LCI-11
00 INDEX AND FOREWORD INDEX

FAILURE CODE [879AKA].................................................................................................................... 80-58

FAILURE CODE [879AKB].................................................................................................................... 80-59
FAILURE CODE [879BKA].................................................................................................................... 80-60
FAILURE CODE [879BKB].................................................................................................................... 80-62
FAILURE CODE [879CKA].................................................................................................................... 80-64
FAILURE CODE [879CKB].................................................................................................................... 80-65
FAILURE CODE [879DKZ].................................................................................................................... 80-66
FAILURE CODE [879EMC] ................................................................................................................... 80-68
FAILURE CODE [879FMC] ................................................................................................................... 80-69
FAILURE CODE [879GKX] ................................................................................................................... 80-70
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-72
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...
.......................................................................................................................................................... 80-74
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-77
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-79
TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-81
CONNECTION OF SERVICE TOOL ..................................................................................................... 80-84
METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-84
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-86
HANDLE COMPRESSOR OIL .............................................................................................................. 80-88
METHOD FOR REPLACING DESICCANT ........................................................................................... 80-90
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
ABBREVIATION LIST ............................................................................................................................. 90-3
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-9
HYDRAULIC CIRCUIT DIAGRAM (1/2) ......................................................................................... 90-13
HYDRAULIC CIRCUIT DIAGRAM (2/2) ......................................................................................... 90-15
HYDRAULIC CIRCUIT DIAGRAM (1/2) ......................................................................................... 90-17
HYDRAULIC CIRCUIT DIAGRAM (2/2) ......................................................................................... 90-19
ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-21
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-21
ELECTRICAL CIRCUIT DIAGRAM (1/12)...................................................................................... 90-25
ELECTRICAL CIRCUIT DIAGRAM (2/12)...................................................................................... 90-27
ELECTRICAL CIRCUIT DIAGRAM (3/12)...................................................................................... 90-29
ELECTRICAL CIRCUIT DIAGRAM (4/12)...................................................................................... 90-31
ELECTRICAL CIRCUIT DIAGRAM (5/12)...................................................................................... 90-33
ELECTRICAL CIRCUIT DIAGRAM (6/12)...................................................................................... 90-35
ELECTRICAL CIRCUIT DIAGRAM (7/12)...................................................................................... 90-37
ELECTRICAL CIRCUIT DIAGRAM (8/12)...................................................................................... 90-39
ELECTRICAL CIRCUIT DIAGRAM (9/12)...................................................................................... 90-41
ELECTRICAL CIRCUIT DIAGRAM (10/12) .................................................................................... 90-43
ELECTRICAL CIRCUIT DIAGRAM (11/12) .................................................................................... 90-45
ELECTRICAL CIRCUIT DIAGRAM (12/12) .................................................................................... 90-47
ELECTRICAL CIRCUIT DIAGRAM (1/13)...................................................................................... 90-49
ELECTRICAL CIRCUIT DIAGRAM (2/13)...................................................................................... 90-51
ELECTRICAL CIRCUIT DIAGRAM (3/13)...................................................................................... 90-53
ELECTRICAL CIRCUIT DIAGRAM (4/13)...................................................................................... 90-55
ELECTRICAL CIRCUIT DIAGRAM (5/13)...................................................................................... 90-57
ELECTRICAL CIRCUIT DIAGRAM (6/13)...................................................................................... 90-59
ELECTRICAL CIRCUIT DIAGRAM (7/13)...................................................................................... 90-61
ELECTRICAL CIRCUIT DIAGRAM (8/13)...................................................................................... 90-63
ELECTRICAL CIRCUIT DIAGRAM (9/13)...................................................................................... 90-65
ELECTRICAL CIRCUIT DIAGRAM (10/13) .................................................................................... 90-67
ELECTRICAL CIRCUIT DIAGRAM (11/13) .................................................................................... 90-69

PC210LCI-11 00-21
INDEX 00 INDEX AND FOREWORD

ELECTRICAL CIRCUIT DIAGRAM (12/13).................................................................................... 90-71

ELECTRICAL CIRCUIT DIAGRAM (13/13) .................................................................................... 90-73
INDEX..................................................................................................................................................................1

00-22 PC210LCI-11
00 INDEX AND FOREWORD ABBREVIATION LIST

ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake When the tires skid (wheels stop rotating), the
ABS Anti-skid Brake System brakes are released, and when the wheels start
(HD, HM) to rotate, the brakes are applied again.
Automatic Idling Setting
AISS Engine This function automatically sets the idle speed.
System
Steering A lever is used to perform the steering operations
Advanced Joystick instead of a steering wheel. Moreover, it shifts
AJSS
Steering System (WA) gear and changes direction (FORWARD or RE-
VERSE).
Travel and brake When the accelerator pedal is released while the
Automatic Retarder Ac- machine is traveling downhill, this function auto-
ARAC
celerator Control (HD, HM) matically applies the retarder with a constant
braking force.
Travel and brake When the accelerator pedal is released while the
machine is traveling downhill, this function auto-
Automatic Retarder
ARSC matically applies the retarder to ensure that the
Speed Control (HD, HM) machine speed does not accelerate above the
speed set by the operator.
Travel and brake When the tires spin on soft ground surfaces, this
Automatic Spin Regula-
ASR function automatically uses the optimum braking
tor (HD, HM) force to drive both wheels.
A device that can be fixed onto the standard ma-
ATT Attachment Work equipment
chine in order to enable it to do different jobs.
Brake When the retarder is not being used, this valve
Brake cooling oil control
BCV bypasses part of the brake cooling oil to reduce
valve (HD) the load on the hydraulic pump.
Communication and elec- One of communication standards that is used in
CAN Controller Area Network
tronic control the network on the machine.
A regulator valve which is installed to KCCV ven-
Crankcase Depression
CDR Engine tilator. It is written as CDR valve and it is not
Regulator
used independently.
This system can simultaneously actuate multiple
Closed-center Load
CLSS Hydraulic system actuators regardless of the load (provides better
Sensing System
combined operation than OLSS).
Engine controller electronically controls supply
pump, common rail, and injector. This function
CRI Common Rail Injection Engine
maintains optimum fuel injection amount and fuel
injection timing.

PC210LCI-11 00-23
ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Electronic control device uses the signals from
Electronic Control Mod- the sensors on the machine. These signals indi-
ECM Electronic control system
ule cate the optimum actuation to the actuators.
(Same as ECU)
Transmission Proportional electromagnetic valve that gradually
Electronic Control Mod-
ECMV increases oil pressure to engage clutch and re-
ulation Valve (D, HD, WA, etc) duces transmission shock.
Travel This system ensures smooth high-speed travel
Electronically Controlled
ECSS by absorbing vibration of machine during travel
Suspension System (WA) with hydraulic spring effect of accumulator.
Electronic control device uses the signals from
the sensors on the machine. These signals indi-
ECU Electronic Control Unit Electronic control system
cate the optimum actuation to the actuators.
(Same as ECM)
This function recirculates part of exhaust gas to
Exhaust Gas Recircula-
EGR Engine combustion chamber in order to reduce combus-
tion
tion temperature, controls emission of NOx.
This system allows data (filter, oil replacement in-
Equipment Manage- terval, malfunctions on machine, failure code,
EMMS Machine monitor
ment Monitoring System and failure history) from each sensor on the ma-
chine to be checked on the monitor.
Electromagnetic Propor- This mechanism allows actuators to be operated
EPC Hydraulic system
tional Control in proportion to the current supplied.
This structure protects the operator's head from
Falling Object Protective falling objects.
FOPS Cab and canopy
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication Global Positioning System: This system uses sat-
Global Positioning Sys-
GPS (KOMTRAX, KOMTRAX ellites to determine the current location on the
tem
Plus) earth.

Communication Global Navigation Satellite System: This system

Global Navigation Satel-
GNSS (KOMTRAX, KOMTRAX uses satellites such as GPS, GALILEO, etc. to
lite System
Plus) determine the current location on the earth.

Steering This function uses a combination of hydraulic

Hydrostatic Steering motor and bevel shaft to control difference in
HSS
System (D) travel speed of right and left tracks. Accordingly
machine can turn without using steering clutch.
Transmission This function uses a combination of hydraulic
Hydro Static Transmis-
HST pump and hydraulic motor for stepless shifting of
sion (D, WA) the speed range without using gears.
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This valve is installed at inlet port of pump, and it
adjusts fuel intake amount in order to control fuel
IMA Inlet Metering Actuator Engine
discharged volume of supply pump. (Same as
IMV)

00-24 PC210LCI-11
00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This valve is installed at inlet port of pump, and it
adjusts fuel intake amount in order to control fuel
IMV Inlet Metering Valve Engine
discharged volume of supply pump. (Same as
IMA)
This mechanism separates oil in blowby gas and
Komatsu Closed Crank-
KCCV Engine returns it to the intake side to combust it there. It
case Ventilation
primarily consists of filters.

Komatsu Catalyzed This filter captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst is used for purifying exhaust gas.
Komatsu Diesel Oxida-
KDOC Engine It is built in to KDPF or assembled with the muf-
tion Catalyst
fler.
This component is used to purify the exhaust
Komatsu Diesel Particu- gas. KDOC (catalyst) and KCSF (filter to capture
KDPF Engine soot) are built-in it.
late Filter
It is installed in place of the conventional muffler.
Travel and brake This function recovers the drive force of the
wheels by braking automatically with the opti-
Komatsu Traction Con- mum force and at the same time activates the in-
KTCS
trol System (HM) ter-axle differential lock when the wheels idle
while the machine travels on the soft ground
road.
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor
which assembles in the liquid crystal element.
It refers to semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- One of communication standards that is used in
LIN
work tronic control the network on the machine.
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharged volume corre-
sponding to load.
Low Voltage Differential Communication and elec- One of communication standards that is used in
LVDS
Signaling tronic control the network on the machine.
This indicates engine intake air flow. It is not
used independently but it is used as combined
MAF Mass Air Flow Engine
with sensor. Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and reception of
Multimedia Messaging
MMS Communication short messages consisting of characters or voice
Service
or images between cell phones.
Characteristics of electrical or hydraulic circuits.
Electrical system, Hydraul-
NC Normally Closed Circuit is normally closed if it is not actuated, and
ic system
it opens when it is actuated.

PC210LCI-11 00-25
ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Characteristics of electrical or hydraulic circuits.
Electrical system, Hydraul-
NO Normally Open Circuit is normally open if it is not actuated, and it
ic system
closes when it is actuated.
Open-center Load Hydraulic system that can operate multiple actua-
OLSS Hydraulic system
Sensing System tors at the same time, regardless of the load.
PC Pressure Compensation Hydraulic system A function used to correct oil pressure.
Steering System in which a controller instantly analyses
Palm command control data from each lever, pedal, and dial, and per-
PCCS
system (D) forms optimum electronic control of the engine
and transmission.
This valve is installed at inlet port of pump and it
PCV Pre-stroke Control Valve Engine adjusts fuel intake amount in order to control fuel
discharged volume of supply pump.
This system is used for controlling proportional
Proportional Pressure
PPC Hydraulic system pressure. It moves actuators in proportion to the
Control
oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism.

Power Tilt and power Work equipment This function performs hydraulic control of the tilt
PTP
Pitch dozer (D) and pitch of the bulldozer blade.

Sturcture protects the operator who wear the

seatbelt so that he will not be crushed by a ma-
Roll-Over Protective chine when it is tipped. (Operator Protective
ROPS Cab and canopy structure when tipping)
Structure
Structure which is standardized as ISO 3471 or
ISO 12117-2.
It is exhaust gas purifier using urea water con-
verts nitrogen oxides (NOx) to harmless nitrogen
Selective Catalytic Re-
SCR Urea SCR system and water by oxidation-reduction reaction. It may
duction
also be mentioned as exhaust gas purification
catalyst or part of the name of related devices.
Abbreviation for "Le Systeme International d' Uni-
Le Systeme Internation-
tes". It is the universal unit system and "a single
SI al d' Unites (Internation- Unit
unit for a single quantity" is the basic principle ap-
al unit system)
plied.
It refers to an actuator consisting of a solenoid
SOL Solenoid Electrical system and an iron core that is moved by the magnetic
force when the solenoid is energized.
Solenoid valve that switches over direction of
TWV 2-Way Valve Hydraulic system
flow.
Sturcture protects the operator who wear the
seatbelt so that he will not be crushed by a ma-
Tip-Over Protectuive chine when it is overtuned.(Hydraulic excavator
TOPS Cab and canopy
Structure tip-over protective structure)
Structure which is standardized as ISO 12117.

00-26 PC210LCI-11
00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Variable Geometry Tur- The turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is made variable.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature

PC210LCI-11 00-27
ABBREVIATION LIST 00 INDEX AND FOREWORD

Abbreviation Actual word spelled out

T/C Torque Converter
T/M Transmission

00-28 PC210LCI-11
00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL

FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. "STRUC-
TURE AND FUNCTION" is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the ad-
justing method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in "STANDARD VALUE TABLE".
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

PC210LCI-11 00-29
HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD

Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.

Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.

Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

00-30 PC210LCI-11
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpos-
es.

• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.

PC210LCI-11 00-31
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Always wear the protective eyeglasses when hitting parts

with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang "UNDER REPAIR" warning tag in the operator's
compartment Before starting work. ,&
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang "UNDER REPAIR" warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.

,&

Precautions during work

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).

00-32 PC210LCI-11
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.

• Before starting work, shut down the engine. When working

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.

PC210LCI-11 00-33
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.

,&

Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.

00-34 PC210LCI-11
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.

• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

PC210LCI-11 00-35
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK

Weight of component whose weight is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND
ASSEMBLY".
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.

Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope ( mm) Allowable load ( kN { t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}

00-36 PC210LCI-11
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10

When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).

PC210LCI-11 00-37
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, "Pre-
cautions for disconnection and connection of air conditioner
piping".

00-38 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE

PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.

PC210LCI-11 00-39
PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD

• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.

00-40 PC210LCI-11
00 INDEX AND FOREWORD ACTIONS IF FIRE OCCURS

ACTIONS IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.

PC210LCI-11 00-41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.

00-42 PC210LCI-11
00 INDEX AND FOREWORD ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

This machine conforms to either regulation of Tier4 Final (North America) or Stage IV (Europe).
This machine is equipped with the following two exhaust gas treatment systems:
• Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu-
rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
• Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas
into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction
between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen
oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea
as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertiliz-
er, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and
conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
• In Europe, use AdBlue®.
• In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).
The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification
Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).

PC210LCI-11 00-43
PRECAUTIONS FOR DEF 00 INDEX AND FOREWORD

PRECAUTIONS FOR DEF

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.

PRECAUTIONS FOR ADDING

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapor may escape. Keep your face away from
the filler port during opening or refilling.

PRECAUTIONS FOR STORING

If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up
its container for storage. When opening the container, perform it where there is good ventilation. For storage,
see “STORE AdBlue/DEF”.
Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not
exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum con-
tainer, toxic gas may develop and a chemical reaction may corrode the container.

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base
of “Actions if fire occurs”.
If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unattend-
ed and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reac-
tions.

THE OTHER PRECAUTIONS

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.

00-44 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is
dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or
when disassembling, or assembling the hydraulic components.
Select an appropriate workplace
• In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the
machine.
Disassembly and maintenance work in the field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit
and it may result in serious personal injury or death when removing and disassembling of the hy-
draulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.

• In the field, there is a risk of dust entering the component

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.

Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.

PC210LCI-11 00-45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD

Preventing intrusion of foreign materials during refilling

• During refilling with the hydraulic oil, do not let water enter
the electrical components.
• Clean the oil filler port and its around, refilling pump, oil
jug, or etc.
• Refilling by using an oil cleaning device is better method
since it can filtrate the contaminants accumulated in the oil
during storage.

Replacing hydraulic oil while its temperature is high

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.

Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.

00-46 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.

PC210LCI-11 00-47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as-
sembly" of the components, observe the following precautions.
Precautions for removal and disassembling work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the matchmarks which indicate the installing position, and put matchmarks on the places where they
seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses so that installation is done to the correct installing positions.
• Check the thickness and number of shims when storing shims.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the
appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and
transporting the machine.
Introduction of parts for the disassembly of the face seal type hoses and tubes

Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018

00-48 PC210LCI-11
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Introduction of parts for the disconnection of the taper seal type hoses and
tubes

Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422

Introduction of parts for the disconnection of the split flange type hoses and
tubes

Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032

PC210LCI-11 00-49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645

Introduction of parts for the removal of O-ring boss type joint

Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234

00-50 PC210LCI-11
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Introduction of parts for the removal of taper pipe thread type joint

Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415

06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222

14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026

Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.

PC210LCI-11 00-51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.
NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.

00-52 PC210LCI-11
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.
Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY
AND ASSEMBLY".

PC210LCI-11 00-53
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they
occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed.
This section deals particularly with correct repair procedures for mechatronics components and is aimed at im-
proving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical
equipment".
Handling wiring harnesses and connectors
• Wiring harnesses consist of wires connecting one compo-
nent to another component, connectors used for connect-
ing and disconnecting one wire from another wire, and pro-
tectors or tubes used for protecting the wires.
• Compared with other electrical components fitted in boxes
or cases, wiring harnesses are likely to be directly affected
by rain water, heat, or vibration. Furthermore, during in-
spection and repair operations, they are frequently re-
moved and installed again, so they are likely to suffer de-
formation or damage. For this reason, it is necessary to be
extremely careful when handling and maintenance of the
wiring harnesses.
• If AdBlue/DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact.
Be careful not to spill it over electrical equipment, wiring harness and connectors since AdBlue/DEF is
strongly corrosive to metal.
Main causes of failure in wiring harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor,or because one or both of connectors are deformed or the
position is not correctly aligned, or because there is corrosion
or oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connec-
tors approximately 10 times.

Defective crimping or soldering of connectors

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.

00-54 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.

Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.

PC210LCI-11 00-55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the
parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may
cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign
material may enter or leaked oil may pollute the environ-
ment.
Do not discard the oil inconsiderately. Ask the customer
for disposal or bring it back to dispose it appropriately.

How to clean parts when dirt is stuck

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.

00-56 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.

PC210LCI-11 00-57
PRACTICAL USE OF KOMTRAX 00 INDEX AND FOREWORD

PRACTICAL USE OF KOMTRAX

Various information which KOMTRAX system transmits by using the radio communication is useful for KOM-
TRAX operator to provide various services for the customers.
When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by
KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.
REMARK
(KOMTRAX may not be installed to the machine in some countries or areas.)
Merit of using KOMTRAX
• The location where the machine is working at can be checked on the map in a personal computer.
• Operation information such as service meter, operating hours, fuel consumption, and occurred caution as
well as failure code can be checked.
• The operator can check the hours used and replacement interval of consumable parts of the machine such
as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
• Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be
checked, and it is used to presume the machine operating condition.
• Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is
utilized as an advice tool for the user and operator.
• KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the
soundness of machine, in addition to KOMTRAX function described above. These data can be used on per-
sonal computer screens.
How to make a full use of KOMTRAX
Making use of KOMTRAX enables the following activities.
• Quick response to a request for immediate repair
1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair re-
quest from a user.
2. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
3. To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
• Proactive maintenance
1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure
code indicated by a red or yellow flag.
2. To check the condition of the machine with the customer and to make a plan to visit.
3. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
• Practice of periodic maintenance and periodic inspection service
1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits
for the consumable parts indicated by red flags are over.
2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replace-
ment work to the customer.
3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to operate KOMTRAX
For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.

00-58 PC210LCI-11
00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).

2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.

3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.

Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).

PC210LCI-11 00-59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

2. After inserting the hose in the mating adapter perfectly, pull

it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves
approximately 3.5 mm toward the hose, but it is not a prob-
lem.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

00-60 PC210LCI-11
00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

PC210LCI-11 00-61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

00-62 PC210LCI-11
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

TORS
Disconnecting connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the con-
necting portion. If the connector is fixed with screw, loosen
the screw of the connector completely, hold the both of
male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing
the stopper (1) with your thumb.
2. When removing a connector from a clip
• Both of the connector and clip have stoppers (2),
which are engaged with each other when the connec-
tor is connected.
• When removing a connector from a clip, pull the con-
nector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the
right or left, it may break the housing.

3. Action to be taken after removing connectors

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.

Connecting connectors
1. Check the connector visually.
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).

PC210LCI-11 00-63
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.

• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.

• If the connector clamp is removed, be sure to return it

to its original position. Check that there is no loose-
ness.

Drying wiring harness

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.

00-64 PC210LCI-11
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.

2. Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the
connector.
NOTICE
Hot air from a dryer can be used, but limit the time of
using a dryer to prevent the connector or related parts
from becoming too hot, as this will cause deformation
or damage to the connector.

3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.

Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.

PC210LCI-11 00-65
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).

Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.

00-66 PC210LCI-11
 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
00 INDEX AND FOREWORD CONNECTOR

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

TOR
Method for disconnecting Deutsch connector
While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).

Method for connecting Deutsch connector

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.

PC210LCI-11 00-67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

CONNECTOR
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA-
TOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if
connector (1) does not come out when it is pulled toward
you, push up portion A with a small flat-head screwdriver
while pressing lock (L2), and then pull out connector (1) to-
ward you.

Method for connecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
Insert it straight until it clicks.

Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).

00-68 PC210LCI-11
 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR

2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.

Method for connecting slide lock type connector (FRAMATOME-24)

Insert it straight until it clicks.

PC210LCI-11 00-69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PULL 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PULL
Method for disconnecting connector with lock to pull
Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.

Method for connecting connector with lock to pull

Insert the connector securely until it "clicks".

00-70 PC210LCI-11
 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PUSH

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series

• 107 series

REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.

Method for connecting connector with lock to push (BOSCH-3)

Insert it straight until it clicks.

PC210LCI-11 00-71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PUSH 00 INDEX AND FOREWORD

Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.

Method for connecting connector with lock to push (AMP-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.

Method for connecting connector with lock to push (SUMITOMO-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-4)

While pressing lock (D), pull out connector (4) in the direction
of the arrow.

Method for connecting connector with lock to push (SUMITOMO-4)

Insert it straight until it clicks.

00-72 PC210LCI-11
 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH HOUSING TO ROTATE

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

HOUSING TO ROTATE
Method for disconnecting connector with housing to rotate
Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.

Method for connecting connector with housing to rotate

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.

PC210LCI-11 00-73
HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

HOW TO READ ELECTRICAL WIRE CODE

In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electrical wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in (Table 1).
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on
the diagram.)
Indicates size of wire by nominal No.
0.85
Sizes (Nominal Nos.) are shown in (Table 2).
Indicates color of wire by color code.
L
Color codes are shown in (Table 3).

Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)

Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)

Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place

00-74 PC210LCI-11
00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

Dimensions

(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
20 7 30 11 50 16 37 26 58 41 65
strands
Diameter of
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
( mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coating D

AV Standard - - - - - - - 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
50 84 41 70 85 108 127 169 217
strands
Diameter of
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
( mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
strands
Diameter of round compres- round compres-
- - round compression
strand sion sion
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
( mm2)
d (approx.) - 0.9 - 1.1 - 1.4

PC210LCI-11 00-75
HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coating D

CAVS Standard - 1.6 - 1.8 - 2.1

REMARK
“f” of nominal No. denotes "flexible".
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White

REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the
color of the marking.
Example) GW indicates that the background is "Green" and marking is "White".

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00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE

Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -

PC210LCI-11 00-77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called "tolerance".
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126

• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/
lower limit of tolerance)."
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0

00-78 PC210LCI-11
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