PC210 10

SEN05842-01
HYDRAULIC PC210LC -10

EXCAVATOR
SERIAL NUMBERS 450001 and up
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
00 Index and foreword

1 00 Index and foreword
PC210LC-10 00-1
Index
Index (ALL-0310-001-A-00-A)
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-14
Important safety notice ....................................................................................................... 00-14
How to read the shop manual.............................................................................................. 00-21
Explanation of terms for maintenance standard .................................................................... 00-23
Handling equipment of fuel system devices .......................................................................... 00-25
Handling of intake system parts........................................................................................... 00-26
Handling of hydraulic equipment.......................................................................................... 00-27
Method of disconnecting and connecting of push-pull type coupler ......................................... 00-29
Handling of electrical equipment.......................................................................................... 00-32
How to read electric wire code............................................................................................. 00-40
Precautions when performing operation ............................................................................... 00-43
Practical use of KOMTRAX ................................................................................................. 00-47
Standard tightening torque table.......................................................................................... 00-48
List of abbreviation ............................................................................................................. 00-52
Conversion table ................................................................................................................ 00-57
01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-8
Table of fuel, coolant, and lubricants ...................................................................................... 01-9
10 Structure and function ................................................................................................................... 10-1
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-16
EGR cooler........................................................................................................................ 10-18
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Power train............................................................................................................................... 10-29
Power train system............................................................................................................. 10-29
Swing circle ....................................................................................................................... 10-31
Swing machinery ............................................................................................................... 10-32
Final drive ......................................................................................................................... 10-34
Undercarriage and frame........................................................................................................... 10-36
Track frame and idler cushion ............................................................................................. 10-36
Hydraulic system ...................................................................................................................... 10-38
Hydraulic equipment layout drawing .................................................................................... 10-38
Valve control...................................................................................................................... 10-40
Hydraulic tank.................................................................................................................... 10-42
CLSS ................................................................................................................................ 10-44
Main pump ........................................................................................................................ 10-49
Control valve ..................................................................................................................... 10-74
Swing motor .................................................................................................................... 10-131
Travel motor .................................................................................................................... 10-143
PPC valve ....................................................................................................................... 10-156
Solenoid valve ................................................................................................................. 10-178
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-181
00-2 PC210LC-10
Index
Attachment circuit selector valve (for low pressure circuit).................................................... 10-183

Center swivel joint ............................................................................................................ 10-186
Accumulator .................................................................................................................... 10-188
Work equipment ..................................................................................................................... 10-189
Work equipment............................................................................................................... 10-189
Work equipment shim....................................................................................................... 10-190
Bucket play adjustment shim............................................................................................. 10-191
Cab and its attachments .......................................................................................................... 10-192
Cab mount and cab tipping stopper ................................................................................... 10-192
ROPS cab ....................................................................................................................... 10-193
Electrical system .................................................................................................................... 10-194
Electrical control system ................................................................................................... 10-194
Machine monitor system ................................................................................................... 10-245
KOMTRAX system ........................................................................................................... 10-267
Sensor ............................................................................................................................ 10-270
20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-18
30 Testing and adjusting .................................................................................................................... 30-1
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ......................................................................................................... 30-9
Testing exhaust gas color ................................................................................................... 30-11
Measuring and adjusting valve clearance ............................................................................. 30-13
Testing compression pressure............................................................................................. 30-16
Testing blowby pressure ..................................................................................................... 30-20
Testing engine oil pressure ................................................................................................. 30-21
Testing EGR valve and KVGT oil pressures .......................................................................... 30-22
Measuring fuel pressure ..................................................................................................... 30-23
Measuring fuel delivery, return and leakage .......................................................................... 30-29
Bleeding air from fuel system .............................................................................................. 30-34
Checking fuel circuit for leakage .......................................................................................... 30-36
Handling cylinder cutout mode operation.............................................................................. 30-37
Handling no injection cranking operation .............................................................................. 30-38
Checking and adjusting air conditioner compressor belt tension ............................................. 30-39
Replacing fan belt .............................................................................................................. 30-41
Power train............................................................................................................................... 30-42
Testing swing circle bearing clearance ................................................................................. 30-42
Testing and adjusting track shoe tension .............................................................................. 30-43
Releasing remaining pressure from hydraulic circuit .............................................................. 30-44
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-45
Testing oil pressure of control circuit .................................................................................... 30-49
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-52
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-55
Testing output pressure of solenoid valve ............................................................................. 30-60
Testing PPC valve output pressure ...................................................................................... 30-64
Adjusting play of work equipment and swing PPC valves....................................................... 30-66
Testing pump swash plate sensor ........................................................................................ 30-67
Isolating the parts causing hydraulic drift in work equipment................................................... 30-68
Testing oil leakage ............................................................................................................. 30-69
PC210LC-10 00-3
Index
Bleeding air from hydraulic circuit ........................................................................................ 30-72

Cab and its attachments ............................................................................................................ 30-74
Checking cab tipping stopper .............................................................................................. 30-74
Adjusting mirrors ................................................................................................................ 30-75
Electrical system ...................................................................................................................... 30-77
Special functions of machine monitor ................................................................................... 30-77
Adjusting rearview camera angle ....................................................................................... 30-148
Handling voltage circuit of engine controller........................................................................ 30-150
Handling battery disconnect switch .................................................................................... 30-151
Testing diodes ................................................................................................................. 30-152
Pm clinic ................................................................................................................................ 30-153
Pm Clinic service ............................................................................................................. 30-153
40 Troubleshooting............................................................................................................................ 40-1
General information on troubleshooting ........................................................................................ 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Testing before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedure for troubleshooting ................................................................... 40-38
Symptom of probable failure and troubleshooting No............................................................. 40-41
Information in troubleshooting table ..................................................................................... 40-44
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-46
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-59
T-branch box and T-branch adapter table ............................................................................. 40-95
Fuse location table ........................................................................................................... 40-101
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-103
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-106
Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-107
Failure codes table........................................................................................................... 40-108
Troubleshooting by failure code (Display of code) ...................................................................... 40-117
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-117
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-118
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-119
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-120
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-121
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-122
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-123
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-124
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-125
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-126
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-127
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-128
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-129
Failure code [A1U0N3]: KDPF Dry Request (HC Release)................................................... 40-130
Failure code [A1U0N4] KDPF Dry Request (HC Release).................................................... 40-132
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-134
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-136
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-138
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-139
Failure code [B@BCNS] Engine Coolant Overheat ............................................................. 40-140
Failure code [B@BCZK] Radiator Coolant Level Low .......................................................... 40-141
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-143
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-144
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-145
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-147
00-4 PC210LC-10
Index
Failure code [CA131] Throttle Sensor High Error................................................................. 40-149

Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-151
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-153
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-155
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-157
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-159
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-161
Failure code [CA221] Ambient Press Sens High Error ......................................................... 40-163
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-165
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-167
Failure code [CA234] Eng Overspeed ................................................................................ 40-168
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-169
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-170
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-171
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-173
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-175
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-176
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-188
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-189
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-192
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-194
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-197
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-199
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-201
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-202
Failure code [CA442] Battery Voltage High Error................................................................. 40-204
Failure code [CA449] Rail Press Very High Error................................................................. 40-205
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-206
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-208
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-210
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-211
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-213
Failure code [CA553] Rail Press High Error ........................................................................ 40-215
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-216
Failure code [CA559] Rail Press Low Error......................................................................... 40-218
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-220
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-221
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-223
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-225
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-227
Failure code [CA697] ECM Int Temp Sensor High Error ....................................................... 40-229
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-230
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-231
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-233
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-238
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-239
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-241
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-244
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-246
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-248
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-250
PC210LC-10 00-5
Index
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-252
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-254
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-256
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-259
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-267
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-268
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-271
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-273
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-275
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-276
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-278
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-281
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-282
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-283
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-285
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-287
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-288
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-290
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-292
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-294
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-296
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-298
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-301
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-303
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-305
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-306
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-307
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-309
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-311
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-313
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-316
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-317
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-318
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-320
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-322
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-326
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-329
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-332
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-335
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-338
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-341
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-347
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-350
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-353
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-357
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-360
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-364
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-368
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-372
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-375
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-379
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-381
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-383
Failure code [D110KB] Battery Relay Output Voltage .......................................................... 40-384
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-386
Failure code [D811MC] KOMTRAX Error............................................................................ 40-389
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-390
00-6 PC210LC-10
Index
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)........................ 40-391

Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .......................... 40-393
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-394
Failure code [DA20MC] Pump Controller............................................................................ 40-395
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-396
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-398
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-401
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ........................ 40-403
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ........................... 40-405
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-406
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-409
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-410
Failure code [DAF0MC] Monitor Error ................................................................................ 40-411
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-412
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-414
Failure code [DAFGMC] GPS Module Error........................................................................ 40-415
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-416
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor)................................ 40-418
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-419
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-420
Failure code [DAZQKR] CAN2 Discon (AC)........................................................................ 40-421
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-426
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-431
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40-435
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-437
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-438
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-441
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....................................................... 40-444
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-446
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-449
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality....................................... 40-452
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..................................... 40-455
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...................................... 40-458
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-461
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-464
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-467
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-470
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-473
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-476
Failure code [DKR0MA] F pump S/P sensor Abnormality..................................................... 40-479
Failure code [DKR1MA] R pump S/P sensor Abnormality .................................................... 40-481
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-483
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-487
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-489
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-491
Failure code [DW45KA] Swing holding brake Sol Open Circuit ............................................. 40-493
Failure code [DW45KB] Swing holding brake Sol Short Circuit ............................................. 40-496
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-499
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-501
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-503
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-505
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-507
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...................................................... 40-509
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-511
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-513
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ................................................. 40-515
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ................................................. 40-517
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-519
PC210LC-10 00-7
Index
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-521

Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-523
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-525
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-527
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-529
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-531
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-533
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-535
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-537
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-539
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-541
Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-543
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-545
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-547
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-549
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-551
Troubleshooting of electrical system (E-mode) .......................................................................... 40-553
E-1 Engine does not start (Engine does not crank) .............................................................. 40-553
E-2 Manual preheating system does not work..................................................................... 40-559
E-3 Automatic preheating system does not work................................................................. 40-562
E-4 Preheating monitor does not light up when preheater is operated ................................... 40-564
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-566
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-569
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-570
E-8 Coolant temperature monitor lights up in white while engine is running ........................... 40-571
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-572
E-10 Charge level monitor lights up while engine is running ................................................. 40-573
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-574
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-575
E-13 Water separator monitor lights up while engine is running ............................................ 40-576
E-14 Coolant temperature monitor lights up in red while engine is running............................. 40-577
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-578
E-16 Engine oil pressure monitor lights up in red while engine is running .............................. 40-579
E-17 Fuel gauge indicates either full or empty and does not move ........................................ 40-580
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-581
E-19 Coolant temperature gauge indicates either Min. or Max. and does not move ................ 40-582
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor
Max.) ................................................................................................................. 40-583
E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not
move ................................................................................................................. 40-584
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min.
nor Max.) ........................................................................................................... 40-586
E-23 Content of display on machine monitor is different from that of actual machine .............. 40-587
E-24 Machine monitor does not display some items ............................................................ 40-588
E-25 Function switch does not work................................................................................... 40-589
E-26 Automatic preheating system does not work (In cold season)....................................... 40-590
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration
switch is operated ............................................................................................... 40-591
E-28 Auto-deceleration is not actuated or canceled when lever is operated ........................... 40-592
E-29 Working mode selection screen is not diplayed when working mode switch is
operated ............................................................................................................ 40-593
E-30 Engine or hydraulic pump setting does not change when working mode is
changed............................................................................................................. 40-594
E-31 Travel speed monitor does not change when travel speed switch is operated ................ 40-595
E-32 Travel speed does not change while travel speed selection is changed......................... 40-596
E-33 Alarm buzzer does not stop sounding......................................................................... 40-597
00-8 PC210LC-10
Index
E-35 Service mode cannot be selected .............................................................................. 40-599

E-36 Any of work equipment, swing and travel does not work............................................... 40-600
E-37 Any of work equipment, swing and travel cannot be locked .......................................... 40-602
E-38 Machine cannot swing while swing brake cancel switch is canceled ............................. 40-603
E-39 Swing brake does not operate while swing brake cancel switch is locked ...................... 40-605
E-40 One-touch power maximizing function does not work or monitor is not displayed ........... 40-607
E-41 One-touch power maximizing function cannot be canceled .......................................... 40-609
E-42 Travel alarm does not sound when machine travels..................................................... 40-610
E-43 Alarm does not stop sounding while machine is stopped.............................................. 40-611
E-44 Horn does not sound ................................................................................................ 40-612
E-45 Horn does not stop sounding..................................................................................... 40-614
E-46 Wiper monitor does not light up or go out when wiper switch is operated ....................... 40-615
E-47 Wiper does not operate when wiper switch is operated ................................................ 40-616
E-48 Window washer does not operate when window washer switch is operated................... 40-618
E-49 BOOM LOWER indication is not displayed properly with monitoring function ................. 40-619
E-50 ARM DUMP indication is not displayed properly with monitoring function ...................... 40-620
E-51 ARM IN indication is not displayed properly with monitoring function............................. 40-621
E-52 BOOM RAISE indication is not displayed properly with monitoring function ................... 40-622
E-53 BUCKET CURL indication is not displayed properly with monitoring function ................. 40-623
E-54 BUCKET DUMP indication is not displayed properly with monitoring function ................ 40-624
E-55 SWING indication is not displayed properly with monitoring function ............................. 40-625
E-56 TRAVEL indication is not displayed properly with monitoring function............................ 40-626
E-57 Service is not displayed properly with monitoring function ............................................ 40-627
E-58 Attachment hydraulic circuit cannot be changed.......................................................... 40-630
E-59 KOMTRAX system does not operate normally ............................................................ 40-631
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-633
Information described in troubleshooting table (H-mode) ..................................................... 40-633
System chart for hydraulic system ..................................................................................... 40-634
Failure mode and cause table ........................................................................................... 40-636
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-644
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-647
H-3 All work equipment, swing and travel does not work ...................................................... 40-650
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-651
H-5 Fine control performance or response is poor ............................................................... 40-652
H-6 Boom speed or power is low ....................................................................................... 40-654
H-7 Arm speed or power is low .......................................................................................... 40-658
H-8 Bucket speed or power is low...................................................................................... 40-663
H-9 Work equipment does not move in single operation....................................................... 40-666
H-10 Hydraulic drift of boom is large .................................................................................. 40-667
H-11 Hydraulic drift of arm is large ..................................................................................... 40-668
H-12 Hydraulic drift of bucket is large ................................................................................. 40-669
H-13 Time lag of work equipment is large ........................................................................... 40-670
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-672
H-15 One-touch power maximizing function does not operate .............................................. 40-673
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-674
H-17 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-675
H-18 In combined operations of swing and travel, travel speed drops largely......................... 40-676
H-19 Machine does not travel straight ................................................................................ 40-677
H-20 Travel speed is slow ................................................................................................. 40-680
H-21 Machine is hard to steer or travel power is low ............................................................ 40-682
H-22 Travel speed does not change, or travel speed is too slow or fast ................................. 40-685
H-23 One of tracks does not run ........................................................................................ 40-686
H-24 Upper structure does not swing to the right or left ........................................................ 40-688
H-25 Upper structure swing only to the right or left .............................................................. 40-689
H-26 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-690
H-27 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-691
PC210LC-10 00-9
Index
H-28 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-692
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-693
H-30 Shock is large when upper structure stops swinging.................................................... 40-694
H-31 Large unusual noise is heard when upper structure stops swinging .............................. 40-695
H-32 Swing drift on a slope is large while swing holding brake is applied............................... 40-696
H-33 Swing drift on a slope is large while swing holding brake is released............................. 40-697
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-698
H-35 Oil flow in attachment circuit cannot be controlled ....................................................... 40-699
Troubleshooting of engine (S-mode)......................................................................................... 40-700
Information mentioned in troubleshooting table (S mode)..................................................... 40-700
S-1 When starting switch is turned to START position, engine does not crank ....................... 40-701
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-702
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-703
S-4 Engine startability is poor ............................................................................................ 40-704
S-5 Engine does not pick up smoothly ............................................................................... 40-706
S-6 Engine stops during operation ..................................................................................... 40-708
S-7 Engine runs rough or is unstable ................................................................................. 40-710
S-8 Engine lacks power .................................................................................................... 40-711
S-9 Exhaust smoke is black (KDPF clogs up early) ............................................................. 40-713
S-10 Engine oil consumption is excessive .......................................................................... 40-715
S-11 Engine oil becomes contaminated early...................................................................... 40-716
S-12 Fuel consumption is excessive .................................................................................. 40-717
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-718
S-14 Engine oil pressure drops ......................................................................................... 40-719
S-15 Fuel is contaminated in engine oil .............................................................................. 40-720
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)................................. 40-721
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-722
S-18 Unusual noise is heard ............................................................................................. 40-723
S-19 Vibration is excessive ............................................................................................... 40-724
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-725
S-21 Active regeneration is executed frequently ................................................................. 40-726
S-22 Active regeneration takes time................................................................................... 40-727
S-23 White smoke is exhausted during active regeneration ................................................. 40-728
50 Disassembly and assembly ........................................................................................................... 50-1
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-19
Removal and installation of supply pump assembly............................................................... 50-19
Removal and installation of injector assembly....................................................................... 50-24
Removal and installation of cylinder head assembly.............................................................. 50-33
Removal and installation of radiator assembly ...................................................................... 50-53
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-55
Removal and installation of aftercooler assembly .................................................................. 50-58
Removal and installation of engine and main pump assembly ................................................ 50-60
Removal and installation of engine front oil seal .................................................................... 50-72
Removal and installation of engine rear oil seal..................................................................... 50-76
Removal and installation of fuel cooler assembly .................................................................. 50-79
Removal and installation of fuel tank assembly ..................................................................... 50-80
Removal and installation of engine hood assembly ............................................................... 50-83
Removal and installation of KDPF assembly......................................................................... 50-86
Disassembly and assembly of KDPF ................................................................................... 50-94
Removal and installation of KCCV assembly ...................................................................... 50-102
Removal and installation of air cleaner assembly ................................................................ 50-106
00-10 PC210LC-10
Index
Power train............................................................................................................................. 50-109

Removal and installation of travel motor and final drive assembly ......................................... 50-109
Disassembly and assembly of final drive ............................................................................ 50-110
Removal and installation of swing motor and swing machinery assembly .............................. 50-118
Disassembly and assembly of swing machinery.................................................................. 50-121
Removal and installation of swing circle assembly .............................................................. 50-128
Undercarriage and frame......................................................................................................... 50-129
Separation and connection of track shoe assembly ............................................................. 50-129
Removal and installation of sprocket.................................................................................. 50-132
Removal and installation of idler and idler cushion assembly ............................................... 50-133
Disassembly and assembly of idler assembly ..................................................................... 50-134
Disassembly and assembly of idler cushion........................................................................ 50-137
Disassembly and assembly of track roller assembly ............................................................ 50-139
Disassembly and assembly of carrier roller......................................................................... 50-141
Removal and installation of revolving frame assembly ......................................................... 50-144
Removal and installation of counterweight assembly ........................................................... 50-146
Hydraulic system .................................................................................................................... 50-149
Removal and installation of center swivel joint assembly ..................................................... 50-149
Disassembly and assembly of center swivel joint ................................................................ 50-152
Removal and installation of hydraulic tank assembly ........................................................... 50-153
Removal and installation of main pump assembly ............................................................... 50-157
Removal and installation of control valve assembly ............................................................. 50-161
Disassembly and assembly of control valve........................................................................ 50-168
Disassembly and assembly of work equipment PPC valve................................................... 50-173
Disassembly and assembly of travel PPC valve.................................................................. 50-175
Work equipment ..................................................................................................................... 50-178
Removal and installation of work equipment assembly ........................................................ 50-178
Disassembly and assembly of work equipment cylinder....................................................... 50-181
Removal and installation of operator's cab assembly........................................................... 50-187
Removal and installation of operator cab glass (adhered glass) ........................................... 50-192
Removal and installation of front window assembly ............................................................. 50-202
Removal and installation of floor frame assembly................................................................ 50-208
Removal and installation of air conditioner unit assembly..................................................... 50-214
Removal and installation of operator's seat......................................................................... 50-218
Removal and installation of seat belt .................................................................................. 50-220
Removal and installation of front wiper assembly ................................................................ 50-222
Removal and installation of air conditioner compressor assembly......................................... 50-229
Removal and installation of air conditioner condenser assembly .......................................... 50-232
Removal and installation of engine controller assembly ....................................................... 50-234
Removal and installation of pump controller assembly......................................................... 50-236
Removal and installation of machine monitor assembly ....................................................... 50-239
Removal and installation of pump swash plate sensor ......................................................... 50-241
Removal and installation of mass air flow and temperature sensor ....................................... 50-242
Removal and installation of KOMTRAX terminal assembly .................................................. 50-243
60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Power train................................................................................................................................. 60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery ................................................................................................................. 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Idler .................................................................................................................................. 60-14
PC210LC-10 00-11
Index
Track roller ........................................................................................................................ 60-16

Carrier roller ...................................................................................................................... 60-17
Track shoe ........................................................................................................................ 60-18
Hydraulic tank.................................................................................................................... 60-24
Main pump ........................................................................................................................ 60-25
Control valve ..................................................................................................................... 60-26
Swing motor ...................................................................................................................... 60-36
Travel motor ...................................................................................................................... 60-38
Work equipment and swing PPC valve................................................................................. 60-41
Travel PPC valve ............................................................................................................... 60-44
1st-line attachment PPC valve (with EPC valve) ................................................................... 60-47
2nd-line attachment PPC valve ........................................................................................... 60-50
Solenoid valve ................................................................................................................... 60-52
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-53
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-54
Center swivel joint .............................................................................................................. 60-55
Work equipment ....................................................................................................................... 60-56
Work equipment................................................................................................................. 60-56
Boom cylinder (large diameter piston) .................................................................................. 60-65
Arm cylinder ...................................................................................................................... 60-66
Bucket cylinder .................................................................................................................. 60-67
80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Air conditioner condenser ................................................................................................... 80-20
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Input and output signals of the air conditioner controller ......................................................... 80-29
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Testing sunlight sensor ....................................................................................................... 80-43
Testing (dual) pressure switch for refrigerant......................................................................... 80-44
Testing relays .................................................................................................................... 80-45
Troubleshooting chart 1 ...................................................................................................... 80-46
Failure code list related to air conditioner.............................................................................. 80-51
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-52
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-53
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-54
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-56
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-58
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-59
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-60
00-12 PC210LC-10
Index
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-62

Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-63
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-64
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)................................................ 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-70
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-72
Troubleshooting with gauge pressure................................................................................... 80-74
Connection of service tool................................................................................................... 80-77
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-79
Handling of compressor oil.................................................................................................. 80-81
Desiccant replacement ....................................................................................................... 80-83
90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electric circuit diagram........................................................................................................ 90-13
Electric circuit diagram for air conditioner unit ....................................................................... 90-25
Index.................................................................................................................................................................... 1
PC210LC-10 00-13
Foreword, safety and general information
Foreword, safety and general information (ALL-0370-001-A-00-A)
Important safety notice (ALL-1120-012-A-01-A)
(Rev. 2012/01)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.
General precautions knowledge of welding perform the work. When

performing welding work, always wear welding
k Inappropriate handling causes an extreme gloves, apron, shielding goggles, cap, etc.
danger. Read and understand what is • Before starting work, warm up your body
described in the operation and maintenance thoroughly to start work under good condition.
manual before operating the machine. Read • Avoid continuing work for long hours and take
and understand what is described in this rests with proper intervals to keep your body in
manual before starting the work. good condition. Take a rest in a specified safe
place.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For Safety points
the locations of the safety labels and detailed 1 Good arrangement
explanation of precautions, see the operation 2 Correct work clothes
and maintenance manual.
3 Observance of work standard
• Locate a place in the repair workshop to keep
4 Practice of making and checking signals
the tools and removed parts. Always keep the
Prohibition of operation and handling by
tools and parts in their correct places. Always 5
unlicensed workers
keep the work area clean and make sure that Safety check before starting work
6
there is no dirt, water or oil on the floor. Smoke
Wearing protective goggles (for cleaning or
only in the areas provided for smoking. Never 7 grinding work)
smoke while working.
Wearing shielding goggles and protectors (for
• When performing any work, always wear the 8 welding work)
safety shoes and helmet. Do not wear loose
9 Good physical condition and preparation
work cloths, or clothes with buttons missing.
Precautions against work which you are not
1. Always wear the protective eyeglasses when 10 used to or you are used to too much
hitting parts with a hammer.
2. Always wear the protective eyeglasses when Preparation
grinding parts with a grinder, etc. • Before adding oil or making any repairs, place
• When performing any work with two or more the machine on a firm and level ground, and
workers, always agree on the working procedure apply the parking brake and chock the wheels or
before starting. While working, always keep tracks to prevent the machine from moving.
conversations of the work between your fellow • Before starting work, lower the work equipment
workers and your self on any step of the work. (blade, ripper, bucket, etc.) to the ground. If it is
During the work, hang the warning tag of not possible to lower the equipment to the
"UNDER WORKING" in the operator's ground, insert the lock pin or use blocks to
compartment. prevent the work equipment from falling. And be
• Only qualified workers must perform the work sure to lock all the work equipment control levers
and operation which require license or and hang a warning tag on them.
qualification. • When performing the disassembling or
• Keep the tools in good condition. And learn the assembling work, support the machine securely
correct way to use the tools, and use the proper with blocks, jacks, or stands before starting the
ones among them. Before starting the work, work.
thoroughly check the tools, forklift truck, service • Remove all of mud and oil from the steps or
car, etc. other places used to get on and off the machine
• If welding repairs is required, always have a completely. Always use the handrails, ladders of
trained and experienced welder with good
00-14 PC210LC-10
steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
the OFF (Q) position and remove the switch key. parts which must not be used with new ones.
For the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning two holes, never insert your
coolant and oil in the circuits are hot. Be careful fingers or hand into the holes. Align the holes
not to get scalded by the hot coolant and oil. with care so that your fingers are not caught in
Start the work after checking that the coolant the hole.
and oil are cooled down sufficiently. • When measuring hydraulic pressure, check that
• Start the work after the engine is shut down. Be the measuring tools are correctly installed.
sure to shut down the engine when working on • Pay attention to safety when removing and
or around the rotating parts in particular. When installing the tracks of the track type machines.
checking the machine without shutting down the When removing the track, it separates suddenly.
engine (measuring oil pressure, engine speed, The workers should not stand at either end of
oil or coolant temperature), take extreme care the track.
not to get caught in the rotating parts or the • If the engine is operated for a long time in a
working equipment. closed place which is not ventilated well, you
• The hoist or crane must be used to sling the may suffer from gas poisoning. Accordingly,
components weighing 25 kg or heavier. Check open the windows and doors to ventilate the
the slings (wire rope, nylon sling, chain and place well.
hook) for damage before the work. Use the
slings with ample capacity and install them to Precautions for slinging work and making
the proper places. Operate the hoist or crane signals
slowly to prevent the component from hitting any • Only one appointed worker must make signals
other part. Do not work with any part still raised and co-worker must communicate with each
by the hoist or crane. other frequently. The appointed signaler must
• When removing the part which is under internal make specified signals clearly at the place
pressure or reaction force of the spring, always where the signaler is well seen from the
leave two bolts in diagonal positions. Loosen operator's seat and where the signaler can see
those two bolts gradually and alternately and the working condition easily. The signaler must
release the pressure, then, remove the part. always stand in front of the load and guide the
• When removing the part, be careful not to break operator safely.
or damage the electrical wiring. The damaged 1. Do not stand under the load.
wiring may cause electrical fires. 2. Do not step on the load.
• Check the slings before starting sling work.
PC210LC-10 00-15
• Keep putting on the gloves during sling work. • Use the specified eye bolts and fix wire ropes,
(Put on the leather gloves, if available.) chains, etc. to them with shackles, etc.
• Measure the weight of the load by the eye and • Apply wire ropes to the middle portion of the
check its center of gravity. hook.
• Use the proper sling according to the weight of
a Slinging near the tip of the hook may cause
the load and method of slinging. If too thick wire
the rope to slip off the hook during hoisting.
ropes are used to sling a light load, the load may
The hook has the maximum strength at the
slip and fall.
middle part.
• Do not sling a load with one wire rope only. If do
so, the load may rotate or the sling gets loose
and the sling may slip off. Install two 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 dangerous accident.
• Hanging angle must be 60 degrees or smaller as
a rule.
• When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower • Do not use twisted or kinked wire ropes.
than that of the hook. • When slinging up a load, observe the following.
a When slinging a load with two ropes or more, 1. Wind up the rope slowly until the wire rope
the larger the hanging angle is, the larger the tensions. When putting your hands on the
tension of each rope. The figure bellow wire ropes, do not grasp them but press them
shows the variation of allowable load in kN down from above. If you grasp them, your
{kg} when hoisting is made with two ropes, fingers may be caught.
each of which is allowed to sling up to 9.8 kN 2. After the wire ropes are stretched, stop the
{1000kg} a load vertically, at various hanging crane and check the condition of the slung
angles. When the two ropes sling a load load, wire ropes, and pads.
vertically, up to19.6 kN {2000 kg} of total 3. If the load is unstable or the wire rope or
weight can be suspended. This weight is chains are twisted, lower the load and lift it
reduced to 9.8 kN {1000 kg} when the two up again.
ropes make a hanging angle of 120 degrees. 4. Do not lift up the load at an angle.
If the two ropes sling a 19.6 kN {2000 kg} • When lowering a load, pay attention to the
load at a hanging angle of 150 degrees, each following.
rope is subjected to a force as large as 39.2 1. When lifting down a load, stop it temporarily
kN {4000 kg}. at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. 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

a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.
• 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.
00-16 PC210LC-10
Precautions for using overhead traveling crane Nominal

diameter of rope Allowable load
k The hoist or crane must be used to sling the mm kN ton
components weighing 25 kg or heavier. A
12 12.7 1.3
part weighing 25 kg or heavier in
14 17.3 1.7
"disassembly and assembly" section is
16 22.6 2.3
indicated with the symbol of 4 . 18 28.6 2.9
20 35.3 3.6
• Before starting work, check the wire ropes,
25 55.3 5.6
brake, clutch, controller, rails, over winding
prevention device, ground fault circuit interrupter 30 79.6 8.1
for electric shock prevention, crane collision 40 141.6 14.4
prevention device, and energizing warning lamp, 50 221.6 22.6
and check the following safety items. 60 318.3 32.4
• Observe the signals for sling work.
• Operate the hoist at a safe place. a The allowable load is calculated as one sixth of
• Be sure to check the directions of the direction the breaking load of the rope to be used (safety
indication plate (north, south, east and west) and coefficient: 6).
the operating button. Precautions for disconnecting and connecting
• Do not sling a load at an angle. Do not move the hoses and tubes in air conditioner circuit
crane while the slung load is swinging.
• Do not raise or lower a load while the crane is Disconnection
moving longitudinally or laterally. k When replacing the air conditioner unit, air
• Do not drag a sling. conditioner compressor, condenser or
• When lifting up a load, stop it just after it leaves receiver drier, etc., collect the refrigerant (air
the ground and check safety, and then lift it up. conditioner gas: R134a) from the air
• Consider the travel route in advance and lift up a conditioner circuit before disconnecting the
load to a safe height. air conditioner hoses.
• Place the control switch in a position where it will
not be an obstacle to work and passage. a Ask a qualified person for collecting, adding and
• After operating the hoist, do not swing the filling operations of the refrigerant (air
control switch. conditioner gas: R134a).
• Remember the position of the main switch so
that you can turn off the power immediately in an a Never release the refrigerant (air conditioner
emergency. gas: R134a) to the atmosphere.
• Shut down the main switch when the hoist stops k If refrigerant gas (air conditioner gas: R134a)
because of a blackout. When turning on a switch gets in your eyes, you may lose your sight.
which is turned OFF by the ground fault circuit And if it touches your skin, you may suffer
interrupter for electric shock prevention, check from frostbite. Put on protective eyeglasses,
that the devices related to that switch are not in gloves and working cloth with long sleeves
operating condition. while collecting the refrigerant or filling the
• If you find an obstacle around the hoist, stop the air conditioner circuit with the refrigerant.
operation.
• After finishing the work, stop the hoist at the • When loosening the nuts fixing air conditioner
specified position and raise the hook to at least hoses and tubes, be sure to use two wrenches;
two meters above the floor. Do not leave the use one wrench to fix and use the other one to
sling attached to the hook. loosen the nut.
Selecting wire ropes Connection
• Select adequate ropes depending on the weight • When installing the hose for the air conditioner
of the parts to be hoisted, referring to the table circuit, take care not to allow invasion of dirt,
below dusts and water into the hose.
Wire ropes (standard "Z" twist ropes without • Check that the O-rings are fitted to the joints
galvanizing) (JIS G3525, Type 6x37-A) when connecting the air conditioner piping.
Nominal • Once an O-ring is used, it is deformed and
diameter of rope Allowable load deteriorated. Accordingly, do not reuse it.
mm • When removing the O-rings, use a soft tool so
kN ton
that the piping is not damaged.
10 8.8 0.9
PC210LC-10 00-17
• Check that the O-ring is not damaged or

deteriorated.
• Apply compressor oil for refrigerant (R134a) to
the O-ring.
a However, do not apply oil to the threaded
portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL ZXL100PG (equivalent to
SYSTEMS PAG46)
SANDEN SP-10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with
the other wrench to the specified torque (Use a
torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of the air
conditioner piping.
For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".
00-18 PC210LC-10
Fire prevention (ALL-0000-001-K-27-A)
Action if fire occurs (ALL-0000-17A-K-01-A)

• Turn the starting switch to the OFF position to
shutdown the engine.
• Use the handrails and steps to get off the
machine.
• Do not jump off the machine. You may fall or
suffer serious injury.
• The fume generated by a fire contains harmful 9 J D 0 1 7 2 0
materials which have a bad influence on a
human body when they are sucked.
Don't breathe a fume.
• After a fire, there may be harmful compounds
left. If it touches your skin it may have a bad
influence on your body.
Be sure to wear rubber gloves when handle the
materials left after the fire.
The material of the gloves, which is
recommended is polychloroprene (Neoprene) or
polyvinyl chloride (in the lower temperature 9 J D 0 1 7 2 1
environment).
When wearing cotton-work-gloves, wear rubber • Fire caused by accumulation or attachment
gloves under them. of flammable material
• Remove any dry leaves, chips, pieces of
Prevent fire (ALL-0000-17B-K-03-A) paper, coal dust, or any other flammable
• Fire caused by fuel, oil, coolant or window materials accumulated or attached to or
washer fluid around the engine exhaust manifold, muffler,
Do not bring any flame or fire close to flammable or battery, or on the undercovers.
substances such as fuel, oil, coolant or window • To prevent fires from being caught, remove
washer fluid.There is danger that they may catch any flammable materials such as dry leaves,
fire. Always observe the following. chips, pieces of paper, coal dust, or any
• Do not smoke or use any flame near fuel or other flammable materials accumulated
other flammable substances. around the cooling system (radiator, oil
• Shut down the engine before adding fuel. cooler) or on the undercover.
• Do not leave the machine when adding fuel • Fire coming from electric wiring
or oil. Short circuits in the electrical system can cause
• Tighten all the fuel and oil caps securely. fire. Always observe the following.
• Be careful not to spill fuel on overheated • Keep all the electric wiring connections clean
surfaces or on parts of the electrical system. and securely tightened.
• After adding fuel or oil, wipe up any spilled • Check the wiring every day for looseness or
fuel or oil. damage. Reconnect any loose connectors or
• Put greasy rags and other flammable refasten wiring clamps. Repair or replace any
materials into a safe container to maintain damaged wiring.
safety at the workplace. • Fire caused by piping
• When washing parts with oil, use a non- Check that all the clamps for the hoses and
flammable oil. Do not use diesel oil or tubes, guards, and cushions are securely fixed
gasoline.There is danger that they may catch in position.
fire. If they are loose, they may vibrate during
• Do not weld or use a cutting torch to cut any operation and rub against other parts.There is
pipes or tubes that contain flammable liquids. danger that this may lead to damage to the
• Determine well-ventilated areas for storing oil hoses and cause high-pressure oil to spurt out,
and fuel. Keep the oil and fuel in the leading to fire and serious personal injury or
specified place and do not allow death.
unauthorized persons to enter. • Fire around the machine due to highly heated
• When performing grinding or welding work exhaust gas
on the machine, move any flammable This machine is equipped with KDPF (Komatsu
materials to a safe place before starting. Diesel Particulate Filter).
PC210LC-10 00-19
KDPF is a system for purifying soot in exhaust

gas. The exhaust gas discharged during the
purification process (regeneration) can be higher
temperature than that of existing models. Do not
bring any flammable material close to the outlet
of the exhaust pipe.
• If there are thatched houses, dry leaves or
pieces of paper around the job site, set the
system to the "Regeneration Disable" before
starting operation to prevent fire hazard of
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 itself,
follow the instructions in the operation and
maintenance manual.
Dispose of waste materials (ALL-0000-99A-K-
02-A)
To prevent pollution, pay full attention to the way to

dispose of waste materials.
• Always put the oil and coolant drained from the
machine in containers. Never drain the oil and
coolant directly onto the ground or dump into the
sewage system, rivers, the sea, or lakes.
• Observe the related laws and regulations when
disposing of harmful objects such as oil, fuel,
coolant, solvent, filters, and batteries.
Some kinds of rubber and plastics may produce

poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.
00-20 PC210LC-10
How to read the shop manual (ALL-0320-010-A-01-A)
(Rev. 2012/01)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual

• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are described. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
described.
Tightening The tightening torques that require special attention during assembly
3 torque work are described.
PC210LC-10 00-21
Symbol Item Remarks

The places to be coated with adhesives, etc. during assembling are
2 Coat
indicated.
Oil, coolant The places to which oil is supplied and the quantity of the oil are
5 indicated.
6 Drain The places from which oil is drained and quantity of the oil are indicated.
Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.
00-22 PC210LC-10
Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)
(Rev. 2012/01)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.
Standard dimension and tolerance

• To be accurate, the finished dimension of a part
is slightly different from one to another.
• To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
• The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
• The standard dimension and tolerance are
indicated by attaching the symbols of + or - and
a number on the right side of the standard
dimension.
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 a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance. Standard interference
• Indication of dimension of rotating shaft and hole • When the diameter of a hole of a part shown in
and their related drawing. the given standard dimension and tolerance
Example: table is smaller than that of the shaft to be
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
• When some parts are repaired, the value of the parts can not be used any longer. This value
performance/function is set to the standard is called "repair limit".
value. • If a part is worn to the repair limit, it must be
replaced or repaired.
PC210LC-10 00-23
• The performance and function of the products

lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.
Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.
Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.
00-24 PC210LC-10
Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)
(Rev. 2012/01)
• The 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.
Use care for working environment

• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.
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.
• The 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 element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.
PC210LC-10 00-25
Handling of intake system parts (PC220-A900-2A4-K-00-A)
(Rev.2012/01)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) 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 air intake system.
Be careful of working environment

• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
components which are removed, with the caps,
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.
00-26 PC210LC-10
Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)
(Rev. 2012/01)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.
Be careful of working environment

• Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or at
places where there is a lot of dust.
Disassembly and maintenance work in the field

• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.
Sealing openings
components which are removed with the caps,
from entering. Never leave the openings of the
pipes and hoses without being covered or Replacing hydraulic oil while its temperature is
high
plugged with cloth as foreign material may enter
• When the hydraulic oil is warm, it flows easily. In
them or environment may be polluted by the oil
addition, sludge can also be drained from the
leaked. Do not discard the waste oil somewhere
circuit together with the oil. So, it is better to
or other. Hand it over to your customer for
change the hydraulic oil while it is warm. When
disposal, or dispose it by yourself.
changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.
PC210LC-10 00-27
Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.
Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.
00-28 PC210LC-10
Method of disconnecting and connecting of push-pull type coupler (ALL-

C930-001-P-00-A)
(Rev. 2012/01)
k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.
k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.
Type 1 (ALL-C930-925-P-01-A)
Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move toward the hose,
however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.
PC210LC-10 00-29
Type 2 (ALL-C930-925-P-02-A)
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)
00-30 PC210LC-10
Type 3 (ALL-C930-925-P-03-A)
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)
PC210LC-10 00-31
Handling of electrical equipment (ALL-E000-2A4-P-01-A)
(Rev. 2012/01)
• 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 improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".
Precautions for handling electric equipment
Handling wiring harnesses and connectors

• Wiring harnesses consist of wires connecting
one component to another component,
connectors used for connecting and
disconnecting one wire from another wire, and
protectors or tubes used for protecting the wires.
• Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they Defective crimping or soldering of connectors
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely • The pins of the male and female connectors are
careful when handling the wiring harnesses. attached to wires by crimping or soldering. If
excessive force is applied to the wire, the joining
area may become loose, which may result in a
defective connection or breakage.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female connectors) Disconnections in wiring
• Problems with defective contact are likely to • If the wiring harness is pulled to disconnect the
occur because the male connector is not connector, or the components are lifted with a
properly inserted into the female connector,or crane while the wiring harness is still connected,
because one or both of connectors are or a heavy object hits the wiring harness, the
deformed or the position is not correctly aligned, crimping of the connector may separate, or the
or because there is corrosion or oxidization of soldering may be damaged, or the wiring
the contact surfaces. The corroded or oxidized harness may be broken.
contact surfaces may become shiny again (and
contact may become normal) by connecting and
disconnecting the connectors approximately ten
times.
00-32 PC210LC-10
blow it with compressed air and spray it with

electrical contact restorer.
a When wiping the joint portion of the
connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed air, it
causes the contacts to become dirtier. So,
remove the oil and water from the
compressed air completely before cleaning
the connector with the compressed air.
High-pressure water entering connector

• The connector is designed to make it difficult for
water to enter (drip-proof structure), but if high-
pressure water is sprayed directly on the
connector, water may enter the connector,
depending on the direction of the water jet.
Accordingly, take care not to spray water over
the connector.
The connector is designed to prevent water from
entering, but once water does enter, it is difficult
to drain it. If water should get into the connector,
the pins will be short-circuited by the water. So if
any water gets in, immediately dry the connector Removing, installing, and drying connectors
and wiring harnesses
or take other appropriate action before passing
Disconnecting connectors
electricity through it.
1. Hold the connectors when disconnecting.
• Disconnect connectors by holding the
connector bodies. For the connectors held by
a screw, loosen the screw fully, then hold the
male and female connectors with each hand
respectively and pull them apart horizontally.
For the connectors with lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull the connector with one hand.
Entry of water, mud or dirt when disconnecting a

connector
• If any water, mud or dirt 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 piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt 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 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or
PC210LC-10 00-33
• Check that there is no oil, dirt or water stick

to the connector pins (joint portion).
• Check that the connector pins are free from
deformation, defective contact, corrosion, or
damage.
• Check that external surfaces of the
connectors are free from damage or
breakage.
a If any oil, water or dirt is stuck to the
connector, wipe it off with a dry cloth. If any
water is inside the connector, warm the
connector and the inside of the wiring
• When removing a connector from a clip, pull harness with a dryer. But be careful not to
the connector in a parallel direction to the clip make it too hot as it causes short circuit.
for removing stoppers. a If there is any damage or breakage, replace
a If the connector is pried up and down or the connector.
to the right and left, the housing may 2. Fix the connector securely.
break. • Align the connectors correctly, and fit them
securely. For the connectors with the lock
stopper, push in the connectors until "click" is
heard.
3. Action to take after removing connectors

• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
Connecting connectors
1. Check the connector visually.
00-34 PC210LC-10
• If the connector clamp is removed, be sure to • If there is any oil or dirt on the wiring harness,
return it to its original position. And check wipe it off with a dry cloth. Avoid washing by
that it is securely installed. using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.
Deutsch connector (DT8-pin, DT12-pin)

Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).
2. Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector.
a Hot air from the dryer can be used, but
regulate the time to use hot air in order to
prevent the connector or related parts from
Connection becoming too hot, as it causes deformation
1. Push in female connector (2) horizontally until or damage to the connector.
the lock clicks. (Arrow: x)
2. Since locks (a) and (b) may not be set
completely, push in female connector (2) with
curving movement until the locks are set
normally. (Arrow: x, y, and z)
a Lock (a) in the figure is pulled down (not set
completely), and lock (b) is set completely.
3. Perform a continuity test on the connector.

After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
Drying wiring harness
PC210LC-10 00-35
2. While pressing lock (L2), pull out connector (1).

Handling of connectors used on engine
Slide, lock type (Type 1) (FRAMATOME-3,

FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).
Connection
1. Insert the connector securely until a click is
heard. Connection
Slide, lock type (Type 2) (FRAMATOME-24) heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.
00-36 PC210LC-10
Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
Push lock type (1) (BOSCH-3) Push lock type (2) (SUMITOMO-4)
Disconnection Disconnection
1. While pressing lock (C), pull out connector (3) in 1. While pressing lock (C), pull out connector (4) in
the direction of the arrow. the direction of the arrow.
• 114 series Connection
heard.
• 107 series
Push lock type (3) (AMP-3)

Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
Example) Fuel pressure sensor in common rail:
PFUEL etc (AMP-3)
a 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 arrow.
PC210LC-10 00-37
Example) Injection pressure control valve of

supply pump: PCV (SUMITOMO-2)
Connection
1. Insert the connector to the end while aligning its
Example) Speed sensor of supply pump: G grove to the other.
(SUMITOMO-3) 2. Turn housing (H1) in the direction of the arrow
until it "clicks".
a Pull the connector straight up.
Connection Handling controller

• The electronic circuits for control including the
microcomputers are assembled in the controller.
heard.
These electronic circuits in the controller must
Turn-housing type (Round green connector) be handled with care as they control the
(CANNON-4) machine.
Disconnection • Do not place objects on top of the controller.
1. Turn housing (H1) in the direction of the arrow.
a Unlock the connector by turning housing (H1).
When the lock is release the housing is felt
tight to turn.
2. Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.
• Cover the control connectors with tape or a vinyl

bag. Never touch the connector contacts.
• During rainy weather, do not leave the controller
in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high
00-38 PC210LC-10
temperature even for a short period of time.

(Place it on a suitable dry stand.)
• Precautions when performing arc welding

When performing arc welding on the machine
body, disconnect all the wiring harness
connectors connected to the controller. Put the
arc welding ground to the place close to the
welding point.
Precautions for troubleshooting electrical

circuits
• Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a 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.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• 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 reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.
PC210LC-10 00-39
How to read electric wire code (ALL-E500-030-P-00-A)

(Rev. 2012/01)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage 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.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is 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 thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And 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
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
Type 2
Heat-
resistant low- (Safety factor:
Heat-resistant cross
voltage wire AEX linked polyethylene -50 to +110 Wiring at high-temperature
for place
automobile
00-40 PC210LC-10
Dimension
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (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
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (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
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D
CAVS Standard — 1.6 — 1.8 — 2.1
a "f" of nominal No. denotes "flexible".
PC210LC-10 00-41
Color codes table

(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".
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 — D —
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 — — —
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Appendix Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —
00-42 PC210LC-10
Precautions when performing operation (ALL-1160-927-A-00-A)
(Rev. 2012/01)
• When performing "removal or installation" and "disassembly or assembly" of the components, observe the
following general cautions.
Precautions for removal work

• If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks 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
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• 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
foreign material from entering after removal.
a Precautions when handling piping during disassembly
Use the plugs indicated below for the pipes disconnected at the disassembly.
Face seal type hoses and tubes
Nominal No. Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
Split flange type hoses and tubes
Nominal No. Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
PC210LC-10 00-43
If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part No.
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
Precautions for installation work

• Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply two to three 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 dirt or damage.
• Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• 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, dirt, or water, then
connect them securely.
• Use the eye bolts with no 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 excessive tightening on
one side.
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end four to five times.
3. Operate the hydraulic cylinder three to four times to the end of its stroke.
00-44 PC210LC-10
a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.
PC210LC-10 00-45
Precautions at the time of completing work

Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir 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 oil reservoir 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
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Check of installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Check of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Cooling system for water leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Fuel system for fuel leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".
00-46 PC210LC-10
Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)

(Rev. 2012/01)
KOMTRAX system transmits various machine information by use of the radio communication and KOMTRAX
operator can refer this information in the office and provide various services to the customers.
When KOMTRAX is installed on the machine, the machine information can be checked through the
KOMTRAX system and the testing and troubleshooting can be performed efficiently.
(KOMTRAX may not be installed on the machine in some countries or areas.)
Merit of using KOMTRAX

• The working place of the machine can be checked in the map on PC.
• Operation information such as service meter reading, operating hours, fuel consumption, occurred caution
and failure code can be checked.
• The hours used and replacement time of consumable parts of the machine such as fuel filter, hydraulic oil
filter, hydraulic oil and engine oil can be checked.
• The information of machine working condition (idling time, traveling time, digging time, relieving time, etc.)
can be checked and the machine operating condition can be presumed with these information.
• Various reports such as "Fuel saving operation support", "Summary of operation", etc. can be generated
and utilized as an advice tool for the user and operator.
How to use KOMTRAX practically

With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) 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, see "KOMTRAX basic operation manual".
PC210LC-10 00-47
Standard tightening torque table (ALL-M140-03B-P-01-A)
(Rev. 2012/01)
Table of tightening torque for bolts and nuts

Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
1. The following table applies to the bolts in Fig. A.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (Nm) (kgm)
6 10 (10) 11.8 to 14.7 1.2 to 1.5
8 13 (12) 27 to 34 2.8 to 3.5
10 17 (14) 59 to 74 6.0 to 7.5
12 19 (17) 98 to 123 10.0 to 12.5
14 22 157 to 196 16 to 20
16 24 245 to 309 25 to 31.5
18 27 343 to 427 35 to 43.5
20 30 490 to 608 50 to 62
22 32 662 to 829 67.5 to 84.5
24 36 824 to 1,030 84 to 105
27 41 1,180 to 1,470 120 to 150
30 46 1,520 to 1,910 155 to 195
33 50 1,960 to 2,450 200 to 250
36 55 2,450 to 3,040 250 to 310
39 60 2,890 to 3,630 295 to 370
a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
6 10 5.9 to 9.8 0.6 to 1.0
8 12 13.7 to 23.5 1.4 to 2.4
10 14 34.3 to 46.1 3.5 to 4.7
12 17 74.5 to 90.2 7.6 to 9.2
Fig. A Fig. B
a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)
00-48 PC210LC-10
Table of tightening torque for split flanged bolts

a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below.
10 14 59 to 74 6.0 to 7.5
12 17 98 to 123 10.0 to 12.5
16 22 245 to 309 25 to 31.5
Table of tightening torque for O-ring boss piping joints

a Unless otherwise specified, tighten the pipe joint for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})
Nominal No. diameter across flats
(mm) mm Range Target
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
— 18 Varies 59 to 98 {6.0 to 10.0} 78 {8.0}
03, 04 20 depending 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 on type of 128 to 186 {13.0 to 19.0} 157 {16.0}
10, 12 33 connector. 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1,010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})
Nominal No. diameter across flats
(mm) mm Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}
PC210LC-10 00-49
Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Tightening torque (Nm {kgm}) Taper seal Face seal
Width
Nominal across Nominal No. - Thread root
No. of Thread size threads per
flats Range Target diameter
hose (mm) (mm) inch, type of (reference)
thread
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16 -18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16 -16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16 -16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16 -12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —
Table of tightening torque for face seal joints

a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Outer Tightening torque (Nm {kgm}) Face seal
Width
diameter of Nominal No. - Thread root
across flats
pipe Range Target threads per inch, diameter
(mm)
(mm) type of thread (Reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16 -18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16 -16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16 -16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1-3/16 -12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.
00-50 PC210LC-10
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —
Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the
torque shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material In cast iron or steel In aluminum
Tightening torque Tightening torque
Thread diameter (inch)
(Nm) (kgm) (Nm) (kgm)
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
PC210LC-10 00-51
List of abbreviation (ALL-0360-005-A-00-A)

(Rev. 2012/01)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, 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(marked witha).
• 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 shop manual

Purpose of use (major
Abbrevia- Full Spelling applicable machine (*), or Explanation
tion equipment/device)
Function with which when the tires skid
Anti-skid Brake Travel and brake (wheels stop rotating), the brakes are
ABS System released, and when the wheels start to rotate,
(HD, HM)
the brakes are applied again.
Automatic Idling
AISS Engine Automatic setting function of idling speed
Setting System
Function that a lever can perform the steering
Advanced Joystick Steering operations, shifting gear speed operation and
AJSS Steering System changing direction operation instead of a
(WA)
steering wheel.
Function that the retarder works automatically
Automatic Retarder Travel and brake with a certain braking force when the
ARAC
Accelerator Control (HD, HM) accelerator pedal is released while the
machine travels downhill.
Function that the retarder works automatically
with a certain braking force so that the
Automatic Retarder Travel and brake machine travels with the speed not exceeding
ARSC Speed Control (HD, HM) the speed set by the operator when the
accelerator pedal is released while the
machine travels downhill.
Function with which, when the rear wheels
Automatic Spin Travel and brake spin on soft ground surfaces, this function
ASR Regulator (HD, HM) automatically uses the optimum braking force
to drive both wheels.
A device that can be fixed onto a machine in
ATT Attachment Work equipment
order to enable it to do different jobs.
Brake Valve that bypasses part of the brake cooling
Brake cooling oil oil to reduce the load on the hydraulic pump
BCV
control valve (HD) when the retarder is not being used.
Controller Area Communication and One of communication standards that is used
CAN
Network electronic control in the network on the machine
Crankcase Depression Regulator valve that is installed to the KCCV
CDR Engine ventilator It is not used independently and
Regulator
described CDR valve.
System that can simultaneously actuate
Closed-center Load multiple actuators regardless of the load
CLSS Oil pressure
Sensing System (provides better combined operation
comparing to OLSS).
Function to maintain optimum fuel injection
amount and fuel injection timing by using
CRI Common Rail Injection Engine
engine controller to perform electronic control
of supply pump, common rail, and injector.
Electronic control device that uses the signals
Electronic Control from the sensors on the machine to indicate
ECM Electronic control system
Module the optimum actuation to the actuators .
(Same as ECU)
00-52 PC210LC-10

Transmission Proportional electromagnetic valve that
Electronic Control
ECMV gradually increases oil pressure to engage
Modulation Valve (D, HD, WA, etc.)
clutch and reduces transmission shock.
System that ensures smooth high-speed
Electronically Travel travel by using hydraulic spring effect of
ECSS Controlled Suspension
(WA) accumulator to absorb vibration of machine
System
during travel
Electronic control device that uses the signals
from the sensors on the machine to indicate
ECU Electronic Control Unit Electronic control system the optimum actuation to the actuators .
(Same as ECM)
Function to recirculate part of exhaust gas to
Exhaust Gas Engine combustion chamber in order to reduce
EGR
Recirculation combustion temperature and to control
emission of NOx.
Equipment System that allows data (filter, oil replacement
Management interval, malfunctions on machine, failure
EMMS Machine monitor
Monitoring System code, and failure history) from each sensor on
the machine to be checked on monitor.
Electromagnetic Electromagnetic proportional control
EPC Oil pressure Mechanism that actuator works in proportion
Proportional Control
to current
Structure that protects operator's head from
Falling Object Cab and canopy falling objects. (Structure to protect operator)
FOPS
Protective Structure
Performance standardized in ISO 3449
Forward-Neutral- Operation
F-N-R Forward - NEUTRAL - REVERSE
Reverse
Communication Global Positioning System Satellite
Global Positioning
GPS System (KOMTRAX ､KOMTRAX positioning system that is used to determine
Plus) the current location on the earth
Steering function that uses a combination of
Hydrostatic Steering Steering hydraulic motor and bevel shaft to control
HSS System difference in travel speed of right and left
(D) tracks to turn machine without using steering
clutch.
Hydraulic transmission system that uses a
Hydro Static Transmission combination of hydraulic pump and hydraulic
HST motor to shift gear steplessly without using
Transmission (D, WA)
gears.
Valve that adjusts fuel intake amount at inlet
Inlet Metering Actuator Engine port of pump in order to control fuel discharge
IMA
amount of supply pump. Same meaning as
IMV
Valve adjusting fuel intake amount at inlet port
IMV Inlet Metering Valve Engine of pump in order to control fuel discharge
amount of supply pump. Described IMV (IMA)
This mechanism separates oil in blowby gas
Komatsu Closed Engine and returns it to the intake side to afterburn it
KCCV
Crankcase Ventilation there. It primarily consists of filters.
This filter is used to capture soot in exhaust
Komatsu Catalyzed Engine gas.
KCSF
Soot Filter
It is built in to KDPF.
The catalyst used for purifying exhaust gas.
Komatsu Diesel
KDOC Engine It is built in to KDPF.
Oxidation Catalyst
PC210LC-10 00-53

This component with built-in KDOC (catalyst)
and KCSF purifies exhaust gas.
Komatsu Diesel Engine
KDPF Part building in (soot-capturing filter)
Particulate Filter
It is installed in place of the currently used
muffler.
Function that recovers the drive force of the
wheels by braking automatically with the
Komatsu Traction Travel and brake optimum force and at the same time activates
KTCS Control System the inter-axle differential lock when the wheels
(HM system)
idle while the machine travels on the soft
ground road.
Komatsu Variable
The turbocharger on which the cross-section
KVGT Geometry Engine
area of the exhaust passage is made variable.
Turbocharger
Liquid Display Image display equipment such
LCD Liquid Crystal Display Machine monitor as the monitor which assembles in the liquid
crystal element.
Light Emitting Diode Semi-conductor element
LED Light Emitting Diode Electronic parts that emits light when the voltage is applied in
the normal direction.
Local Interconnect Communication and One of communication standards that is used
LIN
Network electronic control in the network on the machine
Function that detects differential pressure of
LS Load Sensing Oil pressure pump and controls discharge amount
according to load.
Low Voltage Communication and One of communication standards that is used
LVDS Differential Signaling electronic control in the network on the machine
It means the intake air flow of the engine. It is
Engine not used independently but used together with
MAF Mass Air Flow
the sensor. The mass air flow sensor may be
called MAF sensor.
Service that allows transmission and
Multimedia Messaging reception of short messages consisting of
MMS Communication characters or voice or images between cell
Service
phones.
Device actuated to open electric or hydraulic
NC Normally Closed Electric and hydraulic circuits that are normally closed if not
actuated.
Device actuated to close electric or hydraulic
NO Normally Open Electric and hydraulic
circuits that are normally open if not actuated.
Open-center Load Hydraulic system that can operate multiple
OLSS Oil pressure actuators at the same time, regardless of the
Sensing System
load.
Pressure
PC Oil pressure A function used to correct oil pressure.
Compensation
System in which a controller instantly
Palm command control Steering analyses data from each lever, pedal, and
PCCS system dial, and performs optimum electronic control
(D)
of the engine and transmission.
Valve installed at inlet port of pump to adjust
Pre-stroke Control Engine fuel intake amount in order to control fuel
PCV
Valve discharge amount of supply pump.
Proportional pressure control Mechanism that
Proportional Pressure Oil pressure actuator works in proportion to hydraulic
PPC
Control pressure
Piston Pump and Oil pressure
PPM Piston pump and motor.
Motor (D, PC, etc.)
PTO Power Take Off Power transmission Power take-off mechanism
00-54 PC210LC-10

Power Tilt and power Work equipment Function that performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
Structure that protects operator fastening seat
belt from being crushed when machine tips
Roll-Over Protective Cab and canopy over (Structure to protect operator when
ROPS
Structure machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
International unit
SI Unit Unit system that is employed worldwide, and
system
"one unit against one factor"
Actuator that moves a part with a movable iron
SOL Solenoid Electric core in the coil (solenoid), which is moved by
energizing the coil.
Two Way Valve Hydraulic and electric Solenoid valve that switches the direction of
TWV
flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated 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
PC210LC-10 00-55
Abbreviation Actual word spelled out

T/C Torque Converter
T/M Transmission
00-56 PC210LC-10
Conversion table (ALL-2150-931-A-00-A)

(Rev. 2012/01)
Method of using the conversion table

• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit
from millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
1 mm ＝ 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
PC210LC-10 00-57
Millimeters to inches
1 mm ＝ 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilograms to pounds
1 kg ＝ 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
l to U.S. Gallons
1 l＝ 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
00-58 PC210LC-10
l to U.K. Gallons
1 l＝ 0.21997 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm ＝ 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
PC210LC-10 00-59
kg/cm2 to lb/in2
1 kg/cm2 ＝ 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
00-60 PC210LC-10
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C ＝ 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
PC210LC-10 00-61
00-62 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
01 Specification
2 01 Specification
PC210LC-10 01-1
01 Specification
Table of contents
Table of contents (ALL-0310-002-A-00-A)

01 Specification................................................................................................................................. 01-1
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-8
Table of fuel, coolant, and lubricants ...................................................................................... 01-9
01-2 PC210LC-10
01 Specification
Specification drawing
Specifications (ALL-2111-001-A-00-A)
Specification drawing (ALL-2110-001-A-00-A)
PC210LC-10 (PC200_10-2110-931-A-00-A)
Item Unit PC210LC-10

Machine weight kg 21,600
Bucket capacity m3 0.8
Engine model — Komatsu SAA6D107E-2 diesel engine
Engine flywheel horsepower
• Net [ISO 9249/SAE J1349] kW {HP}/min-1 118 {158}/2,000 {2,000}
• Gross [SAE J1995] {rpm} 123 {165}/2,000 {2,000}
A Overall length mm 9,625
Overall height (including head
B mm 2,970
guard)
C Overall width mm 3,080
D Shoe width mm 700
E Cab height mm 3,045
F Tail swing radius mm 2,940
G Overall length of track mm 4,450
Distance between tumbler mm 3,655
H
centers
I Over handrail height mm 3,135
Min. ground clearance mm 440
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Swing speed min-1 {rpm} 12.4 {12.4}
a The engine flywheel horsepower is indicated in the net value and gross value. Gross value is the flywheel
horsepower measured of the bear engine. While, net value is the value measured of the engine under the
same condition essentially as the condition that it is installed on the machine.
PC210LC-10 01-3
01 Specification
Working range drawings
Working range drawings (ALL-2110-001-A-02-A)
PC210LC-10 (PC200_10-2110-931-A-01-A)
Item Unit PC210LC–10

A Max. digging reach mm 9,875
B Max. digging depth mm 6,620
C Max. digging height mm 10,000
D Max. vertical wall digging depth mm 5,980
E Max. dumping height mm 7,110
F Min. dumping height mm 2,645
Max. digging reach at ground mm 9,700
G
level
01-4 PC210LC-10
01 Specification
Specifications
Specifications (ALL-2111-001-A-00-A)
PC210LC-10 (PC200_10-2111-931-A-00-A)
Machine model PC210LC-10

Serial number 450001 and up
Bucket capacity m3 0.8
Machine weight kg 21,600
Performance
Max. digging depth mm 6,620
Working ranges
Max. vertical wall digging depth mm 5,980

Max. digging reach mm 9,875
Max. digging reach at ground mm 9,700
level
Max. digging height mm 10,000
Max. dumping height mm 7,110
Max. digging force 138.3 {14,100}
kN {kg}
(with power maximizing function) (149.1 {15,200})
Swing speed min-1 {rpm} 12.4 {12.4}
Swing operation max. slope angle deg. 25
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Gradeability deg. 35
Ground pressure (standard shoe) kPa {kg/cm2} 38.2 {0.39}
Dimensions
Overall length mm 9,625
Overall width mm 3,080
Overall height (for transport) (*1) mm 3,135
Cab height (*1) mm 3,045
Ground clearance of upper structure
mm 1,085
(*2)
Min. ground clearance mm 440
Tail swing radius mm 2,940
Min. swing radius of work equipment mm 3,040
Top height at min. swing radius of
mm 8,005
work equipment
Overall width of track mm 2,980
Overall length of track mm 4,450
Track gauge mm 2,380
Distance between tumbler centers mm 3,655
Cab height (*3) mm 2,250
Standard shoe width mm 700
*1: Excluding grouser height (26 mm) included.
*2: Not excluding grouser height (26 mm) not included.
*3: Excluding engine hood.
PC210LC-10 01-5
01 Specification
Specifications
Engine
Model SAA6D107E–2
4-cycle, water-cooled, in-line vertical,
Type direct injection type with turbocharger
and air-cooled aftercooler
No. of cylinders - bore x stroke mm 6-107x124
Piston displacement l {cc} 6.69 {6,690}
Flywheel horsepower
• Net [ISO 9249/SAE J1349] 118 {158}/2,000 {2,000}
kW {HP}/min-1 {rpm}
• Gross [SAE J1995] 123 {165}/2,000 {2,000}
Performance
Max. torque Nm {kgm}/in-1 {rpm} 634 {65}/1,500 {1,500}

Max. speed with no load
• At mounted on machine 1,850 ± 50
rpm
• At bear engine 2,060 ± 50
Min. speed with no load rpm 1,050 ± 25
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
Starting motor 24 V, 5.5 kW
Alternator 24 V, 60 A
Battery (*2) 12 V, 140 Ah x 2
Radiator core type CF90-4
*4: When swing is locked.
*5: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine flywheel horsepower is indicated in the net value and gross value. Gross value is the flywheel
horsepower measured of the bear engine. While, net value is the value measured of the engine under the
same condition essentially as the condition that it is installed on the machine.
Undercarriage
Carrier roller 2 (each side)
Track roller 9 (each side)
Assembly type triple grouser, 49 (each
Track shoe side)
01-6 PC210LC-10
01 Specification
Specifications
Hydraulic system
Variable displacement piston type (HPV
Hydraulic pump
Type x number
125 + 125) x 2
Delivery l/min 245 x 2
Set pressure MPa {kg/cm2} 37.2 {380}
Type x number 6-spool type x1

Control valve
Operating method Hydraulic
Variable displacement piston type (HMV

Hydraulic motor
Travel motor 120 - 2) x 2

(with brake valve and parking brake)
Fixed displacement piston type
(KMF125ABE - 6) x 1
Swing motor
(with safety valve and swing holding
brake)
Type Double-acting piston
Cylinder bore mm 130
Boom (*3)
Piston rod diameter mm 90

Stroke mm 1,335
Max. distance between pins mm 3,205
Min. distance between pins mm 1,870
Hydraulic cylinder

Arm (*4)

Stroke mm 1,490
Bucket

Stroke mm 1,120
Hydraulic tank Box-shaped sealed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled type (CF91)
*6: With head side cushion.
*7: With head side cushion and bottom side cushion.
PC210LC-10 01-7
01 Specification
Weight table
Weight table (ALL-2120-001-A-01-A)
PC210LC-10 (PC200_10-2120-931-A-00-A)
k This weight table is prepared for your reference when handling or transporting the components.
Unit:kg
Engine assembly 886
• Engine 690
• Damper 6
• Main pump 190
Radiator and oil cooler assembly 150
Hydraulic tank and filter assembly (excluding hydraulic oil) 120
Fuel tank assembly (excluding fuel) 155
Revolving frame 2,115
Operator's cab (including head guard and front half guard) 430
Operator seat 35
Counterweight 3,600
Swing machinery 169
Control valve 235
Swing motor 51.5
Travel motor 93 × 2
Center swivel joint 36
Track frame assembly (excluding piping) 4,957
2,662
• Track frame
273
• Swing circle
• Idler 101 × 2
• Idler cushion 127 × 2
• Carrier roller 13 × 4
• Track roller
• Final drive (including travel motor and sprocket) 36 × 18
355 × 2
Track shoe assembly
• Triple grouser shoe (700 mm {31.50 in}) 1,530 × 2
Boom assembly 1,506
Arm assembly 795
Bucket assembly 759
Boom cylinder assembly 204 × 2
Arm cylinder assembly 224
Bucket cylinder assembly 133
Bucket link (large) assembly 83
Bucket link (small) assembly 22 × 2
Boom foot pin 42
Boom cylinder bottom pin 8×2
Boom cylinder head pin 28
Arm cylinder bottom pin 10
Arm cylinder head pin 12
Boom and arm connecting pin 26
Bucket cylinder bottom pin 8
Bucket pin 20 × 2
Bucket link pin 13 × 2
01-8 PC210LC-10
01 Specification
Table of fuel, coolant, and lubricants
Table of fuel, coolant, and lubricants (PC200_10-RA19-05A-K-00-A)
a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.
Unit: l
PC210LC-10
Reservoir
Specified Refill
Engine oil pan 25.4 23.1
Swing machinery case 7.1 6.5
Final drive case (right and left respectively) 5.4 5.0
Damper case 0.65 0.65
Hydraulic system 236 132
Cooling system 30.7 30.7
Fuel tank 400 —
PC210LC-10 01-9
01 Specification
Table of fuel, coolant, and lubricants
01-10 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
10 Structure and function

3 10 Structure and function
PC210LC-10 10-1
Table of contents

10 Structure and function ................................................................................................................... 10-1
Engine related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-16
EGR cooler........................................................................................................................ 10-18
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Power train............................................................................................................................... 10-29
Power train system............................................................................................................. 10-29
Swing circle ....................................................................................................................... 10-31
Swing machinery ............................................................................................................... 10-32
Final drive ......................................................................................................................... 10-34
Hydraulic equipment layout drawing .................................................................................... 10-38
Valve control...................................................................................................................... 10-40
Hydraulic tank.................................................................................................................... 10-42
CLSS ................................................................................................................................ 10-44
Main pump ........................................................................................................................ 10-49
Control valve ..................................................................................................................... 10-74
Swing motor .................................................................................................................... 10-131
Travel motor .................................................................................................................... 10-143
PPC valve ....................................................................................................................... 10-156
Solenoid valve ................................................................................................................. 10-178
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-181
Attachment circuit selector valve (for low pressure circuit).................................................... 10-183
Center swivel joint ............................................................................................................ 10-186
Accumulator .................................................................................................................... 10-188
Work equipment ..................................................................................................................... 10-189
Work equipment............................................................................................................... 10-189
Work equipment shim....................................................................................................... 10-190
Bucket play adjustment shim............................................................................................. 10-191
Cab mount and cab tipping stopper ................................................................................... 10-192
ROPS cab ....................................................................................................................... 10-193
Electrical control system ................................................................................................... 10-194
Machine monitor system ................................................................................................... 10-245
KOMTRAX system ........................................................................................................... 10-267
Sensor ............................................................................................................................ 10-270
10-2 PC210LC-10
Engine related parts
Engine and cooling system (ALL-R401-001-K-00-A)
Engine related parts (PC200_10-A001-041-K-00-A)
1. EGR cooler (*2)
PC210LC-10 10-3
Engine related parts
2 Engine oil filter

3. KDPF (*3)
4. KCCV ventilator (*4)
5. Vibration damper (*1)
6. Auto-tensioner
7. Air cleaner (*1)
8. KVGT (*5)
9. Damper assembly
9a. Drive plate
9b. Torsion spring
9c. Stopper pin
9d. Friction plate
10. Rear engine mount
11. Front engine mount
*1: For the details, see Engine Shop Manual.
*2: For EGR cooler, see "EGR cooler".
*3: For KDPF, see "KDPF".
*4: For KCCV ventilator, see "KCCV ventilator".
*5: For KVGT, see "KVGT".
Specifications (PC220-A001-030-K-00-A)
Damper type Wet type

Oil used for damper TO30
Damper oil capacity (l) 0.65
10-4 PC210LC-10
KVGT
KVGT (WA380-AA10-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and it is variable displacement
turbocharger.
a The shape is subject to machine models.
PC210LC-10 10-5
KVGT
1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation (ENG107-AA10-044-K-00-A)
1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speeds but also at
low engine speeds. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
• To obtain a high EGR ratio especially at low engine speeds, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speeds.
• The turbine impeller (T) drives the blower impeller (C) via a shaft. In turn the blower impeller (C) sends a
large amount of air to the cylinders for combustion. When the air flow from KVGT (2) increases, more fuel
can be injected, and the engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.
10-6 PC210LC-10
KVGT
a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
• Exhaust gas enters from (C) of turbine housing (4), flows through section (P) and out from (D). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area changes when push rod (8) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the EGR valve, and also controls the right/left slide of push rod (8).
• Exhaust gas hits vane (6), and then turbine impeller (11) drives blower impeller (10) via shaft (9). This
works as a compressor and the air entered from (A) is compressed and sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speeds), push
rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by KVGT speed sensor (2).
When nozzle ring is closed

• At low engine speeds, exhaust gas inlet passage (P) is narrowed (L1). (Not completely closed)
• When the turbine inlet pressure increases while the nozzle ring is closed, the flow speed to the turbine
increases and the turbocharger speed increases.
PC210LC-10 10-7
KVGT
When nozzle ring is open

• At high engine speeds, exhaust gas inlet passage (P) is widened (L2).
• As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).
a Nozzle ring (7), vane (6), and push rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.
10-8 PC210LC-10
KVGT
Hydraulic actuator operation

• Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to EGR valve
(10).
• The force for the movement is the oil pressure supplied from boost oil pump (12).
a The shape in the following figure is subject to machine models.
• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).
PC210LC-10 10-9
KVGT
1. Air cleaner
2. Mass air flow and temperature sensor
3. KVGT
4. KVGT speed sensor
5. KVGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler, EGR valve)
11. EGR orifice temperature sensor
12. Boost oil pump
C: Blower impeller
T: Turbine impeller
KVGT control system

• Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and
KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil
pressure controlled by EPC valve (8), to move the piston.
• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure
sensor, and automatically controlling the fuel injection and the KVGT.
• The KVGT is protected by controlling its speed to prevent overspeeds.
Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication.
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.
10-10 PC210LC-10
KVGT
Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Coolant return flows from the center housing and joins the flow at the EGR cooler outlet piping, then flows
through the water inlet connector to the water pump.
PC210LC-10 10-11
EGR system piping drawing
EGR system piping drawing (WA380-A9J0-04D-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation.

1. KVGT
2. EGR valve
3. Air intake pipe
4. Air intake connector
5. Exhaust manifold
6. EGR cooler
Function (ENG107-A9J0-042-K-00-A)
• EGR valve (driven hydraulically)

Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is
higher than the boost pressure, the exhaust gas flows to the air intake side.
• EGR cooler
10-12 PC210LC-10
EGR system piping drawing
Cools the exhaust gas.

Engine coolant is used for cooling.
• Air intake connector
Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
• Each sensor
Controls the EGR according to the operating condition.
Troubleshoots the system.
• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.
PC210LC-10 10-13
EGR system circuit diagram
EGR system circuit diagram (ENG107-A9J0-052-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation
1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR orifice temperature sensor
6. EGR cooler
7. EGR valve
8. Hydraulic actuator (power piston)
9. EPC valve (for EGR valve)
10. EGR valve lift sensor
12. Exhaust manifold
13. Boost oil pump
14. Intake manifold
15. Charge (boost) pressure and temperature sensor
C: Blower impeller
T: Turbine impeller
Operation (ENG107-A9J0-044-K-00-A)
• The engine controller outputs signals for opening EGR valve (7) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (12)
through EGR piping to EGR cooler (6).
10-14 PC210LC-10
EGR system circuit diagram
• The exhaust gas cooled by EGR cooler (6) flows through EGR valve (7) and mixes with the intake air in
the air intake connector, and then flows in the air intake manifold (14).
PC210LC-10 10-15
EGR valve
EGR valve (ENG107-A9K1-041-K-00-A)
1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
6. EGR valve lift sensor
7. EPC valve (for EGR valve)
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
E: KVGT control oil pressure outlet
F: KVGT drive oil pressure outlet
Structure
• The EGR valve consists of the EGR gas flow control mechanism and the EPC valves
• There are two EPC valves, one for the EGR valves control and one for the KVGTcontrol.
10-16 PC210LC-10
EGR valve
Operation (ENG107-A9K1-044-K-00-A)
• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
• Spool (4) is pressed to the right by the force of spring (5), and EGR valve (1) is closed by the force of
spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
• When force (Fp) becomes larger than force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas
will flow to the intake side.
• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4).
• The valve position is controlled by the engine controller by controlling the spool position with the control
pressure of the EPC valve.
• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
• Position of spool (4) is sensed by the EGR valve lift sensor.
PC210LC-10 10-17
EGR cooler
EGR cooler (ENG107-A9L0-041-K-00-A)
1. Tube
A: EGR gas inlet
B: Air vent
C: Coolant outlet
D: EGR gas outlet (to EGR valve)
E: Coolant inlet
1. Flat tube
2. Inner fin
Operation (ENG107-A9L0-044-K-00-A)
• The EGR gas enters from (A) and flows through 11 flat tubes (1).
• Coolant enters from (E) and flows around flat tube (1) in shell and then goes out from (C).
• The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet
(D).
10-18 PC210LC-10
KCCV layout drawing
KCCV layout drawing (PC200_10-A180-04D-K-00-A)
KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation

1. KCCV ventilator
2. KVGT
3. Blowby duct
4. Flywheel housing
5. Check valve
6. CDR valve
7. Crankcase pressure sensor
A: Blowby gas (from flywheel housing)
B: Engine oil-free blowby gas (to KVGT)
C: Engine oil (to oil pan)
• Formerly, blowby gas has been released to the atmosphere. However, since the tightened exhaust gas
regulation also regulates blowby gas, the blowby gas recirculation system is adopted.
• Since blowby gas (A) contains engine oil mist, which may cause the following problems when recirculated
to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to aherence of engine oil
PC210LC-10 10-19
KCCV layout drawing
Operation (ENG107-A180-044-K-00-A)
a The figure on the left shows the flow of blowby gas released to the atmosphere from conventional engines.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.
1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil mist is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
• Removed engine oil (C) flows through a check valve and falls to the oil pan.
10-20 PC210LC-10
KCCV ventilator
KCCV ventilator (PC200_10-A18H-041-K-00-A)
1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
A: Blowby gas inlet (from flywheel housing)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlet
Function (PC200_10-A18H-042-K-00-A)
• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
• Warming KCCV ventilator with the warmed engine coolant can prevent the blowby gas passage from
being plugged by the frozen gas.
PC210LC-10 10-21
KCCV ventilator
Operation (ENG107-A18H-044-K-00-A)
• Blowby gas enters from (A). The larger drops of oil mist are removed from the blowby gas when it flows
through the impactor (5) holes in filter (6).
• Smaller drops of oil mist are removed by filter (6).
• Removed oil flows down along the case wall to oil drain port (C) and then flows to the oil pan.
• The CDR valve operates when the pressure inside the crankcase becomes negative, to prevent excessive
negative pressure in the crankcase.
• Crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
• When the engine controller determines that the filter is clogged from crankcase pressure sensor (3)
signals, failure code CA555 is issued. If the pressure increases further, failure code CA556 is issued.
• Relief valve (4) is installed in case (1). It operates to protect the KCCV ventilator and engine when filter (6)
is blocked.
CDR valve (ENG107-A18A-041-K-00-A)
CDR: Abbreviation for Crankcase Depression Regulator
1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.
10-22 PC210LC-10
KDPF
KDPF (WA380-A9H0-041-K-00-A)
KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Inlet unit
2. KDOC inlet temperature sensor
3. KDOC outlet temperature sensor
4. KCSF unit
5. Connector box
6. KDPF outlet temperature sensor
7. Outlet unit
8. KDPF differential pressure sensor port
9. KDPF differential pressure sensor
10. KDPF differential pressure sensor port
11. KDOC unit
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
• The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11)
that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and
outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit
(4).
• KDOC unit (11) consists of a ceramic honeycomb coated with oxidation calatyst material.
PC210LC-10 10-23
KDPF
• The ceramic honeycomb supports the oxidization of NO (nitrogen monoxide) into NO 2 (nitrogen dioxide),
and also contributes to burn the injected fuel during automatic regeneration and manual stationary
regeneration (*1).
• The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
• The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
• KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
• Inside the KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
• Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
• Temperature signals from the three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
• The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Soot is cleaned (oxidized) during the process.
k During engine operation and for a while after engine shutdown, the surface of the KDPF and
adjacent pipings are very hot. When working near the KDPF, be careful not to get burned.
Function (ENG107-A9H0-042-K-00-A)
A: Flow of exhaust gas

1. KDOC (oxidation catalyzer)
2. KCSF
3. Plug (ceramic)
4. Cell
5. Ceramic honeycomb
10-24 PC210LC-10
KDPF
• The KDPF is installed to meet the very strict requirements of the latest exhaust gas regulation. The KDPF
purifies the exhaust gas by catching most of the PM (Particulate Matter such as soot) included in the
exhaust gas from the engine.
• KCSF (2) is made of ceramic. Inside the KCSF, there are many cells partitioned by ceramic walls. Cells
plugged at the inlet side and cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) is naturally oxidized and burned away by the effect of KDOC (1), in
operating conditions with relatively high exhaust gas temperatures. (This is referred to as "passive
regeneration".)
• When the exhaust temperature is relatively low, in conditions such as continued low load operations, the
deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF differential pressure sensor signals.
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. This is referred to as "exhaust temperature-raising control".
• As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
• KDOC (1) burns (oxidize) soot by utilizing the catalyzer.
• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
KCSF (2) will increase.
• If the soot deposit in KCSF (2) exceeds a certain level, it will be necessary to perform "manual stationary
regeneration" to burn away (oxidize) the soot.
• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration".
Types of regeneration (WA380-A9H0-042-K-00-A)
a Regeneration refers to a process of purifying (oxidizing) the soot deposited in the soot collecting filter
(KCSF) inside the KDPF.
1. Passive regeneration
When the exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will be
stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration
1) Automatic regeneration
If the soot deposit exceeds a certain level, the engine controller switches to exhaust temperature-
raising control (*1), performs fuel dosing (*2), and automatically starts the regeneration process.
Another type of automatic regeneration is performed by the engine controller at certain intervals,
regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGT are controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process. No.
1, 2, and 3 injectors are used for fuel dosing.
2) Manual stationary regeneration
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service)
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.
PC210LC-10 10-25
KDPF
• When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KCSF. If some of the conditions for automatic drying are not met,
manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping
KDPF regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the
KDPF, leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is
low. Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGT automatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes
and the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low
temperatures, white smoke may come out from the exhaust pipe for a short time, but this is
normal. Be sure to perform regeneration at a well ventilated place since carbon monoxide can
be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be
smelled from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at
the exhaust pipe can exceed 650 °C. Make sure that there is no flammable material near the
exhaust system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe,
and pay sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
DOC_In (KDOC inlet DOC_Out (KDOC outlet KDPF_Out (KDPF outlet
temperature sensor) temperature sensor) temperature sensor)
Not regenerating (idling) 100 to 250 °C
Regenerating (under
exhaust temperature-raising 100 to 250 °C 400 to 550 °C
control: 1,000 rpm)
10-26 PC210LC-10
Cooling system
Cooling system (PC200_10-B000-041-K-00-A)
1. Reservoir tank
2. Oil cooler
3. Radiator cap
PC210LC-10 10-27
Cooling system
4. Radiator
5. Aftercooler
6. Fuel cooler inlet
7. Fuel cooler
8. Fuel cooler outlet
9. Condenser
10. Air conditioner condenser switching bracket
11. Oil cooler inlet
12. Aftercooler outlet hose
13. Fan guard
14. Radiator inlet hose
15. Oil cooler outlet
16. Aftercooler inlet hose
17. Shroud
18. Fan
19. Radiator outlet hose
20. Radiator drain plug
Specifications (PC200_10-B000-030-K-00-A)
Radiator Oil cooler Aftercooler Fuel cooler

Core type Aluminum wave type Drawn cup
CF90-4 CF91
4 rows
Fin pitch (mm) 3.5/2 3.5/2 3.5/2 4.0/2
Total heat
dissipation area (m2) 60.87 10.61 x 2 9.98 0.30
Pressure valve
cracking pressure 0.05 {0.5} — — —
(MPa {kg/cm2})
Vacuum valve
cracking pressure –0.005 {-0.05} — — —
(MPa {kg/cm2})
10-28 PC210LC-10
Power train system
Power train (ALL-C100-001-K-00-A)
Power train system (PC220-C100-041-K-00-A)
1. Control valve
1a. Self-pressure reducing valve
1b. Merge-divider valve
1c. Travel junction valve
2. Main pump
3. Engine
4. Travel motor
5. Final drive
6. Swing motor
6a. Swing 2-stage relief valve
7. Center swivel joint
8. Idler
PC210LC-10 10-29
Power train system
9. PPC lock solenoid valve

10. 2-stage relief solenoid valve
11. Swing brake solenoid valve
12. Travel speed increase solenoid valve
13. Travel junction solenoid valve
14. Swing 2-stage relief solenoid valve
15. Attachment selector solenoid valve (a machine ready for installing attachments)
16. Swing machinery
17. Swing circle
10-30 PC210LC-10
Swing circle
Swing circle (PC200_10-J110-041-K-00-A)
1. Swing circle pinion grease filler port

2. Swing circle bearing grease fitting
3. Inner race (number of teeth: 96)
4. Ball
5. Outer race
6. Seal
a. Inner race soft zone position
b. Outer race soft zone position
Specification (PC200_10-J110-030-K-00-A)
Reduction ratio -96 / 13 = -7.385

Grease G2-LI
Grease quantity (l) 14.6
PC210LC-10 10-31
Swing machinery
Swing machinery (PC200_10-J130-041-K-00-A)
1. Swing pinion (number of teeth: 13)

2. No. 2 planetary carrier
3. No. 2 sun gear (number of teeth: 18)
10-32 PC210LC-10
Swing machinery
4. No. 2 planetary gear (number of teeth: 19)

7. Swing motor
8. Breather
9. Oil level gauge doubling oil filler port cap
11. Ring gear (number of teeth: 58)
12. Swing machinery case
13. Drain plug
Specification (PC200_10-J130-030-K-00-A)
Reduction ratio ((17 + 58)/17) x ((18 + 58)/18) = 18.627

Swing reduction ratio 18.627 x (96/13) = 137.553
Swing speed
12.4
(rpm)
PC210LC-10 10-33
Final drive
Final drive (PC220-DF10-041-K-00-A)
1. Level plug
3. Drain plug
10-34 PC210LC-10
Final drive
4. No. 1 sun gear shaft (number of teeth: 10)

7. Cover
8. Ring gear (number of teeth: 95)
10. Ring nut
11. Hub
12. Sprocket
13. Floating seal
14. Travel motor
Specifications (PC220-DF10-030-K-00-A)
Reduction ratio -((10 + 95)/10) x ((21 + 95)/21) + 1 = -57.000
PC210LC-10 10-35
Track frame and idler cushion
Undercarriage and frame (ALL-DT00-001-K-00-A)
Track frame and idler cushion (PC200_10-DT20-041-K-00-A)
1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Idler cushion
9. Front guard
10-36 PC210LC-10
Specification (PC200_10-DT20-030-K-00-A)
• Number of track rollers

Model Quantity (each side)
PC210LC–10 9
• Standard shoe
Model PC210LC-10
Shoe width (mm) 700
Link pitch (mm) 190
Number of shoes (each side) 49
PC210LC-10 10-37
Hydraulic equipment layout drawing
Hydraulic system (ALL-C000-001-K-00-A)
Hydraulic equipment layout drawing (PC220-C000-04D-K-00-A)
1. Bucket cylinder
10-38 PC210LC-10
Hydraulic equipment layout drawing
2. Arm cylinder
3. R.H. PPC valve for work equipment
4. Swing motor
5. Hydraulic tank
6. Main pump
7. Control valve
8. Accumulator (for PPC circuit)
9. Oil cooler
10. Travel motor
11. Solenoid valve
12. L.H. PPC valve for work equipment
13. Attachment 2 PPC valve (*1)
14. Travel PPC valve
16. Center swivel joint
17. Boom cylinder
*1: Machine ready for installation of attachment
PC210LC-10 10-39
Valve control
Valve control (PC-PK01-041-K-00-A)
1. Attachment 1 control pedal (*1)

2. Travel lever
3. R.H. PPC valve for work equipment
4. R.H. work equipment control lever (for boom and bucket control)
5. Control valve
6. Junction block
7. Accumulator (for PPC circuit)
8. Solenoid valve
9. L.H. work equipment control lever (for arm and swing control)
10. L.H. PPC valve for work equipment
11. Lock lever
12. Attachment 2 control pedal (*1)
10-40 PC210LC-10
Valve control
14. Travel PPC valve

15. Travel pedal
17. Lock pin (*1)
*1: Machine ready for installation of attachment
PC210LC-10 10-41
Hydraulic tank
Hydraulic tank (PC200_10-PM30-041-K-00-A)
1. Main pump
2. Hydraulic tank
3. Filler cap
4. Sight gauge
5. Drain plug
6. Bypass valve
7. Strainer
8. Filter element
9. Suction strainer
Specifications (PC220-PM30-030-K-00-A)
Hydraulic tank capacity (l) 190

Amount of oil in hydraulic tank (l) 132
Bypass valve set pressure (MPa {kg/cm2}) 0.15 ± 0.03 {1.5 ± 0.3}
10-42 PC210LC-10
Hydraulic tank
Oil filler cap (PC-AD1C-041-K-00-A)
1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring
Prevention of negative pressure in tank

• The hydraulic tank is sealed and pressurized. When the oil level in the hydraulic tank drops, negative
pressure is generated in the tank. To prevent this negative pressure generation, seam valve (4) is opened
to draw the atmosphere to the tank.
(Intake valve set pressure: 0 to 0.49 kPa {0 to 0.005 kg/cm2})
Prevention of pressure rise in tank

• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate, and the oil level and temperature increase in the tank. If the pressure in the tank rises
above the set value, bottom plate (2) is pushed up to release the pressure in the tank.
(Exhaust valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2 })
PC210LC-10 10-43
CLSS
CLSS (ALL-PNJ1-001-K-00-A)
CLSS: Abbreviation for Closed center Load Sensing System

Structure of CLSS (ALL-PNJ1-041-K-00-A)
CLSS: Abbreviation for Closed center Load Sensing System
Features
• Fine control not influenced by load
• Control performance that allows digging even when fine control operation is turned on
• Ease of combined operation enabled by the flow divider function that is determined by the opening areas
of spools during combined operations
• Energy saving by variable pump control
Configuration
• CLSS consists of variable capacity piston pump, control valve, and actuators.
• The main pump consists of pump itself, PC valve and LS valve.
10-44 PC210LC-10
CLSS
Basic principle
Pump swash plate angle control

• The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (dPLS), which is
the difference between pump delivery pressure (PP) and LS pressure (PLS)) (load pressure of actuator) at
control valve outlet, is constant.
• [LS differential pressure (dPLS) = Pump delivery pressure (PP) - LS pressure (PLS)]
• The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate
angle shifts toward the minimum position.
PC210LC-10 10-45
CLSS
LS differential pressure (d
d PLS) and pump swash plate angle
a See “Main pump“ for the explanation of the operation.
Pressure compensation control
10-46 PC210LC-10
CLSS
• A pressure compensation valve is installed to the outlet port side of each control valve to balance the load
pressure.
• When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the
load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.
System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.
1. Front pump
2. Rear pump
3. Main relief valve
4. Unload valve
5. Merge-divider valve
6. Control valve
PC210LC-10 10-47
CLSS
7. Actuator
8. Pump circuit
9. LS circuit
10. Tank circuit
11. Valve
12. Spring
13. LS bypass plug
14. LS valve
15. PC valve
10-48 PC210LC-10
Main pump
Main pump (PC220-C200-041-K-00-A)
Model: HPV125 + 125
IMF: Front pump PC mode selector current

IMR: Rear pump PC mode selector current
PC210LC-10 10-49
Main pump
ISIG: LS set pressure selector current

PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Front pump pressure input port
PD3R: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PENF: Front pump control pressure pickup port
PENR: Rear pump control pressure pickup port
PEPC: EPC source pressure input port
PEPB: EPC source pressure pickup port
PFC: Front pump delivery pressure pickup port
PLSF: Front pump load pressure input port
PLSFC: Front pump load pressure pickup port
PLSR: Rear pump load pressure input port
PLSRC: Rear pump load pressure pickup port
PMF: Front pump PC mode selector pressure pickup port
PMR: Rear pump PC mode selector pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port
1. Front pump
2. Rear pump
3. LS - EPC valve
4. Front pump PC - EPC valve
5. Rear pump PC - EPC valve
6. Rear pump PC valve
7. Rear pump swash plate sensor
8. Rear pump LS valve
9: Front pump LS valve
10. Front pump swash plate sensor
11: Front pump PC valve
10-50 PC210LC-10
Main pump
1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. PC valve
13. Servo piston
14. Slider
PC210LC-10 10-51
Main pump
15. Spline
16. Bearing
17. LS valve
Outline
• This pump consists of two variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve,
and swash plate sensor.
Function
• The pump converts the engine speed and torque transmitted to its shaft (1) into oil pressure and delivers
pressurized oil corresponding to the load.
• It is possible to change the delivery by changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by spline (15).
• Shaft (1) is supported by each bearing (16) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped together with shoe (5).
• Piston (6) and shoe (5) constitute a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) transmits high pressure oil to cylindrical surface (B) with cradle (2), which is secured to the
case, and forms a static pressure bearing when it slides.
• Piston (6) performs reciprocal motion in the axial direction inside each cylinder chamber of cylinder block
(7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• The oil pressure balance on the valve plate is maintained properly.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Operation (PC220-C200-044-K-00-A)
• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.
• If swash plate angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7),
plane (A) functions as a cam against shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Each piston (6) sucks and discharges oil by (F) - (E).
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• The volume of chamber (F) grows larger and, in this process, the oil is sucked.
10-52 PC210LC-10
Main pump
• As center line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the
difference between volumes (E) and (F) inside cylinder block (7) equals 0.
• Suction and delivery of pressurized oil is not carried out in this state. Namely pumping action is not
performed. (Actually, however, the swash plate angle is not set to 0 deg.)
Control of delivery
• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and pump
delivery (Q) increases.
• Swash plate angle (a) is changed by servo piston (13).
• Servo piston (13) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating movement is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• Output pressure (PEN) of the LS valve is transmitted to the pressure chamber of the large diameter piston
side.
• The areas receiving the pressure on the right and left sides of servo piston (13) are different from each
other, and delivery pressure (self pressure) (PP) of the main pump is constantly transmitted to the
pressure chamber of the small diameter piston side.
• The movement of servo piston (13) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas receiving the pressure
of the small diameter piston and large diameter piston.
PC210LC-10 10-53
Main pump
10-54 PC210LC-10
Main pump
LS valve (PC-C2J0-041-K-00-A)
LS: Abbreviation for Load Sensing
PA: Pump port

PDP: Drain port
PLP: LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Control pressure input port
PSIG: LS mode selector pilot port
1. Sleeve
2. Piston
3. Spool
4. Spring
5. Seat
6. Sleeve
7. Plug
8. Lock nut
Function (PC-C2J0-042-K-00-A)
• The LS (load sensing) valve detects the load and controls the pump delivery.
• This valve controls main pump delivery (Q) according to differential pressure (dPLS) [= PP - PLS], called
the LS differential pressure (the difference between main pump delivery pressure (PP) and control valve
outlet port pressure (PLS)).
• This valve receives main pump delivery pressure (PP), pressure (PLS) (called the LS pressure) coming
from the control valve output, and pressure (PSIG) (called the LS set selector pressure) from the
proportional solenoid valve.
• The relation between the pump delivery (Q) and the differential pressure (dPLS) [= (PP) - (PLS)] between
the main pump pressure (PP) and LS pressure (PLS) is changed by the LS set pressure selector current
(ISIG) of the LS-EPC valve as shown in the figure below.
• When the (ISIG) changes from 0 A to 1 A, the spring setting force will change accordingly, to let the center
of the standard value range of the pump delivery selector point vary within the range from 0.27 MPa {2.78
kg/cm2} to 1.7 MPa {17.75 kg/cm2}.
PC210LC-10 10-55
Main pump
Operation (PC-C2J0-044-K-00-A)
When control valve is in “NEUTRAL“ position
• The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of
control valve is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port
(H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery
pressure (self pressure) (PP) determine the position of spool (6).
10-56 PC210LC-10
Main pump
• However, magnitude of the output pressure (PSIG) (called the LS set selector pressure) of the EPC valve
for the LS valve entering port (G) also changes the position of spool (6).(Setting force of the spring is
changed)
• Before the engine is started, servo piston (12) is pushed to the left. (See the following figure)
• If the control lever is at the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa
{0 kg/cm2}. (It is connected to the drain circuit through the control valve spool.)
• Spool (6) is pushed to the right, and port (C) and port (D) are connected.
• Pump delivery pressure (PP) is transmitted to the larger diameter end of the pump from the port (K).
• The same pump delivery pressure (PP) is transmitted to the smaller diameter end at the port (J).
• According to the area difference of servo piston (12), the servo piston is moved to the right, in the direction
which makes the swash plate angle minimum. (See the previous figure.)
PC210LC-10 10-57
Main pump
When pump delivery is increased
• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve opening area increases and
pump delivery pressure (PP) decreases), the combined force exerted by LS pressure (PLS) and spring (4)
pushes spool (6) to the left.
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain
pressure (PT). (PC valve operation will be explained later.)
• The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and
pump pressure (PP) is constantly transmitted to port (J) on the small diameter end. Accordingly, servo
piston (12) is pushed to the left and the swash plate is moved to increase the delivery.
• At this time, when the output pressure from the EPC valve for the LS valve is transmitted to port (G), a
force is applied on piston (7) to move the piston to the right.
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential
pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6)
are connected.
10-58 PC210LC-10
Main pump
When pump delivery is decreased
• When servo piston (12) moves to the right (the direction that reduces pump delivery) and LS differential
pressure (dPLS) increases (for example, when the control valve opening area decreases and pump
delivery pressure (PP) increases), the force exerted by pump delivery pressure (PP) pushes spool (6) to
the right.
• The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston
through port (C), port (D) and port (K).
• Pump delivery pressure (PP) is also transmitted to port (J) of the small diameter end of the piston, but
because of the difference in area between the large diameter end and the small diameter end on servo
piston (12), it is pushed to the right. As the result, the servo piston (12) moves into the direction of reducing
the swash plate angle.
• When the LS set selector pressure (PSIG) is transmitted to port (G), the spring (4) setting force is
weakened.
PC210LC-10 10-59
Main pump
When servo piston is balanced
• The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of
the piston, the area receiving the pressure at the small diameter end and the pressure transmitted to the
large diameter end of the piston, respectively.
• When the force exerted by main pump pressure (PP) of the LS valve is balanced with the combined force
exerted by LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (12) stops in that position.
• The swash plate of the pump is held at the intermediate position. [The swash plate stops at a position
where the openings from port (D) to port (E) and from port (C) to port (D) of spool (6) are approximately
equal]
• The relationship between the area receiving the pressure at both ends of servo piston (12) is (A0) : (A1) =
3 : 5, and the pressures transmitted to both ends of the piston when the piston is balanced is (PP) : (PEN)
C 5 : 3.
• The force of spring (4) is adjusted so that spool (6) can be balanced at the specified center when (PP) -
(PLS) = 1.7 MPa {17.75 kg/cm2}.
• When (PSIG) [LS-EPC valve output pressure, 0 to 2.9 MPa {0 to 30 kg/cm 2}] is transmitted to port (G), the
balanced position changes in proportion to the (PSIG) pressure within a range of (PP) - (PLS) = 1.7 MPa
{17.75 kg/cm2} to 0.27 MPa {2.78 kg/cm2}.
10-60 PC210LC-10
Main pump
PC valve (PC-C2K0-041-K-00-A)
PC: Abbreviation for Pressure Compensation
PA: Pump port

PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring
Function (PC-C2K0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depends on the delivery pressure) even if the travel of
the control valve is increased extremely. This is to ensure the horsepower absorbed by the pump not to
exceed the engine horsepower, when pump delivery pressures (PP1) (self pressure) and (PP2) (other
pump's pressure) are high.
• If the pump delivery pressure (PP) increases due to increased load during work, this valve decreases the
pump delivery.
• And if the pump delivery pressure goes low, it increases the pump delivery.
• The relation between the average delivery pressure of front and rear pumps [(PP1) + (PP2)] / 2 and pump
delivery (Q) is as shown in the following figure, as a parameter for each current (X) value applied to the
PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to
recover the speed.
• When the load increases and the engine speed decreases below a preset value, the controller increases
the command current to the PC-EPC valve solenoid depending on the amount of engine speed decrease,
to decrease the swash plate angle.
PC210LC-10 10-61
Main pump
Operation (PC-C2K0-044-K-00-A)
When the pump controller is normal
When load on the actuator is small and pump pressures (PP1) and (PP2) are low
Actuation of PC-EPC valve solenoid (1)

• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).
10-62 PC210LC-10
Main pump
• Spool (3) stops at a position where the combined force exerted by springs (4) and (6) is equalized to the
combined force exerted by pump pressure (PP1) (self pressure) and pump pressure (PP2) (other pump's
pressure) acting on spool (3).
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
• The amperage of the command current (X) depends on the type of work (lever operation), work mode
selection, engine speed setting, and the actual engine speed.
a Other pump's pressure denotes the pressure of the pump situated on the opposite side.
For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump
pressure, the other pump's pressure is that of the front pump.
Action of spring
• The spring force of springs (4) and (6) in the PC valve depends on the position of the swash plate.
• When servo piston (9) moves to the right, spring (6) is compressed.
• When the piston moves further to the right, the piston comes in contact with seat (5) and spring (6) is fixed.
• Then, only spring (4) operates.
• When servo piston (9) compresses or decompresses springs (4) and (6), the spring force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring forces of springs (4) and (6) are also varied by the PC-EPC valve solenoid command current
(X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Self pressure (PP1) is transmitted to the small diameter end of servo piston (9) and port (B), and other
pump's pressure (PP2) is transmitted to port (A).
• When pressures (PP1) and (PP2) are low, spool (3) is on the left.
PC210LC-10 10-63
Main pump
• Port (C) and port (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter end of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump delivery goes to increase.
• Springs (4) and (6) extend according to the movement of servo piston (9), and the reaction force of spring
decreases.
• When the reaction force of spring decreases, spool (3) moves to the right. Ports (C) is disconnected from
port (D), and pump delivery pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
• Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
force exerted by pressures (PP1) and (PP2), the thrust generated by the PC-EPC valve solenoid, and the
force exerted by springs (4) and (6) acting on the spool (3) are balanced.
When load on the actuator is large and pump pressures (PP1) and (PP2) are high
Outline
• When the load is large and the pump delivery pressures (PP1) and (PP2) are high, the thrust moving
spool (3) to the right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP2), because
a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown above.
• When spool (3) moves to the left, the opening of ports (C) and (D) widens.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.
10-64 PC210LC-10
Main pump
• Servo piston (9) stops at a position further to the right than the position when pump pressures (PP1) and
(PP2) are low.
Operation
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP2) increases more and spool (3) moves further to the right, pump pressure (PP1)
flows to port (C) to minimize the pump delivery.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and spool (3) is pushed
back.
• The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their
positions can be represented by the polygonal line in the figure because springs (4) and (6) form the 2-
stage springs.
• The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q)
becomes as shown below.
• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
average pump pressure (PP1 + PP2)/2 and pump delivery (Q) is shifted parallel in proportion to the thrust
of PC-EPC valve solenoid.
• Namely, the thrust of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the
pump pressure transmitted to the spool (3), so the relationship between the average pump pressure (PP1
+ PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased.
PC210LC-10 10-65
Main pump
When the pump controller malfunctions and the emergency pump drive switch is at “ON“ position
When load on the main pump is small
• If the pump controller fails, turn the emergency pump drive switch to "ON" position to select the resistor
side.
• In this case, power is taken directly from the battery, however, the current is too high as is, a resistor is
needed to control the current supplied to PC-EPC valve solenoid (1).
• Since the current is constant, the thrust applied to piston (2) is constant.
• When main pump pressures (PP1) and (PP2) are low, the combined force exerted by PC-EPC valve
solenoid (1) thrust and the pump pressure is smaller than the combined force exerted by the springs.
Spool (3) stays balanced at the left.
• Port (C) is connected to port (D) at drain pressure, and the pressure at the large diameter end of servo
piston (9) comes to drain pressure (PT) through the LS valve.
• Since the pressure at the small diameter end of the piston is large, servo piston (9) moves in the direction
to increase the delivery.
10-66 PC210LC-10
Main pump
When load on the main pump is large
• As mentioned before, when the emergency pump drive switch is turned to "ON" position, the command
current (X) sent to PC-EPC valve solenoid (1) is constant.
• Therefore, the thrust applied by piston (2) to spool (3) comes to constant.
• When main pump pressures (PP1) and (PP2) increase, spool (3) moves to a position further to the right
than when the main pump load is small, and stays balanced as shown above.
• Since the pressure from port (B) flows into port (C), servo piston (9) moves to the right (delivery
decreases), and stops at a position further to the right than when the pump load is small.
• When the emergency pump drive switch is turned to "ON" position, the curve indicating the relation
between the pump delivery pressure (PP) and delivery (Q) is plotted in accordance with the current
supplied through the resistor to the PC-EPC valve solenoid.
• When the emergency pump drive switch is turned to "ON" position, the curve is plotted as (B), which is
shifted toward the left than curve (A) for a normal pump controller.
PC210LC-10 10-67
Main pump
10-68 PC210LC-10
Main pump
LS (PC)-EPC valve (PC200_10-C2M0-041-K-00-A)

EPC: Abbreviation for Electromagnetic Proportional Control
C: To LS (PC) valve
P: From self-pressure reducing valve
T: To hydraulic tank
1. Connector
2. Coil
3. Valve body
4. Spring
5. Spool
6. Rod
7. Plunger
PC210LC-10 10-69
Main pump
Function (PC-C2M0-042-K-00-A)
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
• When the EPC valve receives signal current (i) from the controller, it develops EPC output pressure
proportional to the amperage of the current and supplies the pressure to the control valve.
10-70 PC210LC-10
Main pump
Operation (PC-C2M0-044-K-00-A)
When signal current is zero amp. (coil is de-energized)
• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the self-pressure reducing valve does not flow to the LS
(PC) valve.
• The pressurized oil from the LS (PC) valve is drained to the tank through port (C) and then port (T).
PC210LC-10 10-71
Main pump
When signal current is minute (coil is energized)
• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
reaction force exerted by spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and port (P) is shut off from port (C).
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the force
exerted by pressure at port (C) and the reaction force exerted by spring (4).
• The circuit pressure between the EPC valve and LS (PC) valve is controlled in proportion to the amperage
of signal current.
10-72 PC210LC-10
Main pump
When signal current is maximum (coil is energized)
• Coil (2) is energized when signal current is supplied to coil (2).

• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and LS (PC) valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.
PC210LC-10 10-73
Control valve
Control valve (PC200_10-C030-041-K-00-A)
a In this section, only the 7-spool valve (6-spool valve + service valve) is shown.
A1: To bucket cylinder head

A2: To L.H. travel motor
10-74 PC210LC-10
Control valve
A3: To boom cylinder bottom

A4: To swing motor
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To attachment
ATT: From attachment
B1: To bucket cylinder bottom
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To attachment
BP1: From LS select solenoid valve
BP5: From attachment selector solenoid valve
C: To oil cooler
P1: From R.H. work equipment PPC valve (bucket DUMP)
P2: From R.H. work equipment PPC valve (bucket CURL)
P3: From travel PPC valve (L.H. travel REVERSE)
P4: From travel PPC valve (L.H. travel FORWARD)
P5: From R.H. work equipment PPC valve (boom RAISE)
P6: From R.H. work equipment PPC valve (boom LOWER)
P7: From L.H. work equipment PPC valve (swing RIGHT)
P8: From L.H. work equipment PPC valve (swing LEFT)
P9: From travel PPC valve (R.H. travel REVERSE)
P10: From travel PPC valve (R.H. travel FORWARD)
P11: From L.H. work equipment PPC valve (arm OUT)
P12: From L.H. work equipment PPC valve (arm IN)
P-1: From R.H. attachment PPC valve
P-2: From R.H. attachment PPC valve
PLS1: To rear pump LS valve
PLS2: To front pump LS valve
PLSC: LS pressure pickup port
PP1: From rear pump
PP2: From front pump
PP1S: Front pump oil pressure sensor mounting port
PPC: Pilot source pressure pickup port
PP2S: Rear pump oil pressure sensor mounting port
PPS2: To front pump LS valve
PR: To solenoid valve, PPC valve, and EPC valve
PST: From travel junction solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
T1: To hydraulic tank
TS: To hydraulic tank
TSW: From swing motor
PC210LC-10 10-75
Control valve
IS1: Pump merge-divider EPC valve (for main spool) drive signal
IS2: Pump merge-divider EPC valve (for LS spool) drive signal
IS3: Variable back pressure solenoid valve drive signal
1. Variable back pressure valve
2: Variable back pressure solenoid valve
3. Pump merge-divider EPC valve (for LS spool)
4. Pump merge-divider EPC valve (for main spool)
5. Arm hydraulic drift prevention valve (if equipped)
6. Boom hydraulic drift prevention valve
7. Service valve
8. Cover A
9. 7-spool valve
10. Arm quick return valve
11. Cover B
10-76 PC210LC-10
Control valve
1. Pressure compensation valve (arm OUT)

2. Pressure compensation valve (R.H. travel REVERSE)
3. Pressure compensation valve (swing RIGHT)
4. Pressure compensation valve (boom RAISE)
PC210LC-10 10-77
Control valve
5. Pressure compensation valve (L.H. travel REVERSE)

6. Pressure compensation valve (bucket DUMP)
7. Pressure compensation valve (service)
8. Pressure compensation valve (bucket CURL)
9. Pressure compensation valve (L.H. travel FORWARD)
10. Pressure compensation valve (boom LOWER)
11. Pressure compensation valve (swing LEFT)
12. Pressure compensation valve (R.H. travel FORWARD)
13. Pressure compensation valve (arm IN)
15. Unload valve
17. Spool (service)
18. Spool (bucket)
19. Spool (L.H. travel)
20. Spool (boom)
21. Spool (swing)
22. Spool (R.H. travel)
23. Spool (arm)
10-78 PC210LC-10
Control valve
1. Suction valve (arm OUT)

2. Suction valve (R.H. travel REVERSE)
3. Suction valve (boom RAISE)
4. Suction valve (L.H. travel REVERSE)
5. Suction safety valve (bucket DUMP)
6. Suction safety valve (service)
7. 2-stage suction safety valve (service)
8. Suction safety valve (bucket CURL)
9. Suction valve (L.H. travel FORWARD)
PC210LC-10 10-79
Control valve
10. Suction safety valve (boom LOWER)

11. Suction valve (R.H. travel FORWARD)
12. Suction safety valve (arm IN)
13. LS shuttle valve (arm)
14. LS shuttle valve (R.H. travel)
15. LS selector valve
16. LS shuttle valve (boom)
17. LS shuttle valve (L.H. travel)
18. LS shuttle valve (bucket)
19. LS shuttle valve (service)
20. LS check valve
10-80 PC210LC-10
Control valve
1. Unload valve
2. Safety valve for hydraulic drift prevention valve (boom “RAISE“ and arm “OUT“)
Arm valve
6. LS shuttle valve
8. Pressure compensation valve (IN)
PC210LC-10 10-81
Control valve
9. Spool
10. Suction safety valve (IN)
11. Cooler check valve
12. Regeneration circuit check valve
13. Suction valve (OUT)
14. Pressure compensation valve (OUT)
R.H. travel valve

15. LS shuttle valve
16. Pressure compensation valve (FORWARD)
17. Spool
18. Suction valve (FORWARD)
19. Suction valve (REVERSE)
20. Pressure compensation valve (REVERSE)
Swing valve
22. Pressure compensation valve (L.H.)
23. Spool
24. Pressure compensation valve (R.H.)
10-82 PC210LC-10
Control valve
1. Return spring
2. Merge-divider valve (for LS)
3. Valve (sequence valve)
4. Spring (sequence valve)
5. Merge-divider valve (main)
6. Return spring
Boom valve
8. LS shuttle valve
PC210LC-10 10-83
Control valve
9. Pressure compensation valve (LOWER)

10. Spool
11. Suction safety valve (LOWER)
12. Regeneration circuit check valve
13. Suction valve (RAISE)
14. Pressure compensation valve (RAISE)
L.H. travel valve

15. Merge-divider valve (travel junction valve)
16. Return spring
18. Pressure compensation valve (FORWARD)
19. Spool
20. Suction valve (FORWARD)
21. Suction valve (REVERSE)
22. Pressure compensation valve (REVERSE)
Bucket valve
24. Pressure compensation valve (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)
10-84 PC210LC-10
Control valve
Service valve
1. LS shuttle valve
2. Pressure compensation valve
3. Spool
4. 2-stage suction safety valve
5. Suction safety valve
6. Unload valve
8. LS bypass plug
Structure
• The control valves of the following types are set.
6-spool valve (without service valve)
7-spool valve (6-spool valve with service valve)
• This control valve consists of a 6-spool valve (unit type) and a set of service valve. A merge-divider valve,
a variable back pressure valve and a boom hydraulic drift prevention valve are installed to it.
• Since all the valves are assembled together with connecting bolts and their passes are connected to each
other inside the assembly, the assembly is compact and easy to maintain.
• With one spool provided for one work equipment, this control valve is simple in structure.
PC210LC-10 10-85
Control valve
Hydraulic circuit diagram and names of valves (PC200_10-C030-054-K-00-A)
1. Arm valve
2. R.H. travel valve
10-86 PC210LC-10
Control valve
3. Swing valve
4. Boom valve
5. L.H. travel valve
6. Bucket valve
7. Service valve
8. Arm valve spool
9. R.H. travel valve spool
10. Swing valve spool
11. Boom valve spool
12. L.H. travel valve spool
13. Bucket valve spool
14. Service spool
16. Suction valve
17. Check valve (for boom regeneration circuit)
18. Check valve (for arm regeneration circuit)
22. LS bypass plug
27. Self-pressure reducing valve
28. Travel junction valve
31. Cooler check valve
33. Main relief valve (for boom, L.H. travel, bucket, and attachment circuits)
Set pressure: 35.4 ± 0.5 MPa {360.5 ± 5 kg/cm2}
When one-touch power max. switch is set to ON position: 38.0 ± 0.5 MPa {387 ± 5 kg/cm 2}
34. Main relief valve (for arm, R.H. travel, and swing circuits)
Set pressure: 35.4 ± 0.5 MPa {360.5 ± 5 kg/cm2}
When one-touch power max. switch is set to ON position: 38.0 ± 0.5 MPa {387 ± 5 kg/cm 2}
35. Unload valve (for boom, L.H. travel, bucket, and attachment circuits)
Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
36. Unload valve (for arm, R.H. travel, and swing circuits)
Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
40. Suction 2-stage safety valve
PC210LC-10 10-87
Control valve
1st stage set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}

2nd stage set pressure: 20.6 ± 0.5 MPa {210 ± 5 kg/cm2}
41. Safety valve for hydraulic drift prevention valve
10-88 PC210LC-10
Control valve
Unload valve (PC220-PQD5-041-K-00-A)
1. LS circuit
2. Valve
3. Pump circuit
4. Tank circuit
5. Spring
Function (PC220-PQD5-042-K-00-A)
• When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump
delivery with swash plate angle at the minimum.
• The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred
to as P1).
• Since LS pressure is drained from LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}.
Operation (ALL-PQD5-044-K-00-A)
• Pressure of pump circuit (3) is received by the end of valve (2).
• Since the control valve is in NEUTRAL position, pressure of LS circuit (1) is 0 MPa {0 kg/cm 2}.
• Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
• If this pressure grows larger than the force of spring (5), valve (2) moves to the left.
• Ports (b) and (c) are interconnected, and the pump pressurized oil flows to tank circuit (4).
• The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit
(4).
• When this valve is actuated, the LS pressure becomes nearly equal to the tank pressure.
• Since the pump delivery pressure - LS circuit pressure during unloading is larger than pump LS control
pressure, the signal is output to minimize the pump swash plate angle.
• During operation (when a given work is done within the delivery available with the minimum swash plate
angle), the delivery pressure corresponding to the minimum pump swash plate angle is set to LS pressure
+ P1 pressure.
• The LS differential pressure (dPLS) with the swash plate angle at the minimum becomes P1 pressure.
Operation of relief valve

• When cylinder reaches its stroke end, main relief valve opens.
• Pump delivery (Q) is relieved to the tank. (For details, see " System diagram" of “Structure of CLSS“.
• Since the pump delivery pressure (PP) and LS pressure (PLS) do not flow neither to the upstream nor
downstream, they become approximately the same and LS differential pressure (dPLS) becomes 0 MPa
{0 kg/cm2}.
• As LS differential pressure (dPLS) is lower than the LS set pressure of LS valve, LS valve operates to
make the pump swash plate angle maximum.
• Mechanically, operation of PC valve has priority over that of LS valve.
• The pump is maintained at the minimum swash plate angle due to PC valve cut-off function.
PC210LC-10 10-89
Control valve
10-90 PC210LC-10
Control valve
Introduction of LS pressure (PC220-C2A4-041-K-00-A)

1. Main pump
2. Main spool
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve
Function (PC220-C2A4-042-K-00-A)
• The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted and led to LS shuttle valve (7) as LS pressure.
• Connected to actuator port (B) through valve (4), and makes LS pressure C actuator load pressure.
• In main spool (2), leading hole (a) with a small diameter also acts as an orifice.
• LS pressure works as source pressure when closing unload vale while control lever is operated, and this
pressure also functions as operating pressure when pressure compensation valve is compensated.
Operation (PC220-C2A4-044-K-00-A)
• When main spool (2) is operated, the pump pressure is transmitted to port (c) through leading hole (a) and
is led to LS circuit.
• When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the
pressurized oil flows.
PC210LC-10 10-91
Control valve
LS bypass plug (PC220-PNSH-041-K-00-A)
1. Main pump
2. Main spool
4. LS shuttle valve
5. LS bypass plug
6. LS circuit
Function (ALL-PNSH-042-K-00-A)
• This valve relieves the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Depending on the bypass flow from LS bypass plug (5), pressure loss is generated due to the circuit
resistance from orifice (c) of main spool (2) to LS shuttle valve (4).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.
10-92 PC210LC-10
Control valve
Pressure compensation valve (PC220-L6D0-040-K-00-A)

When the work equipment is operated independently and the load pressure is the maximum
(When the load pressure is higher than other work equipment during a combined operation)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• Pressure compensation valve works as the load check valve.
• If the pump pressure (LS pressure) is lower than the load pressure at port (c), shuttle valve (3) in pressure
compensation valve piston (4) interconnects spring chamber (E) and port (C).
• The force of spring (5) operates piston (4) and valve (2) to the closing direction.
Integrated pressure compensation valve

• When a high peak pressure or continuous and repetitive peak pressure (as in breaker operation) is
generated in the actuator circuit, valve (2) may collide with valve chamber seat (C), producing high stress
in the parts.
• To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used.
• With this machine, this valve is adopted for the travel valve, bucket valve (cylinder bottom), and the
service valve.
PC210LC-10 10-93
Control valve
When compensated
(When the load pressure is lower than other work equipment during a combined operation)
Function
• The pressure compensation valve closes by the LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment.
• Since the spool meter-in upstream pressure of port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A) pressure] - downstream pressure [port (B) pressure]
becomes equivalent to all the spools in operation.
• Pump flow is divided according to the ratio of the meter-in opening areas.
Operation
• Spring chamber (E) is interconnected to port (D).
• Piston (4) and valve (2) are moved in the closing direction (to the right) by the LS circuit pressure of port
(F) from other work equipment.
• Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with the LS
pressure.
10-94 PC210LC-10
Control valve
Area ratio of pressure compensation valve
Function
• The state of division changes according to the area ratio of pressure compensation portions (A1) and (A2).
Area ratio = (A2)/(A1)
• When the area ratio is equal to 1: As the spool meter-in downstream pressure is equal to the maximum
load pressure, the oil flow is divided in the ratio as same as the opening area ratio.
• When the area ratio is more than 1: As the spool meter-in downstream pressure is higher than the
maximum load pressure, the oil flow to the compensated side is divided in a ratio lower than the opening
area ratio.
• When the area ratio is below 1: As the spool meter-in downstream pressure is lower than the maximum
load pressure, the oil flow to the compensated side is divided in a ratio higher than the opening area ratio.
PC210LC-10 10-95
Control valve
Shuttle valve in pressure compensation valve (PC220-L6D3-040-K-00-A)

When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)
1. Main pump
2. Valve
3. Shuttle valve
4. Piston
Operation
• Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is
disconnected from port (C).
• Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).
10-96 PC210LC-10
Control valve
When traveling
Structure
• Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.
PC210LC-10 10-97
Control valve
Boom regeneration circuit (PC220-L511-040-K-00-A)

When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)
1. Main pump
2. Boom valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the
cylinder head when the boom is lowered.
Operation
• When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the
cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).
• The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom
through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
10-98 PC210LC-10
Control valve
When cylinder head pressure is higher than bottom pressure (digging operation, etc.)
Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to
the head.
PC210LC-10 10-99
Control valve
Arm regeneration circuit (PC220-L911-040-K-00-A)

When cylinder head pressure is higher than bottom pressure
1. Main pump
2. Arm valve spool
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flowing
to the cylinder bottom (pump delivery + regeneration flow) during arm IN operation in order to accelerate
the cylinder.
Operation
• When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the
cylinder head flows to drain circuit (B) through the notch of arm spool (2).
• The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder
bottom through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).
10-100 PC210LC-10
Control valve
When cylinder head pressure is lower than bottom pressure
Function
• Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder
head to the bottom.
PC210LC-10 10-101
Control valve
Merge-divider valve (PC220-PP30-040-K-00-A)

When oil flowing from two pumps are merged [pump merge-divider valve changeover signals (IS1)
and (IS2) are OFF]
1. Main spool
2. Spring
3. LS spool
4. Spring
5. LS circuit (for bucket valve)
6. LS circuit (for bucket valve)
7. LS circuit (for arm valve)
8. LS circuit (for arm valve)
9. Pump merge-divider EPC valve (for main spool changeover)
10. Pump merge-divider EPC valve (for LS spool changeover)
Function
• This valve merges the pressurized oil (P1) and (P2) from the two pumps or divides them (enables them to
flow to respective control valve groups).
• This valve merges or divides LS circuit pressures as well.
10-102 PC210LC-10
Control valve
Operation
• Since drive signal (IS1) of the EPC valve for the main spool is OFF, the output pressure of the pump
merge-divider EPC valve is 0 MPa {0 kg/cm2}.
• Main spool (1) is pressed to the right by spring (2). As a result, ports (E) and (F) are interconnected.
• Pressurized oil (P1) and (P2) discharged from the two pumps merge at ports (E) and (F), and flow to the
control valve which requires the oil.
• Since drive signal (IS2) of the EPC valve for LS spool (3) is also OFF, LS spool (3) is pressed to the right
by spring (4). As a result, ports (A) and (B) are interconnected and ports (B) and (C) are interconnected.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to all the pressure compensation valves.
When oil flowing from two pumps are divided [pump merge-divider valve changeover signals (IS1)
and (IS2) are ON]
Operation
• Since drive signal (IS1) of the main spool is ON, main spool (1) is moved to the left by the output pressure
from the pump merge-divider EPC valve. As a result, port (E) is disconnected from port (F).
• The pressurized oil from the two pumps are sent to respective control valve groups.
Pressure P1: To bucket, left travel, boom
Pressure P2: To swing, right travel, arm
• When drive signal (IS2) of the EPC valve for LS spool (3) becomes ON, LS spool (3) is also moved to the
left by the output pressure from the pump merge-divider EPC valve. As a result, ports (A) and (C) are
interconnected, and other ports remain disconnected from each other.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to respective control valves.
PC210LC-10 10-103
Control valve
LS selector valve (PC220-J6PA-041-K-00-A)
a The illustration shows the condition when the combined operation of swing and R.H. travel is performed.
[When pilot pressure (BP) is supplied]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing valve spool
6. R.H. travel valve spool
7. Arm valve spool
8. LS shuttle valve
9. LS circuit
Function (PC220-J6PA-042-K-00-A)
• This valve prevents the high LS pressure of the swing valve from entering the LS circuits of work
equipment valves when the swing and work equipment are in combined operation.
• This valve serves to improve operability of the work equipment by blocking the high pressure generated
during swing operation.
Operation (ALL-J6PA-044-K-00-A)
When pilot pressure (BP) is shut off

• Since pilot pressure (BP) is shut off, piston (3) is pressed to the left by force of spring (2).
• If the swing lever is moved, swing LS pressure (P1) passing through swing spool (5) enters port (A).
• Swing LS pressure (P1) presses valve (1) to the left, and port (A) and port (B) are interconnected.
• Swing LS pressure (P1) is transmitted from port (A) to LS shuttle valve (8) through port (B).
10-104 PC210LC-10
Control valve
When pilot pressure (BP) is supplied

• When pilot pressure (BP) is supplied, pilot pressure (BP) moves piston (3) to the right against the force of
spring (2).
• When piston (3) moves to the right, valve (1) disconnects ports (A) and (B).
• Since ports (A) and (B) are disconnected, swing LS pressure (P1) is not transmitted to LS shuttle valve
(8).
• Swing LS pressure (P1) cannot affect other LS circuits, even if it rises.
PC210LC-10 10-105
Control valve
Self-pressure reducing valve (PC220-PL30-042-K-00-A)

Function
• This valve serves to reduce the delivery pressure of main pump and provide it for solenoid valves, EPC
valves, etc. for use as the control pressure.
Operation (ALL-PL30-044-K-00-A)
When engine is stopped

• Poppet (11) is pressed against the seat by spring (12), so port (PR) is disconnected from port (TS).
• Valve (14) is pressed to the left by spring (13), so port (P2) is disconnected from (TS).
• Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).
10-106 PC210LC-10
Control valve
When load pressure (P2) is low

a When all control levers are in NEUTRAL position, or when load pressure (A2) is lower than output
pressure (PR) of the self-pressure reducing valve
PC210LC-10 10-107
Control valve
• Force of spring (8) and the force exerted by the pressure (PR) (0 MPa {0 kg/cm 2}, when engine is stopped),
are applied to valve (7) in the direction to disconnect the circuit ports (P2) and (A2).
• When the pressurized oil flows in from port (P2), valve (7) balances at a position where [Force (Area fd x
Pressure P2) = Force of spring (8) + Force (Area fd x Pressure PR)] holds.
• The opening of valve (7) is adjusted so that pressure (P2) remains at a constant level higher than pressure
(PR).
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
When load pressure (P2) is high

• As load pressure (A2) increases with the digging operation, etc, the pump delivery increases accordingly.
• Pressure (P2) increases, and [Force (Area fd x Pressure P2] becomes larger than [Force of spring (8) +
Force (Area fd x Pressure PR)]. As a result, valve (7) moves fully to the right.
• Since the area of the opening between ports (P2) and (A2) increases, the passage resistance reduces,
reducing the engine horsepower loss.
• When pressure (PR) rises above the set pressure, poppet (11) opens.
• The pressurized oil flows from port (PR) to orifice (a) in spool (14), then flows to seal drain port (TS) from
the opening of poppet (11).
• Differential pressure generated across orifice (a) in spool (14) moves spool (14) in the direction that the
spool closes the opening between ports (P2) and (PR).
• Pressure (P2) is reduced to a constant pressure (the set pressure) by the opening and supplied for use as
pressure (PR).
10-108 PC210LC-10
Control valve
When abnormally high pressure is generated

• If pressure (PR) of the self-pressure reducing valve becomes abnormally high, ball (16) contracts spring
(15) and separates from the seat.
• This allows the pressurized oil to flow to drain port (TS) from port (PR), lowering pressure (PR).
• As a result, components such as PPC valves and solenoid valves are protected from abnormally high
pressure.
PC210LC-10 10-109
Control valve
10-110 PC210LC-10
Control valve
Travel junction valve (PC220-C6C0-042-K-00-A)

Function
• When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot
pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each
other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability.
• When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST)
from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and
independent amount of oil is supplied to right and left travel motors to secure turning ability.
PC210LC-10 10-111
Control valve
Operation (ALL-C6C0-044-K-00-A)
When pilot pressure (PST) is shut off (travel junction)
• If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is pressed
back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are interconnected.
• If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows
through the opening of travel junction spool (2) from port of higher pressure side to port of lower pressure
side supplying the difference of oil to the lower pressure side so that the oil flow rates to both motors will
be equalized.
10-112 PC210LC-10
Control valve
When pilot pressure (PST) is supplied (travel independent)
• When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2)
compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected.
• The oil flow rate to both right and left motors becomes independent.
PC210LC-10 10-113
Control valve
Travel PPC shuttle valve (PC220-C6V1-042-K-00-A)
PPC: Abbreviation for Proportional Pressure Control
Function
• If boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when the machine is
traveling up a steep, the pilot pressure from the travel PPC valve serves to restrict the travel of respective
spools of boom, arm and bucket valves so that the oil flow rates to respective cylinders are restricted.
• To limit the travel of the boom, arm or bucket spool, the pilot pressure from the travel PPC valve passes
through the internal circuit of respective control valves and acts on the spool.
Operation (ALL-C6V1-044-K-00-A)
When travel levers are in NEUTRAL
• The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons (3)
and (4) build in the travel spring case, and then is drained through the travel PPC valve.
• When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left until it contacts the end face of spring case (2) (st0).
10-114 PC210LC-10
Control valve
When travel lever is operated
• If the right travel lever is moved to REVERSE (or FORWARD) position, the pilot pressure from the travel
PPC valve moves spool (7) to the left (or right).
• Spool (7) pushes piston (3) and orifice (5) is closed. As a result, stroke limiting signal chamber (a) and the
drain circuit from the travel PPC valve are disconnected.
• At this time, the pilot pressure from the travel PPC valve passes through orifice (6) of piston (4), acts on
the left end of piston (8) and pushes piston (8) to the right.
• When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left.
• Maximum travel of the spool is limited to (st1) that has reduction in travel by the amount of movement (st2)
of piston (8) to the right.
PC210LC-10 10-115
Control valve
Boom hydraulic drift prevention valve (PC220-L6C0-042-K-00-A)

Function
• While boom is not operated by the right work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from boom cylinder bottom through spool (1) to prevent the boom from
drifting hydraulically.
Operation (ALL-L6C0-044-K-00-A)
In boom “RAISE“ operation
• When operating boom “RAISE“, the pressurized oil from the control valve exerts a left-hand force on the
right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which
inside diameter is seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and flows
to the boom cylinder bottom.
10-116 PC210LC-10
Control valve
In boom “NEUTRAL“ operation
• When the boom is operated to “NEUTRAL“ position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped
area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat
diameter (d2).
• The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5) to
the right.
• The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylinder
bottom side is kept.
PC210LC-10 10-117
Control valve
In boom “LOWER“ operation
• When operating boom “LOWER“, the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
10-118 PC210LC-10
Control valve
Arm hydraulic drift prevention valve (PC220-L9K0-042-K-00-A)
(if equipped)
Function
• While arm is not operated by the left work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from arm cylinder head through spool (1) to prevent the arm from drifting
hydraulically.
Operation (PC-L9K0-044-K-00-A)
In arm “OUT“ operation
• During arm “OUT“ operation, the pressurized oil from the control valve exerts a left-hand force on the right
side of area (S) of ring-shaped surface, of which outside diameter is equal to diameter (d1) of poppet (5)
and of which inside diameter is equal to seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, pressurized oil from the control valve flows to the arm cylinder head through the opening of
poppet (5).
PC210LC-10 10-119
Control valve
In arm “NEUTRAL“ operation
• When the arm is operated to “NEUTRAL“ position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of arm cylinder head exerts a right-hand force on the left side of ring-shaped area
(S), of which outside diameter is equal to diameter (d1) of poppet (5) and of which inside diameter is equal
to seat diameter (d2).
• The combined force of right-hand force on area (S) and the reaction force of spring (4) moves poppet (5)
to the right.
• The circuit from control valve to arm cylinder head shuts off, then the oil pressure of the arm cylinder head
side is kept.
10-120 PC210LC-10
Control valve
In arm “IN“ operation
• When arm is operated “IN“, the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the arm cylinder head flows from orifice (c) to drain port (T) through orifice (a) and
chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.
PC210LC-10 10-121
Control valve
Suction safety valve for hydraulic drift prevention valve (PC220-L9K2-044-K-00-A)

Operation when abnormally high pressure is generated
• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B)
opens check valve (6) to actuate safety valve (3).
• When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the
pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure,
whichever has higher pressure, opens check valve (6) or (6A) to actuate safety valve (3).
10-122 PC210LC-10
Control valve
Arm quick return valve (PC220-L9K1-042-K-00-A)

Function
• Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
• The valve reduces this pressure loss.
Operation (ALL-L9K1-044-K-00-A)
In arm “OUT“ operation
• In arm “OUT“ operation, the pilot pressure from the PPC valve pushes pilot piston (1).
• The pressurized oil in chamber (b) inside the valve is drained through orifice (c).
• The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiving
surface of [Area (S2) of fd2 (surface of seat diameter)] on the port (A) side exceeds the combined force of
the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side of valve (2)
and the spring force.
• The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring).
• Valve (2) is pressed to the right and pressurized oil flows from port (A) to port (B).
• The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).
PC210LC-10 10-123
Control valve
In arm “NEUTRAL“ operation
• When the arm is operated from arm “OUT“ to “NEUTRAL“, the pilot pressure from PPC valve is shut off.
• The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston (1).
• The holding pressure of the arm cylinder bottom side exerts a left-hand force on the right side of ring-
shaped surface, whose area is equal to the area of (S2 - S1) of valve (2).
• The combined force of the force exerted on the ring-shaped surface and the spring force of the spring (3)
moves valve (2) to the left and shuts off port (A) and port (B).
10-124 PC210LC-10
Control valve
Variable back pressure valve (PC220-PQ81-042-K-00-A)
Function
• This valve creates back pressure in the drain circuit to prevent cavitation caused by negative pressure in
each actuator circuit (motors, cylinders, etc.).
• In order to reduce output loss, this valve reduces the back pressure in the drain circuit when any operation
other than the travel and swing is performed.
Operation (ALL-PQ81-044-K-01-A)
When engine is stopped

• Pressurized oil is not supplied from the main pump to self-pressure reducing valve (1).
• No oil pressure is transmitted from variable back pressure solenoid valve (3) to spring chamber (C), and
valve (6) is pressed to the right by the reaction force of spring (5).
• Drain circuit (A) of the control valve is interconnected to port (T) through orifice (b) of valve (6).
When engine is running (during swing or travel operation)

• The pressurized oil (PR) from self-pressure reducing valve (1) flows to variable back pressure solenoid
valve (3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is “OFF“, pressurized oil (PR) is flown
to spring chamber (C) of variable back pressure valve (4).
• Pressurized oil (PR) transmitted to spring chamber (C) exerts a force on the left end face of valve (6)
(surface of fd), and it pushes valve (6) to the right as a combined force with the reaction force of spring
(5).
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = (Area of
surface fd) x Pressure (PR) + Reaction force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
PC210LC-10 10-125
Control valve
When engine is running (other than swing or travel operation)

• The pressurized oil from self-pressure reducing valve (1) flows to variable back pressure solenoid valve
(3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is “ON“, the pressurized oil (PR) from
self-pressure reducing valve (1) flown to spring chamber (C) of variable back pressure valve (4) is drained
through variable back pressure solenoid valve (3).
• Only the reaction force of spring (5) pushes valve (6) to the right.
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = Reaction
force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.
10-126 PC210LC-10
Control valve
PC210LC-10 10-127
Control valve
Main relief valve (PC220-PQ91-041-K-00-A)
1. Spring
2. Poppet
Function (PC220-PQ91-042-K-00-A)
• This valve has two selectable settings for its set pressure.
• If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is
applied to it from the 2-stage relief solenoid valve.
• The relief valve set pressure is determined by the load at installed length of spring (1). (1st stage set
pressure)
• When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set.
Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure.
Operation (PC-PQ91-044-K-00-A)
When pilot pressure (P) is shut off (low pressure setting)

• The set pressure is determined by the load at installed length of spring (1).
When pilot pressure (P) is supplied (high pressure setting)

• The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to the
area of diameter (d1) of poppet (2), raising the set pressure to higher level.
10-128 PC210LC-10
Control valve
2-stage suction-safety valve (PC220-PQJ2-041-K-00-A)

[Installed to port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function (PC220-PQJ2-042-K-00-A)
• This valve has two settings for its set pressure.
• This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
• ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
• The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
• The set pressure of the low-pressure setting is determined by the travel of the piston.
Operation (ALL-PQJ2-044-K-00-A)
When pilot pressure (P) is shut off (high pressure setting)

• Since pilot pressure (P) is shut off, piston (2) is pressed to the left by force of spring (3). [Load at installed
length of spring (1) < Load at installed length of spring (3).]
• The load at installed length of spring (1) becomes maximum, inducing high-pressure setting.
• Passage (B) is interconnected to the drain circuit via passage (C) and chamber (D).
PC210LC-10 10-129
Control valve
When pilot pressure (P) is supplied (low pressure setting)

• When pilot pressure (P) is supplied, the pilot pressure is transmitted to part (A) through passage (B).
• The pilot pressure acts on the pressure receiving diameter at part (A) [(d1) – (d2)] of piston (2).
• Piston (2) compresses spring (3) by receiving pilot pressure and moves to the right until it contacts holder
(4).
• Since spring (1) is expanded and reducing its load at installed length, the set pressure is lowered.
• The amount of pressurized oil for stroke of piston (2) is drained from passage (C) via chamber (D) .
10-130 PC210LC-10
Swing motor
Swing motor (PC-J610-041-K-00-A)
MA: From control valve (left swing port)

MB: From control valve (right swing port)
B: From swing holding brake solenoid
S: From control valve (variable back pressure valve)
PI: From 2-stage relief solenoid valve
1. Reverse prevention valve
2. 2-stage swing relief valve
PC210LC-10 10-131
Swing motor
1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston
10-132 PC210LC-10
Swing motor
10. Cylinder block

11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Specifications (PC220-J610-030-K-00-A)
Type KMF125ABE-6
Theoretical delivery (cm3/rev) 125
2-stage swing relief valve pressure (MPa {kg/cm2}) 28.4 {290}
Low-pressure setting 180

2-stage swing relief oil flow (l/min)
High-pressure setting 70
Rated speed (rpm) 1,694
Brake release pressure (MPa{kg/cm2}) 1.6 ± 0.4 {16 ± 4}
PC210LC-10 10-133
Swing motor
Swing holding brake (PC-J6A0-044-K-00-A)

When solenoid valve is “de-energized“
• When the swing holding brake solenoid valve is de-energized, the pressurized oil from the self-pressure
reducing valve is blocked.
• Port (B) is connected to tank circuit (T).
• Brake piston (7) is pushed downward by brake spring (1).
• Disc (5) and plate (6) are pushed against each other to apply the brake.
10-134 PC210LC-10
Swing motor
When solenoid valve is “energized“
• When the swing holding brake solenoid valve is energized, the valve is switched.
• The pressurized oil from self-pressure reducing valve enters port (B), and flows into brake chamber (a).
• After entering chamber (a), the pressurized oil compresses brake spring (1) and moves brake piston (7)
upward.
• Disc (5) is separated from plate (6), releasing the brake.
Relief valve (PC220-J6B1-041-K-00-A)

• The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).
Function (PC220-J6B1-044-K-00-A)
• When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is
continued by inertial force.
• If the pressure of motor outlet circuit becomes abnormally high, it may cause damage to the motor.
• In order to prevent the motor damage, the relief valve relieves the abnormally high pressure to port (S)
from the motor outlet (high-pressure side).
PC210LC-10 10-135
Swing motor
Operation (PC-J6B1-044-K-00-A)
When swing is started
• When the swing control lever is moved to the “swing RIGHT position“, the pressurized oil from the pump is
supplied to port (MA) through control valve (6).
• The pressure in port (MA) rises, the starting torque is generated in the motor, and the motor starts to
rotate.
• During swing acceleration, the pilot pressure from 2-stage relief solenoid valve (7) is applied to port (PI) to
limit the relief volume.
• The pressurized oil from the outlet of the motor returns to the tank through port (MB) and control valve (6).
10-136 PC210LC-10
Swing motor
When swing is stopped
• When the swing control lever is returned to “NEUTRAL“ from “swing RIGHT“ position, the supply of
pressurized oil from the pump to port (MA) is stopped.
• The pressurized oil from the motor outlet cannot return to the tank since the return circuit to the tank is
blocked by control valve (6). Thus, pressure in port (MB) increases.
• If the pressure in port (MB) becomes too high, the pressurized oil returns to the hydraulic tank through
relief valve (1) and port (S).
• Rotation resistance is exerted on the motor and the brake starts working.
• If the pressure in port (MB) becomes higher than that in port (MA), it presses shuttle valve (4).
• The pressure in chamber (C) becomes the same as that in port (MB), and increases to the set pressure of
relief valve (1).
• A high braking torque works on the motor, thereby stopping the motor.
• While relief valve (1) is actuated, the relieved pressurized oil and the pressurized oil from port (S) are
routed to port (MA) through the check valve (3).
• Thus, cavitations in port (MA) is prevented.
PC210LC-10 10-137
Swing motor
2-stage swing relief valve (PC-JA1A-041-K-00-A)
1. Valve seat
2. Valve
3. Poppet
4. Spring
5. Spring
6. Piston
Function (PC220-JA1A-042-K-00-A)
• This valve has two selectable settings for set pressure.
• The set pressure of this valve is determined by the load at installed length of spring (4).
• During swing acceleration, this valve receives pilot pressure (PI) from the 2-stage swing relief solenoid
valve and decreases the relief quantity (drain quantity).
• If pressure (P) is constant, energy loss can be reduced by decreasing oil flow (Q), or relief quantity (drain
quantity), according to the formula of [Energy loss = Pressure (P) x Oil flow (Q)]. Decrease in energy loss
leads to improvement of fuel consumption.
A: When pilot pressure is “shut off“ (low-pressure setting)

B: When pilot pressure is “transmitted“ (high-pressure setting)
P: 28.4 MPa {290 kg/cm2}
Q1: 180 l/min
Q2: 70 l/min
10-138 PC210LC-10
Swing motor
Operation (PC220-JA1A-044-K-00-A)
When pilot pressure (PI) is shut off (low pressure setting)

• The set pressure is determined by the load at installed length of spring (4).
When pilot pressure (PI) is supplied (high pressure setting)

• During swing acceleration, pilot pressure (PI) from the 2-stage swing relief solenoid valve acts on the
power receiving area (d2 – d1).
• Spring (4) is compressed, the load at installed length of the spring is increased, and then the passage
between valve (2) and valve seat (1) is narrowed while the pump delivery is decreased by the controller.
As a result, the flow rate to hydraulic relief decreases when relief pressure is constant.
PC210LC-10 10-139
Swing motor
Swing motor reverse prevention valve (PC-J6B2-041-K-00-A)
MA: From control valve (left swing port)

MB: From control valve (right swing port)
10-140 PC210LC-10
Swing motor

1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)
Explanatory drawing of effects
Function (PC220-J6B2-042-K-00-A)
• At the stop of swing operation, the upper structure may swing back. This is due to inertia of the mass of
the upper structure, the backlash and rigidity of the swing machinery system, and compressibility of the
hydraulic oil. This valve prevents such movement.
• The valve contributes to prevention of load spillage when the swing is stopped and also contributes to
reduction in the cycle time (enhances the positioning performance, enabling you to proceed to the next
work quicker than ever).
PC210LC-10 10-141
Swing motor
Operation (PC220-J6B2-044-K-00-A)
When brake pressure is generated in port (MB)
• Pressure (MB) is led to chamber (d) through notch (g).

• As (fD1 > fD2) holds in regards to circle areas of spool (5), spring (6) is compressed and spool (5) is
moved to the left.
• Port (MB) and chamber (e) are interconnected to each other.
• Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the
pressurized oil is blocked. Thus the braking force is ensured.
When motor reversing pressure is generated in port (MA)
• The trapped pressure in port (MB) turns the motor in the opposite direction. (1st reverse rotation)
• Reversing pressure is generated in port (MA). Pressure (MA) is transmitted to chamber (a).
• As (fD3 > fD4) holds in regard to circle areas of spool (2), spring (3) is compressed and spool (2) is
moved to the right.
• Port (MA) and chamber (b) are interconnected to each other.
• Port (b) is interconnected to port (f) through the drilled hole (h) in spool (5). This bypasses the reversing
pressure in port (MA) to port (T), thereby preventing the 2nd reverse rotation of the motor.
10-142 PC210LC-10
Travel motor
Travel motor (PC200_10-C400-041-K-00-A)
L.H. travel motor

PA: From control valve (L.H. travel FORWARD port)
PB: From control valve (L.H. travel REVERSE port)
R.H. travel motor
PA: From control valve (R.H. travel REVERSE port)
PB: From control valve (R.H. travel FORWARD port)
P: From travel speed increase solenoid valve
B: Plug (Brake release pressure port)
MA: Port pressure pickup port
MB: Port pressure pickup port
PC210LC-10 10-143
Travel motor
1. Regulator piston
2. Regulator valve
3. Motor case
5. Check valve
6. Rocker cam
7. Retainer guide
8. Output shaft
9. Pin
10-144 PC210LC-10
Travel motor
10. Retainer
11. Piston
12. Cylinder block
13. Valve plate
14. Counterbalance valve spool
15. Ring
16. Brake piston
17. Plate
18. Disc
19. Ball retainer
Specification (PC200_10-C400-030-K-00-A)
Model HMV120-2
Min. 82
Theoretical delivery (cm3/rev)
Max. 120
Rated pressure: MPa {kg/cm2} 37.3 {380}
Min. 2,565
Rated speed (rpm)
Max. 1,595
Brake release pressure
1.18 {12}
(MPa {kg/cm2})
Travel speed changeover pressure
0.78 {8.0}
(MPa {kg/cm2})
PC210LC-10 10-145
Travel motor
Operation of travel motor (PC-C400-044-K-00-A)

Travel speed at low-speed setting (motor swash plate angle is at maximum)
• When the solenoid valve is de-energized, the pilot pressure oil from the self-pressure reducing valve does
not flow to port (P).
• Regulator valve (9) is pushed to the right by spring (10).
• The pressurized oil flowing from the control valve to end cover (8) through check valve (22) is stopped by
regulator valve (9).
• The fulcrum (a) of rocker cam (4) is located eccentric to the point of action (b) for the resultant force of
piston thrusts of cylinders (6).
• The resultant force of piston thrusts acts on rocker cam (4) as a moment that tilts the rocker cam toward
the maximum swash plate angle position.
• The pressurized oil in regulator piston (15) flows through orifice (c) in regulator valve (9), and is drained
into the motor case.
• Rocker cam (4) reaches the maximum swash plate angle position, thus, the motor capacity is maximized
and the travel speed is set to low-speed setting.
10-146 PC210LC-10
Travel motor
Travel speed at high-speed setting (motor swash plate angle is at minimum)
• When the solenoid valve is energized, the pilot pressure oil from the self-pressure reducing valve flows to
port (P).
• Regulator valve (9) is pressed to the left.
• The pressurized oil from the control valve flows through passage (d) of regulator valve (9), and enters
regulator piston (15).
• Regulator piston (15) is pressed to the right.
• Rocker cam (4) tilts toward the minimum swash plate angle position. The motor capacity is minimized and
the travel speed is set to high-speed setting when the rocker cam reaches the position.
PC210LC-10 10-147
Travel motor
Operation of parking brake (PC-C4A0-044-K-00-A)

When starting travel
• When the travel lever is operated, the pressurized oil from the pump acts on counterbalance valve spool
(19) to make the parking brake circuit.
• The oil flows into chamber (e) of brake piston (12), compresses spring (11), and pushes piston (12) to the
left.
• Since the force pressing plate (13) and disc (14) against each other is eliminated, they are separated and
the brake is released.
10-148 PC210LC-10
Travel motor
When stopping travel
• When the travel lever is returned to NEUTRAL, counterbalance valve spool (19) returns to the neutral
position, and the parking brake circuit is blocked.
• The pressurized oil in chamber (e) of brake piston (12) is drained to the case through orifice (f) of brake
piston (12).
• Brake piston (12) is pressed to the right by spring (11).
• Plate (13) and disc (14) are pressed against each other, and the brake is applied.
• When brake piston (12) is returned, the flow of pressurized oil is restricted by slow return valve (22).
• This makes a delay in the application of the parking brake. The parking brake is applied after the machine
has stopped.
PC210LC-10 10-149
Travel motor
Brake valve (ALL-C4Q0-041-K-00-A)
• Brake valve is comprised of suction safety valves (18A) and (18B), and counterbalance valve (18).
Counterbalance valve (PC220-C4N0-042-K-00-A)
Function
• When the machine travels down a slope, its travel speed tends to get faster than the motor (engine) speed
because of the downward force generated from its own weight.
• Traveling the machine with the engine running at a low speed may induce idle run of the motor that allows
the machine to run out of control, posing a danger.
• These valves serve to prevent the above problem by enabling the machine to travel at a speed that
matches the engine speed (pump delivery).
10-150 PC210LC-10
Travel motor
Operation (PC-C4N0-044-K-00-A)
Operation when pressurized oil is supplied
• When the travel lever is operated, the pressurized oil is supplied from the control valve to port (PA).
• The oil opens suction safety valve (18A), and then flows from motor inlet port (MA) to motor outlet port
(MB).
• Since the motor outlet circuit is blocked by suction safety valve (18B) and spool (19), the pressure of the
supply side circuit increases.
PC210LC-10 10-151
Travel motor
• The pressurized oil of the supply side circuit flows through orifices (E1) and (E2) of spool (19) to chamber
(S1).
• When the pressure in chamber (S1) becomes higher than the spool selector pressure (reaction force of
spring (20)), spool (19) is pushed to the right.
• Both motor outlet port (MB) and port (PB) are connected to outlet passage (B1). As the result, the motor
outlet side opens and the motor rotates.
10-152 PC210LC-10
Travel motor
Braking while travelling downhill
• When the machine almost run out of control during downhill travel, the motor runs idle and the pressure of
the inlet side circuit decreases.
• The pressure in chamber (S1) decreases through orifices (E1) and (E2).
• When the pressure in chamber (S1) becomes lower than the spool selector pressure, spool (19) is
returned to the left by the reaction force of spring (20) and outlet passage (B1) is throttled.
• The pressure of the motor outlet side circuit increases and rotational resistance is generated in the motor,
preventing the machine from running out of control.
• Spool (19) moves to a position where the two forces acting on the spool balance with each other; one is
the force exerted by the pressure in the motor outlet port and the other is the sum of the force due to
machine's own weight and the force exerted by the pressure in the motor inlet port.
• Narrowing down the motor outlet side circuit in this way allows the machine to travel at a speed that
matches the pump delivery.
Suction safety valve (PC220-C660-042-K-00-A)
Function
• While the machine is stopped (or when it is travelling downhill), the counterbalance valve blocks the
passage between the inlet and outlet circuits of the motor.
• Since the motor is rotated by inertial force, the pressure in the motor outlet port is abnormally increased,
potentially causing damage to the motor and piping.
• The safety valve releases this abnormal pressure to the inlet port of the motor to prevent damage of the
equipment.
PC210LC-10 10-153
Travel motor
Operation (PC-C660-044-K-00-A)
When machine stops traveling (or traveling downhill) (when motor rotating clockwise)
• When the travel lever is set to NEUTRAL position, pressure (PA) in the motor inlet port decreases and the
pressure in chamber (S1) also decreases.
• When pressure drops below the changeover pressure of spool (19), spool (19) is pushed to the left by
reaction force of sprig (20) and narrows outlet passage (B1).
• Since inertial force maintains motor rotation, pressure (MB) of the outlet port side circuit increases.
• The pressurized oil pushes open check valve (17) and flows to the inlet side circuit on the opposite side
through notch (A1) of spool (19).
• If the pressure becomes higher than the set pressure of suction safety valve (18A), poppet (1) opens.
• When motor rotates counterclockwise, it operates reverse for clockwise rotation.
10-154 PC210LC-10
Travel motor
When starting travel (or when traveling normally)
• When the travel lever is operated, the pressurized oil from the pump moves spool (19) to the right.
• The pressurized oil flows to suction safety valve (18B) through check valve (16) and port (A2).
• Since the pressurized oil flowing through the circuit is throttled at notch (20), the pressure difference
between the inlet side and outlet side increases.
• The pump pressure rises and the large drawbar pull is obtained.
PC210LC-10 10-155
PPC valve
PPC valve (ALL-CW10-001-P-00-A)

Work equipment and swing PPC valve (PC-PL28-041-K-00-A)
L.H. work equipment control lever

P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
10-156 PC210LC-10
PPC valve
P3: To control valve (LEFT swing port)

P4: To control valve (RIGHT swing port)
R.H. work equipment control lever
P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic oil tank
PC210LC-10 10-157
PPC valve
1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)
10-158 PC210LC-10
PPC valve
5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter
Operation (PC-PL28-044-K-00-A)
When control lever is in NEUTRAL position

• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).
When control lever is in fine control range
(When moved from NEUTRAL to fine control range)

• When piston (4) is pushed by disc (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downward.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure from the main pump is transmitted from port (P1) to port (A) through the fine control
hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
exerted by the pressure in port (P1).
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
PC210LC-10 10-159
PPC valve
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.
(When returned to fine control range)

• When disc (5) begins to return, spool (1) is pushed up by the force of centering spring (3) and the force
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is depressed by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is supplied until the pressure at port (P1) recovers to the level corresponding to the
lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.
10-160 PC210LC-10
PPC valve
When control lever is moved to stroke end

• Disc (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').
PC210LC-10 10-161
PPC valve
10-162 PC210LC-10
PPC valve
Travel PPC valve (PC-C6V0-041-K-00-A)

P1: To control valve (L.H. travel REVERSE port)
P2: To control valve (L.H. travel FORWARD port)
P3: To control valve (R.H. travel REVERSE port)
P4: To control valve (R.H. travel FORWARD port)
PC210LC-10 10-163
PPC valve
1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper
10-164 PC210LC-10
PPC valve
Operation (PC-C6V0-044-K-00-A)
When control lever is in NEUTRAL position

• Ports (A) and (B) of the control valve and ports (P1) and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) in spool (1).
(When moved from NEUTRAL to fine control range)

• When piston (4) is pushed by lever (5), retainer (9) is pushed and spool (1) is also pushed by metering
spring (2) and moves downwards.
• When fine control hole (f) is disconnected from drain chamber (D), it is connected to pump pressure
chamber (PP) at almost the same time.
• The pilot pressure from the control pump is transmitted from port (P1) to port (A) through the fine control
hole (f).
• When the pressure in port (P1) becomes higher, spool (1) is pushed back and fine control hole (f) is
disconnected from pump pressure chamber (PP). At almost the same time, it is connected to drain
chamber (D) to release the pressure in port (P1).
• Accordingly, spool (1) moves up and down until the force of metering spring (2) is balanced with the force
• The positional relationship between spool (1) and valve body (10) [fine control hole (f) is located between
drain chamber (D) and pump pressure chamber (PP)] does not change until retainer (9) comes in contact
with spool (1).
• Metering spring (2) is compressed in proportion to the control lever travel.
• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.
PC210LC-10 10-165
PPC valve
(When returned to fine control range)

• When lever (5) starts to return, spool (1) is pushed up by the force of centering spring (3) and the force
• Fine control hole (f) is connected to drain chamber (D), and the pressurized oil in port (P1) is released.
• If the pressure in port (P1) is excessively reduced, spool (1) is depressed by metering spring (2).
• Fine control hole (f) is disconnected from drain chamber (D), and at almost the same time, it is connected
to pump pressure chamber (PP).
• The pump pressure is supplied until the pressure at port (P1) recovers to the level corresponding to the
lever position.
• When the spool of the control valve returns, the pressurized oil in drain chamber (D) flows in through fine
control hole (f') in the valve on the side that is not operated. The oil passes through port (P2) and flows into
port (B) to replenish the port with pressurized oil.
10-166 PC210LC-10
PPC valve
When control lever is moved to stroke end

• Lever (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').
PC210LC-10 10-167
PPC valve
10-168 PC210LC-10
PPC valve
1st-line attachment PPC valve (with EPC valve) (PC200_10-PL29-041-K-00-A)
(if equipped)
a For details of operation, see “Work equipment and swing PPC valve“.
PC210LC-10 10-169
PPC valve

P1: To control valve (service valve 1 port)
10-170 PC210LC-10
PPC valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Valve body
7. EPC valve
EPC valve (PC200_10-PL2B-041-K-00-A)

(if equipped)

C: To PPC valve (R.H. attachment)
1. Valve body
PC210LC-10 10-171
PPC valve
2. Spool
3. Spring
4. Coil
5. Plunger
6. Push pin
7. Connector
Function (PC-PL2B-042-K-00-A)
• The EPC valve consists of the proportional solenoid portion and the hydraulic valve.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and output to the control valve.
Operation (PC200_10-PL2B-044-K-00-A)
When signal current is zero amp. (coil is de-energized)

• Since the signal current from the controller does not flow through coil (4), coil (4) is de-energized.
• Spool (2) is pushed to the left by spring (3).
• Port (P) is blocked, so the pressurized oil from the front pump does not flow to the control valve.
• The pressurized oil from the control valve is drained to the tank through port (C) and port (T).
10-172 PC210LC-10
PPC valve
When signal current is minute (coil is energized)

• When minute signal current flows through coil (4), coil (4) is energized and the thrust pushing plunger (5)
lightward is generated.
• Push pin (6) pushes spool (2) to the light, and the pressurized oil from port (P) flows to port (C).
• The pressure in port (C) increases and the combined force of the force applied on surface (a) of spool (2)
and the reaction force of spring (3) become larger than the thrust of plunger (5).
• Spool (2) is pressed to the left, so port (P) is disconnected from port (C) and port (C) is connected to port
(T).
• Spool (2) moves to a position where the thrust of plunger (5) is equal to the total of the force exerted by the
pressure in port (C) and the force of spring (3).
• Thus, the circuit pressure between the EPC valve and the control valve is controlled in proportion to the
amperage of the signal current.
PC210LC-10 10-173
PPC valve
When signal current is maximum (coil is energized)

• Coil (4) is energized when the signal current flows through coil (4).
• As the signal current is the maximum, the thrust of plunger (5) is also maximized.
• Spool (2) is pushed to the light by push pin (4).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and control valve is maximized.
• Port (T) is blocked, so no pressurized oil flows to the hydraulic tank.
10-174 PC210LC-10
PPC valve
PC210LC-10 10-175
PPC valve
2nd-line attachment PPC valve (PC-PL2A-041-K-00-A)
(if equipped)
a For details of operation, see "Work equipment and Swing PPC valve".

10-176 PC210LC-10
PPC valve
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Valve body
PC210LC-10 10-177
Solenoid valve
Solenoid valve (ALL-PQPT-041-K-00-A)
a The figure shows the valve for a machine ready for installation of attachment.
P1: From self-pressure reducing valve

A1: To PPC valve
10-178 PC210LC-10
Solenoid valve
A2: To control valve [Port (PX1) and (PX2)]

A3: To swing motor [Port (B)]
A4: To travel motor [Port (P)]
A5: To control valve [Port (PST)]
A6: To swing motor 2-stage relief valve
A7: To attachment circuit selector valve
ACC: To accumulator (for PPC circuit)
3. Swing holding brake solenoid valve
6. Swing 2-stage relief solenoid valve
7. Attachment circuit selector solenoid valve (for machines ready for installation of attachment)
Solenoid valve
8. Coil (ON/OFF type)
9. Push pin
10. Valve spool
11. Sleeve
12. Block
13. Plug
Check valve
14. Plug
15. Plunger
Operation (ALL-PQPT-044-K-00-A)
Operation of check valve
• This valve is installed between port (P) and the PPC solenoid valve. When the engine is stopped, plunger
(1) is pushed back to the left by the reaction force of spring (2), so the passage between ports (ACC) and
(P) is blocked, keeping the pressure in the accumulator.
• When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P),
so port (P) is connected to port (ACC).
PC210LC-10 10-179
Solenoid valve
Operation of solenoid valve
When solenoid valve is “de-energized“ (circuit is blocked)
• Coil (1) is de-energized when no signal current flows through coil (1).
• Spool (2) is pushed back to the left by reaction force of spring (3).
• As the passage between ports (P) and (A) is blocked, the pilot pressure is not fed to the actuator through
port (A). At the same time, the passage to port (T) is made, so the oil from the actuator is drained to the
hydraulic tank.
When solenoid valve is “energized“ (circuit is made)
• Coil (1) is energized when the signal current flows through coil (1).
• Spool (2) is pushed to the right by push pin (4).
• The passage between ports (P) and (A) is made, so the pilot pressure flows to the actuator through port
(A). At the same time, the passage to port (T) is blocked, so the oil from the actuator does not flow to the
hydraulic tank.
10-180 PC210LC-10
Attachment circuit selector valve (for high pressure
circuit)
Attachment circuit selector valve (for high pressure circuit) (ALL-PQJ5-041-K-00-A)
(if equipped)
PI: From attachment circuit selector solenoid valve

ACC: To accumulator
ATT: To attachment
1. Spool
• For a machine equipped with a breaker, this valve allows the oil from the breaker to return directly to the
hydraulic tank without passing through the main valve.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to interconnect the
attachment to the main valve.
Operation (ALL-PQJ5-044-K-00-A)
When attachment other than breaker is installed
PC210LC-10 10-181
Attachment circuit selector valve (for high pressure
circuit)
• Spool (1) is pressed to the left by the force of spring (2).

• Since port (ATT) is disconnected from port (ACC), no oil flows to the accumulator.
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is interconnected to port (ACC) and oil flows to the accumulator, so oil pulsation is absorbed by
the accumulator.
10-182 PC210LC-10
Attachment circuit selector valve (for low pressure
circuit)
Attachment circuit selector valve (for low pressure circuit) (PC-PQJ3-041-K-00-A)
(if equipped)
PI: From attachment circuit selector solenoid valve

V: To control valve attachment 1 port
ACC: To accumulator
ATT: To attachment
1. Spool
• For a machine equipped with a breaker, this valve serves to interconnect between the main circuit from the
control valve to the breaker and the accumulator.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to disconnect the main
circuit from the accumulator.
PC210LC-10 10-183
circuit)
Operation (PC-PQJ3-044-K-00-A)
When attachment other than breaker is installed
• Spool (1) is pressed to the left by the force of spring (2).

• Port (ATT) is interconnected to port (V) and is disconnected from port (T). Thus, the attachment is
interconnected to the control valve.
10-184 PC210LC-10
circuit)
When breaker is installed
• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is disconnected from port (V) and is interconnected to port (T).
• The pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without
passing through the control valve.
PC210LC-10 10-185
Center swivel joint
Center swivel joint (PC220-J8E0-041-K-00-A)
A1: To L.H. travel motor port (PB)

A2: From control valve (L.H. travel FORWARD port)
B1: To L.H. travel motor [Port (PA)]
B2: From control valve (L.H. travel REVERSE port)
C1: To R.H. travel motor [Port (PA)]
C2: From control valve (R.H. travel FORWARD port)
D1: To R.H. travel motor [port (PB)]
D2: From control valve (R.H. travel REVERSE port)
E1: To L.H. and R.H. travel motor [port (P)]
E2: From travel speed increase solenoid valve
DR1: From L.H. and R.H. travel motor [port (T)]
DR2: To hydraulic tank
1. Cover
10-186 PC210LC-10
Center swivel joint
2. Slipper seal
3. Rotor
4. Dust seal
5. O-ring
6. Cover
7. Shaft
PC210LC-10 10-187
Accumulator
Accumulator (PC-PL40-001-K-00-A)
PPC accumulator (PC-PL40-041-K-00-A)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications (PC-PL40-030-K-00-A)
Gas to be used Nitrogen gas

Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. operating pressure
6.86 {70}
(MPa {kg/cm2})
Function (PC-PL40-042-K-01-A)
• The accumulator is installed on the solenoid valve. If the engine is stopped with the work equipment raised,
the pressure of the compressed nitrogen gas in the accumulator develops the pilot pressure to be supplied
to the control valve. Therefore, the spool can be operated to lower the work equipment by its own weight.
10-188 PC210LC-10
Work equipment
Work equipment (ALL-L000-001-K-00-A)
Work equipment (PC-L410-041-K-00-A)
1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder
PC210LC-10 10-189
Work equipment shim
Work equipment shim (PC220-L413-040-K-00-A)

Outline
• There are two types of the work equipment shims; one is the iron shims and the other is the plastic shims.
• The work equipment shims are inserted so that the clearance in each joint of the work equipment will be
the standard value.
Function
Iron shims
• The iron shims are primarily inserted in the parts that need to be greased every 100 hours.
• One purpose of the iron shims is to reduce the play of the work equipment in the lateral direction.
a The shims need to be inserted on only the right or left side and do not need to be inserted on the
adjustment side, depending on the adjusting quantity of the clearance.
Plastic shims
• The plastic shims are primarily inserted in the parts that need to be greased every 500 hours.
• The purposes of the plastic shims are to reduce the play of the work equipment in the lateral direction and
prevent squeaks and scuffing caused by rubbing of the steel parts at the end faces of the joint portions.
• Combined with the greasing interval extension bushings, the plastic shims prevent squeaks caused by
lack of grease and extend the greasing intervals.
• The plastic shims are inserted in every contact face of each part so that the steel parts at the end faces of
the joint portion will not come in contact with each other.
a Combined with the greasing interval extension bushings and dust seals, the plastic shims extend the
greasing interval to 500 hours.
10-190 PC210LC-10
Bucket play adjustment shim
Bucket play adjustment shim (PC220-LBKB-040-K-00-A)

Outline
• The separated iron shims are used for the connection of arm and bucket.
• By adjusting the number of shims, play at connecting part can be adjusted.
a Play can be reduced by deleting some shims when the play becomes large.
PC210LC-10 10-191
Cab mount and cab tipping stopper
Cab and its attachments (ALL-K000-001-K-00-A)
Cab mount and cab tipping stopper (PC-K138-041-K-00-A)
1. Front damper
2. Rear damper
3. Cab tipping stopper
Structure
• 4 dampers are located in front and rear of cab (2 each), and fix cab and floor frame onto revolving frame.
• Oil-filled damper is used to absorb vibration.
• Cab tipping stopper (3) installed at a place in the rear section aims to secure the cab when the machine
tips over.
• As shown in following table, various dampers are available upon its mounting location.
Color of identifying seal
Location of damper Bent of craw
(printing)
Front left Not bent Yellow (215)
Front right Bent Blue (200)
Rear left Not bent Yellow (215)
Rear right Not bent Yellow (215)
10-192 PC210LC-10
ROPS cab
ROPS cab (PC-K000-041-K-00-A)
ROPS: Abbreviation for Roll-Over Protective Structure
1. Front window
2. Windshield wiper
3. Head lamp
4. Ceiling window
5. KOMTRAX communication antenna
6. KOMTRAX GPS antenna
7. Radio antenna
8. Door
9. Mirror
Function (PC220-K000-042-K-00-A)
• ROPS cab is a structure which protects the operator fastening a seat belt not to be crushed when the
machine tips over.
PC210LC-10 10-193
Electrical control system
Electrical system (ALL-RA1D-001-K-01-A)
Electrical control system (PC220-C050-001-K-00-A)
Machine control system diagram (PC220-C050-051-K-00-A)
a Items marked with "*1" in drawing are the optional equipment.
10-194 PC210LC-10
PC210LC-10 10-195
10-196 PC210LC-10
Engine control function (PC220-AK60-042-K-00-A)
1. Battery disconnect switch

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Fuel supply pump
17. Sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller
Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start until the lock lever is set to the “LOCK“ position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7)
is usable for stopping the engine.
Starting the engine

• If starting switch (6) is turned to “ON“ position , engine controller (8) sends command current to fuel supply
pump (16).
PC210LC-10 10-197
For this reason, a fail-safe mechanism is provided with the electrical system to stop the engine when an
electrical failure occurs.
• If starting switch (6) is turned to “START“ position when lock lever (9) is in the “LOCK“ position, starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in the “FREE“ position, starting motor cut-off relay (11) cuts off the starting current to
starting motor (15), thus the engine does not start. This is the neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) causes starting motor cut-off relay (12) to cut off the starting current to starting motor
(15), therefore the engine does not start.
Engine speed control

• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects lower throttle signal, and sends command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.
Engine stop
• If starting switch (6) is turned to “OFF“ position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops fuel feed, decreasing the engine speed until the engine stops.
Stopping the engine with engine shutdown secondary switch

• If engine shutdown secondary switch (7) is turned to “Stop Engine“ position, the current from ACC terminal
of starting switch (6) to engine controller (8) is forcibly cut off.
Above induces the same state as when starting switch (6) is turned to “OFF“ position, stopping the engine.
10-198 PC210LC-10
Engine and pump combined control function (PC200_10-C3W0-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
9. Machine monitor
10. Emergency pump drive switch
13. Sensors
16. One-touch power max. switch
17. Front pump oil pressure sensor
18. Rear pump oil pressure sensor
PC210LC-10 10-199
19. Oil pressure sensor

20. Oil pressure switch
21. Front pump
21a. Servo
21b. LS valve
21c. PC valve
22. Rear pump
22a. Servo
22b. LS valve
22c. PC valve
23. Control valve
24. Front pump PC-EPC valve
25. Rear pump PC-EPC valve
26. LS-EPC valve
Input and output signals
a: Front pump PC-EPC valve drive signal
b: Rear pump PC-EPC valve drive signal
c: Solenoid valve GND
d: CAN signal
e: LS-EPC valve drive signal
f: Swash plate sensor signal
g: Oil pressure sensor signal
h: One-touch power max. switch signal
i: Oil pressure switch signal
j: 1st throttle signal
k: Supply pump control signal
l: Sensor signals
Function
• This function allows the operator to select any of the six working modes of P, E, L, ATT-P, ATT-E and B
with the working mode selector switch of the machine monitor. The most suitable combination of engine
torque (T) and pump absorption torque can be selected depending on the work contents of the machine. If
“None“ is selected for the attachment in the default setting of the service mode, one of the three modes of
P, E and L is selectable.
• The pump controller calculates the pump absorption upper limit torque based on the working mode, speed
setting by the fuel control dial, and actual engine speed, and controls the pump to maintain it near the
setting matching point for each mode even at high loads.
• When the engine speed is lowered, the controller prevents the engine from stopping by throttling the pump
absorption torque.
10-200 PC210LC-10
Control method in each mode

P, E, L, ATT-P and ATT-E modes
Matching point
Working mode Matching point
P and ATT-P 100.7 kW/1,700 rpm
(During work) {135 HP/1,700 rpm}
E and ATT-E 86.1 kW/1,680 rpm
(During work) {115.4 HP/1,680 rpm}
• In P, E, ATT-P and ATT-E modes, the engine speed is always controlled so that it is kept around the
matching point specified for each mode.
• At light loads, the engine operates at high speeds. As the load increases, the engine speed decreases
while the torque is increased, until the matching point with pump absorption torque upper limit (PT) is
reached. [See (1) in graph]
• As the load increases further, the engine speed decreases further. [See (2) in graph]
• The controller lowers the pump absorption upper limit torque (PT) to reduce the load on the engine. [See
(3) in graph]
PC210LC-10 10-201
• As the engine load decreases, the engine speed increases. [See (4) in graph]
• The controller raises the pump absorption upper limit torque (PT) to maintain it near the matching point.
[See (5) in graph]
• To save fuel consumption, the controller lowers the engine matching speed (Nm) at low loads (low delivery
and torque). [See (6) in graph]
B and L modes
Working mode Partial output point
B 75 %
L 70 %
Matching point
Working mode Matching point
77.2 kW/1,655 rpm
B
{103.5 HP/1,655 rpm}
73.55 kW/1,650 rpm
L
{98.60 HP/1,650 rpm}
• In B or L mode, engine output is controlled to a constant level.
10-202 PC210LC-10
• The controller controls the pump absorption upper limit torque (PT) to keep the engine torque constant
along the equal engine horsepower curve.
Control function when travelling

• The engine speed (N) increases when if machine travels in P or ATT-P mode.
• Traveling the machine in E, ATT-E or B mode leaves the working mode unchanged, but raises the pump
absorption torque and engine speed (N) to values same as those in P mode.
• If the machine travels in L mode, the working mode and engine speed (N) do not change, but the pump
absorption torque is increased.
PC210LC-10 10-203
Control function that becomes available when emergency pump drive switch is turned on.
• Even if any abnormality occurs in the controller and no work is possible because the main pump does not
work properly, operating emergency pump drive switch (1) temporarily enables to maintain functions of the
machine with absorption torque quite similar to those in the E mode.
In this case, a constant current flows from the battery to the PC-EPC valve, so the oil pressure is sensed
by only the PC-EPC valve.
a: Emergency (when abnormal)
b: Normal (when normal)
a Emergency pump drive switch (1) is an alternative type. If the machine is operated at “Emergency (a)“
position when the machine is normal condition, Action Level “L03“ will be shown on the display.
10-204 PC210LC-10
PC210LC-10 10-205
Pump and valve control function (PC220-C3W1-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Sensors
16. Front pump
16a. Servo
16b. LS valve
10-206 PC210LC-10
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18d. Main relief valve
18e. Variable back pressure valve
21. LS-EPC valve

a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve GND
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Pump merge-divider EPC valve (for main spool) drive signal
h. Pump merge-divider EPC valve (for LS spool) drive signal
i. Travel junction solenoid valve drive signal
j. 2-stage relief solenoid valve drive signal
k. Variable back pressure solenoid valve drive signal
l. 1st throttle signal
m. Fuel supply pump control signal
n. Sensor signals
Function
• The LS control function, cut-off function, and 2-stage relief function enable the machine to maintain the
optimum matching under various working conditions.
LS control function
• According to the actuator operation, the output pressure from the LS-EPC valve to LS valve varies in order
to change the selector point for pump delivery [LS set differential pressure (DLS)] in the LS valve.
• The build-up time of pump delivery will be optimized, and the ease of combined operation and fine control
will be improved.
PC210LC-10 10-207
A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig) = 1.8 MPa {18 kg/cm2}
Cut-off function
• This function increases PC-EPC current (J) to reduce the flow rate at relief, improving fuel consumption.
Operating for turning on cut-off function
When the one-touch power maximizing function is not activated and the average of front pump and rear
pump oil pressure sensor values is 27.9 MPa {285 kg/cm2} or higher.
The cut-off function does not work, however, while the machine is travelling, swing lock switch is in “ON“
position.
A: PC-EPC current at cut-off

2-stage relief function
• If the operating conditions of 2-stage relief function are met, relief pressure during work increases.
Operating conditions for 2-stage relief function Relief pressure
• When traveling 34.8 MPa
• When swing lock switch is turned to “ON“ position {355 kg/cm2}
• In boom LOWER operation O
• When one-touch power maximizing function is turned
on 37.2 MPa
• When L mode is selected {380 kg/cm2}
Variable back pressure function

• Set pressure of the back pressure valve varies depending on the operating conditions of the machine.
Operating conditions Setting of back pressure valve
When swinging and travelling High-pressure setting
When operation other than swinging or travelling Low-pressure setting
10-208 PC210LC-10
One-touch power maximizing function (PC220-PT23-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Sensors
14. One-touch power max. switch
17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve
PC210LC-10 10-209
19. Control valve

19d. Main relief valve

d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power max. switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Sensor signals
Function
• By operating the one-touch power max. switch on the L.H. work equipment control lever knob, the power
is increased for a limited time.
• This can be used to increase digging force for a limited time, for example, when digging out a rock during
excavating work.
• If the one-touch power max. switch is pressed in P mode, E mode, ATT-P mode or ATT-E mode when the
load pressure is high, the hydraulic force will be increased by approx. 7%, and the horsepower will be
increased by approx. 12% to boost the digging force.
• The functions are automatically set as follows.
Function Setting
Engine and pump combined control Matching at rated output point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Cut-off function Cancel
a This function maintains the power maximizing operation as long as the one-touch power max. switch is
pressed. This function, however, is cancelled in about 8.5 seconds regardless of pressing of the switch.
10-210 PC210LC-10
Auto-deceleration function (PC-AF60-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Sensors
9. Main pump
10. Control valve
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. 1st throttle signal
e. Fuel supply pump control signal
f. Sensor signals
PC210LC-10 10-211
Function
• When all the control levers are set to NEUTRAL position for waiting for a dump truck or work, the engine
speed is automatically reduced to its controlled speed, and fuel consumption and noise are lowered.
• When any control lever is operated, the engine speed returns immediately to the speed set with the fuel
control dial.
Operation
When control lever in NEUTRAL position

• If all control levers are in NEUTRAL position for 4 seconds or more while the engine runs at a speed
higher than approx. 1,050 rpm, the engine speed is decelerated to approx. 1,050 rpm and held at this level
until any control lever is operated.
When control lever is operated

• If any control lever is operated when the engine speed is maintained at the controlled speed (approx.
1,050 rpm), the engine speed increases immediately to the speed set with the fuel control dial.
A: All work equipment control levers in “NEUTRAL“

B: All work equipment control levers in “OPERATED“
C: Fuel control dial set speed
D: Controlled engine speed (approx. 1,050 rpm)
E: 4 sec.
F: Max. 2 sec.
G: Max. 1 sec.
10-212 PC210LC-10
Engine automatic warm-up function (PC-AP13-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
10. Air conditioner unit
14. Sensors
15. Hydraulic oil temperature sensor
16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
PC210LC-10 10-213


a: Front pump PC-EPC valve drive signal
b: Rear pump PC-EPC valve drive signal
c: Solenoid valve GND
d: CAN signal
e: Hydraulic oil temperature signal
f: 1st throttle signal
g: Fuel supply pump control signal
h: Sensor signals
Function
• This is a function that raises the engine speed automatically to warm up the engine if the coolant
temperature is low after start-up of the engine.
• There are two types of the engine automatic warm-up function depending on the purpose; one is "Heater
warm-up" and the other is "Normal warm-up"
• The purpose of the heater warm-up is to raise the coolant temperature and improve the heater efficacy.
• The purpose of the normal warm-up is to warm up the engine to prevent it from being damaged by
operation in low temperature.
Operating conditions 1
Machine specification: with air conditioner
Air conditioner: blower “ON“
Coolant temperature: below 55°C
Ambient temperature: below 5°C
Manual stationary regeneration: OFF
oot accumulation: Max. 2 g/l
O O
If any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up is disabled (normal warm-up) Heater warm-up is enabled
Operating conditions 2 (all required for operation) O
Coolant temperature: below 30°C
O
Engine speed: Max. 1,200 rpm
O O
Operation Operation
Engine speed: 1,200 rpm Engine speed: Min. 1,300 rpm
O O
Condition for cancellation Condition for cancellation
(Canceled when either one of the following (Canceled when either one of the following
conditions is met.) conditions is met.)
Coolant temperature: Min. 30°C Coolant temperature: Min. 60°C
Auto Duration of automatic warming-up: Min.
Ambient temperature: Min. 10°C
10 minutes
10-214 PC210LC-10
Fuel control dial: held at over 70% of full

Manual speed (MAX.) for 3 seconds or more
O O
Cancellation
Engine speed: as desired
PC210LC-10 10-215
Overheat prevention function (PC-B717-042-K-00-A)
a See "Engine automatic warm-up function" for the system circuit diagram.
• Prevents overheating to protect the engine and hydraulic components by reducing load on the pump and
lowering the engine speed if the coolant or hydraulic oil temperature becomes too high.
Operating condition Operation/Remedy Resetting condition
Hydraulic oil temperature:

Below 95°C
o Working mode: Travel o • Under above condition,
Hydraulic oil temperature: Engine speed: Keep as is
Min. 95°C controller is returned to the
Travel speed: Lower condition before operation
of function (automatic
reset).
Coolant temperature: Below

Working mode: P, E, ATT-P and 95°C
Coolant temperature: Min. ATT-E modes Hydraulic oil temperature:
100°C o Engine speed: Keep as is o Below 95°C
or • Torque control signal • Under above condition,
Hydraulic oil temperature: decreases the pump controller is returned to the
Min. 100°C absorption torque to reduce condition before operation
the load on the engine. of function (automatic
reset).

Working mode: P, E, ATT-P and 102°C
Coolant temperature: Min. ATT-E modes Hydraulic oil temperature:
102°C o Engine speed: Keep as is o Below 102°C
reset).

Working mode: B mode 102°C
Coolant temperature: Min. Engine speed: Keep as is Hydraulic oil temperature:
102°C o Alarm monitor: Lights up o Below 102°C
reset).
10-216 PC210LC-10

105°C
Coolant temperature: Min. Working mode: Any mode Below 105°C
105°C o o Fuel control dial: Return the
Engine speed: Low idle
or pointer to low idle (MIN)
Alarm monitor: Lights up position.
Min. 105°C Alarm buzzer: Sounds • Under above condition,
controller is returned to the
condition before operation
of function (manual reset).
PC210LC-10 10-217
Turbocharger protection function (PC200_10-AA90-042-K-00-A)
a See "Engine automatic warm-up function" for the system circuit diagram.
• Prevents seizure of the turbocharger by limiting the engine speed if the engine speed is increased
exponentially when starting the engine.
Operating condition Operation

o Turbocharger protection
Engine oil pressure: Below 50 kPa {0.51 kg/cm2}
(See the figure below)
A: Start engine
B: Duration of turbocharger protection (approx. 0 - 20 sec.)
C: Modulating time (approx. 1 sec.)
D: 500 rpm
E: Approx. 1,050 rpm
F: 1,650 rpm (*1)
*1: Working mode: P mode
Fuel control dial: Full speed (MAX) position
When travel lever is operated
10-218 PC210LC-10
Swing control function (PC-JA01-042-K-01-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Swing brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
12. Main pump
13. Control valve
14. Swing motor
14a. 2-stage relief valve
15. Swing holding brake solenoid valve
16. 2-stage swing relief solenoid valve

a. Swing brake cancel switch signal
b. Swing holding brake solenoid valve drive signal
c. CAN signal
d. Swing lock switch signal
e. 2-stage swing relief solenoid valve drive signal
f. Oil pressure sensor signal
g. Oil pressure switch signal
PC210LC-10 10-219
Function
Swing lock and swing holding brake function
• On machines with swing lock (manual), swing can be locked at any position by turning swing lock switch
(1) to “ON“ position.
• Interlocked with the swing operation, the swing holding brake (automatic lock) prevents hydraulic drift from
occurring after the swing stops.
• Interlocked with the L.H. and R.H. work equipment control levers and attachment control pedals
operations, the swing holding brake is canceled to reduce the load on the swing equipment during
excavation work.
Swing lock
OFF ON
switch
Swing lock Not lighting Lights up
monitor
Function Swing holding brake Swing lock
• When the L.H. and R.H. work equipment • Swing holding brake works and locks the
control levers and attachment control swing of the upper structure.
pedals are set to NEUTRAL position, the • Even if the L.H. work equipment control
swing holding brake works in approx. 5 lever is operated for swing, the swing
sec. holding brake cannot be canceled, and
Operation
• When the L.H. and R.H. work equipment the upper structure does not swing.
control lever or attachment control pedal is
operated, the swing holding brake is
canceled and the upper structure
becomes free to swing.
A: When work equipment control lever or attachment control pedal is operated (Swing holding brake
“canceled“)
B: When work equipment control levers and attachment control pedals are in “NEUTRAL“ position
C: Swing holding brake “applied“
D: Approx. 5 sec.
10-220 PC210LC-10
Swing holding brake cancel function

• If any abnormality should occur in the controller and no swing is possible because the swing holding brake
does not work properly, operating swing brake cancel switch (2) releases the swing holding brake and
allows swing operation.
a: Cancel (when abnormal)
b: Normal (when normal)
Swing brake Cancel Normal
cancel switch (when controller has trouble) (when controller is normal)
Swing lock switch ON OFF ON OFF
Swing holding brake Swing holding brake
Swing brake Swing lock applied Swing lock applied
is released(*1) applied
*1: Hydraulic brake applied by relief valve.
a Even if swing brake cancel switch (2) is set to “CANCEL (a)“ position, swing holding brake is not released
while swing lock switch is set to “ON“ position.
a When the swing holding brake is released, only the hydraulic brake with the relief valve is effective for
holding the upper structure. So, note that, when the swing stops on a slope, a hydraulic drift may occur.
a Swing brake cancel switch (2) is of the alternative type. When the switch is turned to “CANCEL (a)“
position, the swing lock monitor in the machine monitor will blink.
Quick warm-up function

• If swing lock switch (1) is turned to “ON“ position, the pump cut-off function is cancelled and the main relief
pressure increases.
• If the work equipment is relieved with the main relief pressure increased, the hydraulic oil temperature
increases quickly and the warm-up time can be shortened.
Operating condition Main relief pressure
34.8 MPa {355 kg/cm2}
• Swing lock switch: ON O
37.2 MPa {380 kg/cm2}
PC210LC-10 10-221
2-stage swing relief function

• During swing acceleration, the set pressure of the 2-stage swing relief valve is changed to decrease the
flow rate to hydraulic relief and improve the fuel consumption ratio.
Operating condition Flow rate to hydraulic relief
• During swing acceleration 180 l/min
(excluding sharp change operation of swing O
direction) 70 l/min
Relation between set pressure and flow
A: When pilot pressure is “shut off“ (low-pressure setting)

B: When pilot pressure is “transmitted“ (high-pressure setting)
P: 28.4 MPa {290 kg/cm2}
Q1: 180 l/min
Q2: 70 l/min
Characteristics of 2-stage relief valve
A: Oil flow at low-pressure setting

B: Oil flow at high-pressure setting
C: Flow necessary for swing
Z: Area where the loss by relief flow is reduced (fuel consumption improved)
10-222 PC210LC-10
Travel control function (PC200_10-C7H1-042-K-00-A)
1. Pump controller
3. Machine monitor
5. Fuel supply pump
6. Sensors
10. Travel alarm
11. Front pump
11a. Servo
11b. LS valve
11c. PC valve
12. Rear pump
12a. Servo
12b. LS valve
12c. PC valve
13. Control valve
14. Travel motor
PC210LC-10 10-223

17. LS-EPC valve
a. Oil pressure sensor signal
b. CAN signal
c. LS-EPC valve drive signal
d. Solenoid valve GND
e. Travel junction solenoid valve drive signal
f. Travel speed increase solenoid valve drive signal
g. Oil pressure sensor signal
h. Travel alarm buzzer operation signal
i. 1st throttle signal
j. Fuel supply pump control signal
k. Sensor signals
Function
Travel speed selector function
1. Travel speed “Manual“ change
• Switching the travel speed selector switch to “Hi“, “Mi“ or “Lo“ changes the motor capacity, which
changes the machine travel speed.
Lo Mi Hi
Travel speed selector switch
(low speed) (medium speed) (high speed)
Motor flow rate (%) 75 70 100
Motor capacity (Max.) (Min.) (Min.)
Travel speed (km/h) 3.0 4.1 5.5
2. Travel speed “Automatic“ change
1) Automatic change corresponding to engine speed
• If you adjust the engine speed to 1,500 rpm or less with the fuel control dial, the travel speed does
not switch to “Hi“ when the machine is traveling in “Mi“, and automatically changes to “Mi“ when the
machine is travelling in “Hi“.
2) Automatic change according to pump delivery pressure
• If the travel circuit oil pressure increases on an uphill with the travel speed selector switch in “Hi“,
and the travel circuit oil pressure of 33.3 MPa {340 kg/cm 2} or above continues for 0.5 seconds or
more, the travel motor capacity is switched to that for medium speed travel (equivalent to “Mi“)
automatically (the travel speed switch position remains in “Hi“).
• If the travel circuit oil pressure decreases on a level ground or downhill during low speed travel
caused by the automatic speed change due to increase in the load on the travel circuit, and the
travel circuit oil pressure of 19.6 MPa {200 kg/cm2} or below continues for 0.5 seconds or more, the
travel motor capacity is switched back to that for speed of “Hi“ automatically.
10-224 PC210LC-10
A: 16.7 MPa {170 kg/cm2}

B: 30.4 MPa {310 kg/cm2}
C: Min. 0.5 sec.
D: Min. 0.5 sec.
Pump control function when travelling
a For details, see "Engine and pump composite control function".
Travel junction function

• The controller detects the pilot pressure when travel control lever is operated, and judges the operator's
intention, the straight travel or turning operation.
• For straight-travel, a signal is sent to the travel junction solenoid valve, controlling the pump flow rate
between the right and left to be equal, to prevent travel deviation and improve straight-travel ability.
• For turning operation, the signal to the travel junction solenoid valve is shut off. This separates the pump
flow rate to the right and left travel motors from each other and improves the traction while turning.
PC210LC-10 10-225
PPC lock function (PC-PX16-042-K-00-A)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
Function
• Interlocked with the lock lever, PPC lock switch is turned off when the lock lever is moved to “LOCK“
position.
• When the PPC lock switch is turned off, current to the PPC lock solenoid valve is shut off. Even if each
control lever or pedal is operated, the work equipment and machine do not move.
10-226 PC210LC-10
System operating lamp function (PC-AW1Q-042-K-00-A)

2. Battery
3. Fusible link
4. Fuse box
5. System operating lamp
6. Machine monitor
8. Pump controller
9. KOMTRAX terminal
10. ID Key controller
Function
• The operating condition of each controller can be checked with the system operating lamp to prevent the
abnormal end of the disconnection of the battery power supply circuit while the controllers are in
operation.
a Before cutting off the battery power supply circuit, turn the starting switch to the “OFF“ position, and check
that the system operating lamp is OFF, then turn the battery disconnect switch to the “OFF“ position.
a If you turn the battery disconnect switch to the “OFF“ position (battery power supply circuit is cut off) while
the system operating lamp is lit, Controller Data Lost Error may occur. Do not operate the battery
disconnect switch as long as the system operating lamp is lit.
a The system operating lamp goes out in 2 minutes longest after the starting switch is turned to the “OFF“
position.
a The system operating lamp may sometimes light up while the starting switch is turned to the “OFF“
position because KOMTRAX terminal may maintain its communication under this condition.
Lighting up and going out of system operating lamp

• Voltage of 24 V is always applied to the one end of the system operating lamp (LED).
• When any controller is in operation, the output from the controller to the system operating lamp becomes
Low (0 V). This allows electric current to flow through the diode, lighting up the system operating lamp.
• When all controllers are resting, the output from each controller to the system operating lamp becomes Hi
(24 V). The electric current does not flow through the diode, and the system operating lamp goes out.
a The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the
minute leakage of current and not an abnormal phenomenon.
• The KOMTRAX terminal performs communication periodically even if the starting switch is kept in the
“OFF“ position, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the conditions including
the communication status and machine stop time. So the lamp can be lit as long as approximately 1 hour.
PC210LC-10 10-227
a When you want to cut off the battery circuit for maintenance but the system operating lamp keeps on
lighting up, turn the starting switch to the “ON“ position once, then turn it to the “OFF“ position. The
lamp will go out in 2 minutes longest.
After the system operating lamp goes out, turn the battery disconnect switch immediately to the “OFF“
position.
10-228 PC210LC-10
Attachment flow control function (PC-PT24-042-K-00-A)
(Machine with provision for attachment)

2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
7. Pump controller
9. Machine monitor
13. Sensors
15. Front pump
15a. Servo
15b. LS valve
15c. PC valve
16. Rear pump
16a. Servo
16b. LS valve
16c. PC valve
17. Control valve
PC210LC-10 10-229

18. Attachment selector solenoid valve
20. Oil flow rate adjuster EPC valve for attachment
23. Attachment circuit selector valve (high pressure side)
24. Attachment circuit selector valve (low pressure side)
25. Attachment
26. Accumulator
d. CAN signal
e. Attachment selector solenoid valve drive signal
f. Oil flow rate adjuster EPC valve drive signal for attachment
g. Oil pressure switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Sensor signals
Function
• Setting of the working mode and oil flow rate on the machine monitor allows controlling the oil flow rate to
the attachment when the attachment control pedal is fully depressed.
• Attachment operation switches depending on the working mode as shown below.
Working mode Attachment operation
ATT–P, ATT–E Double-acting
B Single-acting
10-230 PC210LC-10
System component parts (ALL-RA1C-001-K-00-A)
Engine controller (PC220-AP70-041-K-00-A)
Input and output signals (PC-AP70-03C-K-00-A)

• The following is the list of the symbols used for signal category in the input/output signal table.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication
DRC26-60P(1)[ECM J1(CN-CE01)]
Pin No. Signal name Signal category
1 (*1) —
2 (*1) —
3 Crankcase pressure sensor B
4 (*1) —
5 Charge temperature sensor B
6 Intake air temperature (MAF) sensor B
7 CAN_C (+) E
8 CAN_B (+) (KOMNET/r) E
9 Bkup (camshaft) speed sensor (+) B
10 (*1) —
11 (*1) —
12 (*1) —
13 GND C
14 Coolant temperature sensor B
15 Charge pressure sensor B
16 Ambient pressure sensor B
PC210LC-10 10-231

17 CAN_C (-) E
18 CAN_B (-) (KOMNET/r) E
19 (*1) —
20 (*1) —
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow and temperature sensor B
24 Water-in-fuel sensor B
25 (*1) —
26 Ne (crankshaft) speed sensor (+) B
27 (*1) —
28 (*1) —
29 (*1) —
30 IMV(+) D
31 Engine oil pressure switch B
32 GND C
33 (*1) —
34 (*1) —
35 (*1) —
37 NE (crankshaft) speed sensor (-) C
38 (*1) —
39 (*1) —
40 IMV (-) C
41 (*1) —
42 (*1) —
43 Injector #4 (+) D
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 Injector #4 (-) C
59 GND C
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
10-232 PC210LC-10

5 (*1) —
6 EGR actuator (+) D
7 (*1) —
8 (*1) —
9 (*1) —
10 KVGT actuator (+) D
11 (*1) —
12 (*1) —
13 (*1) —
14 (*1) —
15 (*1) —
16 EGR actuator (-) C
17 (*1) —
18 GND C
19 (*1) —
20 KVGT actuator (-) C
21 GND C
22 (*1) —
23 (*1) —
24 CAN_B (+) E
25 CAN_B (-) E
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
32 KVGT speed sensor (+) B
33 KVGT speed sensor (-) C
34 Exhaust manifold pressure sensor B
35 (*1) —
36 (*1) —
37 (*1) —
38 KVGT position sensor B
39 (*1) —
40 (*1) —
41 (*1) —
42 (*1) —
43 (*1) —
44 Common rail pressure sensor B
45 (*1) —
46 GND C
47 GND C
48 EGR orifice temperature sensor B
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 (*1) —
54 (*1) —
55 (*1) —
56 (*1) —
PC210LC-10 10-233

57 (*1) —
58 (*1) —
59 EGR valve lift sensor B
60 (*1) —
DRC26-60P(3)[CN-CE03]
1 Continuous power supply (24 V) A
3 Starting switch ACC signal B
4 Intake air heater relay (+) D
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 System operating lamp D
10 (*1) —
13 GND C
14 (*1) —
15 (*1) —
16 (*1) —
17 CAN_A (+) (KOMNET/c) E
18 CAN_A (-) (KOMNET/c) E
19 GND C
20 (*1) —
21 GND C
22 GND C
23 (*1) —
24 (*1) —
25 (*1) —
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
30 (*1) —
31 GND C
32 GND C
33 (*1) —
34 (*1) —
35 (*1) —
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 GND C
43 GND C
44 (*1) —
10-234 PC210LC-10

45 KDOC inlet temperature sensor B
46 (*1) —
47 (*1) —
48 KDOC outlet temperature sensor B
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
53 (*1) —
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 (*1) —
57 (*1) —
58 KDPF outlet pressure sensor B
59 (*1) —
60 (*1) —
PC210LC-10 10-235
Pump controller (PC-C3V1-041-K-00-A)
10-236 PC210LC-10
Input and output signals (PC-C3V1-03C-K-00-A)

AMP-81P [CN-CP01]
Pin No. Signal name Input/Output signal
1 Continuous power supply (24 V) Input
2 Continuous power return Input
3 Window washer Output
5 Continuous power return Input
6 Potentiometer power supply (5 V) Output
7 CAN (R)_H Input/Output
8 Service oil pressure sensor Input
9 (*1) —
10 (*1) —
11 Front pump oil pressure sensor Input
12 R.H. swing PPC oil pressure sensor Input
13 Boom LOWER PPC oil pressure sensor Input
14 Arm IN PPC oil pressure sensor Input
15 L.H. travel REVERSE PPC pressure sensor Input
16 (*1) —
17 (*1) —
18 GND (analog signal) —
19 (*1) —
20 Swing lock switch Input
21 Model selection 3 Input
22 (*1) —
23 (*1) —
24 Starting switch ACC signal Input
25 (*1) —
26 CAN (R)_L Input/Output
27 (*1) —
28 Hydraulic oil temperature sensor Input
29 (*1) —
30 Rear pump oil pressure sensor Input
31 L.H. swing PPC oil pressure sensor Input
32 Boom RAISE PPC oil pressure sensor Input
33 (*1) —
34 L.H. travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) —
37 (*1) —
38 (*1) —
39 Swing brake cancel switch Input
41 (*1) —
42 One-touch power max. switch Input
44 (*1) —
45 CAN (C)_H Input/Output
46 GND (analog signal) Input
47 (*1) —
48 (*1) —
49 Front pump swash plate sensor Input
50 Bucket DUMP PPC oil pressure sensor Input
PC210LC-10 10-237

51 Arm OUT PPC oil pressure sensor Input
52 (*1) —
53 R.H. travel REVERSE oil pressure sensor Input
54 (*1) —
55 (*1) —
56 Wiper motor reverse (W) Input
57 (*1) —
60 (*1) —
61 Starting switch C signal Input
62 External start signal Input
63 NC —
64 CAN (C)_L Input/Output
65 (*1) —
66 (*1) —
67 (*1) —
68 Rear pump swash plate sensor Input
69 Bucket CURL PPC oil pressure sensor Input
70 (*1) —
71 (*1) —
72 R.H. travel FORWARD PPC oil pressure sensor Input
73 (*1) —
74 (*1) —
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
78 (*1) —
79 PPC lock switch Input
81 (*1) —
AMP-40P [CN-CP02]
82 (*1) —
83 (*1) —
84 (*1) —
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 (*1) —
88 LS-EPC valve Output
89 Pump merge-divider EPC valve (LS) Output
90 (*1) —
91 (*1) —
92 (*1) —
93 Travel speed increase solenoid valve Output
94 Swing 2-stage relief solenoid valve Output
95 (*1) —
96 Front pump PC-EPC valve Output
97 Attachment oil flow rate adjustment EPC valve Output
98 (*1) —
10-238 PC210LC-10

99 (*1) —
100 System-in-use signal Output
101 Swing holding brake solenoid valve Output
102 (*1) —
103 (*1) —
104 Rear pump PC-EPC valve Output
105 (*1) —
106 (*1) —
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 (*1) —
111 (*1) —
112 Pump merge-divider EPC valve (main) Output
113 Variable back pressure solenoid valve Output
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
119 Wiper motor (+) Output
PC210LC-10 10-239
Fuel control dial (PC-AGJ7-041-K-01-A)
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function (PC-AGJ7-042-K-00-A)
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes
and a throttle signal is sent to the engine controller.
• The hatched areas in the graph are abnormality detection areas. If the throttle voltage is within the area,
the engine speed drops down to low idle.
10-240 PC210LC-10
Resister for PC-EPC valve (PC200_10-C3VR-041-K-00-A)

1. Resistance
2. Connector
Specifications (PC220-C3VR-030-K-00-A)
Resistance: 20 z
Function (PC-C3VR-042-K-00-A)
• When the emergency pump drive switch or the emergency work equipment drive switch is turned to “ON“
position, this resistor sends an electric current to each PC-EPC valve that is appropriate for their condition.
a No electric current flows in the normal condition.
PC210LC-10 10-241
CAN terminating resistor (PC220-Q2V1-041-K-00-A)

CAN: Abbreviation for Controller Area Network
1. Connector (with built-in resistor)
Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z
Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.
Engine oil pressure switch (PC-ABK6-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Specifications (PC220-ABK6-030-K-00-A)
Contact type: Normally closed
Function (PC-ABK6-042-K-00-A)
10-242 PC210LC-10
• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the
switch to "ON" position when the pressure goes below the specified value.
PC210LC-10 10-243
PPC oil pressure switch (PC-E610-041-P-00-A)

1. Plug
2. Switch
3. Connector
Specifications (PC220-E610-030-P-00-A)
Contact type: Normally open
Operating (ON) pressure: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}
Function (PC220-E610-042-P-00-A)
• Two sensors are installed to attachment PPC valve. They detect PPC oil pressure during attachment
operation and turn the switch to “ON“ position if the pressure is equal or higher than the specified
pressure.
10-244 PC210LC-10
Machine monitor system
Machine monitor system (PC-Q170-042-K-01-A)
1. Machine monitor
2. Battery
3. Pump controller
5. Air conditioner controller
6. KOMTRAX terminal
7. Sensors and switches
8. Wiper motor and window washer motor
9. Camera
a. Power supply
b. CAN signal
c. Sensor and switch signals
d. Drive signal
e. Camera signal
Function
• The monitor system keeps the operator informed of all machine functions, by monitoring the machine
conditions by using the sensors and switches installed in various parts of the machine and processing
them instantly to display on the machine monitor.
PC210LC-10 10-245
The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has trouble
2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have an operating function to control the machine.
10-246 PC210LC-10
Machine monitor (PC-Q180-042-K-01-A)
Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.
Precautions on the machine monitor display

• One of the features of liquid crystal display panels is that there may be black spots (spots that do not light
up) or white spots (spots that stay lit up) on the screen. If there are fewer than 10 black or white spots, this
is not a failure or a defect. Products having 10 or less black or bright spots conform the product
specification; such the condition is quite normal.
• When the engine is started, the battery voltage may drop suddenly, depending on the ambient
temperature and the condition of the battery. In this case, the machine monitor display may go off for a
moment. However, this phenomenon is not a failure.
• Continuous operation of the machine monitor may display blue bright spots on the screen having a black
background; it is quite normal.
Blue bright spots can never be a problem as the screen has usually blue or white background. (White in
the LCD is made up of red, green and blue.)
PC210LC-10 10-247
Input and output signals (PC-Q180-03C-K-00-A)

070-18P[CN-CM01]
3 GND (continuous power supply) —
4 GND (continuous power supply) —
5 External start signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) —
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 (*1) —
15 Fuel level sensor Input
16 Charge level (Alternator R terminal) Input
17 (*1) —
18 (*1) —
070-12P [CN-CM02]
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 (*1) —
7 CAN (C) terminating resistor terminal —
10 CAN (R) terminating resistor terminal —
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
070-20P [CN-CM03]
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 (*1) —
12 (*1) —
10-248 PC210LC-10

13 (*1) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
19 (*1) —
20 (*1) —
070-8P [CN-CM04]
1 Camera power supply (8 V) Output
2 Camera NTSC signal 1 Input
5 GND (Camera power supply) —
6 Switching camera 2 to original/mirror image Output
7 Switching camera 3 to original/mirror image Output
8 Shield GND —
PC210LC-10 10-249
Display (PC-Q1LA-042-K-00-A)
A: Standard screen
B: Check before starting screen
C: Maintenance interval warning screen
D: Warning screen
E: Guidance screen
F: Camera image screen
a Camera image screen (F) shown in the figure is when two or more cameras are installed
1. Message monitor
2. KDPF regeneration monitor
3. Engine stop monitor
4. Seatbelt monitor
5. Air conditioner monitor
6. Wiper monitor
10-250 PC210LC-10
7. Swing lock monitor

8. Engine preheating monitor
9. Service meter
10. Auto-deceleration monitor
11. Working mode monitor
12. Travel speed monitor
13. Fuel level gauge
14. Fuel level monitor
15. Eco gauge
16. Fuel consumption gauge
17. Hydraulic oil temperature monitor
18. Hydraulic oil temperature gauge
19. Engine coolant temperature monitor
20. Engine coolant temperature gauge
21. Radiator coolant level monitor
22. Charge level monitor
23. Engine oil pressure monitor
24. Engine oil level monitor
25. Air cleaner clogging monitor
26. Water separator monitor
27. Clock
28. Maintenance interval warning monitor
29. System status monitor
30. Action level monitor
31. ECO guidance
PC210LC-10 10-251
Gauge
Gauge Display item Description Remarks
Temperature Background • Indicates
Range
(°C) color corresponding
W1 105 Red temperature range.
(*1) • Alarm buzzer sounds
W2 102 Red
Engine coolant when the temperature
W3 100 Blue is 105°C or higher.
temperature
gauge W4 85 Blue • If the monitor
W5 60 Blue background appears
white, warm-up the
W6 30 White engine.
Temperature Background • Indicates
Range
(°C) color corresponding
H1 105 Red temperature range.
H2 102 Red
when the temperature
Hydraulic oil H3 100 Blue is 105°C or higher.
temperature H4 85 Blue • If the monitor
gauge H5 40 Blue background appears
white, warm up the
H6 20 White hydraulic
components.
Range Quantity (l) Background • Indicates
color corresponding
F1 304 Blue remaining fuel level.
(*1) F2 245 Blue
Fuel level gauge F3 200 Blue
F4 100 Blue
F5 60 Blue
F6 41 Red
• Indicates
instantaneous fuel
Segment Load level consumption
(average of fuel
consumption per 3
minutes) in 10 steps.
(*2) Light to (It is displayed when
Green 1 to 8
Eco gauge medium the user menu's
“ECO guidance“ o
“Display setting“ o
“Eco gauge display“
Orange 9 , 10 Heavy is set.)
• Indicates
accumulated engine
operating hours (the
Service meter 00000.0 h to 99999.9 h alternator is running).
(F4 switch changes it
to clock display.)
10-252 PC210LC-10
Gauge Display item Description Remarks

• Displays time.
• 12-hour display (AM/PM) (F4 switch changes it
Clock • 24-hour display to service meter
display.)
• Indicates average
fuel consumption.
(Display is switched
when the user menu's
“ECO guidance“ o
“Display setting“ o
“Fuel gauge display“
are specified.)
(*2)
• 1 day
Fuel
• Split
consumption
• Not installed
gauge
*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer
disappears.
*2: Display item is switched when the user menu's “ECO guidance“ o “Display setting“ are specified.
PC210LC-10 10-253
Caution monitor
Description
Monitor
Symbol Display item display Action level Remarks
Range
(Background monitor
color)
Lights up • Background color
Min. 102°C (Red) L02 changes depending
Min. 30°C or Lights up on the temperature
— detected.
below 102°C (Blue)
Engine coolant when the temperature
temperature is 105°C or higher.
Lights up • If the monitor
Below 30°C —
(White) background appears
white, warm-up the
engine.
Min. 102°C (Red) L02 changes depending
Min. 20°C or Lights up on the temperature
— detected.
below 102°C (Blue)
• Alarm buzzer sounds
(*1) when the temperature
Hydraulic oil is 105°C or higher.
temperature • If the monitor
Lights up background appears
Below 20°C —
(White) white, warm up the
hydraulic
components.

Below 41 l —
(*1) (Red) changes depending
Lights up on the remaining fuel
Fuel level —
Min. 41 l (Blue) level.
When • When failure is
abnormal detected with the
(*1) Lights up (*3) engine stopped, the
(When below (Yellow)
Radiator coolant specified L01 monitor lights up on
level level) the screen.
When normal Lights out —
• The monitor lights up
When charge
is defective on the screen and
alarm buzzer sounds
(*1) (Charge Lights up when failure is
(Red) L03
Battery charge voltage < detected while the
condition battery engine running.
voltage)
When • The monitor lights up
abnormal on the screen and
(*1) Lights up alarm buzzer sounds
(When below (Red) L03
Engine oil specified when failure is
pressure level) detected while the
— engine running.
When normal Lights out
10-254 PC210LC-10
Description
Monitor
Range
(Background monitor
color)
Lights up (*3) engine stopped, the
(*1) (When below (Yellow) L01 monitor lights up on
Engine oil level specified
level) the screen.
(*1) Lights up (*3) engine running, the
(When above (Yellow)
Clogging of air specified L01 monitor lights up on
cleaner level) the screen.
(There is engine running, the
water Lights up monitor lights up on
(*1) — the screen.
collected (Red)
Water separator above the
specified
amount.)
When • The display changes
exceeding Lights up depending on the
—
maintenance (Red) time to/after the
interval maintenance.
• After the starting
Maintenance (*2) switch is turned to
interval warning “ON“ position , the
When Lights up monitor turns on if the
exceeding —
(Yellow) monitor light-up
maintenance conditions are met,
notifying time and then goes out in
30 seconds.
When action • When failure is
level “L04“ or Lights up detected in the
(Red) L04 and L03
“L03“ is machine system, the
System status detected monitor lights up.
• When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
(Red) L04 and L03
“L03“ is engine system, the
State of engine detected monitor lights up.
system • When the
When action (*3)
Lights up background color is
detected
sounds.
PC210LC-10 10-255
Description
Monitor
Range
(Background monitor
color)
(Red) L04 and L03
“L03“ is hydraulic system, the
State of detected monitor lights up.
hydraulic system • When the
detected
sounds.
level “L04“ or Lights up detected in the KDPF
(Red) L04 and L03
“L03“ is system, the monitor
State of KDPF detected lights up.
system • When the
detected
sounds.
When action • The monitor lights up
level “L04“ or Lights up when soot is
(Red) L03
“L03“ is deposited inside
detected KDPF or cleaning
Deposition of function is abnormally
soot on KDPF degraded.
When action Lights up (*3) When the
level “L01“ is (Yellow) L01 background color is
detected
red, the alarm buzzer
sounds.
• The monitor lights up
Engine Engine Lights up and alarm buzzer
overspeed overspeed is (Red) L02 sounds when engine
detected overspeed is
detected.
• When failure is
State of air When air (*3) detected in the air
Lights up
conditioner conditioner is conditioner system,
(Yellow) L01
system abnormal the monitor lights up.
When action Lights up • When failure is
level “L04“ is (Red) L04 detected on the
detected machine, the monitor
When action Lights up lights up.
level “L03“ is (Red) L03 When the
detected background color is
Action level
When action Lights up red, the alarm buzzer
level “L02“ is (Red) L02 sounds.
detected
When action Lights up (*3)
level “L01“ is (Yellow)
detected L01
*1: It is included in the check before starting items. After the staring switch is turned to “ON“ position, the
monitor turns on for two seconds, and changes to the standard screen if no failure is found.
*2: The notifying time is changeable from the items in “Maintenance mode display setting“ of the service mode.
*3: Monitor goes out after lighting up for 2 seconds.
10-256 PC210LC-10
Pilot monitor
Symbol Display item Description Remarks
• It operates automatically • Indicates preheat
at a low temperature. operating status.
Automatic (Symbol lights up as long
preheating as for approx. 30
seconds)
• It goes off after the engine
is started.
Elapsed time
Preheating after turning
the starting Monitor
switch to display
Manual “HEAT
preheating (Preheating)“
0 to 30 sec. Lights up
30 to 40 sec. Flashes
After 40 sec.
Lights out
or longer
One-touch • Indicates the
power max. Monitor display operating status of
switch one-touch power
One-touch Lights up maximizing function.
power max.
ON (Goes out if pressed for 8.5
seconds)
OFF Lights out
Swing lock Swing brake Monitor • Indicates swing lock
switch cancel switch display operating status.
OFF OFF Lights out
Swing lock ON OFF Lights up
OFF ON Flashes
ON ON Flashes
• Indicates front glass
INT: Intermittent operation
wiper operating
Wiper ON: Continuous operation condition.
Lights out: Holds in position
• Indicates air
Lights up: ON conditioner and air
Air conditioner blower operating
Lights out: OFF
status.
• Indicates whether
seatbelt is fastened.
Lights up: Not fastened

Seatbelt
Lights out: Fastened
• Indicates the engine

Lights up: When engine is stopped operating status.
Engine stop
Lights out: While engine is running
• Indicates
KDPF Lights up: KDPF is being regenerated regenerating state of
regeneration Lights out: KDPF regeneration is finished KDPF.
PC210LC-10 10-257
Symbol Display item Description Remarks

• Indicates
regenerating state of
KDPF.
• When manual
stationary
regeneration is
Lights up: KDPF regeneration is stopped required, “KDPF soot
Stop of KDPF
deposition monitor“
regeneration Lights out: KDPF regeneration is finished lights up.
• State of the message

Message Lights up: There is unread message. is displayed.
(Unread) Lights out: No message
Message • State of the message

(No return Lights up: There is an already-read message is displayed.
message, but return message for it is not sent yet.
already-read Lights out: No message
message)
• Indicates auto-
Auto- Lights up: ON decelerator operating
deceleration Lights out: OFF status.
P: Heavy-duty operation • Displays working

E: Low-fuel consumption operation mode.
L: Fine operation
Working mode B: Breaker operation
ATT-P: Double-acting attachment operation
ATT-E: Double-acting attachment and low-
fuel consumption operation
• Displays travel speed
Lo: Low speed
setting.
Travel speed Mi: Middle speed
Hi: High speed
• Idle stop guidance • Guidance for
• Guidance on deterrence of hydraulic relief supporting the
ECO guidance • E-mode recommendation guidance machine operation
• Travel partial recommendation guidance and control are
• Low oil level guidance displayed.
10-258 PC210LC-10
Switches (PC-Q1C0-042-K-00-A)
No. Name Function Operation

Switches the auto-deceleration • When working mode is “L“, this switch
Auto-deceleration function ON/OFF. is always “OFF“ after engine started.
1 switch OFF io ON
Lights up: ON
[Numeric keypad: 1]
Lights out: OFF
Displays the working mode selector P: Heavy-duty operation
screen. E: Low-fuel operation
(*1) L: Fine operation
Working mode selector B: Breaker operation
2 switch ATT-P: Double-acting attachment
[Numeric keypad: 2] operation
ATT-E: Double-acting attachment and
low-fuel operation
Changes the travel speed. • Speed is sequentially changed as
Travel speed selector Lo lights up: Low speed shown below.
3 switch Lo (Low speed) o Mi (Medium
Mi lights up: Medium speed speed) o Hi (High speed) o Lo (Low
[Numeric keypad: 3]
Hi lights up: High speed speed)
Stops the alarm buzzer. • The alarm buzzer stops sounding.
Buzzer cancel switch (Some alarm buzzer does not stop • The alarm buzzer sounds again if
4 another error worth alarming is
[Numeric keypad: 4] sounding even if the switch is
pressed.) detected.
Operates the front glass wiper. • Pressing the switch sequentially
(*2) changes the wiper operation.
INT: Intermittent operation
5 Wiper switch OFF (Stop) o INT (Intermittent) o
ON: Continuous operation ON (Continuous) o OFF (Stop)
[Numeric keypad: 5]
Lights out: Holds in position
(*2) Sprays washer fluid onto the front ON: Washer fluid is sprayed and
6
Window washer switch window glass. windshield wiper works continuously.
PC210LC-10 10-259
No. Name Function Operation

[When wiper stops]
OFF: Windshield wiper works twice
continuously and stops after the switch is
released.
[Numeric keypad: 6]
[When wiper operates intermittently]
OFF: Windshield wiper works twice
continuously and returns to intermittent
operation after the switch is released.
Fan switch (increase) Controls the air flow of the air • The air flow increases immediately
7a conditioner in 6 levels. after the air conditioner adjustment
[Numeric keypad: 7] screen appears.
(Low, Medium 1, Medium 2,
Medium 3, Medium 4 and High) • The air flow decreases immediately
7b Fan switch (decrease) after the air conditioner adjustment
screen appears.
Temperature control Controls the temperature inside the • The preset temperature increases
8a switch (raise) cab. immediately after the air conditioner
[Numeric keypad: 8] (18.0℃ to 32.0℃: Setting is adjustment screen appears.
Temperature control available in 0.5°C steps) • The preset temperature decreases
8b switch (lower) immediately after the air conditioner
[Numeric keypad: 0] adjustment screen appears.
Operates the air conditioner and air • The air flow, combination of vents,
(*3) flow with automatic operation. and selection of FRESH/RECIRC air
AUTO lights up: Automatic are automatically selected according
9 Auto switch
operation to the set temperature immediately
[Numeric keypad: 9] after the air conditioner adjustment
screen appears.
Selects the air conditioner ON/OFF. • Switches to the air conditioner
(*4) A/C ON lighted: Manual operation adjustment screen, and pressing it
10
Air conditioner switch Not lighting: Stop again switches ON/OFF.
OFF io ON
Changes the FRESH/RECIRC. • Switches to the air conditioner
FRESH/RECIRC air adjustment screen, and pressing it
11 changeover switch again switches FRESH/RECIRC.
RECIRC io FRESH
Selects the air vent mode from 6 • Switches to the air conditioner
modes. adjustment screen, and pressing it
1. Front vent again switches air vent mode.
1o2o3o4o5o6o1
2. Front and rear vents
12 Vent selector switch
3. Front, rear and foot vents
4. Foot vent
5. Foot and defroster vents
6. Defroster vent
Stops the fan and air conditioner. • The fan and air conditioner stop.
13 OFF switch
Lights OFF: OFF
14a Guidance icon
See “Guidance icon and function switch“
14b Function switch
*1: When the working mode is changed, the auto-decelerator function turns “ON“.
*2: When the front window is open, the wiper and washer do not operate even if the switch is pressed.
*3: If temperature is set to 18.0°C or 32.0°C, the air flow from the fan is always set to “High“ and does not
change even if the set temperature is reached.
*4: Air conditioner cannot be operated while the fan stops.
10-260 PC210LC-10
Guidance icon and function switch (PC-Q1C1-042-K-00-A)

• Functions available with the function switch vary depending on the guidance icon displayed above the
switch.
• No function is available if no guidance icon appears above the function switch.
• The following is the list of guidance icons and the functions displayed above the function switches.
Guidance
Item Function
icon
Selects user menu screen.
Background colors allow confirming the type of information
transmitted.
Selection of user mode • Gray: When the condition is normal
screen • Red: When soot accumulation abnormality (L3) is detected, or
exceeding maintenance interval
• Yellow: When soot accumulation abnormality (L1) is detected, or
exceeding maintenance interval warning
• Green: When there is unread KOMTRAX message
Switching clock/service Switches clock/service meter display.

meter
Switching to camera Switches to camera image display screen.

screen
Enters selected/setting item.

Background colors allow confirming the type of information
Enter transmitted.
• Gray: When the condition is normal
• Green: When energy saving guidance is displayed
Return Returns to the previous screen or status.
Selects the item right above the current item

Switching the select item
(To the bottom item from the top item.)
Selects the item right below the current item

(To the top item from the bottom item.)
Green arrow: Selects the item on the right side of the tab.
Switching the select item White arrow: Selects the item on the right side of the current item.
(To the leftmost item from the rightmost item.)
Green arrow: Selects the item on the left side of the tab.
Switching the select item White arrow: Selects the item on the left side of the current item.
(To the rightmost item from the leftmost item.)
Selects the page right above the current page.

(To the bottom page from the top page.)
PC210LC-10 10-261
Guidance
Item Function
icon
Selects the page right below the current page.

(To the top page from the bottom page.)
Clear Clears selected/displayed item.
Sets selected item back to default.

Restores default value
(Used for screen adjustment.)
Set Performs setting.
Starts function.
Start (Used for starting measurement of split fuel consumption on the fuel
consumption display screen.)
Stops operation.
Stop (Used for stopping measurement of split fuel consumption on fuel
consumption display screen.)
Saving Saves setting
Switching to the name

Switches the current screen to the name setting screen
setting screen
Switching to ATT1 oil flow Switching the current screen to attachment 1 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Switching to ATT2 oil flow Switching the current screen to attachment 2 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)
Holds the value of the target item of monitoring.

HOLD
(Used when monitoring is turned on)
Resets the currently held value of the target item of monitoring.

Resetting the hold
(Used when monitoring is turned on)
Switching the fuel

Switches the graphs on the fuel consumption record screen.
consumption record screen
Switching to oil flow setting Switches to the attachment and breaker oil flow setting screen.
screen
10-262 PC210LC-10
Guidance
Item Function
icon
Switches to the currently occurring failures list screen.
Switching to the currently Background colors allow confirming the type of information
occurring failures list transmitted.
screen • Red: When an action level of L2, L3 or L4 is displayed
• Yellow: When the action level of L1 is displayed
Display No. 1 camera Selects No. 1 camera image display screen.

screen

screen

screen
Display No. 1 and No. 2 Display both images of No. 1 and No. 2 cameras simultaneously.
camera screens
PC210LC-10 10-263
Operator mode function (PC-Q193-042-K-00-A)

• The operator can select the information to be displayed usually on the screen and the function to be used
by operating the switches.
Display and setting of some functions require special operation of the switch.
• Items available in the operator mode are as follows:
Category Display order (*2)
Item
(*1) V W X Y Z
KOMATSU logo screen 1 1 1 1 1
Password input screen 2 — — — —
Breaker mode check screen — — 2 — —
Checks before starting screen 3 2 3 2 2
Warning screen after check before starting — — — 3 —
A — — — —
Overdue maintenance time item screen 3
Working mode and travel speed check screen 4 3 4 4 4
Standard screen 5 4 5 5 5
Engine shutdown secondary switch screen
End screen
Selecting auto-deceleration function
Selecting working mode
Selecting travel speed
Stopping alarm buzzer
Operating windshield wiper
Operating window washer
Operating air conditioner
Operating camera mode display
B Switching between clock display and service meter display
Checking maintenance information
Setting and displaying user menu
• “ECO Guidance“
• “Machine Setting“
• “KDPF Regeneration“
• “Maintenance“
• “Monitor Setting“
• Message display (including KOMTRAX messages for user)
Displaying ECO guidance
Displaying caution monitor
C
Displaying KDPF regeneration
Displaying action level and failure code
LCD (Liquid Crystal Display) display condition checking function
D Service meter reading checking function
Access restriction setting/password changing function
*1: The items available in the operator mode are categorized as shown below.
A: Displays that appear since starting switch is turned to “ON“ position until the standard screen appears, and
the displays that appear after starting switch is turned to “OFF“ position .
B: Displays that appear when the switch on the machine monitor is operated.
C: Displays when a certain condition is satisfied
D: Displays that require special switch operations.
*2: Display sequence from “ON“ of starting switch to the standard screen varies depending on the settings
and conditions of the machine as follows:
V: When engine start lock is set effective
W: When engine start lock is disabled
X: When working mode at start is set to “Breaker Mode (B)“.
Y: When a failure is detected during check before starting.
10-264 PC210LC-10
Z: When a maintenance time overdue is detected for an item.

a For how to operate the operator mode functions, see the Operation and Maintenance Manual or “Operator
mode (Outline)“ section in Testing and adjusting.
a For how to set the engine start lock on/off, see " Password setting/cancel manual" .
PC210LC-10 10-265
Service mode function (PC-Q194-042-K-00-A)

• The functions in this mode are not displayed usually on the screen. Information display and various
settings can be made only by the technician through the special operation of the switches.
This mode is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring / Pre-defined
Monitoring / Custom
Abnormality Record “Mechanical Systems“
“Electrical Systems“
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default “Key-on Mode“
“Unit“
“With/Without Attachment“
“Camera“
Diagnostic Tests “Cylinder Cut-out“
“Regeneration for Service“
“KDPF Memory Reset“
Adjustment “Pump Absorption Torque (F)“
“Pump Absorption Torque (R)“
“Low Speed“
“Attachment Flow Adjustment“
“Cal F pump swash plate sensor“
“Cal R pump swash plate sensor“
No Injection
KOMTRAX Settings “Terminal Status“
“GPS & Communication Status“
“Modem Status“
Service Message
a For how to operate the service mode functions, see “Service mode“ section in Testing and adjusting.
10-266 PC210LC-10
KOMTRAX system
KOMTRAX system (PC-Q210-042-K-00-A)
• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to refer the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.
PC210LC-10 10-267
KOMTRAX system
KOMTRAX terminal (PC220-Q220-042-K-00-A)
Type: TC330
1. GPS antenna connection

2. Machine harness connection (070-18P)
3. Machine harness connection (070-12P)
4. Communication antenna connection
Input and output signals (PC220-Q220-03C-K-00-A)

070-18P[CN-CK01]
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P [CN-CK02]
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
10-268 PC210LC-10
KOMTRAX system

9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
Function (PC-Q220-042-K-00-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of “KOMTRAX setting“ in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.
PC210LC-10 10-269
Sensor
Sensor (ALL-E700-001-P-00-A)
Ambient pressure sensor (ENG-AAP2-041-K-00-A)
1. Connector
2. Sensor
Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.
Output characteristics
10-270 PC210LC-10
Sensor
Charge (boost) pressure and temperature sensor (ENG-AAM7-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-AAM7-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged
engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and
temperature".
PC210LC-10 10-271
Sensor
Coolant temperature sensor (ENG-BA87-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-BA87-042-K-00-A)
• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AG42-042-K-00-A)
• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to
the gear rotation.
10-272 PC210LC-10
Sensor
Bkup (camshaft) speed sensor (ENG-AG62-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AG62-042-K-00-A)
• This sensor, installed to the ring of camshaft on the engine front cover, outputs the pulse voltage due to
the gear rotation.
Common rail pressure sensor (ENG-AE28-041-K-00-A)
1. Connector
2. Sensor
Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.
PC210LC-10 10-273
Sensor
Exhaust manifold pressure sensor (ENG-AAN5-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (ENG-AAN5-042-K-00-A)
• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects
the exhaust pressure to output the corresponding variable voltage.
EGR orifice temperature sensor (ENG-A9U5-041-K-00-A)
1. Connector
2. Sensor
3. Washer
Function (ENG-A9U5-042-K-00-A)
• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts
the temperature variation into the resistance variation, and outputs the corresponding signals.
10-274 PC210LC-10
Sensor
EGR valve lift sensor (ENG-A9S2-041-K-00-A)
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG-A9S2-042-K-00-A)
• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the
• The relation between stroke and output voltage is as shown in the following graph.
PC210LC-10 10-275
Sensor
KVGT speed sensor (ENG-AAQ4-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. Sensor
2. O-ring
3. Connector
Function (ENG-AAQ4-042-K-00-A)
• This sensor, installed to KVGT in the engine, outputs the pulse voltage due to the rotation of KVGT
turbine.
a The 3-pole connector is applied for this sensor, however, available pins are the pin No. 1 and No. 2 only,
and it has no pin No. 3.
KVGT position sensor (ENG-AAQ3-041-K-00-A)
KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG-AAQ3-042-K-00-A)
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.
10-276 PC210LC-10
Sensor
Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)
1. Connector
2. O-ring
3. Sensor
Function (ENG-A96H-042-K-00-A)
• This sensor, installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.
PC210LC-10 10-277
Sensor
KDPF differential pressure and outlet pressure sensor (ENG-A9HL-041-K-00-A)
1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor
Function (ENG-A9HL-042-K-00-A)
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
• The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).
KDOC inlet temperature sensor (ENG-A9HG-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function (ENG-A9HG-042-K-00-A)
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
10-278 PC210LC-10
Sensor
KDOC outlet temperature sensor (ENG-A9HH-041-K-00-A)
KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst
1. Sensor
2. Connector
Function (ENG-A9HH-042-K-00-A)
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDPF outlet temperature sensor (ENG-A9HJ-041-K-00-A)
1. Sensor
2. Connector
Function (ENG-A9HJ-042-K-00-A)
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.
PC210LC-10 10-279
Sensor
Crankcase pressure sensor (ENG-A18C-041-K-00-A)
1. Connector
2. Sensor
3. O-ring
Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
Engine oil level sensor (ENG-AB45-041-K-00-A)
1. Connector
2. Bracket
3. Float
4. Switch
Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns “OFF“ by the lowered float, if the oil level
becomes lower than specified.
10-280 PC210LC-10
Sensor
Fuel level sensor (PC-AD41-041-K-00-A)
1. Connector
2. Float
3. Arm
4. Valve body
5. Spring
6. Variable resistor
Function (PC-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
• The movement of the float activates the variable resistor through the arm. As a result, the source voltage
is changed according to the resistance change due to the arm angle change and is output as a signal.
PC210LC-10 10-281
Sensor
Coolant level sensor (PC-B252-041-K-00-A)
1. Float
2. Sensor
3. Connector
4. Reservoir tank
Function (PC-B252-042-K-00-A)
• This sensor is integrated with reservoir tank, and is activated by the lowered float, if the coolant level
becomes lower than specified.
10-282 PC210LC-10
Sensor
Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)
1. Connector
2. Plug
3. Thermistor
Function (PC-PMT1-042-K-00-A)
• This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change
in thermistor resistance, and outputs the corresponding signals.
Front pump oil pressure sensor (PC-C3W4-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-C3W4-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the front pump and outputs
variable voltage signal.
PC210LC-10 10-283
Sensor
Rear pump oil pressure sensor (PC-C3W5-041-K-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-C3W5-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the rear pump and outputs
variable voltage signal.
10-284 PC210LC-10
Sensor
PPC oil pressure sensor (PC-E720-041-P-00-A)
1. O-ring
2. Sensor
3. Connector
Function (PC-E720-042-P-00-A)
• PPC oil pressure sensors, 8 of which are installed to interconnect blocks in the pilot circuit between control
valves and PPC valve, and 4 of which are installed to travel PPC valves, detect the pilot pressures, and
output the corresponding variable voltage.
PC210LC-10 10-285
Sensor
Air cleaner clogging sensor (PC-A968-041-K-01-A)
1. Adapter
2. Hood
3. Indicator
4. Connector
Function (PC-A968-042-K-00-A)
• This sensor is installed on the air cleaner outlet side. The switch is turned to “ON“ position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).
Front pump swash plate sensor (PC-C3W9-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
Function (PC200_10-C3W9-042-K-00-A)
• This senor is installed to the front pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
10-286 PC210LC-10
Sensor
• The relation between oil flow of pump and output voltage is as shown in the following graph.
Rear pump swash plate sensor (PC-C3WB-041-K-00-A)
1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)
PC210LC-10 10-287
Sensor
Function (PC200_10-C3WB-042-K-00-A)
• This senor is installed to the rear pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.
• The relation between oil flow of pump and output voltage is as shown in the following graph.
10-288 PC210LC-10
Sensor
Water-in-fuel sensor (PC-AEB3-041-K-00-A)
1. Connector
2. Tube
3. Sensor
4. O-ring
Function (PC-AEB3-042-K-00-A)
• This sensor is installed to the cup of fuel prefilter.
• This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.
PC210LC-10 10-289
10-290 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
20 Standard value tables

4 20 Standard value tables
PC210LC-10 20-1
Table of contents

20 Standard value tables.................................................................................................................... 20-1
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-18
20-2 PC210LC-10
Standard value table for engine
Standard service value table (ALL-A000-001-K-00-A)
Standard value table for engine (PC200_10-A000-033-K-00-A)

Engine SAA6D107E-2
Category
Standard
Item Measurement condition Unit value for new Repair limit
machine
High idle rpm 1,850 ± 70 1,850 ± 70
• Coolant temperature: 30 to rpm
Low idle 1,050 ± 50 1,050 ± 50
Rotating speed 102°C
• Swing lock switch: ON Rated rpm 2,000 2,000
speed
• Coolant temperature: 30 to 102°C

• Hydraulic oil temperature: 45 to 55°C kPa Min. 120 Min. 93
Boost pressure
• Swing lock switch: ON {mmHg} {Min. 900} {Min. 700}
• Arm IN relief + One-touch power max. ON
Engine
outlet
• Coolant temperature: 30 to (between Bosch
102°C — 2.7
turbochar- index
Exhaust gas • At relief with arm IN ger and
color • Swing lock switch: ON KDPF inlet)
• After kept for 5 seconds at
KDPF outlet
normal condition Bosch
(exhaust — 0.5
pipe outlet) index
Intake valve mm 0.25 0.152 to 0.381
• Coolant temperature :
Valve clearance Normal temperature Exhaust mm 0.51 0.381 to 0.762
Engine
valve
Compres- MPa Min. 2.41 Min. 1.69
sion
Compression • Engine oil temperature: 40 to pressure {kg/cm2} {Min. 24.6} {Min. 17.2}
pressure 60°C
Engine rpm
speed 250 to 280 250 to 280
Blowby • Hydraulic oil temperature: 45 to 55°C kPa Max. 0.98 Max. 1.96
pressure • Arm IN relief + One-touch power max. ON {mmH2O} {Max. 100} {Max. 200}
• KCCV circuit disconnected
MPa Min. 0.29 Min. 0.25
• Coolant temperature: 30 to High idle
Engine oil {kg/cm2} {Min. 3.0} {Min. 2.5}
pressure 102°C
MPa Min. 0.10 Min. 0.07
• SAE15W-40 oil Low idle
{kg/cm2} {Min. 1.0} {Min. 0.7}
EGR valve and
MPa Min. 1.2 Min. 1.2
KVGT drive oil • Coolant temperature: 30 to
102°C {kg/cm2} {Min. 12.0} {Min. 12.0}
pressure Low idle
• Hydraulic oil temperature: 45
KVGT control oil MPa 0.3 to 1.0 0.3 to 1.0
to 55°C
pressure {kg/cm2} {3.1 to 10.2} {3.1 to 10.2}
Engine oil
• Whole speed range (inside oil pan) °C 80 to 110 MAX.120
temperature
Auto- Auto-
• Between fan pulley and alternator pulley tensioner tensioner
Fan belt tension • Deflection when pressed with finger at 98 mm
N {10 kg} (Automatic (Automatic
adjustment) adjustment)
PC210LC-10 20-3
Standard value table for engine

Engine SAA6D107E-2
Category
Standard
machine
Air conditioner • Between compressor pulley and fan pulley
compressor belt • Deflection when pressed with finger at 60 mm 6.3 to 8.7 6.3 to 8.7
tension N {6.2 kg}
20-4 PC210LC-10
Standard value table for machine
Standard value table for machine (PC200_10-0000-033-K-00-A)
Engine speed
Machine model PC210LC–10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: 45 to 55°C
At 2-pump relief • Engine: High idle rpm 1,850 ± 100 1,850 ± 100
Rotating speed • Power mode (P)
• Swing lock switch: OFF
• At relief with arm IN
Speed at 2-pump
• Engine: High idle rpm
relief + One-touch 1,950 ± 100 1,950 ± 100
• Power mode (P)
power max. is ON
• Arm IN relief + Left knob switch in ON
position
Speed when auto- • Engine: High idle
deceleration is • Auto-deceleration switch in ON position rpm 1,050 ± 100 1,050 ± 100
operated • All control levers at NEUTRAL
Control valve spool stroke
Standard
new
machine
• Engine stopped RAISE mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve • For measuring point, see LOWER mm 9.5 ± 0.5 9.5 ± 0.5
"Control valve". DIGGING mm 11.5 ± 0.5 11.5 ± 0.5
Arm control valve
DUMP mm 9.5 ± 0.5 9.5 ± 0.5
DIGGING
Bucket control valve mm 9.5 ± 0.5 9.5 ± 0.5
DUMP
Left swing
Swing control valve mm 9.5 ± 0.5 9.5 ± 0.5
Right swing
Forward
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse
PC210LC-10 20-5
Travel of control lever

Standard
new
machine
Boom control lever • Engine stopped mm 85 ± 10 85 ± 10
Arm control lever • Center of lever knob mm 85 ± 10 85 ± 10
Bucket control lever • Read max. value through travel end mm 85 ± 10 85 ± 10
(excluding play at NEUTRAL).
Swing control lever mm 85 ± 10 85 ± 10
Travel control lever mm 115 ± 12 115 ± 12
Work
mm Max. 15 Max. 20
Play of control lever equipment
Traveling mm Max. 20 Max. 25
Operating effort of control lever and pedal
Standard
new
machine
• Hydraulic oil temperature: 45 to 55°C N 15.7 ± 3.9 Max. 24.5
Boom control lever • Engine: High idle {kg} {1.6 ± 0.4} {Max. 2.5}
• Control lever: At center of grip
N 15.7 ± 3.9 Max. 24.5
Arm control lever • Pedal: At tip of pedal
• Read max. value through travel end. {kg} {1.6 ± 0.4} {Max. 2.5}
N 12.7 ± 2.9 Max. 21.6
Bucket control lever
{kg} {1.3 ± 0.3} {Max. 2.2}
N 12.7 ± 2.9 Max. 21.6
Swing control lever
{kg} {1.3 ± 0.3} {Max. 2.2}
N 24.5 ± 5.9 Max. 39.2
Travel control lever
{kg} {2.5 ± 0.6} {Max. 4.0}
N 74.5 ± 18.6 Max. 107.6
Travel control pedal
{kg} {7.6 ± 1.9} {Max. 11}
20-6 PC210LC-10
Oil pressure
Standard
new
machine
• Engine: High idle MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure • Power mode (P)
• Hydraulic pump output pressure with all {kg/cm 2} {36 ± 10} {36 ± 10}
control levers in NEUTRAL position
• Hydraulic oil temperature: 45 34.8 (+1.5 /
to 55°C At normal MPa -1.2) 33.1 to 37.2
• Engine: High idle relief {kg/cm } {355 (+15 /
2 {338 to 380}
• Power mode (P) -12)}
Boom relief pressure • Hydraulic pump outlet
37.3 (+1.5 /
pressure with all
At power MPa -1.2) 36.1 to 39.7
measurement circuits
relieved maximizing {kg/cm } {380 (+15 /
2 {368 to 405}
-12)}
34.8 (+1.5 /
At normal MPa -1.2) 33.1 to 37.2
relief {kg/cm2} {355 (+15 / {338 to 380}
Arm relief pressure -12)}
37.3 (+1.5 /
At power MPa -1.2) 36.1 to 39.7
maximizing {kg/cm2} {380 (+15 / {368 to 405}
-12)}
34.8 (+1.5 /
At normal MPa -1.2) 33.1 to 37.2
relief {kg/cm } {355 (+15 /
2 {338 to 380}
-12)}
Bucket relief pressure
37.3 (+1.5 /
At power MPa -1.2) 36.1 to 39.7
maximizing {kg/cm } {380 (+15 /
2 {368 to 405}
-12)}
• Hydraulic oil temperature: 45 to 55°C MPa 29.3 ±1.5 27.4 to 31.3
Swing relief pressure • Engine: High idle {kg/cm2} {300 ± 15} {280 to 320}
• Power mode (P)
38.7 (+1.0 /
• Hydraulic pump outlet pressure with all
MPa -2.0) 36.8 to 40.2
Travel relief pressure measurement circuits relieved
• Sudden turning back must be avoided {kg/cm 2} {395 (+10 / {375 to 410}
-20)}
• Engine: High idle 3.23 (+0.2 /
Control circuit oil MPa 2.75 to 3.43
• Self-pressure reducing valve outlet -0.3)
pressure {kg/cm2} {28 to 35}
pressure with all control levers in {33 (+2 / -3)}
NEUTRAL position
• Hydraulic oil temperature: 45 All control MPa 3.5 ± 1.0 3.5 ± 1.0
to 55°C levers in
{kg/cm2} {36 ± 10} {36 ± 10}
• Engine: High idle NEUTRAL
• Power mode (P)
LS differential 1.8 (+0.05 / 1.8 (+0.05 /
• Travel speed: Hi
pressure Travel MPa -0.1) -0.1)
• Run either track idle
• LS differential pressure = levers at
{kg/cm2} {18 (+0.5 / {18 (+0.5 /
Pump pressure - LS half stroke
-1.0)} -1.0)}
pressure
PC210LC-10 20-7
Swing
Standard
new
machine
• Engine: High idle deg. Max. 100 Max. 130
Overswing • Power mode (P)
• Overswing of swing circle after one turn (mm) (-) (-)
• For measuring posture, see "Swing 1"
• Hydraulic oil temperature: 45 90 degrees sec. 3.1 ± 0.3 Max. 3.7
to 55°C
• Engine: High idle
• Power mode (P)
Swing drift on a slope • Time required to pass 90 180
degrees and 180 degrees sec. 4.4 ± 0.4 Max. 5.5
degrees
points after starting swing
• For measuring posture, see
"Swing 1"
Time required to finish • Power mode (P)
sec. 24.2 ± 2.5 Max. 30
swinging • Time required to complete five turns after
one turn
• Engine stopped
• On slope of 15 deg., set upper structure
Amount of Hydraulic crosswise and make matchmarks on inner
mm 0 0
drift of swing race and outer race of swing circle.
• Distance that matchmarks move apart
after 5 minutes
Leakage from swing • Engine: High idle
• Swing lock switch: ON l/min Max. 5 Max. 10
motor
• Leakage in 1 minute during swing relief
20-8 PC210LC-10
Traveling
Machine model PC210LC–10
Standard
new
machine
• Hydraulic oil temperature: 55.9 (+3.9/-
Lo sec. 48.6 to 63.8
Within operating range 7.3)
• Engine: High idle Mi sec. 40.8 ± 4.1 36.7 to 48.9
Travel speed (idle • Power mode (P)
running) • Time required to make five
idle turns of track off ground
after one idle turn Hi sec. 28.8 ± 1.5 27.3 to 32.3
"Travel 1"
• Hydraulic oil temperature: 24 (+1.7 /
Lo sec. 20.9 to 26.7
Within operating range -3.1)
• Engine: High idle Mi sec. 17 ± 2.5 14.5 to 20.5
Travel speed (actual • Power mode (P)
running) • Time required for traveling 20
m after 10 m trial run Hi sec. 13 ± 1.0 12.0 to 15.0
"Travel 2"
• Hydraulic oil temperature: Within
operating range
• Power mode (P)
Travel deviation • Travel speed: Lo mm Max. 150 Max. 250
• Travel deviation (x) in travel of 20 m after
running up 10 m on firm and level ground
• For measuring posture, see "Travel 2" and
"Travel 3"
operating range
• Engine stopped
Machine drift on a • Place machine on slope of 12 deg. with
mm 0 0
slope sprocket on uphill side.
• Travel distance by hydraulic drift of travel
for 5 minutes
• For measuring posture, see "Travel 4"
operating range
Leakage from travel • Engine: High idle l/min 13.6 27.2
motor • Lock sprocket with pin, etc.
• Leakage in 1 minute during travel relief
PC210LC-10 20-9
Work equipment
• Hydraulic drift of work equipment
Standard
machine
Whole work • Hydraulic oil temperature: Within operating
mm Max. 600 Max. 900
equipment range
Hydraulic drift of • Measure on level and flat surface.
• Bucket filled up with dirt and sand, or at the mm Max. 18 Max. 27
boom cylinder
Hydraulic drift of rated load (0.8 m3: 1,440 kg)
• Horizontal boom top face, fully retracted mm Max. 160 Max. 240
boom cylinder
arm, fully extended bucket cylinder
• Engine stopped
• Work equipment control lever in NEUTRAL
position
• Fall amount for 15 minutes as measured
every 5 minutes starting immediately after
initial setting
Hydraulic drift of • Whole work equipment: Hydraulic drift
measured at tooth tip mm Max. 40 Max. 58
bucket cylinder
• Boom cylinder: Retraction amount of
cylinder
• Arm cylinder: Extension amount of cylinder
• Bucket cylinder: Retraction amount of
cylinder
• For measuring posture, see "Work
equipment 1"
• Work equipment speed
Standard
machine
• Hydraulic oil temperature: RAISE sec. 3.6 ± 0.4 Max. 4.7
Within operating range
• Power mode (P)
• Time required to move boom
Boom speed
between RAISE stroke end LOWER sec. 2.9 ± 0.3 Max. 3.7
and ground touch point of
bucket
"Work equipment 2"
• Hydraulic oil temperature: DIGGING sec. 3.5 ± 0.4 Max. 4.5
• Power mode (P)
Arm speed • Time required to move bucket
between DUMP stroke end DUMP sec. 2.7 ± 0.3 Max. 3.5
and CURL stroke end
"Work equipment 3"
• Hydraulic oil temperature: DIGGING sec. 2.6 ± 0.3 Max. 3.3
• Power mode (P)
Bucket speed • Time required to move bucket
between DUMP stroke end DUMP sec. 1.9 ± 0.2 Max. 2.7
and CURL stroke end
"Work equipment 4"
20-10 PC210LC-10
• Time lag
Standard
machine
• Hydraulic oil temperature: Within operating
range
• Engine at low idle
• Power mode (P)
• Set boom at full RAISE position. Move
Boom time lag boom control lever to LOWER position. sec. Max. 1.0 Max. 1.2
Measure length of time before front of
machine starts lifting off the ground after
work equipment touches the ground.
equipment 5"
range
• Power mode (P)
• Set arm to the max. DUMP position. Move
Arm time lag arm control lever to IN position. The time sec. Max. 2.0 Max. 2.8
required from when the arm is stopped once
at an approximately vertical orientation until
it starts moving to the IN side again.
equipment 6"
range
• Power mode (P)
• Set bucket at full DUMP position. Move
bucket control lever to CURL position. The
Bucket time lag sec. Max. 1.0 Max. 3.6
time required from when the bucket is
stopped once at an approximately vertical
orientation until it starts moving to the CURL
side again.
equipment 7"
• Oil leakage
Standard
machine
Cylinder internal • Hydraulic oil temperature: Within operating
oil leakage range cc/min 4.5 20
Center swivel joint • Leakage amount for 1 minute during relief of cc/min 10 50
cylinder to be measured or travel motor
PC210LC-10 20-11
Performance of combined operation

Standard
new
machine
operating range
Travel deviation in
• Power mode (P)
combined operation of mm
• Travel speed: Lo Max. 200 Max. 220
work equipment and
• Travel deviation (x) in travel of 20 m after
travel
running up 10 m on firm and level ground
• For measuring posture, see "Travel 2" and
"Travel 3"
Pump swash plate sensor
Standard
new
machine
• Hydraulic oil temperature: All control
Within operating range levers at V 1.35 ± 0.20 1.35 ± 0.63
• Engine: High idle NEUTRAL
• Power mode (P) When
Pump swash plate
• Travel speed: Hi running
sensor output voltage
• Run either track idle track idle
off ground V 3.35 ± 0.20 3.35 ± 0.63
(lever at
travel end).
Characteristics of PC flow control
Standard
new
machine
operating range
• Power mode (P)
Time required for • Bucket with rated load (0.8 m3: 1,440 kg)
swinging from 0 to 90 • On hard and level ground, set arm 4.2 ± 0.4
sec.
deg. with boom vertically and lower back of bucket to (Reference value)
RAISE ground
• Time required for swinging from 0 to 90
deg. with boom RAISE
equipment 8"
20-12 PC210LC-10
Hydraulic pump
Discharge Discharge
Item Measurement condition Unit Standard Repair limit
value
• Pump speed (rpm): 1,700 rpm
• PC-EPC current value (mA): 440 mA
• Test pump discharge pressure (MPa {kg/
cm2})
: P1 Q Q
Performance of
• Discharge pressure of another pump (MPa l/min
hydraulic pump (See graph) (See graph)
{kg/cm2})
: P2
• Average discharge pressure (MPa {kg/
cm2})
: Pp＝(P1＋P2)/2
a Bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump discharge and the engine speed at the time of
measurement, and use them as a base for calculating the pump discharge at the specified speed.
PC210LC-10 20-13
Posture of machine for measuring performance and measurement

procedure (PC220_10-0000-321-K-00-A)
Control valve: Spool travel
Swing 1: Overrun when stopping swing, time required for starting swing, time required for swing
Swing 2: Amount of Hydraulic drift of swing
20-14 PC210LC-10
Travel 1: Travel speed (idle running)
Travel 2: Travel speed (actual run), travel deviation
Travel 3: Travel deviation
Travel 4: Hydraulic drift of travel
PC210LC-10 20-15
Work equipment 1: Hydraulic drift of the work equipment
Work equipment 2: Boom speed
Work equipment 3: Arm speed
Work equipment 4: Bucket speed
20-16 PC210LC-10
Work equipment 5: Boom time lag
Work equipment 6: Arm time lag
Work equipment 7: Bucket time lag
Work equipment 8: PC flow characteristics control
PC210LC-10 20-17
Standard value table for electrical system
Standard value table for electrical system (D155-E000-001-P-00-A)
Controller (PC200_10-RA1E-033-K-00-A)
Equipment name Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position, and set the battery disconnect switch
to OFF position.
2. Insert T-adapter into connector CE03.
Continuous 3. Turn the battery disconnect switch to ON position.
Engine power 4. Measure voltage with the starting switch at OFF position and when starting
controller supply engine.
voltage Between CE03 (1) and (21) 20 to 30 V
Between CE03 (2) and (31) 20 to 30 V
Voltage
1. Turn the starting switch to OFF position, and disconnect the battery ground
Continuous cable.
power 2. Disconnect connector CP01, and connect T-adapter to female side.
supply 3. Connect the ground cable, and turn the starting switch to ON position.
voltage Between CP01(female) (1) and (2) 20 to 30 V
Voltage
Between CP01 (female) (4) and (5) 20 to 30 V
Pump
controller 1. Turn the starting switch to OFF position, and disconnect the battery ground
cable.
Solenoid 2. Disconnect connector CP02, and connect T-adapter to female side.
power 3. Connect the ground cable, and turn the starting switch to ON position.
supply
Between CP02(female) (116) and ground 20 to 30 V
voltage
Voltage Between CP02(female) (118) and ground 20 to 30 V
Between CP02(female) (121) and ground 20 to 30 V
1. Turn the starting switch to OFF position, and set the battery disconnect switch
to OFF position.
Continuous 2. Insert T-adapter into connector CM01.
Machine power 3. Turn the battery disconnect switch to ON position, and turn the starting switch
monitor supply to ON position (connect ACC).
voltage
Between CM01 (1) and (3) 20 to 30 V
Voltage
20-18 PC210LC-10
Engine control (PC200_10-AG10-033-K-00-A)

1. Turn the starting switch to OFF position.
EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapter to male side.
Resistance Between EGR-SOL (male) (1) and (2) 5 to 10 z
KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapter to male side.
Resistance Between VGT-SOL (male) (1) and (2) 5 to 10 z
2. Disconnect connector P23, and connect T-adapter to male side.
3. Turn the starting switch to ON position.
When the air
cleaner is
Air cleaner clogging
normal.
switch
(Air cleaner
Resistance Between P23 (male) (1) and (2) Max.1Ω
suction
resistance:
Max. -3,430 Pa
{-350mmH2O})
2. Disconnect connector COOLANT TEMP, and connect socket to male side.
a Regard the coolant temperature sensor as normal if its resistance is 700 z to
37 kz when the coolant temperature is 0°C or higher.
Coolant temperature
sensor 0°C 30 to 37 kz
25°C 9.3 to 10.7 kz
Between COOLANT TEMP
Resistance (male) (1) and (2) 50°C 3.2 to 3.8 kz
80°C 1.0 to 1.3 kz
95°C 700 to 800 z
2. Disconnect connector BOOST PRESS & IMT, and connect socket to male
side.
a Regard charge temperature sensor as normal if its resistance is 80 z to 48
Kz .
Charge temperature -40°C 41 to 48 kz
sensor -20°C 14 to 16 kz
Between BOOST PRESS &
IMT (male) (3) and (4) 0°C 5.4 to 6.1 kz
Resistance 30°C 1.6 to 1.8 kz
a Charge temperature- 60°C 560 to 600 kz
Resistance characteristics
90°C 230 to 250 z
130°C 80 to 90 z
2. Disconnect connector P55 and connect T-adapter to male side.
-30°C 25 to 28 kz
Intake air temperature
Between P55 (male) (3) and (4) 0°C 5.5 to 6.1 kz
sensor
Resistance a Intake air temperature- 25°C 1.9 to 2.1 kz
Resistance characteristics 40°C 1.1 to 1.2 kz
100°C 180 to 185 z
2. Disconnect connector TEMP1 and connect T-adapter to female side.
-10°C 33 to 65 kz
KDOC inlet temperature Between TEMP1 (female) (1)
sensor and (2) 0°C 25 to 47 kz
Resistance 50°C 7.8 to 12.2 kz
a Temperature-Resistance 100°C 3.2 to 4.5 kz
characteristics
400°C 200 to 240 z
PC210LC-10 20-19

700°C 64 to 69 z
Between TEMP1 (female) (1) and ground Min. 100 Kz
-10°C 33 to 65 kz
Between TEMP2 (female) (1) 0°C 25 to 47 kz
KDOC outlet temperature and (2) 50°C 7.8 to 12.2 kz
sensor
Resistance a Temperature-Resistance 100°C 3.2 to 4.5 kz
characteristics 400°C 200 to 240 z
700°C 64 to 69 z
-10°C 33 to 65 kz
KDPF outlet temperature Between TEMP3 (female) (1) 0°C 25 to 47 kz
sensor and (2) 50°C 7.8 to 12.2 kz
Resistance
700°C 64 to 69 z
2. Disconnect connector EXHAUST GAS TEMPERATURE and connect T-
adapter to male side.
-30°C 760 to 880 kz
0°C 380 to 515 kz
Between EXHAUST GAS 25°C 155 to 225 kz
TEMPERATURE (male) (1) and 80°C 21 to 29 kz
EGR orifice temperature (2)
sensor 900 to 1,050
200°C
kz
Resistance a Temperature-Resistance
characteristics 300°C 150 to 200 kz
400°C 40 to 56 z
500°C 15 to 22 z
Whole range between EXHAUST GAS
TEMPERATURE (male) (2) and ground (sensor Min. 100 kz
body)
2. Disconnect connector INLET METERING VALVE, and connect T-adapter to
male side.
Supply pump actuator
Between INLET METERING VALVE (male) (1)
（IMV/PCV1） 1 to 5 z
and (2)
Resistance
Between INLET METERING VALVE (male) (1)
and ground Min. 100 kz

2. Disconnect INJECTOR CYL1 & 2, and connect T-adapter to male side.
NO1. INJECTOR Between INJECTOR CYL1&2 (male) (3) and (4) Max. 2 z
Resistance Between INJECTOR CYL1&2 (male) (3) and
ground Min. 100 kz

2. Disconnect INJECTOR CYL5&6, and connect T-adapter to male side.
NO5. INJECTOR Between INJECTOR CYL5&6 (male) (3) and (4) Max. 2 z
ground Min. 100 kz

NO3. INJECTOR 2. Disconnect connector INJECTOR CYL3&4, and connect T-adapter to male
side.
20-20 PC210LC-10

Between INJECTOR CYL3&4 (male) (3) and (4) Max. 2 z
ground Min. 100 kz

NO6. Injector Between INJECTOR CYL5&6 (male) (1) and (2) Max. 2 z
ground Min. 100 kz

NO2. Injector Between INJECTOR CYL1&2 (male) (1) and (2) Max. 2 z
ground Min. 100 kz

2. Disconnect connector INJECTOR CYL3&4, and connect T-adapter to male
side.
NO4. Injector
Between INJECTOR CYL3&4 (male) (1) and (2) Max. 2 z
ground Min. 100 kz

Charge (Boost) pressure 2. Insert T-adapter into connector ECMJ1.
sensor 3. Turn the starting switch to ON position.
Voltage Between ECMJ1 (15) and (59) Sensor output 0.3 to 4.7 V
2. Disconnect connector OILPRESSURE SWITCH, and connect T-adapter to
Engine oil pressure switch male side.
Between OIL PRESSURE SWITCH (male) (1)
Voltage Max. 10 z
and ground
Engine oil level sensor
Resistance Between P44 (male) (1) and ground Max. 1 z
2. Disconnect connector P24, and connect T-adapters to male side.
Coolant level sensor Between FULL
Max. 1 z
and LOW lines
Resistance Between P24 (male) (1) and (2)
Below LOW
Min.1 Mz
line
2. Insert T-adapter into connector ECMJ1.
Ambient pressure sensor
Exhaust manifold 2. Disconnect connector ECMJ2, and connect T-adapter to female side.
pressure sensor 3. Turn the starting switch to ON position.
2. Disconnect connector P47, and connect T-adapter to female side.
Water-in-fuel sensor 3. Turn the starting switch to ON position.
installed to fuel pre-filter a If water is in water separator, drain it.
Between P47 (female) (1) and (2) 10 to 100 kz
Resistance
Between P47 (female) (1) and ground Min. 100 kz
Common rail pressure 1. Turn the starting switch to OFF position.
sensor 2. Insert T-adapter into connector ECMJ2.
PC210LC-10 20-21

2. Insert T-adapter into connector P57.
Crankcase pressure 3. Turn the starting switch to ON position.
sensor
Between P57 (female) (3) and
Voltage Sensor output 0.3 to 4.7 V
(2)
KDPF differential 2. Insert T-adapter into connector E25.
pressure sensor 3. Turn the starting switch to the ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
KDPF outlet pressure 2. Insert T-adapter into connector E25.
sensor 3. Turn the starting switch to the ON position.
Turbocharger speed 2. Disconnect connector VGT REV, and connect T-adapter to female side of
sensor connector.
Resistance Between VGT REV (female) (1) and (2) 600 to 1600 z
Fuel control dial (throttle
Between P20 (male) (1) and (3) 4.0 to 6.0 kz
sensor)
Voltage Between P20 (male) (2) and (3) 0.25 to 5.0 kz
Between P20 (male) (1) and (2) 0.25 to 5.0 kz
2. Insert T-adapter into connector SEGR.
EGR valve lift sensor 3. Turn the starting switch to ON position.
Between SEGR (female) (C) Sensor output
Voltage 1.0 to 4.0 V
and (B)
2. Insert T-adapter into connector SVGT.
KVGT position sensor 3. Turn the starting switch to ON position.
Between SVGT (female) (C) Sensor output
and (B)
20-22 PC210LC-10
Machine control (PC200_10-E000-033-P-00-A)

Travel speed selector 2. Disconnect connector V04, and connect T-adapter to male side.
solenoid Between V04 (male) (1) and (2) 20 to 60 z
Resistance
Between V04 (male) (1) and ground Min. 1 Mz
Swing holding brake 2. Disconnect connector V03, and connect T-adapter to male side.
Resistance
2. Disconnect connector V05, and connect T-adapter to male side.
Travel junction solenoid
Between V05 (male) (1) and (2) 20 to 60 z
Resistance
Attachment return 2. Disconnect connector V07, and connect T-adapter to male side.
selector solenoid Between V07 (male) (1) and (2) 20 to 60 z
Resistance
2-stage relief solenoid
Resistance
Variable back pressure 2. Disconnect connector V25, and connect T-adapter to male side.
Resistance
Swing cut-off solenoid
Resistance
F-PC-EPC solenoid
Resistance
R-PC-EPC solenoid
Resistance
LS-EPC solenoid
Resistance
Attachment flow throttle 2. Disconnect connector V30, and connect T-adapter to male side.
EPC solenoid Between V30 (male) (1) and (2) 3 to 14 z
Resistance
Merge-divider main EPC 2. Disconnect connector V23, and connect T-adapter to male side.
Resistance
Merge-divider LS EPC 1. Turn the starting switch to OFF position.
solenoid 2. Disconnect connector V24, and connect T-adapter to male side.
PC210LC-10 20-23

Resistance
Between P22 (male) 10°C Approx. 90 kz
Hydraulic oil temperature (1) and (2) 30°C Approx. 35 kz
sensor a Temperature- 80°C Approx. 6.5 kz
Resistance
Resistance
100°C Approx. 3.5 kz
characteristics
Between P22 (male) (2) and ground Min. 1 Mz
Front pump pressure 3. Turn the starting switch to ON position.
sensor
Between P25 (2)
and (1)
2. Connect T-adapter to connector P26.
Rear pump pressure 3. Turn the starting switch to ON position.
sensor
Between P26 (2)
and (1)
Arm digging PPC
pressure sensor
Between P04 (2)
and (1)
Bucket digging PPC
pressure sensor
Between P01 (2)
and (1)
Boom RAISE PPC
pressure sensor
Between P06 (2)
and (1)
Boom LOWER PPC
pressure sensor
Between P02 (2)
and (1)
2. Connect T-adapter into connector P07.
Swing R.H. PPC pressure 3. Turn the starting switch to ON position.
sensor
Between P07 (2)
and (1)
Swing L.H. PPC pressure 3. Turn the starting switch to ON position.
sensor
Between P03 (2)
and (1)
Arm dump PPC pressure 3. Turn the starting switch to ON position.
sensor
Between P08 (2)
and (1)
20-24 PC210LC-10

Bucket dump PPC
pressure sensor
Between P05 (2)
and (1)
Left travel FORWARD
PPC pressure sensor
Between P09 (2)
and (1)
Right travel FORWARD
PPC pressure sensor
Between P11 (2)
and (1)
Left travel REVERSE
PPC pressure sensor
Between P10 (2)
and (1)
Right travel REVERSE
PPC pressure sensor
Between P12 (2)
and (1)
Between P27 (male) (A) and (B) Approx. 6 kz
Between P27 (female) (B) and (C) Approx. 6 kz
Resistance
Between P27 (female) (A) and (C) Approx. 170 z
Between P27 (male) (C) and ground Min. 1 Mz
Between P27 (C)
Voltage Sensor output Approx. 3 V
and (B)
Front pump swash plate
sensor 1. Turn the starting switch to OFF position.
4. Start the engine.
Between P27 (C)
and (B)
a Position all
control levers in
Voltage NEUTRAL Sensor output Approx. 1.4 V
position to set
the swash plate
of pump at its
minimum angle.
Rear pump swash plate Between P26 (male) (A) and (B) Approx. 6 kz
sensor Between P26 (female) (B) and (C) Approx. 6 kz
Resistance
Between P26 (female) (A) and (C) Approx. 170 z
PC210LC-10 20-25

2. Connect T-adapter to connector P26.
Between P26 (C)
Voltage Sensor output Approx. 3 V
and (B)
Between P26 (C)
and (B)
a Position all
control levers in
Voltage NEUTRAL Sensor output Approx. 1.4 V
position to set
the swash plate
of pump at its
minimum angle.
20-26 PC210LC-10
Machine monitor (PC200_10-Q170-033-K-00-A)

2. Disconnect the battery ground cable.
3. Insert T-adapter into connector CM01.
Battery charge 4. Connect the battery ground cable.
5. Start the engine and perform troubleshooting while running engine at medium
speed or higher.
Voltage Between CM01 (16) and (3) 20 to 30 V
2. Disconnect the battery ground cable.
3. Insert T-adapter into connector CM01.
4. Disconnect heater relay terminal R16A.
Preheating a To prevent current from flowing through heater when the starting switch is
turned to HEAT position
5. Connect the battery ground cable.
6. Turn the starting switch to HEAT position.
2. Disconnect connector CM01, and connect T-adapter to female side.
Fuel level (fuel level Between CM01 (female) (15) Fuel level: Approx. 12 z
sensor) and ground FULL
Resistance
a Fuel level sensor Fuel level:
85 to 110 z
characteristics EMPTY
PC210LC-10 20-27
20-28 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
30 Testing and adjusting

5 30 Testing and adjusting
PC210LC-10 30-1
Table of contents

30 Testing and adjusting .................................................................................................................... 30-1
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ......................................................................................................... 30-9
Testing exhaust gas color ................................................................................................... 30-11
Measuring and adjusting valve clearance ............................................................................. 30-13
Testing compression pressure............................................................................................. 30-16
Testing blowby pressure ..................................................................................................... 30-20
Testing engine oil pressure ................................................................................................. 30-21
Testing EGR valve and KVGT oil pressures .......................................................................... 30-22
Measuring fuel pressure ..................................................................................................... 30-23
Measuring fuel delivery, return and leakage .......................................................................... 30-29
Bleeding air from fuel system .............................................................................................. 30-34
Checking fuel circuit for leakage .......................................................................................... 30-36
Handling cylinder cutout mode operation.............................................................................. 30-37
Handling no injection cranking operation .............................................................................. 30-38
Checking and adjusting air conditioner compressor belt tension ............................................. 30-39
Replacing fan belt .............................................................................................................. 30-41
Power train............................................................................................................................... 30-42
Testing swing circle bearing clearance ................................................................................. 30-42
Testing and adjusting track shoe tension .............................................................................. 30-43
Releasing remaining pressure from hydraulic circuit .............................................................. 30-44
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-45
Testing oil pressure of control circuit .................................................................................... 30-49
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-52
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-55
Testing output pressure of solenoid valve ............................................................................. 30-60
Testing PPC valve output pressure ...................................................................................... 30-64
Adjusting play of work equipment and swing PPC valves....................................................... 30-66
Testing pump swash plate sensor ........................................................................................ 30-67
Isolating the parts causing hydraulic drift in work equipment................................................... 30-68
Testing oil leakage ............................................................................................................. 30-69
Bleeding air from hydraulic circuit ........................................................................................ 30-72
Cab and its attachments ............................................................................................................ 30-74
Checking cab tipping stopper .............................................................................................. 30-74
Adjusting mirrors ................................................................................................................ 30-75
Electrical system ...................................................................................................................... 30-77
Special functions of machine monitor ................................................................................... 30-77
Adjusting rearview camera angle ....................................................................................... 30-148
Handling voltage circuit of engine controller........................................................................ 30-150
Handling battery disconnect switch .................................................................................... 30-151
Testing diodes ................................................................................................................. 30-152
Pm clinic ................................................................................................................................ 30-153
Pm Clinic service ............................................................................................................. 30-153
30-2 PC210LC-10
General information on testing and adjusting
General information on testing and adjusting (ALL-3831-001-A-00-A)
Tools for testing and adjusting (PC200_10-5320-304-A-00-A)
Testing and Sym-
Q'ty
adjusting item bol Part No. Part name Remarks
Testing boost -101 to 200 kPa {-760 to 1,500
A 799-201-2202 Boost gauge kit 1 mmHg}
pressure
Testing 1 799-201-9002 Handy smoke checker 1
exhaust gas B Commercially Bosch index: 0 to 9
color 2 Smoke meter 1
available
Testing and 1 795-799-1131 Gear 1
adjusting valve C Commercially
2 Feeler gauge 1
clearance available
1 795-502-1590 Gauge assembly 1 0 to 7 MPa {0 to 70 kg/cm2}
2 795-799-6700 Puller 1
Testing
Adapter
compression D 3 795-790-4411 1
pressure 4 6754-11-3130 Gasket 1
Commercially
5 Hose 1 Inside diameter: approx. 15mm
available
1 799-201-1506 Blowby checker 1 0 to 10 kPa {0 to 1,000 mmH2O}
Testing blowby Commercially Plug
2 1 Hose inside diameter: 24 mm
pressure E available
Commercially Pipe outside diameter: 25.4 mm,
3 Plug 2 Pipe inside diameter: 20.4 mm
available
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
1 799-101-5160 • Nipple 1
799-101-5150 • Hose 1
Testing engine
oil pressure F 790-261-1150 • Hose 1
Pressure gauge: 60 MPa {600 kg/
2 790-261-1204 Digital hydraulic tester 1 cm2}
Pressure gauge: 1.0 MPa {10 kg/
3 799-401-2320 Gauge 1 cm2}
1 799-401-3100 Adapter 1
2 799-401-3200 Adapter 1
Measuring 799-101-5160 • Nipple 2 R1/8
EGR valve and • Hose
KVGT oil G 3 799-101-5150 1
790-261-1150 • Hose 1
pressures
799-101-5140 • Gauge 1 cm2}
PC210LC-10 30-3
Testing and Sym-
Q'ty
799-101-5160 • Nipple 1 R1/8
1 799-101-5150 • Hose 1
790-261-1150 • Hose 1
799-101-5140 • Gauge 1 cm2}
Testing fuel 795-790-4430 Adapter 2
pressure H 3 O-ring
6215-81-9710 1
4 795-790-5110 Screw 1 M12 x 1.5 o R1/8
5 799-401-2320 Gauge 1 cm2}
6 795-790-5120 Screw 1 M14 x 1.5 o R1/8
700-201-2202 Boost gauge kit 1
799-101-5160 • Nipple 1 R1/8
7 799-401-2610 • Hose 1
-101 to 200 kPa {-760 to 1,500
799-401-2311 • Gauge 1 mmHg}
1 795-790-4700 Tester kit 1
2 6164-81-5790 Joint 1
3 07206-30812 Joint bolt 1
4 6754-71-1130 Seal washer 1
Testing fuel Commercially
discharge, 5 Stopwatch 1
J available
return and Commercially
leakage 6 Hose 1 Inside diameter: approx. 14 mm
available
Commercially Measuring cylinder
7 1
available
Commercially
8 Hose 1 Inside diameter: approx. 8 mm
available
Measuring
swing circle Commercially Dial gauge
K 1
bearing available
clearance
Testing fuel Developer
circuit for Commercially
L for dye penetrant check 1
leakage available
(color checker)
Measuring and Pressure gauge: 2.5, 6, 40, 60
adjusting oil
pressure in
work M 1 Pressure gauge: 60 MPa {600 kg/
equipment, 790-261-1204 Digital hydraulic tester 1 cm2}
swing, and
travel circuits
30-4 PC210LC-10
Testing and Sym-
Q'ty
Pressure range: 5 MPa {50 Kg/
796T-440-1200 Sensor adapter 1 cm2}
796-440-1150 • Wiring harness 1
1 799-401-2350 • Washer 1
790-261-1130 • Coupling 1
Testing source Pressure range: 5 MPa {50 Kg/
7861-93-1840 • Pressure sensor 1 cm2}
pressure of N
control circuit 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
3
790-261-1204 Digital hydraulic tester 1 cm2}
adjusting oil
pressure in P 1
pump PC 790-261-1204 Digital hydraulic tester 1 cm2}
control circuit
adjusting oil 1
pressure in Q Pressure gauge: 60 MPa {600 kg/
790-261-1204 Digital hydraulic tester 1 cm2}
pump LS
control 2 799-401-2701 Differential pressure gauge 1 50 MPa {500 kg/cm2}
Measuring 1
solenoid valve Pressure gauge: 60 MPa {600 kg/
R 790-261-1204 Digital hydraulic tester 1 cm2}
output
pressure 799-401-3100 Adapter 1 Size: 02
2
02896-11008 O-ring 1
Measuring 1
PPC valve Pressure gauge: 60 MPa {600 kg/
S 790-261-1204 Digital hydraulic tester 1 cm2}
output
pressure 799-401-3100 Adapter 1 Size: 02
2
799-401-3200 Adapter 1 Size: 03
Testing oil Commercially
T Measuring cylinder 1
leakage available
Testing coolant
temperature
— 799-101-1502 Digital thermometer 1 -99.9 to 1,299°C
and oil
temperature
Testing 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
operating effort
and —
79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
depressing
effort
Testing stroke
— Commercially
and hydraulic Ruler 1
available
drift
Testing work
equipment — Commercially Stopwatch 1
speed available
Testing voltage — Commercially
Multimeter 1
and resistance available
PC210LC-10 30-5
Testing and Sym-
Q'ty
Removal and
installation of
boost pressure — Commercially 3.26 mm Torx wrench
Torx wrench 1
and available (KTC Q4T15 or equivalent)
temperature
sensors
Removal and
installation of
engine oil — 795-799-6210 Socket 1 27 mm deep socket
pressure
switch
Removal and
installation of 19 mm deep socket
engine coolant — 795T-981-1010 Socket 1
temperature (MITOLOY 4ML-19 or equivalent)
sensor
30-6 PC210LC-10
Sketch of tools for testing and adjusting (PC200_10-3531-061-A-00-A)
Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
N1: Sensor adapter
—: Socket
PC210LC-10 30-7
Engine and cooling system
Testing engine speed (PC200_10-A000-360-K-00-A)
a Check the engine speed by using the 4) Operate the L.H. work equipment control
"Monitoring/Pre-defined" or "Monitoring lever to relieve the arm circuit at the IN stroke
Function" of the machine monitor. end and test the engine speed.
5. Measuring speed (around rated speed) at 2-
a Check the engine speed under the following
pump relief + one-touch power maximizing
conditions.
function
1) Start the engine and operate the arm cylinder
to arm IN stroke end.
Testing (PC200_10-A000-388-K-00-A) 2) Set the fuel control dial to high idle (MAX)
position and set the working mode to Power
1. Preparation
mode (P).
Operate the machine monitor so that it can
3) While operating the L.H. work equipment
monitor the engine speed.
control lever to relieve the arm circuit at arm
a For the machine monitor operating method, IN stroke end and pressing the one-touch
see the section of "Special functions of power maximizing switch, measure the
machine monitor". engine speed.
a Monitoring code: 01002 “Engine speed“ a The one-touch power maximizing function is
reset automatically in approximately 8.5
seconds even if the switch is kept pressed.
Accordingly, test the engine speed in that
period.
a You may measure with the swing lock switch
ON.
6. Measuring the engine speed when auto-
deceleration is activated
1) Start the engine, set the fuel control dial to
high idle (MAX) position, and turn the auto-
deceleration function ON.
2) Set all the levers and pedals for work
equipment control, swing control, and travel
2. Testing low idle speed in neutral and test the engine speed when
1) Start the engine and set the fuel control dial the auto-decelerator operates.
to low idle (MIN) position.
2) Set all the levers and pedals for work a The engine speed automatically lowers to a
equipment control, swing control, and travel certain level approximately 5 seconds after
in neutral and test the engine speed. all the levers and pedals are set to the
3. Testing high idle speed NEUTRAL position. This level is the auto-
deceleration speed.
1) Start the engine and set the fuel control dial
to high idle (MAX) position.
2) Set the working mode in Power Mode (P)
and set the auto-deceleration to OFF.
3) Set the swing lock switch to the ON position.
4) Set all the levers and pedals for work
equipment control, swing control, and travel
in neutral and test the engine speed.
4. Measuring engine speed at 2-pump relief
1) Start the engine and operate the arm cylinder
to arm IN stroke end.
2) Set the swing lock switch to the OFF
position.
3) Set the fuel control dial to high idle (MAX)
position and set the working mode to Power
mode (P).
30-8 PC210LC-10
Testing boost pressure (PC200_10-A900-360-K-00-A)
a Testing tools a Repeat opening the self-sealing portion on

Sym- the hose by inserting approximately half of
Part No. Part name the connection part of the gauge into the
bol
A 799-201-2202 Boost gauge kit hose to drain oil.
a When Pm kit (A) is available, you can use air
k Place the machine on a level ground and
bleeding coupling (790-261-1130) in the kit.
lower the work equipment to the ground.
a If oil is left in the hose, the gauge does not
k Be careful not to touch any hot part when work. Accordingly, be sure to drain the oil.
installing or removing the testing tools. 4. Set the working mode to the power mode (P)
and turn the swing lock switch ON.
a Measure the boost pressure under the following
conditions. a If the swing lock switch is turned to the ON
position, the main relief valve is set for high-
• Coolant temperature: 30 to 102°C pressure relief.
5. While running the engine at high idle, relieve the
• Swing lock switch: ON
arm circuit and measure the boost pressure.
• Arm IN relief + One-touch power max. ON
Boost pressure Min. 93 kPa {700 mmHg}
Testing (PC200_10-A900-362-K-00-A)
Testing by use of testing tools
1. Open the engine hood and remove boost
pressure pickup plug (1) from the intake air
connector.
a The method to fully open the engine hood is
described later.
6. After finishing the test, remove the testing tools

and restore the machine.
Checking with machine monitor
a Boost pressure can be measured by using the
"Monitoring/Pre-defined" or "Monitoring
Function" of the machine monitor.
2. Install nipple [1] of boost gauge kit A and a For the machine monitor operating method, see
connect them to gauge [2]. the section of "Special functions of machine
monitor".
a Monitoring code: 36500 “Charge Pressure-A“
3. Run the engine at middle or higher speed and

drain oil from the hose.
PC210LC-10 30-9
How to fully open engine

hood (PC200_10-H540-100-K-00-A)
a If more room to work is needed, the engine hood
can be opened to a maximum of approx. 90
degrees according to the following procedure.
1. Open engine hood (1).
a The figure shows the engine hood opened
normally (at the first slit).
2. Loosen bolt (2).
a Just loosen bolt (2). Do not remove it.
a When closing engine hood (1), hold lock

plate (3) at hole (a), and tighten bolt (2).
3 Bolt (2):
59 to 74 Nm {6 to 7.5 kgm}
a At this time, locating pin (4) of lock plate (3) is

disengaged.
3. Use pin (5) to bring and hold lock plate (3) at
hole (b), and tighten bolt (2).
a The position of lock plate (3) must be

changed to close engine hood (1), otherwise
lock plate (3) will interfere with stay (6).
4. Open engine hood (1) wider and fix stay (6) at

the position shown in the figure (at the second
slit).
30-10 PC210LC-10
Testing exhaust gas color (PC200_10-A900-360-K-01-A)
a Testing tools of handy smoke checker B1 to collect the

Sym- exhaust gas on the filter paper.
Part No. Part name
bol a Collecting time: 1.4 ± 0.2 second
1 799-201-9002 Handy smoke checker
B Commercially
2 Smoke meter
available

k Be careful not to touch any hot part when

installing or removing the testing tools.
k When KDPF regeneration is started, the

high-temperature exhaust gas spurts from
the inspection port, that may cause burn
injury. Therefore, you must stop KDPF
regeneration through the machine monitor 4) Remove the filter paper and compare it with
before starting the inspection. the attached scale for judgment.
5) After finishing the test, remove the testing
(For the stopping procedure for KDPF
tools and restore the machine.
regeneration, see the Operation and
3. Testing by using smoke meter B2
Maintenance Manual.)
a Measure the exhaust gas color under the

following conditions.
• Hold in stationary state for 5 seconds, then
collect the exhaust gas.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker B1. When recording official data, use
smoke meter B2.
Testing (PC200_10-A900-385-K-00-A)
1. Open engine hood and remove step (1) and plug 1) Connect the probe hose, receptacle of the
(2). accelerator switch and air hose to smoke
meter B2.
a The supplied air pressure must be 1.5
MPa {15 kg/cm2} or below.
2) Connect the power cable to the receptacle.
a Before connecting the power cable, make
sure that the power switch of the smoke
meter is turned OFF.
3) Insert probe [1] of the smoke meter B2 into
port (3) for the removed plug.
4) Loosen the cap nut of the suction pump and
place the filter paper.
2. Checking with handy smoke checker B1 a Place the filter paper securely so that the
exhaust gas does not leak.
1) Place a sheet of filter paper to smoke
5) Turn on the power switch of smoke meter B2.
checker B1.
2) Insert the exhaust gas intake pipe into plug
hole (3).
3) Start the engine, run it at high idle, and
perform the arm IN relief. Operate the handle
PC210LC-10 30-11
6) Start the engine and perform the arm IN relief.

Depress the pedal of smoke meter B2 to
collect the exhaust gas on the filter paper.
7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
8) After finishing the test, remove the testing
tools and restore the machine.
3 Plug (2):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug (2):
Seizure prevention compound (LC-G)
30-12 PC210LC-10
Measuring and adjusting valve clearance (ALL-A700-001-K-00-A)
a Testing instrument • Hose (7): KVGT control pressure circuit

Sym- • Hose (8): KVGT drive hydraulic circuit
Part No. Part Name 5. Remove clamp (9).
bol
1 795-799-1131 Gear 6. Disconnect connector (10).
C Commercially • Connector (10): Intermediate connector (INJ
2 Feeler gauge
available CYL 1&2)
k Park the machine on a level ground and
k Turn the battery disconnect switch to the

OFF position and remove the key.
a Test and adjust the valve clearance under the

following condition.
• Coolant temperature: Normal temperature
Testing (PC200_10-A700-361-K-00-A)
1. Open the engine hood and remove step (1)

7. Remove cylinder head covers (11).
a When removing blowby duct (12), take care
that the O-ring will not fall from it.
a Since the O-ring is fitted to the flywheel
housing side of blowby duct (12), blowby
duct (12) may be removed together with
cylinder head cover (11).
2. Disconnect connectors (2) to (5).

• Connector (2): KVGT position sensor
(SVGT)
• Connector (3): KVGT speed sensor
(VGT_REV)
• Connector (4): Connector box (INTER
CONNECT)
• Connector (5): EGR gas temperature sensor
(EXHAUST GAS TEMPERATURE) 8. Remove covers (13) and (14).
3. Disconnect EGR circuit tube (6) from the flange
and tube.
9. Remove plug (15) under the starting motor and

insert gear C1.
4. Disconnect hoses (7) and (8).
PC210LC-10 30-13
a If you can move the rocker arm of air intake

valves (IN) with the hand by the valve
clearance amount, adjust the valves marked
with Q in the valve arrangement drawing.
a If you can move the rocker arms of exhaust
valves (EX) by hand by the valve clearance
amount, adjust the valves marked with q in
the valve arrangement drawing.
a Valve arrangement drawing
10.Rotate the crankshaft forward with gear C1 and

align the yellow paint (line) of vibration damper
(16) with engine oil pan mounting bolt (17).
a The end of engine oil pan mounting bolt (17)
is painted yellow.
a When the crankshaft is set as above, the
piston in the No. 1 or No. 6 cylinder is not set
to the compression top dead center (TDC).
Take care. (76 to 88 degrees before top dead
center)
12.If the valves marked with Q were adjusted,
rotate the crankshaft forward 1 turn and align the
yellow paint (line) of vibration damper (16) with
engine oil pan mounting bolt (17), and then
adjust the valves marked with q in the valve
arrangement drawing.
a If the valves marked with q in the valve
arrangement drawing are adjusted in Step 11,
adjust the valves marked with Q.
13.After finishing the test, remove the testing tools
k Be sure to remove gear C1.

3 EGR circuit tube (6) (flange side):
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 EGR circuit tube (6) (tube side):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 Hose (7):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3 Hose (8):
15 ± 1 Nm {1.53 ± 0.10 kgm}
3 Cylinder head cover (11) mounting
11.Check the movement of the rocker arm of the No. nut:
1 cylinder to inspect the valve clearance. 24 ± 4 Nm {2.45 ± 0.41 kgm}
a The valve clearance is normal if it is within
Adjusting (PC220-A700-27D-K-00-A)
the range of the following standard value.
After testing, adjust the valve clearance according
Intake valve 0.152 to 0.381 mm to the following procedure, if necessary.
Exhaust valve 0.381 to 0.762 mm
1. While fixing adjustment screw (18), loosen lock
nut (19).
30-14 PC210LC-10
2. Insert feeler gauge C2 in the clearance between

rocker arm (20) and crosshead (21) and adjust
the valve clearance with adjustment screw (18).
a With feeler gauge C2 inserted, turn
adjustment screw (18) to a degree that you
can move feeler gauge C2 lightly.
a Adjust the valve clearance to within the
following target value.
Intake valve 0.25 ± 0.05 mm
Exhaust valve 0.51 ± 0.05 mm
3. While fixing adjustment screw (18), tighten lock
nut (19).
3 Lock nut (19):
24 ± 4 Nm {2.45 ± 0.41 kgm}
a After tightening locknut (19), check the valve
clearance again.
4. After finishing adjustment, remove the testing

tools and return the removed parts.
a Be sure to remove gear C1 .
24 ± 4 Nm {2.45 ± 0.41 kgm}
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 Hose (7):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3 Hose (8):
15 ± 1 Nm {1.53 ± 0.1 kgm}
3 Cylinder head cover (11) mounting
nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
PC210LC-10 30-15
Testing compression pressure (ALL-A000-001-K-02-A)
a Testing tools
Sym-
Part No. Part name
bol
1 795-502-1590 Gauge assembly
2 795-799-6700 Puller
3 795-790-4411 Adapter
D
4 6754-11-3130 Gasket
5 Commercially Hose (inside diameter:
available approximately 15 mm)

6. Remove retaining nut (6) and remove inlet
k Turn the battery disconnect switch to the connector (7).
OFF position and remove the key. 7. Remove holder (8).
8. Remove the injector (9).
k When testing the compression pressure,
take care not to get yourself burned by a Remove injector (9) with the impacts of the
touching the exhaust manifold or KDPF, or slide hammer by using puller D2.
get caught in a rotating part. a Do not pry the top of injector (9) to remove.
a Measure the compression pressure under the
• Engine oil temperature: 40 to 60°C
Testing (PC220-A000-36B-K-00-A)
1. Remove the cylinder head cover and set the

piston in the target cylinder of testing to the
compression top dead center. For details, see
"Testing and adjusting valve clearance".
a Check that both the intake rocker arm and
exhaust rocker arm at the compression top
dead center are movable by hand by the
distance equivalent to the valve clearance.
2. After removing fuel spray prevention cap (1),
remove the sleeve nut and disconnect high-
pressure pipe (2).
a When measuring compression pressure, fuel
spurts from the disconnected portion of the
common rail side. Therefore you must
connect hose D5 and drain fuel to an oil pan.
k Do not bend high-pressure pipe when

using it.
3. Loosen injector terminal nuts (3) and remove the
harness terminals from the injector. 9. Install gasket D4 to the tip of adapter D3 and
insert them into the injector mounting portion.
a Insulate the terminals with tape etc. so that 10.Fix adapter D3 with mounting holders (8) for the
the adjacent ones of them do not touch each injector.
other.
4. Remove rocker arm assembly (4). a Tighten the holder (8) mounting bolts
alternately.
a When removing rocker arm assembly (4),
use care not to drop the support and shaft. 3 Holder (8) mounting bolt:
5. Remove crossheads (5). 8 ± 0.8 Nm {0.82 ± 0.08 kgm}
30-16 PC210LC-10
11.Install crosshead assembly (5) and rocker arm

assembly (4).
3 Rocker arm assembly (4) mounting
bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
12.Adjust the valve clearance.
a See "Testing and adjusting valve clearance".
15.Connect gauge assembly D1 to adapter D3.

a If a small amount of oil is applied to the
connecting portions of gauge assembly D1
and adapter D3, air will not leak easily.
13.Connect connectors (11) to (15).

(SVGT)
(VGT_REV)
CONNECT)
• Connector (14): EGR gas temperature
sensor (EXHAUST GAS TEMPERATURE)
16.Operate the machine monitor to set to “No
• Connector (15): Intermediate connector (INJ
Injection“.
CYL 1&2)
14.Connect hoses (16) and (17) and tube (18). a Turn the battery disconnect switch to the ON
• Hose (16): KVGT control pressure circuit position, then turn the starting switch to the
ON position.
3 Hose (16):
a For the method to set to “No Injection“, see
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
"Special functions of machine monitor".
• Hose (16): KVGT drive pressure circuit
3 Hose (17):
15 ± 1 Nm {1.53 ± 0.1 kgm}
• Tube (18): EGR circuit
24 ± 4 Nm {2.45 ± 0.41 kgm}
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
17.Rotate the crankshaft by the starting motor and

measure the compression pressure.
a Read the compression pressure when the
gauge pointer stands still.
a The compression pressure is normal when it
is within the following standard value range.
PC210LC-10 30-17
1.69 MPa 4] When there is a worn part or an uneven

Compression pressure
{17.2 kg/cm2} or above seat contact mark on seat surface (e) at
Engine speed 250 to 280 rpm front-end of inlet connector.
18.After finishing the test, remove the testing tools a If high-pressure fuel leaks through the
and restore the machine. inlet connector, seat surface has fine
streaks or cracks.
a Install the injector and high-pressure pipe
according to the following procedure.
1) Install the injector to the cylinder head while
facing its fuel inlet hole to the air intake
manifold.
a Join protrusion (a) with holder notch (b)
before setting the injector to the cylinder
head.
5) Apply engine oil to the O-ring of inlet

connector (7) and its head side.
2 O-ring and head side of inlet
connector (7):
Engine oil (EO10W30-LA)
6) Tighten inlet connector (7) lightly with
retaining nut (6).
2) Tighten holder mounting bolt (19) by three to a After tightening lightly, it is tightened to
four threads. the specified torque in a succeeding step.
3) Set inlet connector (7). Be sure to tighten it to the specified
a Press it in until you feel the ring clicks in. torque in both steps. Insufficient or
4) Check inlet connector (7) for the following excessive tightening torque can be the
items. If anything wrong is found, replace it. cause for fuel leakage into the engine.
1] When burrs or wear is found in the inlet a Install the inlet connector in so that the
connector top-end (a) and rear-end (b) positioning ball of inlet connector (7)
portions. comes to the guide groove on the
2] When foreign matters are found in the cylinder head side.
edge filter at rear-end (c) of the inlet
connector. 3 Retaining nut (6) (tightening
3] Cracks or deterioration are recognizable lightly):
on the O-ring of the inlet connector upper 15 ± 5 Nm {1.53 ± 0.51 kgm}
(d) portion. 7) Tighten mounting bolts (19) for holder (8)
alternately.
3 Holder (8) mounting bolt (19):
8 ± 0.8 Nm {0.82 ± 0.08 kgm}
8) Tighten retaining nut (6) of inlet connector
(7).
3 Retaining nut (6) (tightening to the
specified torque):
50 ± 5 Nm {5.1 ± 0.51 kgm}
30-18 PC210LC-10
14)Install the cylinder head cover.

9) Tighten sleeve nuts (20) of high-pressure
pipe (2) in the order of cylinder head (21) 3 Cylinder head cover mounting nut:
side and common rail (10) side. 24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Sleeve nut (20):
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
10)Install fuel spray prevention cap (1).

11)Install crosshead assembly (5) and rocker
arm assembly (4).
3 Rocker arm assembly (4) mounting
bolt (22):
36 ± 5 Nm {3.67 ± 0.51 kgm}
12)Adjust the valve clearance.
a See "Measuring and adjusting valve
clearance".
13)Tighten injector terminal nut (3).
3 Terminal nut (3):
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Check that the injector wiring harness
does not interfere with the rocker arm.
PC210LC-10 30-19
Testing blowby pressure (PC200_10-A000-360-K-01-A)
a Testing tools 3 Clamp of hose (3):

Sym- 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
Part No. Part name
bol
1 799-201-1506 Blowby checker
Commercially Plug (hose inside
2 diameter: 24 mm)
available
E
Plug (pipe outside
Commercially diameter: 25.4 mm, pipe
3
available inside diameter: 20.4 mm)

a Measure the blowby pressure under the

• Coolant temperature: 30 to 102°C 4. Start the engine, set the work equipment mode
• Hydraulic oil temperature: 45 to 55°C to power mode (P), and turn the swing lock
Testing (PC200_10-A000-36C-K-00-A)
switch ON.
1. Open the engine hood and remove step (1). a If the swing lock switch is turned to the ON
position, the main relief valve is set for high-
pressure relief.
5. Measure the blowby pressure when the
hydraulic relief is made by arm IN operation at
engine high idle.
a Read the blowby gas pressure when the
gauge pointer stands still.
Blowby pressure Max. 1.96 kPa {200 mm H2O}
2. Disconnect hose (2) on the KCCV gas outlet

side and plug the hose by using plug E2, and
plug the KCCV hose insertion pipe by using plug
E3.
3 Clamp of hose (2):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

3 Clamps of hoses (2) and (3):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
3. Disconnect hose (3) on the KCCV gas inlet side,

plug the KCCV hose insertion pipe with E3,
install tool and adapter [1] of blowby checker E1
to hose (3), and connect gauge [2].
30-20 PC210LC-10
Testing engine oil pressure (PC200_10-AB00-360-K-00-A)
a Tools for testing and adjusting

Sym-
Part No. Part name
bol
799-101-5002 Hydraulic tester
799-101-5160 • Nipple
1
799-101-5150 • Hose
F 790-261-1150 • Hose
2 790-261-1204 Digital hydraulic tester
Gauge (1.0 MPa {10 kg/
3 799-401-2320 cm2})

a Measure the engine oil pressure under the and restore the machine.
following condition.
Testing (PC200_10-AB00-362-K-00-A)
1. Open the side cover on the right side of the

machine. Install nipple [1] and hose [2] of
hydraulic tester F1 to engine oil pressure pickup
port, and connect gauge F3 to it.
a The hose for digital hydraulic tester F2 can
also be used.
2. Start the engine and turn the auto-decelerator

OFF.
3. Run the engine and measure the engine oil
pressure at high idle and low idle.
a The engine oil pressure is normal if it is within
the following standard value range.
Min. 0.25 MPa
At high idle
{2.5 kg/cm2} or above
Min. 0.07 MPa
At low idle
{0.7 kg/cm2} or above
PC210LC-10 30-21
Testing EGR valve and KVGT oil pressures (PC200_10-A9K1-360-K-00-A)
a Testing tools 3. Install adapters G1 and G2, and then install

Sym- nipple [1] and hose [2] of hydraulic tester G3 and
Part No. Part name connect them to gauge [4].
bol
1 799-401-3100 Adapter 3 Adapter G1:
2 799-401-3200 Adapter 15 ± 1.0 Nm {1.53 ± 0.10 kgm}
799-101-5160 • Nipple 3 Adapter G2:
G 25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3 799-101-5150 • Hose
790-261-1150 • Hose a Use gauge [4] of 2.5 MPa {25 kg/cm2}.
799-101-5140 • Gauge
a The nipple and hose of digital hydraulic tester
G4 can also be used.
a Test EGR valve and KVGT oil pressure under

the following conditions.
a The standard values for the EGR valve drive oil
pressure and the KVGT drive oil pressure are
the same, because they share the same circuit.
Testing (PC200_10-A9K1-362-K-00-A)
1. Open the engine hood and remove step (1) 4. Start the engine and measure the oil pressures
at low idle.
a When EGR valve and KVGT driving oil
pressure are within the following standard
range, they are normal.
Drive oil pressure of Min. 1.2 MPa
EGR valve and KVGT Min. {12.0 kg/cm2}
KVGT control oil 0.3 to 1.0 MPa
pressure {3.1 to 10.2 kg/cm2}
2. Disconnect hoses (2) and (3).

• Hose (2): Hydraulic circuit for EGR valve and
KVGT drive
• Hose (3): KVGT control pressure circuit

3 Hose (2):
15 ± 1.0 Nm {1.53 ± 0.10 kgm}
3 Hose (3):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
30-22 PC210LC-10
Measuring fuel pressure (ALL-AE20-001-K-00-A)
a Testing tools
Sym-
Part No. Part Name
bol
799-101-5160 ・ Nipple
1 799-101-5150 ・ Hose
790-261-1150 ・ Hose
799-101-5140 ・ Gauge
795-790-4430 Adapter
3
H 6215-81-9710 O-ring
4 795-790-5110 Screw
5 799-401-2320 Gauge
6 795-790-5120 Screw
799-201-2202 Boost gauge kit
799-101-5160 ・ Nipple
7
799-401-2610 ・ Hose
799-401-2311 ・ Gauge
k When removing and installing the fuel system inspection equipment, stop the engine and wait for
30 seconds until the remaining pressure is released from the fuel circuit. (Do not start inspection
work immediately after the engine is stopped since remaining pressure is present.)
k Park the machine on level ground and lower the work equipment to the ground.
a Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the
supply pump and in the return circuit between the supply pump/common rail/ injector and fuel tank.
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to
the injector is very high and dangerous, do not measure it.
PC210LC-10 30-23
A: Low-pressure circuit inspection position (fuel main filter inlet side)

B: Low-pressure circuit inspection position (fuel main filter outlet side)
C: Return circuit inspection position (supply pump drain port)
D: Negative pressure circuit inspection position (supply pump inlet)
30-24 PC210LC-10
207 to 650 kPa

Testing (PC220-AE20-362-K-00-A) At high idle
{2.11 to 6.63 kg/cm2}
Testing low-pressure circuit (fuel main filter inlet 207 to 500 kPa
side) Cranking
1. Open the side cover on the right side of the {2.11 to 5.1 kg/cm2}
machine body and remove fuel pressure pickup
port plug (1) on the fuel main filter inlet side.
4. After completing measurement, remove the

measuring tools and return the machine to the
2. Install adapter H3 and nipple [1] and hose [2] of original condition.
hydraulic tester H1 and connect them to gauge
[3]. 3 Fuel pressure pickup plug (1):
32 ± 4 Nm {3.26 ± 0.41 kgm}
a When installing adapter H3, be sure to install
the O-rings.
3 Adapter H3:
32 ± 4 Nm {3.26 ± 0.41 kgm}
a Use gauges [3] of 2.5 MPa {25 kg/cm2}.
a The nipples and hoses in digital hydraulic
tester H2 may be used.
3. Start the engine and measure the pressure in

the low-pressure circuit with the engine at high
idle.
a If the engine cannot be started, you can
measure the fuel pressure while rotating the
engine using the starting motor. However, to
protect the starting motor, do not rotate the
engine for more than 20 seconds
continuously.
a If the pressure in the low-pressure circuit (on
the fuel main filter inlet side) is in the
following range, it is normal.
PC210LC-10 30-25
Testing low-pressure circuit (pressure

difference)
1. Remove fuel pressure pickup plug (1) at the fuel
main filter inlet side and fuel pressure pickup
plug (2) on the outlet side.
4. Obtain the pressure difference in the low-

pressure circuit.
a Pressure difference in low-pressure circuit =
Pressure on fuel main filter inlet side -
Pressure on fuel main filter outlet side
2. Install adapters H3 to the inspection holes on
the inlet side and outlet side, and then install a If the pressure difference in the low-pressure
nipples [1] and hoses [2] of hydraulic tester H1 circuit is in the following standard range, it is
and connect them to gauges [3]. normal.
a When installing adapter H3, be sure to install At high idle Max. 81 kPa
the O-rings. Cranking {Max. 0.83 kg/cm2}
3 Adapter H3: a If the pressure is higher than the criteria, the
32 ± 4 Nm {3.26 ± 0.41 kgm} fuel main filter may be clogged. In this case,
replace the fuel main filter and test again.
a Use gauges [3] of 2.5 MPa {25 kg/cm2}.
a The nipples and hoses in digital hydraulic measuring tools and return the machine to the
tester H2 may be used. original condition.
3 Fuel pressure pickup plugs (1), (2):
32 ± 4 Nm {3.26 ± 0.41 kgm}
3. Start the engine and measure the pressure on

the inlet aide and outlet side of the low-pressure
circuit with the engine at high idle.
a If the engine cannot be started, you can
continuously.
30-26 PC210LC-10
Testing return circuit a If the engine cannot be started, you can

1. Remove cover (1). measure the fuel pressure while rotating the
continuously.
a If the pressure in the return circuit is in the
following range, it is proper.
At high idle Max. 18.6 kPa
Cranking {Max. 0.19 kg/cm2}
2. Remove joint bolt (2) of the fuel return hose

between the supply pump and fuel cooler.

original condition.
3 Joint bolt (2):
19.6 to 29.4 Nm {2 to 3 kgm}
3. Install screw H4, and nipple [1] and hose [2] of
hydraulic tester H1 instead of joint bolt (2), and
connect them to gauge H5.
a When installing screw H4, be sure to install
the seal washer.
3 Screw H4:
19.6 to 29.4 Nm {2 to 3 kgm}
4. Start and measure the pressure in the return

circuit while the engine is run at full speed.
PC210LC-10 30-27
Testing negative-pressure circuit

1. Remove joint bolt (3) of the fuel hose between
the fuel pre-filter and supply pump.

original condition.
2. Install screw H6, and nipple [1] and hose [2] of 3 Joint bolt (3):
boost gauge kit H7 instead of joint bolt (3), and 25.4 to 34.3 Nm {2.59 to 3.5 kgm}
connect them to gauge [3].
a When installing screw H6, be sure to install
the seal washer.
3 Screw H6:
25.4 to 34.3 Nm {2.59 to 3.5 kgm}
3. Start the engine and measure the pressure in

the negative pressure circuit with the engine at
high idle.
a If the pressure in the negative pressure
circuit is in the following standard range, it is
normal.
At high idle -305 mmHg or below
a If the pressure is higher than the criteria, the

fuel pre-filter may be clogged. In this case,
replace the fuel pre-filter and test again.
30-28 PC210LC-10
Measuring fuel delivery, return and leakage (ALL-AE20-001-K-01-A)
a Testing tools
Sym-
Part No. Part Name
bol
1 795-790-4700 Multimeter kit
2 6164-81-5790 Joint
3 07206-30812 Joint bolt
4 6745-71-1130 O-ring
Commercially Stopwatch
5
J available
Commercially Hose (inside diameter:
6 about 14 mm)
available
Commercially Measuring cylinder
7
available
Commercially Hose (inside diameter:
8 about 8 mm)
available
k Park the machine on level ground and lower the work equipment to the ground.
a Since some fuel flows out during check, prepare an oil pan of about 20 l .
k When removing and installing the fuel system inspection equipment, stop the engine and wait for
30 seconds until the remaining pressure is released from the fuel circuit. (Do not start inspection
work immediately after the engine is stopped since remaining pressure is present.)
A: Supply pump delivery inspection position

B: Supply pump return rate inspection position
C: Leakage from pressure limiter inspection position
D: Injector return rate inspection position
PC210LC-10 30-29
a In order to protect the starting motor, it is

Testing (PC220-AE20-363-K-00-A)
prohibited to continue cranking for more than
Testing supply pump delivery 20 seconds. “Crank the engine for 15
1. Remove cover (1). seconds, then stop for 15 seconds and crank
it again for 15 seconds.“ Do the
measurement in this manner.
2. Remove fuel spray prevention cap (2).

3. Loosen clamp (4) for spill tube (3) on the
delivery side of the supply pump and disconnect
the spill tube (3). a If the supply pump delivery is in the following
standard range, it is normal.
When cranking (for 30
seconds) 70 ml or more
4. Install hose J6 to the connector on the discharge

side of the supply pump.
a Hose J6 may be clamped with a hose band
for the ease of the work. 6. After completing measurement, remove the
original condition.
3 Spill tube (3) mounting sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
3 Clamp (4) mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
5. Crank the engine for 30 seconds and measure

the delivery with measuring cylinder J7.
30-30 PC210LC-10
Testing supply pump return rate a If the engine cannot be started, you can
1. Disconnect fuel return hose (2) on the return measure the fuel pressure while rotating the
side of the supply pump. engine using the starting motor. However, to
continuously. “Crank the engine for 15
seconds, then stop for 15 seconds and crank
2. Install cap nut [1] of tester kit J1 to fuel return

hose (2) side to prevent the fuel from flowing out.
a When installing cap nut [1], be sure to install
the seal washer.
3. Install joint J2 to the supply pump side and
secure it with joint bolt J3.
a When installing joint J2 and joint bolt J3, be a If the return rate from the supply pump is in
sure to install the seal washer. the following range, it is proper.
3 Joint bolt J3: During low idle

Max. 575 ml
(For 30 sec)
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
4. Install hose J8 to joint J2. Cranking
(min. 150 rpm, for 30 Max. 575 ml
seconds)
5. Run the engine at low idle and measure the fuel

return rate during 30 sec by using measuring
cylinder J7. 6. After completing measurement, remove the
original condition.
3 Mounting joint bolt (1) of fuel return
hose (2):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
PC210LC-10 30-31
Testing leakage from pressure limiter a If the engine cannot be started, you can
1. Remove joint bolt (1) of the pressure limiter and measure the fuel pressure while rotating the
disconnect spill tube (2). engine using the starting motor. However, to
2. Install cap nut [1] of tester kit J1 to spill tube (2)

side to prevent the fuel from flowing out.
the seal washer.
3. Install joint J2 to the pressure limiter side and
secure it with joint bolt J3.
a When installing joint J2 and joint bolt (3), be a If the leakage from the pressure limiter is in
sure to install the seal washer. the following range, it is proper.
3 Joint bolt J3: During low idle

Max. 8 ml
(For 30 sec)
24 ± 4 Nm {2.45 ± 0.41 kgm}
4. Install hose J8 to joint J2. Cranking
(min. 150 rpm, for 30 Max. 5 drops/min.
seconds)
original condition.
3 Mounting joint bolt (1) of spill tube (2):
24 ± 4 Nm {2.45 ± 0.41 kgm}
5. Run the engine at low idle and measure the fuel

leakage in 30 seconds by using measuring
cylinder J7.
30-32 PC210LC-10
Testing injector return rate from injector a If the engine cannot be started, you can
a The fuel return rate from the injector is tested
while spill tube (2) of the pressure limiter is
connected. Accordingly, before testing the return
rate from the injector, check that the leakage
from the pressure limiter is normal.
1. Remove check valve (1) of the cylinder head it again for 15 seconds.“ Do the
and disconnect spill tube (2). measurement in this manner.
2. Install cap nut [1] of tester kit J1 to spill tube (2)

side to prevent the fuel from flowing out. a If the return rate from the fuel injector is in the
following range, it is normal.
the seal washer. During low idle
Max. 125 ml
3. Install joint J2 to the cylinder head side and (For 30 sec)
secure it with joint bolt J3. Cranking
a When installing joint J2, be sure to install the (min. 150 rpm, for 30 Max. 45 ml
seal washer. seconds)
3 Joint bolt J3:

24 ± 4 Nm {2.45 ± 0.41 kgm}
4. Install hose J8 to joint J2.

original condition.
5. Run the engine at low idle and measure the fuel 3 Mounting check valve (1) of spill tube
return rate in 30 seconds by using measuring (2):
cylinder J7. 24 ± 4 Nm {2.45 ± 0.41 kgm}
PC210LC-10 30-33
Bleeding air from fuel system (ALL-AD00-001-K-00-A)
a If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
Bleeding air (PC200_10-AD00-231-K-00-A)
1. Fill the fuel tank up with fuel.

a Add fuel until the fuel level gauge reaches
blue range. (Turn the starting switch to ON
position and check the fuel level from the
gauge.)
2. Open the side cover on the right side of the
machine.
3. Loosen hand primer (1) and pull it out, and then
operate it forward and backward.
a Operate the hand primer (1) until it becomes
heavy.
a The plug at the top of the fuel main filter head
does not need to be removed.
4. After bleeding air, push in and tighten hand

primer (1).
30-34 PC210LC-10
Route for bleeding air from fuel circuit

Fuel tank o prefilter o feed pump o main filter o metering unit o fuel tank
PC210LC-10 30-35
Checking fuel circuit for leakage (ALL-AD00-001-K-01-A)
a Testing tools 9. Stop the engine and check the fuel piping and
Symbol devices for fuel leakage.
Part No. Part Name
Developer for dye a Check the high-pressure circuit for fuel
Commercially penetrant check
L leakage focusing on the area to which color
available (color checker) checker L is sprayed.
k Very high pressure is generated in the high- a If any fuel leakage is detected, repair it and
pressure circuit of the fuel system. If fuel perform inspection again from Step 1.
leaks while the engine is running, it presents a If no fuel leakage is detected, inspection is
a serious danger that could result in a fire. completed.
After checking the fuel system or removing
its parts, check it for fuel leakage according
to the following procedure.

a Clean and degrease the engine and the parts

around it in advance so that you can find easily
fuel leakage.
Testing (PC-AD00-364-K-00-A)
1. Spray color checker (developer) L to the fuel

supply pump, common rail, fuel injectors, and
joints of the high-pressure fuel piping.
2. Start the engine, keep its speed at 1,000 rpm or
below, and stop it when its speed is stabilized.
3. Stop the engine and check the fuel piping and
devices for fuel leakage.
a Check the high-pressure circuit for fuel
leakage focusing on the area to which color
checker L is sprayed.
a If any fuel leakage is detected, repair it and
perform inspection again from Step 1.
4. Start the engine and keep it running at low idle.
6. Start the engine and keep it running at high idle.
8. Run the engine at high idle, then load it.
a Relieve the arm circuit at the IN stroke end.
30-36 PC210LC-10
Handling cylinder cutout mode operation (PC-AD00-34F-K-00-A)
a The cylinder cut-out test mode operation means

to run the engine with the fuel injectors of one or
more cylinders disabled electrically to reduce the
number of active cylinders. The purposes and
effects of this operation are as follows.
1. This mode is used to find out a cylinder which
does not output power properly (or, combustion
in it is abnormal).
2. When a cylinder is selected for the Cylinder Cut-
out Mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has one or
more defects.
The following problems can be considered:
• Compression leak from cylinder head gasket
• Defective injection from injector
• Defective piston or piston ring
• Defective valve mechanism (valve operating
system)
• Defective electrical system
3. The injector of each cylinder is separately
controlled electronically in the common rail fuel
injection system, so the cylinder cut-out test can
be performed easily by the simple operations of
the switches compared with the mechanical fuel
injection system. This allows to find out a
defective cylinder easily.
PC210LC-10 30-37
Handling no injection cranking operation (PC-A000-25L-K-00-A)
a No-injection cranking means to crank the engine

by using the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
Before the engine is started after it or the
machine has been stored for a long period, the
no-injection cranking is performed to lubricate
the engine parts and protect them from seizure.
30-38 PC210LC-10
Checking and adjusting air conditioner compressor belt tension (ALL-K5A0-001-

K-00-A)

Testing (PC200_10-K5A0-285-K-00-A)
1. Open the engine hood and remove belt guard

(1).
2. Loosen nut (3) in direction (A).

a Nut (3) is provided to prevent loosening of
jack bolt (4).
3. Tighten jack bolt (4) and slide compressor (5) in
direction (A), then the compressor belt is tensed.
a To loosen the belt, loosen jack bolt (4) and
2. Press the intermediate point of the belt between slide compressor (5) in direction (B).
fan pulley and compressor pulley with a finger
and measure deflection (a) of the belt.
• Belt depressing force: 60 N {6.2 kg}
• Belt reflection: 6.3 to 8.7 mm
4. When the belt tension becomes appropriate,

tighten three bolts (2).
3 Bolt (2):
3. After finishing testing, return the machine status 59 to 74 Nm {6.0 to 7.5 kgm}
as it was. 5. After tightening nut (3) until it touches boss (6),
then tighten it further in direction (B) to prevent it
Adjusting (PC200_10-K5A0-27C-K-00-A)
from loosening.
a If the belt deflection is improper, adjust it
3 Nut (3):
108 to 132 Nm {11.0 to 13.5 kgm}
1. Loosen three bolts (2).
6. Check again if the belt tension is appropriate.
a Be careful not to loosen bolts (2) too much. Adjust it again if the tension is not within the
proper range.
a Check each pulley for breakage, wear of the
V-groove, and contact of the V-belt with V-
groove.
a If the V-belt is elongated exceeding the
adjustment allowance or it has a cut or a
crack, replace it with a new one.
PC210LC-10 30-39
a When the V-belt is replaced, check and

adjust its tension again after running the
engine for an hour.
7. After finishing the adjustment, restore the

machine.
30-40 PC210LC-10
Replacing fan belt (ALL-B430-001-K-00-A)
a The auto-tensioner is provided for the fan belt. 2. Replace fan belt (2).
Thus, testing and adjustment of the belt is • Check each pulley for breakage and crack.
usually not necessary.
a Disconnect the air conditioner compressor belt
before replacing the fan belt.
Replacing (PC220-B430-923-K-00-A)
1. Set a wrench to portion (A) (width across flats:

12.7 mm) of the tensioner assembly (3), and turn
the wrench in the direction opposite to the
winding-up direction to decrease the fan belt (2)
tension.
k Firmly set the wrench on tensioner

assembly (3) at portion (A) before
applying turning force to the wrench. (If
you try to rotate the wrench before it is
fully inserted due to strong spring force
of tensioner assembly (3), it can
disengage and cause serious physical
injuries.)
k After removing fan belt (2), slowly and

carefully restore tensioner assembly (3).
k Be careful not to catch your fingers

between the pulley and fan belt (2) during
work.
PC210LC-10 30-41
Power train
Testing swing circle bearing clearance (ALL-J117-001-K-00-A)
a Testing tools 5. From this state, read the dial gauge K value.
Sym- a The value indicated by dial gauge K is the
Part No. Part Name
bol clearance of the bearing.
Commercially Dial gauge
K
available
k Be careful not to put a hand or foot under the

undercarriage, while taking measurement.
Testing (PC-J117-365-K-00-A)
1. Fasten dial gauge K to swing circle outer race

(1) or inner race (2), and touch the probe to the
end surface of inner race (2) or outer race (1) on
the opposite side.
a Set dial gauge K in the front side or rear side
of the machine.
6. Return the machine to the condition of step 2
and check that dial gauge K indicates zero point.
a If zero value is not indicated, repeat the steps
3 through 5.
2. Set the work equipment to the maximum reach

posture and set the bucket tip to the height of the
underside of the revolving frame.
a At this time, the front side of the upper
structure rises and the rear side lowers.
3. Set the reading of dial gauge K to the zero point.
4. Set the arm almost perpendicular to the ground

and lower the boom until the front part of the
tracks float by 150 to 200 mm.
a At this time the front of the upper structure
rises and the rear lowers.
30-42 PC210LC-10
Undercarriage and frame
Testing and adjusting track shoe tension (ALL-DTL0-001-K-00-A)
Testing (PC200_10-DTL0-285-K-00-A) a You can add grease until dimension (b)

between the idler guide and the track
1. Run the engine at low idle and move the
machine forward by the length of track on frame end becomes 0 mm. If the tension
is still low, the pins and bushings will
ground, and then stop slowly.
become excessively worn. In this case,
2. Place square bar [1] on the track shoes between
turn 180 deg. , or replace the pins and
the idler and the 1st carrier roller.
bushings.
a As the square bar [1], use an angle steel, etc.
which deflects less.
3. Measure maximum clearance (a) between steel
bar [1] and track shoe.
• Standard maximum clearance (a): 10 to 30
mm
2. Decreasing tension
1) Loosen valve (2) to discharge grease, and
then tighten it.
k Do not loosen the valve more than one

turn. Otherwise, the valve jumps out
Adjusting (PC220-DTL0-27C-K-00-A) because of the high-pressure grease
inside.
a If the track tension is improper, adjust it
according to the following procedure. 2) To check that the tension is proper, run the
1. Increasing tension engine at low idle and move the machine
forward by the length of track on ground,
1) Add grease through grease fitting (1) by
then stop slowly.
using a grease gun.
3) After adjusting, check the track tension again
2) To check that the tension is proper, run the
according to the above procedure.
engine at low idle and move the machine
forward by the length of track on ground,
then stop slowly.
3) After adjusting, check the track tension again
according to the above procedure.
PC210LC-10 30-43
Hydraulic system
Releasing remaining pressure from hydraulic circuit (ALL-C000-001-P-02-A)
Releasing remaining a The control valve is operated by the

pressure (PC200_10-C000-22A-K-00-A) pressure in the accumulator. The
1. Releasing remaining pressure from hydraulic pressure in the accumulator is used up,
tank however, after the work equipment
control levers are operated two to three
k The hydraulic tank is sealed and times.
pressurized. Therefore, when removing a 3) Start the engine and run it at low idle for 5
hose or a plug connected to the hydraulic seconds to raise the pressure in the
tank, release the remaining pressure in accumulator.
the hydraulic tank according to the a The engine does not start unless the lock
following procedure. lever is set to the LOCK position.
1) Lower the work equipment to the ground in a 4) Repeat above steps 2) and 3) two to three
stable posture and stop the engine. times, and all remaining pressure is released
2) Loosen oil filler cap (1) of the hydraulic tank from the piping completely.
gradually to release the air in the tank. 3. Releasing remaining pressure from swing motor
circuit
a The remaining pressure in the swing motor
circuit can be released by performing the
same operation as that described in
preceding "Releasing remaining pressure in
hydraulic cylinder circuit" (Operate the lever
to SWING only, however).
4. Releasing remaining pressure from travel motor
circuit
a The control valve spool of the travel motor
circuit is an open type circuit, so the
remaining pressure in the circuit can be
2. Releasing remaining pressure in hydraulic released by performing the same operation
cylinder circuit as that described in preceding "Releasing
remaining pressure in hydraulic tank".
k When disconnecting a pipe between a
hydraulic cylinder and the control valve,
release the remaining pressure from the
piping according to the following
procedure.
1) Release the remaining pressure in the
hydraulic tank. For details, see preceding
"Releasing remaining pressure in hydraulic
tank".
a Leave the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch to the ON position
and set the work equipment lock lever to the
FREE position, and then operate the right
and left work equipment control levers
forward and backward, and to the right and
left.
30-44 PC210LC-10
Hydraulic system
Testing and adjusting oil pressure in work equipment, swing, and travel
circuits (PC200_10-C000-360-K-00-A)
a Tools for testing and adjusting 2. Start the engine to increase the hydraulic oil
Sym- temperature to 45 to 55°C and measure the
Part No. Part name pump discharge pressure.
bol
M 1
790-261-1204 Digital hydraulic tester
k Lower the work equipment to the ground and

stop the engine. Operate the control levers
several times to release the remaining
pressure in the piping, and then loosen the
oil filler cap of the hydraulic tank slowly to
release the internal pressure.
a Measure the oil pressure in the work equipment,

swing, and travel circuits under the following
condition.
• Hydraulic oil temperature: 45 to 55°C Combination of pump, actuator, and valve
Testing (PC200_10-C000-362-K-00-A) a When the oil flow from the pumps is divided,
the front pump and rear pump actuate each
Measuring method by using oil pressure gauge actuator independently as shown on the
1. Open the side cover on the right side of the table. Note that the relieved valve varies
machine body and connect oil pressure gauge depending on the actuator.
[1] of hydraulic tester M1 to ports (1) and (2).
a When the work equipment circuit or swing
a Use the oil pressure gauge of 60 MPa {600 circuit is relieved singly, the oil flows from the
kg/cm2}. pumps are merged. When the travel circuit is
• (1): Rear pump discharge pressure pickup relieved singly, the oil flows from the pumps
port are divided.
• (2): Front pump discharge pressure pickup
port a The actuators in the table are arranged in the
order that the control valves are viewed from
the front of the machine. (As for the service
valve, the table shows an example in which
an attachment is installed.)
Pump Actuator Valve to be relieved
(R unload valve) (R main relief valve)
Service Safety valve
Rear Bucket R main relief valve
L.H.
R main relief valve
travel
Boom R main relief valve
(Merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
Swing Swing motor safety valve
R.H.
Front F main relief valve
travel
Arm F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
3. Testing unload pressure
1) Start the engine, set the working mode to
power mode (P), and turn the auto
deceleration OFF.
PC210LC-10 30-45
Hydraulic system
2) Set all control levers and pedals to the

NEUTRAL and measure the oil pressure
while running the engine at high idle.
a Hydraulic oil pressure when the unload
valve unloads is displayed.
2) Set the working mode to Power Mode (P).

3) Measure the pressure when the engine is
running at high idle and the travel circuit is
relieved.
k Before operating the travel lever

4. Testing work equipment relief pressure (pedal), check the pin position and
1) Start the engine and operate the cylinder to locked direction of the travel again.
be measured to the stroke end. a The pressure at the time when the main
2) Set the working mode to Power Mode (P). relief valve is relieved is displayed. The
3) Measure hydraulic oil pressure when the travel circuit is always relieved at high
cylinder is relieved while the engine is pressure.
running at high idle. 7. Work after finishing test
a The pressure at the time when the main After finishing the test, remove the testing tools
relief valve is relieved is displayed. and restore the machine.
a If the one-touch power maximizing switch Measuring method by using machine monitor
is not pressed, the low relief pressure is a The oil pressure in the work equipment, swing,
obtained. If the former is pressed, the and travel circuits (pump discharge pressure)
high relief pressure is obtained. can be checked from the “Monitoring/Pre-
a If the swing lock switch is set to the ON defined“ or “Monitoring“ screen of the machine
position, the 2-stage relief valve is kept monitor.
ON and the relief valve is relieved at high 1. Start the engine and set the machine monitor to
pressure. Therefore, keep the swing lock “Monitoring/Pre-defined“ or “Monitoring“ screen.
switch at the OFF position.
5. Testing swing relief pressure a For the setting method, see "Special
functions of machine monitor".
1) Start the engine, set the working mode to the
Power Mode (P), and turn the swing lock • Monitoring code: 01100 “F Pump Pressure“
switch ON. • Monitoring code: 01101 “R Pump Pressure“
2) Measure the hydraulic oil pressure when the • “Monitoring/Pre-defined (8/14)“ screen
engine is running at high idle and the swing
circuit is relieved.
a Hydraulic oil pressure when the swing
motor safety valve is relieved is
displayed.
a The swing motor relief pressure is lower
than that of the main relief valve.
6. Testing travel relief pressure
1) Run the engine and lock the travel
mechanism.
k Insert pin [2] between the sprocket

and the track frame to securely lock • “Monitoring“ screen
the track.
30-46 PC210LC-10
Hydraulic system
2. Increase the hydraulic oil temperature to 45 to 1) Disconnect the pilot hose.

55 °C and measure the pump discharge 2) While fixing holder (5), loosen lock nut (6).
pressure. 3) Turn holder (5) to adjust the pressure.
a See "Measuring method by using oil a If the holder is
pressure gauge" for checking procedure.
• turned clockwise, the pressure is
Adjusting (PC200_10-C000-270-K-00-A) increased.
• turned counterclockwise, the pressure
a Adjustment of the unload valve is not available.
is decreased.
1. Adjusting work equipment and travel relief
pressure a Amount of adjustment per turn of holder:
Approx. 20.5 MPa {Approx. 209 kg/cm2}
a If the relief pressure of the work equipment
4) While fixing holder (5), tighten lock nut (6).
circuit and travel circuit is abnormal, adjust
main relief valves (3) and (4) of the main 3 Lock nut: 49 to 58.8 Nm {5 to 6
relief valve according to the following kgm}
procedure.
• (3): Front main relief valve
• (4): Rear main relief valve
a When adjusting the main relief valve on the
front pump, remove the cover under the
control valve.
a When adjusting the main relief valve for the
rear pump circuit, remove the fuel tank cover.
a Adjust only the low relief pressure of the
main relief valve. If the low relief pressure is
adjusted, the high relief pressure is set
automatically.
5) Connect the pilot hose.
a The low relief pressure is the pressure under 6) After finishing adjustment, check the oil
the following condition: the 2-stage relief pressure again according to the above
solenoid valve is not energized and the pilot measurement procedure.
pressure is not applied to the selector port. 2. Adjusting swing relief pressure
1) If the swing relief pressure is improper, adjust
swing 2-stage relief valve (7) according to
the following procedure.
PC210LC-10 30-47
Hydraulic system
2) While fixing pressure adjustment screw (8),

loosen locknut (9).
3) Adjust the pressure by rotating pressure
adjustment screw (8).
a If the pressure adjustment screw is
• turned clockwise, the pressure is
increased.
• turned counterclockwise, the pressure
is decreased.
a Quantity of adjustment per turn of
pressure adjustment screw:
7.68 MPa {78.3 kg/cm2}
4) While fixing pressure adjustment screw (8),
tighten locknut (9).
3 Lock nut: 58.8 to 78.4 Nm {6 to 8
kgm}
5) After finishing adjustment, check the oil

pressure again according to the above
measurement procedure.
30-48 PC210LC-10
Hydraulic system
Testing oil pressure of control circuit (PC200_10-C010-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
Sensor adapter
796T-440-1200
(5 MPa {50 kg/cm2})
796-440-1150 • Wiring harness
1
799-401-2350 • Washer
790-261-1130 • Coupling
N
7861-93-1840 • Pressure sensor
799-101-5220 Nipple (M10 x 1.25 mm)
2
07002-11023 O-ring
3 3. Start the engine to increase the hydraulic oil
790-261-1204 Digital hydraulic tester temperature to 45 to 55°C.
4. Measure the hydraulic oil pressure, when the
engine is running at full speed and all the control
levers are set to the NEUTRAL.
a Measure the control circuit oil pressure under

the following condition.
Testing (PC200_10-C010-362-K-00-A)
Measuring with oil pressure gauge
1. Remove oil pressure pickup plug (1).

a Do not adjust the relief valve for the oil
pressure in control circuit.
a The oil pressure in control circuit may be
tested at oil pressure pickup port plug (2) on
the hydraulic pump.
2. Install nipple N2 and connect it to oil pressure

gauge [1] of hydraulic tester N3.
a Use the oil pressure gauge of 6.0 MPa {60
kg/cm2}.
Testing by using sensor adapter (special tool)

a Testing by using sensor adapter (special tool) is
described here only as an auxiliary testing
method.
PC210LC-10 30-49
Hydraulic system
a Control circuit oil pressure can be checked on

the “Monitoring/Pre-defined“ or “Monitoring“
screen of the machine monitor by using service
oil pressure connector (CN-P49) (11).
4. Start the engine and set the machine monitor to

“Monitoring/Pre-defined“ or “Monitoring“ screen.
a For the setting method, see "Special
functions of machine monitor".
1. Remove oil pressure pickup plug (1) of the • Monitoring code: 01141 “Service Pressure
control valve. Sensor“
• “Monitoring/Pre-defined“ (10/14) screen
2. Install nipple N2 and connect sensor adapter

N1.
• "Monitoring" screen
3. Connect service oil pressure connector (CN-

P49) (11) and sensor adapter N1. 5. Increase the hydraulic oil temperature to 45 to
55°C.
6. Measure the hydraulic oil pressure, when the
engine is running at full speed and all the control
levers are set to NEUTRAL.
a Read the value displayed on the monitor by
dividing it by 10.
30-50 PC210LC-10
Hydraulic system
a Do not adjust the relief valve for the oil

pressure in control circuit.
a The oil pressure in control circuit may be
tested at oil pressure pickup port plug (2) on
the hydraulic pump.
PC210LC-10 30-51
Hydraulic system
Testing and adjusting oil pressure in pump PC control circuit (PC200_10-C2A3-360-

K-00-A)

Sym-
Part No. Part name
bol
P 1

a Before testing the oil pressure in the pump PC

control circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and
the source pressure of the control circuit are
proper.
a Measure the oil pressure in the pump PC control
circuit under the following condition.
Testing (PC200_10-C2A3-362-K-00-A)
Measuring PC valve output pressure (servo
piston inlet pressure)
a To measure the PC valve output pressure (servo
1. Connect oil pressure gauge [1] of hydraulic
piston inlet pressure), measure the front and
tester P1 to pump discharge pressure pickup
rear pump discharge pressures simultaneously
ports (1) and (2), and control pressure pickup
and compare them.
ports (3) and (4).
a Front pump discharge pressure and rear pump
a Use the oil pressure gauge of 60 MPa {600
discharge pressure can be checked on
kg/cm2}.
“Monitoring/Pre-defined“ or “Monitoring“ screen
of the machine monitor. (For the checking
method, see "Special functions of machine
monitor".)
• Monitoring code: 01100 “F Pump Pressure“
• Monitoring code: 01101 “R Pump Pressure“
a Oil pressure pickup ports are shown below.
• (1): Front pump delivery pressure pickup port
• (2): Rear pump delivery pressure pickup port
• (3): Front control pressure pickup port
• (4): Rear control pressure pickup port
30-52 PC210LC-10
Hydraulic system
Oil pressure to be Oil pressure ratio

measured
Pump discharge
pressure 1
PC valve output
Approximately 0.6 (3/5)
pressure
a If the PC valve or the servo piston is

defective, the PC valve output pressure
(servo piston inlet pressure) comes to the
same pressure as the pump discharge
pressure, or almost 0.
Measuring PC-EPC valve output pressure
• (5): Front PC mode selector pressure pickup
port
• (6): Rear PC mode selector pressure pickup
port
1. Connect oil pressure gauge [1] of hydraulic

tester P1 to PC mode selector pressure pickup
ports (5) and (6).
2. Start the engine to increase the hydraulic oil
kg/cm2}.
temperature to 45 to 55°C.
3. Measure the pump discharge pressure and PC
valve output pressure (servo piston inlet
pressure) at the same time after setting the
machine to the following conditions with the
engine running at full speed.
• Working mode: P mode
(Turning 2-stage relief ON switches to high-
pressure relief)
• Work equipment: Arm IN relief
a Judgment method:
When the ratio of the pump discharge
pressure to the PC valve output pressure
temperature to 45 to 55°C.
(servo piston inlet pressure) reaches the
following value, those pressures are normal.
PC210LC-10 30-53
Hydraulic system
1. Loosen lock nut (9).

a Before loosening the lock nut, make a match
mark on the end face of the adjustment
screw to indicate the original position of the
adjustment screw (so that you can return the
adjustment screw to the original position if
you turn it in the opposite direction).
2. Adjust the pressure by rotating adjustment
screw (10) to the right or left.
a Turn the adjusting screw in the following
directions.
• Turn it clockwise when the work
3. Measure the hydraulic oil pressure with all the equipment speed is low (to increase
control levers set to the NEUTRAL and the pump absorption torque).
engine running at low speed and at full speed. • If the engine speed lowers when the work
a When the PC-EPC valve output pressure load increases, turn it counterclockwise.
changes as shown below, it is normal. (The pump absorption torque will
decrease.)
Engine Control lever Oil pressure
3. Tighten lock nut (9).
2.9 MPa
Low idle 3 Lock nut: 27 to 34 Nm {2.8 to 3.5kgm}
{30 kg/cm2}
Neutral
0 MPa
High idle
{0 kg/cm2}
Adjusting (PC220-C2A3-270-K-00-A)
a If either of the following problem occurs and the

PC valve seems to be defective, adjust PC
valves (7) and (8) according to the procedure
shown below.
• As the work load increases, the engine
speed decreases remarkably.
• The engine rpm is normal but the work
4. After the adjustment, make sure that the PC
equipment speed is low.
• (7): Front pump PC valve
pressure) is normal according to the
• (8): Rear pump PC valve
measurement steps explained earlier.
a The width across flats of the PC valve locknut is
13 mm and that (inside width) of the adjusting
screw is 4 mm.
Do not turn any lock nuts and adjustment screws
other than the above because doing so affects
the hydraulic pump performance.
30-54 PC210LC-10
Hydraulic system
Testing and adjusting oil pressure in pump LS control circuit (PC200_10-C2A4-360-

K-00-A)

Sym-
Part No. Part name
bol
1
Q
Differential pressure
2 799-401-2701 gauge

release the internal pressure. 1. Connect oil pressure gauge [1] of hydraulic
tester Q1 to pump discharge pressure pickup
a Before measuring the oil pressure in the LS ports (1) and (2), and control pressure pickup
control circuit, check that the oil pressure in the ports (3) and (4).
work equipment, swing, and travel circuits and
the oil pressure of the control circuit are normal. a Use the oil pressure gauge of 60 MPa {600
kg/cm2}.
a Test the oil pressure in the pump LS control
circuit under the following condition.
Testing (PC200_10-C2A4-362-K-00-A)
Measuring LS valve output pressure (servo
piston inlet pressure)
a To measure the LS valve output pressure (servo
piston inlet pressure), measure the front and
rear pump discharge pressures simultaneously
and compare them.
• (1): Front pump delivery pressure pickup port
• (2): Rear pump delivery pressure pickup port
• (3): Front control pressure pickup port
• (4): Rear control pressure pickup port
PC210LC-10 30-55
Hydraulic system
Pump Actual measured
Oil pressure to be measured

discharge value is
pressure regarded as 1.
Almost same
LS valve pressure Approx. 0.6 (3/5)
output of above
pressure pressure

temperature to 45 to 55°C, and raise up the
track to be tested by using the work equipment.
• When measuring front circuit: Right track
• When measuring rear circuit: Left track
k Provide a enough work space to run the

track idle off the ground.

Measuring LS differential pressure
a To obtain the LS differential pressure, measure
the front and rear pump discharge pressures
and LS pressure (actuator load pressure)
simultaneously and calculate the difference.
3. Measure the pump discharge pressure and LS a Oil pressure pickup ports are shown below.
valve output pressure (pressure at servo piston • (1): Front pump discharge pressure pickup
inlet) at the same time after setting following port
conditions with the engine running at high idle. • (2): Rear pump discharge pressure pickup
• Working mode: P mode port
• Work equipment, swing and travel: When all • (5): Front load pressure pickup port
levers are at NEUTRAL and when travel • (6): Rear load pressure pickup port
lever is at half stroke (to run a track idle off
ground)
k Run the raised track idle, paying enough

attention to the surroundings for safety.
a Measurement conditions and judgment
method:
When the ratio between the oil pressures is
as shown in the table, the LS valve is normal.
Operation of lever
All control levers Travel lever at
and pedals in half stroke
NEUTRAL (Track runs idle)
30-56 PC210LC-10
Hydraulic system
1. Connect differential pressure gauge Q2 or oil

pressure gauge [1] of hydraulic tester Q1 to load
pressure pickup port (5) or (6).
a When using differential pressure gauge Q3:
Connect pump discharge pressure pickup
port (1) or (2) to the high-pressure side (back
side) coupling, and connect load pressure
pickup port (5) or (6) to the low-pressure side
(lower side) coupling.
The differential pressure gauge needs 12 V
DC power, so connect it to a battery.
a When using the oil pressure gauge:
Use the oil pressure gauge of 60 MPa {600
kg/cm2} with the graduation by 1 MPa {10 kg/
cm2}.
a The differential pressure is approximately 4
MPa {40 kg/cm2} at the maximum, so
perform the measurement by using the same
oil pressure gauge alternately.
• The figure shows the pump discharge
pressure side.

temperature to 45 to 55°C, and raise up the
track to be tested by using the work equipment.
• When measuring front circuit: R.H. track
• When measuring rear circuit: L.H. track
k Provide a enough work space to run the

• The figure shows the LS pressure side.
PC210LC-10 30-57
Hydraulic system
3. While running the engine at high idle under the 1. Connect oil pressure gauge [1] of hydraulic
following condition, measure the pump tester Q1 to LS set selector pressure pickup port
discharge pressure and LS pressure (actuator (7).
load pressure) simultaneously.
kg/cm2}.
• Work equipment, swing and travel: When all
levers are at NEUTRAL and when travel
lever is at half stroke (to run a track idle off
ground)
k Run the raised track idle, paying enough

attention to the surroundings for safety.
a Calculating LS differential pressure (when
the pressure gauge is used):
LS differential pressure = pump discharge
pressure - LS pressure
a When the LS differential pressure is as 2. Start the engine to increase the hydraulic oil
follows, it is normal. temperature to 45 to 55°C.
LS differential 3. Measure the oil pressure when the engine is
Operation of lever running at high idle and the travel speed switch
pressure
3.5 ± 1.0 MPa and travel control lever are operated.
All control levers in NEUTRAL
{36 ± 10 kg/cm2} a When the LS-EPC valve output pressure
1.8 (+0.05/-0.1) changes as follows, it is normal.
Travel lever at half stroke (track MPa
Travel speed Travel levers Oil pressure
running idle off ground) {18 (+0.5/-1.0) kg/ Approx. 2.9 MPa
cm2}
Lo Neutral {Approx. 30 kg/
4. After finishing the test, remove the testing tools cm2}
and restore the machine. 0 MPa
Fine control
Hi (Note)
Measuring LS-EPC valve output pressure {0 kg/cm2}
a Oil pressure pickup ports are shown below. Note: Operate the travel lever to a degree that
the PPC oil pressure switch is just turned on
• (7): LS set selector pressure pickup port
(position just before the machine starts moving).
30-58 PC210LC-10
Hydraulic system

4. After finishing adjustment, check that the LS
Adjusting (PC220-C2A4-270-K-00-A) pressure) is correct according to the testing
a If the LS differential pressure is improper, adjust procedure described above.
LS valves (8) and (9) according to the following
procedure.
• (8): Front LS valve
• (9): Rear LS valve
1. While fixing adjustment screw (10), loosen lock

nut (11).
2. Turn adjusting screw (10) to adjust the pressure.
a Turn the adjusting screw in the following
directions.
• Turned clockwise, the differential
pressure is increased.
• Turned counterclockwise, the differential
pressure is decreased.
a Amount of adjustment (LS differential
pressure) per turn of adjustment screw:
1.1 MPa {10.8 kg/cm2}
3. While fixing adjustment screw (10), tighten lock
nut (11).
3 Lock nut:
49 to 68.6 Nm {5 to 7 kgm}
PC210LC-10 30-59
Hydraulic system
Testing output pressure of solenoid valve (PC200_10-PQPT-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
R
799-401-3100 Adapter (size: 02)
2
02896-11008 O-ring

a Before testing the solenoid valve output

pressure, check that the control circuit source
pressure is normal.
a Measure the solenoid valve outlet pressure
under the following conditions:
Testing (PC220-PQPT-362-K-00-A)
1. Disconnect outlet hoses (1) to (7) of the solenoid a When testing at hoses (2) to (7), remove the
valves to be measured. undercover of the control valve.
No. Target solenoid valves of measurement
1 PPC lock solenoid valve
2 2-stage relief solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed increase solenoid valve
5 Travel junction solenoid valve
6 2-stage swing relief solenoid valve
Attachment selector solenoid valve
7
(for the machine with the attachment)
a When testing at hose (1), remove the

undercover (rear side) of the operator's cab.
2. Install adapter R2 and connect the currently
disconnected hose again.
3. Install nipple [2] and connect it to pressure
gauge [3].
a Use an oil pressure gauge for 6.0 MPa {60
kg/cm2}.
30-60 PC210LC-10
Hydraulic system
a The figure shows the testing tools connected

to outlet hose (1) of the PPC lock solenoid
valve.

5. Run the engine at high idle, operate the control
levers and switches to energize or de-energize
the solenoid valve, and measure the output
pressure.
a For the conditions for turning ON or OFF, see
the operation table of each solenoid valve.
a The operating status of each solenoid valve
can be checked by using monitoring function
of the machine monitor. (For details, see
"Special functions of the machine monitor".)
• Monitoring code: 02300 Solenoid 1
• Monitoring code: 02301 Solenoid 2
a If the output pressure is as shown in the table,
the solenoid valve is normal.
Solenoid valve Outlet pressure
OFF(de-energized) 0 MPa {0 kg/cm2}
ON (energized) 2.9 MPa {30 kg/cm2}
6. After finishing measurement, remove the
measuring tools and return the removed parts to
their original position.
PC210LC-10 30-61
Hydraulic system
Operating condition (PC200_10-PQPT-04C-K-00-A)
(1) Operation table of PPC lock solenoid valve

LOCK position OFF
PPC lock lever
FREE ON
(2) Operation table of 2-stage relief solenoid valve
Overheat 1st setting is ON.
Overheat 2nd setting is ON. OFF
When all the signals for work equipment, swing and travel are OFF.
Swing lock switch is ON.
Travel signal is ON.
When L mode is selected ON
When the boom LOWER signal is ON
Signals other than the "swing only"
When the working mode When one-touch power are ON.
is P or E. max. switch is ON. "Swing only " is ON.
OFF
Other than the above conditions
(3) Operation table of swing holding brake solenoid valve
Signals of work equipment and swing (Work equipment includes All are OFF. OFF
attachment.) Any one is
ON
ON.
(4) Operation table of travel speed increase solenoid valve
Overheat 2nd setting is ON.
Fuel control dial is at 1,500 rpm or below.
Travel speed switch is at Lo.
OFF
Travel signal is OFF.
When F or R pump pressure is 24.5 MPa
Travel speed switch:
{250 kg/cm2} or above.
Mi, Hi Travel signal is ON.
When F or R pump pressure is 15.3 MPa
{150 kg/cm2} or below. ON
Other than the above conditions
(5) Operation table of travel junction solenoid valve
Travel steering signal is ON.
When " travel only" When F or R pump pressure ON
signal is ON. is 24.5 MPa {250 kg/cm2} or
Travel steering signal is OFF.
above.
Other than the above conditions OFF
30-62 PC210LC-10
Hydraulic system
(6) Operation table of 2-stage swing relief valve

When boom RAISE
When F pump
signal is ON
pressure is
When boom RAISE rising and 20.6
PPC pressure is 2.2 MPa {210 kg/
When the swing signal is ON but except MPa {22 kg/cm } or
2
When arm cm2} or above
when the swing back operation is turned below signal is ON
on OFF When F pump
pressure is
When pump flow is decreasing
divided and 25.5 MPa
{260 kg/cm2}
or above
Other than the above conditions OFF
(7) Operation table of attachment selector solenoid valve (attachment installation specification)
Working mode: Other than B mode OFF
Working mode: When B mode is set ON
PC210LC-10 30-63
Hydraulic system
Testing PPC valve output pressure (PC200_10-PW11-360-K-00-A)
a Testing tools
Sym-
Part No. Part name
bol
1
S
799-401-3100 Adapter (Size: 02)
2
799-401-3200 Adapter (Size: 03)
a Check that the control circuit source pressure is

correct before testing the PPC valve outlet
pressure.
a Test the PPC valve outlet pressure under the
following condition. Circuit to be Circuit to be
No. No.
Hydraulic oil temperature: 45 to 55°C measured measured
Bucket CURL Swing RIGHT
a The outlet pressure of the following PPC valve 1 (white) 7 (None)
can be checked by using monitoring function of Bucket DUMP
machine monitor 2 8 Swing LEFT (red)
(black)
(For details, see "Special functions of machine Travel L.H. Travel R.H.
monitor"). 3 FORWARD (red) 9 FORWARD (green)
Monitoring code: 07200 “Arm Curl PPC Travel L.H. Travel R.H.
4 REVERSE (None) 10 REVERSE (blue)
Pressure“
Monitoring code: 07600 “Arm Dump PPC Boom LOWER
5 (brown) 11 Arm IN (blue)
Pressure“
Boom RAISE
Monitoring code: 07300 “Bucket CURL PPC 6 (green) 12 Arm OUT (yellow)
Pressure“
Monitoring code: 07301 “Bucket DUMP PPC • The colors in ( ) are the colors of the bands
Pressure“ installed for piping identification.
Monitoring code: 07400 “Boom raise PPC Testing (PC220-PW11-362-K-00-A)
Pressure“
1. Disconnect hydraulic hose (2) of the tested PPC
Monitoring code: 07500 “Boom Lower PPC circuit, install adapter S2, and connect hydraulic
Pressure“ hose (2) again.
Monitoring code: 09001 “Swing left PPC 2. Install nipple [1] of hydraulic tester S1 to adapter
Pressure“ S2 and connect oil pressure gauge [2].
Monitoring code: 09002 “Swing right PPC a Use an oil pressure gauge for 6.0 MPa {60
Pressure“ kg/cm2}.
Monitoring code: 07102 “Travel Fwd LH PPC
a The figure shows the testing tools installed to
Pressure“
the hydraulic hoses of the bucket dump PPC
Monitoring code: 07103 “Travel Fwd RH PPC circuit.
Pressure“
Monitoring code: 07104 “Travel Rev LH PPC
Pressure“
Monitoring code: 07105 “Travel Rev RH PPC
Pressure“
a Before starting the measurement, disconnect a
hose of control valves on the target circuits (1) to
(12).
3. Start the engine and set the working mode to the

Power Mode (P).
30-64 PC210LC-10
Hydraulic system
4. Measure the pressure when the engine is

running at full speed and the control lever of the
circuit to be measured is kept at the neutral
position and at the full stroke.
a If PPC valve output pressure is at the level
shown below, it is correct.
Lever control Hydraulic
When control
lever is in
0 MPa {0 kg/cm2}
NEUTRAL
position
Almost the same pressure as
When control the control circuit source
lever is moved to pressure (See "Standard
stroke end values table")
5. After finishing measurement, remove the
measuring tools and return the removed parts to
their original position.
PC210LC-10 30-65
Hydraulic system
Adjusting play of work equipment and swing PPC valves (ALL-PL28-001-K-00-A)
a If the right and left work equipment levers have

large play, adjust them according to the following
procedure.
a The play of the lever measured at a position of
200 mm from the pivot must be 0.5 to 3 mm.
Adjusting (PC-PL28-270-K-00-A)
1. Remove boot (1).

2. Loosen locknut (2) and tighten disc (3) until it
touches the heads of four pistons (4).
a Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut (2)
to the specified torque.
3 Lock nut: 93.1 to 112.7 Nm {9.5 to 11.5
kgm}
4. Install boot (1).
30-66 PC210LC-10
Hydraulic system
Testing pump swash plate sensor (PC200_10-C3WG-360-K-00-A)
a Before testing pump swash plate sensor, check a Testing condition and judgment: If the voltages
that oil pressure in work equipment, swing, and are as shown in the table, pump swash plate
travel circuits, control circuit source pressure, sensor is correct.
and no-load travel speed are correct. Pump swash plate
Lever control sensor voltage
a Test pump swash plate sensor under the
following conditions. All control levers and
pedals are at neutral. 1.35 ± 0.63 V
Travel lever is at stroke
• Working mode: P mode end.
3.35 ± 0.63 V
Testing output voltage of pump swash plate (run track idle off
sensor ground)
a Output voltage of pump swash plate sensor can
be checked by using monitoring function of
machine monitor.
(For the operating method, see "Special
functions of machine monitor".)
• Monitoring code:
01138 “F pump sw plate sensor volt“
01140 “R pump sw plate sensor volt“
Testing (PC220-C3WG-36J-K-00-A)
1. Start the engine and raise the track on the side

to be tested, by using the work equipment, and
prepare for running the track idle.
• When testing front pump: right track
• When testing rear pump: left track
k Provide an enough work space to run the

2. Set the working mode to the Power Mode (P)
and set the travel speed to the High.
3. Set the swing lock switch to ON position.
4. While running the engine at full speed, set all the
levers and pedals for work equipment, swing,
and travel to the neutral, and then set the travel
lever to stroke end in order to run a track idle,
and measure the voltage during each operation.
k While taking care of safety around the
machine, run the raised track idle.
PC210LC-10 30-67
Hydraulic system
Isolating the parts causing hydraulic drift in work equipment (ALL-L410-001-K-00-A)
a If the work equipment (cylinder) drifts 2) Operate the arm control lever to the arm IN
hydraulically, perform check to see if the position.
problem is in the cylinder seal or control valve • If the lowering speed is increased at this
according to the following procedure. time, the cylinder seal is defective.
Checking (PC-L410-360-K-00-A) • If the lowering speed does not change at
this time, the control valve is defective.
1. Checking boom cylinder and bucket cylinder
a Operate the control lever with the engine
1) Set the work equipment in the same posture
starting switch in the ON position.
as when measuring hydraulic drift, and stop
the engine. a If there is no more pressure in the
accumulator, run the engine for
a Put a weight equivalent to the rated load
approximately 10 seconds to charge the
or fill the bucket with the earth and sand.
accumulator.
[Reference] In case of the hydraulic drift is
caused by defective cylinder packing, the
reason why the drift speed becomes faster by
above mentioned operation is as follows:
1) If the work equipment is set to the above
posture (where the work equipment holding
pressure is applied to the bottom side), the
oil leaks from the bottom side to the head
side. The volume on the head side is less
than that on the bottom side by the volume of
the rod, so the pressure in the head side is
increased by the oil flowing in from the
bottom side.
2) When testing the boom cylinder, set the 2) As the inner pressure in the head side is
boom control lever to the RAISE position. increased, it is balanced with the pressure in
When testing the bucket cylinder, set the the bottom side at a certain level (which
bucket control lever to the CURL position. depends on the leak quantity), and the
• If the lowering speed is increased at this lowering speed is reduced.
time, the cylinder seal is defective. 3) If the circuit on the head side is opened to
• If the lowering speed does not change at the drain circuit by the above operation of the
this time, the control valve is defective. lever (the bottom side is closed by the check
a Operate the control lever with the engine valve at this time), the oil in the head side
starting switch in the ON position. flows in the drain circuit. As a result, the
pressure is in balanced and the lowering
a If there is no more pressure in the speed is increased.
accumulator, run the engine for 3. Testing PPC valve
approximately 10 seconds to charge the Measure the hydraulic drift of the work
accumulator. equipment when the work equipment lock lever
2. Checking arm cylinder is in the LOCK and FREE positions with the
1) Move the arm cylinder to about 100 mm accumulator charged fully.
before the IN stroke end and stop the engine.
a Operate the control lever with the engine
starting switch in the ON position.
a If there is no more pressure in the
accumulator, run the engine for
approximately 10 seconds to charge the
accumulator.
a If there is any difference in the hydraulic drift
between LOCK and FREE positions, the
PPC valve is defective (some internal
defect).
30-68 PC210LC-10
Hydraulic system
Testing oil leakage (PC200_10-C000-360-P-00-A)
a Testing tools k Release the remaining pressure from

Sym- the piping on the arm cylinder head
Part No. Part name side. For details, see "Releasing
bol
Commercially Measuring cylinder remaining pressure from hydraulic
T circuit" (Operate the lever to arm IN
available
only, however).
a Measure the oil leakage under the following
condition. 2) Disconnect hose (2) on the cylinder head
side and block the hose end by a flange.
Testing (PC200_10-C000-364-K-00-A) k Take care not to disconnect the hoses
1. Measurement of leakage from boom cylinder on the cylinder bottom side.
1) Extend the boom cylinder to the boom a Use the following part to block on the
RAISE stroke end and stop the engine. hose end.
07379-00640 (Flange #06)
k Release the remaining pressure from
the piping on the boom cylinder head
side. For details, see "Releasing
remaining pressure from hydraulic
circuit" (Operate the lever to the boom
RAISE direction only, however).
2) Disconnect hose (1) on the cylinder head
k Take care not to disconnect the hoses

on the cylinder bottom side.
a Use the following part to block on the
hose end. 3) Run the engine at full speed and relieve the
07379-00640 (Flange #06) arm circuit by moving the arm IN.
k Take care not to "move the arm OUT".

4) Start measuring the oil leakage 30 seconds
after relieving is started, and measure the
leak for 1 minute.
5) After finishing testing, return the machine
status as it was.
3. Measurement of oil leakage from bucket cylinder
1) Move the bucket cylinder to the bucket
CURL stroke end and stop the engine.
k Release the remaining pressure from

3) Run the engine at full speed and relieve the the piping on the bucket cylinder head
boom circuit by raising the boom. side. For details, see "Releasing
remaining pressure from hydraulic
circuit" (Operate the lever in the
k Take care not to "lower the boom".
bucket CURL direction only, however).
2) Disconnect hose (3) on the cylinder head
after relieving is started, and measure the
leak for 1 minute.
k Take care not to disconnect the hoses
status as it was.
2. Measurement of oil leakage from arm cylinder on the cylinder bottom side.
1) Move the arm cylinder to the arm IN stroke
end and stop the engine.
PC210LC-10 30-69
Hydraulic system
a Use the following part to block on the 1) Remove the travel motor cover.
hose end. 2) Run the engine, lock the travel mechanism,
07379-00640 (Flange #06) and stop the engine.
k Put pin [1] between the sprocket and

track frame to lock the travel
mechanism securely.
3) Run the engine at full speed and relieve the

bucket circuit by curling the bucket.
k Takecare not to perform "bucket

DUMP operation". 3) Disconnect drain hose (5) of the travel motor
and block the hose end by a plug.
after relieving is started, and measure the a Use the following part to block on the
leak for 1 minute. hose end.
5) After finishing testing, return the machine 07376-70422 (plug #04)
status as it was.
4. Measurement of oil leakage from swing motor
1) Disconnect two drain hoses (4) and block the
hose side end by plugs.
a Use the following part to block on the
hose end.
07376-70522 (Plug #05)
4) Run the engine at full speed, relieve the

travel circuit, and measure the oil leakage.
k Before operating the travel lever,

check the pin position and locked
direction of the travel again.
k Wrong operation of the lever can

2) Set the swing lock switch to the ON position.
3) Run the engine at full speed and relieve the cause the personal injury. Make the
swing circuit by swinging. signals and checks securely.
a Start measuring the oil leakage 30 a Start measuring the oil leakage 30
seconds after relieving is started, and seconds after relieving is started, and
measure the leak for 1 minute. measure the leak for 1 minute.
a After measuring one time, swing 180 deg., a Take measurement several times, moving
and then measure the leak again. the motor a little each time (i.e. change
4) After finishing testing, return the machine the position of the valve plate and
status as it was. cylinder, and that of the cylinder and
5. Measurement of oil leakage from travel motor piston each time).
30-70 PC210LC-10
Hydraulic system

status as it was.
PC210LC-10 30-71
Hydraulic system
Bleeding air from hydraulic circuit (ALL-C000-001-P-04-A)
q: Execution of work
o: Go to next procedure
Air bleeding procedure and item
1 2 3 4 5 6
Bleeding air Checking oil
from Starting the Bleeding air Bleeding air Bleeding air
level and
hydraulic engine from cylinder from swing from travel
operating
pump motor motor
machine
• Replacement of
hydraulic oil q q
q q q q
• Cleaning (See note) (See note)
strainer
• Replacing
return oil filter q o o o q
element
• Replacing or
repairing
hydraulic pump q q q o o q
• Removal of
suction piping
• Replacing or
repairing
control valve
q q o o q
• Removal of
Detail of work, remarks
control valve
piping
• Replacement
or repair of
cylinder q q o o q
• Removal of
cylinder piping
• Replacing or
repairing swing
motor
q o q o q
• Removal of
swing motor
piping
• Replacing or
repairing travel
motor
q o o q q
• Removal of
travel motor
piping
• Replacing or
repairing swivel
joint q o o o q
• Installing swivel
joint piping
Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
2) After oil containing no bubbles flows out,
Bleeding air (PC220-C000-231-P-01-A) tighten air bleeder (1).
1. Air bleeding from hydraulic pump 3 Air bleeder: 7.8 to 9.8 Nm {0.8 to
1.0 kgm}
a Keep the oil filler cap of the hydraulic tank
loosened while the air is bled from the
hydraulic pump.
1) Loosen air bleeder (1) and check that oil
oozes out from it.
30-72 PC210LC-10
Hydraulic system
3 Air bleeder: 27.5 to 35.3 Nm {2.8 to

3.6 kgm}
2. Starting engine
When running the engine after performing step 1,
let it low-idle for 10 minutes.
6. Bleeding air from swivel joint
a When the automatic warm-up operation is 1) Run the engine at low speed.
started due to low engine coolant 2) Raise a track and run it idle slowly (forward
temperature, stop the engine once and and reverse directions) to bleed air. Apply the
cancel the automatic warm-up operation same procedure to the right and left tracks.
using the fuel dial. (You can cancel the 7. Checking oil level and starting work
automatic warm-up function by turning the
1) Run the engine, retract the arm cylinder and
starting switch to the ON position and
bucket cylinder to the stroke end, lower the
keeping the fuel dial in the MAX position for 3
work equipment to the ground, and stop the
seconds or longer.)
engine.
3. Bleeding air from cylinder
a When the cylinder has been replaced, bleed
the air before connecting the work equipment.
The above step is necessary particularly
when boom cylinder is installed on work
equipment because the LOWER side does
not move to the stroke end in this state.
1) Run the engine at low idle for approximately
5 minutes.
2) While running the engine at low speed, raise
and lower the boom four to five times.
a Stop the piston rod approximately 100
mm before each stroke end. Do not
cause the relief. 2) Check the oil level using sight gauge (3) on
3) While running the engine at full speed, the rear side of the hydraulic tank.
perform step 2). a If the oil leakage is between lines (H) and
4) While running the engine at low idle speed, (L), it is normal.
move the piston rod to the stroke end and
relieve the oil. a If the oil level is below line (L), add new
5) Bleed air from the arm cylinder and bucket oil.
cylinder according to steps 2) to 4).
4. Bleeding air from swing motor
1) Run the engine at low speed.
2) Swing to the right and left slowly to bleed air.
5. Bleeding air from travel motor
1) Run the engine at low speed.
2) Loosen air bleeder (2) and check that oil
oozes out from it.
3) After oil containing no bubbles flows out,
tighten air bleeder (2).
PC210LC-10 30-73
Cab and its attachments
Checking cab tipping stopper (ALL-K138-001-K-00-A)
a Check the cab tipping stopper according to the following procedure.

Checking (PC-K138-280-K-00-A)
1. Check the tightening torque of the mounting bolt

(2) of the lock plate (1).
3 Bolt (2):
98 to 123 Nm {10 to 12.5kgm}
[Reference]
• Note that the tightening torque for mounting bolt
(4) of cab tipping stopper (3) is different from that
of a common bolt 30 mm in diameter.
3 Bolt (4):
245 to 309 Nm {25 to 31.5kgm}
30-74 PC210LC-10
Adjusting mirrors (PC200_10-K810-360-K-00-A)
1. Mirror installing positions • Adjust the mirror so that the side of the
machine is reflected in it as shown in the
figure.
3. Adjusting mirror (b)

Adjust mirror (b) so that the operator can see a
person at the right rear end of the machine.
a Install the mirror in the dimension as follows.
(L): 17 degrees (M): 77 degrees (N): 590 mm
(P): 134 mm
a If the mirror is hard to adjust, loosen mirror
bolts (3).
3 Bolt (4) of mirror:
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
2. Adjusting mirror (a)
Adjust mirror (a) so that the operator can see a
person in the rear left end of the machine.
(G): 17 degrees (H): 89 degrees (J): 67 mm
(K): 172 mm
bolts (2).
a Fix mirror stay (1) while the mirror is opened
to the maximum position.
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
PC210LC-10 30-75
• Adjust the mirror so that the side of the

machine is reflected in it as shown in the
figure.
4. Adjusting mirror (c)

Adjust mirror (c) in such way that it best
commands a view of the side face of fuel tank
that situates in the blind angle when seen from
the operator's seat.
(Q): 8 degrees (R): 15 degrees (S): 146 mm
bolts (4).
6.0 to 7.0 Nm {0.61 to 0.71 kgm}
30-76 PC210LC-10
Electrical system
Special functions of machine monitor (PC220-Q170-042-K-01-A)
PC210LC-10 30-77
Electrical system
Upper part of machine monitor (display portion)

(a): Multi-information display
a When the engine is started, the battery voltage
may drop suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the screen display of the machine
monitor may go off for a moment. This
phenomenon is not a failure, however.
Upper part of machine monitor (switch portion)

[F1]: F1 Function switch
a The function of each function switch is indicated
by the icon which is displayed just above the
function switch on the screen of the multi-
information display panel (a).
a If the icon for a function switch is not displayed,
that function switch is not working.
Lower part of machine monitor (switch portion)

[1]: Numeral 1 input switch/Auto-deceleration switch
[2]: Numeral 2 input switch/Working mode selector
switch
[3]: Numeral 3 input switch/Travel speed selector
switch
[4]: Numeral 4 input switch/Alarm buzzer stop
switch
[5]: Numeral 5 input switch/Wiper switch
[6]: Numeral 6 input switch/Window washer switch
[7]: Numeral 7 input switch/Air conditioner switch
Switch having no numerals : Air conditioner switch
a Each switch has the function indicated by the
icon on it and the function of inputting a numeral.
a The machine monitor automatically judges which
function of each switch is currently enabled
according to the screen display of the multi-
information display panel (a).
30-78 PC210LC-10
Electrical system
Ordinary functions and special functions of machine monitor (PC200_10-Q170-042-K-00-A)
The machine monitor has the ordinary functions and special functions and displays information of various
types on the multi-information display panel.
Some information are displayed automatically according to the configuration of the machine monitor and the
others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The information items in this mode are displayed ordinarily. The operator can display and set them by
operating the switches (Display and setting of some items need special operations of the switches).
2. Special function: Service mode
The information items in this mode are not displayed ordinarily. Each technician can display them by
operating the switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.
PC210LC-10 30-79
Electrical system
Operator mode (outline) Service mode

A Display of KOMATSU logo(PAGE 30-83) Monitoring / Pre-defined(PAGE 30-100)
A Password input(PAGE 30-83) Monitoring(PAGE 30-105)
Display of check of breaker mode(PAGE 30- Abnormality record (mechanical systems)
A 83) (PAGE 30-114)
Display of check before starting(PAGE 30- Abnormality record (electrical systems)
A 83) (PAGE 30-115)
Display of warning after check before
A starting(PAGE 30-84) Maintenance Record(PAGE 30-116)
Display of ending of maintenance interval
A (PAGE 30-84) Maintenance Mode Setting(PAGE 30-117)
Display of check of working mode and travel
A speed(PAGE 30-84) Phone number entry(PAGE 30-120)
A Display of standard screen(PAGE 30-84) Default (Key-on Mode)(PAGE 30-120)
A Display of end screen(PAGE 30-85) Default value setting (Unit)(PAGE 30-121)
Display of operation screen for engine Default (With/Without Attachment)(PAGE
A shutdown secondary switch(PAGE 30-85) 30-122)
B Selection of auto-deceleration(PAGE 30-85) Default (Camera)(PAGE 30-123)
Testing (Cylinder Cut-out operation)(PAGE
B Selection of working mode(PAGE 30-85)
30-124)
Testing (Regeneration for Service)(PAGE
B Selection of travel speed(PAGE 30-86) o 30-125)
Operation to stop alarm buzzer(PAGE 30- (Spe- Testing (KDPF Memory Reset)(PAGE 30-
B 86) cial 127)
opera- Adjustment (Pump Absorption Torque (F))
B Operation of windshield wiper(PAGE 30-87) tion)
(PAGE 30-128)
Adjustment (Pump Absorption Torque (R))
B Operation of window washer(PAGE 30-87)
(PAGE 30-128)
Operation of air conditioner/heater(PAGE Adjustment (travel low speed setting)(PAGE
B 30-87) 30-129)
Operation to display camera mode(PAGE Adjustment (Attachment Flow Adjustment)
B 30-87) (PAGE 30-130)
Operation to display clock and service Adjustment (F pump swash plate sensor
B meter(PAGE 30-88) calibration)(PAGE 30-132)
Check of maintenance information(PAGE Adjustment (R pump swash plate sensor
B 30-88) calibration)(PAGE 30-137)
Setting and display of user mode (including
Adjustment (Pump calibration: Matching
B KOMTRAX messages for user)(PAGE 30-
speed check)(PAGE 30-138)
88)
C Display of ECO guidance(PAGE 30-89)
speed calibration)(PAGE 30-142)
C Display of caution monitor(PAGE 30-90) No Injection(PAGE 30-143)
Displaying KDPF regeneration(PAGE 30- KOMTRAX Settings (Terminal Status)
C 91) (PAGE 30-144)
Display of action level and failure code KOMTRAX Settings (GPS and
C (PAGE 30-94) Communication Status)(PAGE 30-145)
KOMTRAX Settings screen (Modem Status)
O (Special operation) (PAGE 30-146)
Function of checking display of LCD (Liquid
D Service Message(PAGE 30-146)
Crystal Display)(PAGE 30-96)
Function of checking service meter(PAGE
D 30-96)
Function of Usage Limitation Setting/
D Change Password(PAGE 30-96)
30-80 PC210LC-10
Electrical system
a Group of screens or functions in operator mode

A: Display or function from turning ON of starting switch to switching to the standard screen is over, and
display after starting switch is turned OFF
B: Display or function when the machine monitor switches are operated
C: Display or function when certain conditions are met
D: Display or function when operation of special switches is required
PC210LC-10 30-81
Electrical system
Operator mode (Outline) (PC200_10-Q193-042-K-00-A) O (Special operation)

a Only outline of the operator mode is described in Function of checking display of LCD (Liquid
this section. Crystal Display)(PAGE 30-96)
Function of checking service meter(PAGE 30-
For details of contents and operations of each 96)
function and display, see "Structure and function
Function of Usage Limitation Setting/ Change
", or the "Operation and Maintenance Manual". Password(PAGE 30-96)
a The following are the screens or functions of the
operator mode explained in this section
(including some items which need special a Display sequence in operator mode
operations). The contents of display from the time when
starting switch is turned ON to time when screen
Display changes to standard screen depends on the
pattern setting and condition of the machine.
A B C D E A: When the engine start lock is set effective
Display of KOMATSU logo 1 1 1 1 1 B: When the engine start lock is set ineffective
(PAGE 30-83) C: When working mode at start is set to breaker
Password input(PAGE 30-83) 2 mode (B)
Display of check of breaker 2 D: When there is abnormal item in check-before-
mode(PAGE 30-83)
starting items
Display of check before starting 3 2 3 2 2
(PAGE 30-83) E: When an overdue maintenance item is
Display of warning after check 3 discovered
before starting(PAGE 30-84)
Display of ending of 3
maintenance interval(PAGE 30-
84)
Display of check of working 4 3 4 4 4
mode and travel speed(PAGE
30-84)
Display of standard screen 5 4 5 5 5
(PAGE 30-84)
Display of end screen(PAGE 30-85)
Display of operation screen for engine
shutdown secondary switch(PAGE 30-85)
Selection of auto-deceleration(PAGE 30-85)
Selection of working mode(PAGE 30-85)
Selection of travel speed(PAGE 30-86)
Operation to stop alarm buzzer(PAGE 30-86)
Operation of windshield wiper(PAGE 30-87)
Operation of window washer(PAGE 30-87)
Operation of air conditioner/heater(PAGE 30-
87)
Operation to display camera mode(PAGE 30-
87)
Operation to display clock and service meter
(PAGE 30-88)
Check of maintenance information(PAGE 30-
88)
Setting and display of user mode (including
KOMTRAX messages for user)(PAGE 30-88)
Display of ECO guidance(PAGE 30-89)
Display of caution monitor(PAGE 30-90)
Displaying KDPF regeneration(PAGE 30-91)
Display of action level and failure code(PAGE
30-94)
30-82 PC210LC-10
Electrical system
Display of KOMATSU logo (PC220-Q180-044-K-01-A) a If this screen is displayed, call the person
When starting switch is turned to ON position, responsible for the operation of KOMTRAX in
KOMATSU logo is displayed for 2 seconds. your Komatsu distributor and ask for remedy.
a After the KOMATSU logo screen is displayed for
2 seconds, the screen changes to "Password
input" screen, or "Check before starting" screen.
Display of check of breaker mode (PC220-Q180-

044-K-03-A)
When the starting switch is turned ON, if the
working mode is set to the breaker mode [B], a
Password input (PC220-Q180-044-K-02-A) message to inform the operator of starting in the
After the KOMATSU logo is displayed, the screen to breaker mode is displayed on the screen.
input the engine start lock password is displayed.
k If an attachment other than the breaker is
a This screen is displayed only when the engine used while the working mode is set to the
start lock function is enabled. breaker mode [B], the machine may move
a When correct password is input, the screen unexpectedly or may not operate normally or
changes to "Check before starting" screen. the hydraulic components may be damaged.
a The machine monitor has some password a After operation to check of the breaker mode is
functions other than the engine start lock. Those finished, the screen changes to "Display of
functions are independent from one another. check before starting".
If [No] is selected: Working mode is set to
economy mode [E]
If [Yes] is selected: Working mode is set to
breaker mode [B]
a The following screen may sometimes be

displayed instead of the above "Password input"
screen.
Display of check before starting (PC220-Q180-044-K-

04-A)
When the screen changes to the check before
starting screen, the check before starting is
performed for 2 seconds.
PC210LC-10 30-83
Electrical system
a If any abnormalities are detected in the check a The maintenance reminder function is enabled
before starting, the screen changes to "Warning or disabled by using the machine monitor in the
after the check before starting" screen or service mode.
"Overdue Maintenance" screen.
a If no abnormalities were detected in the check
before starting, display changes to "Working
Mode and Travel Speed Check" screen.
a The monitors (6 monitors) on the screen shows
the items currently subjected to the check before
starting.
Display of check of working mode and travel

speed (PC220-Q180-044-K-07-A)
If the check before starting is finished normally, the
screen for checking the working mode and travel
speed is displayed for 2 seconds.
a After the "Working mode and travel speed
check" screen is finished, the screen changes to
the "Standard" screen.
Display of warning after check before
starting (PC220-Q180-044-K-05-A)
If any abnormalities are detected in the check
before starting, the alarm monitor is displayed on
the screen.
a The figure shows how air cleaner clogging
monitor (a) warns of clogging on air cleaner.
Display of standard screen (PC220-Q180-044-K-08-A)

If the machine monitor starts normally, the standard
screen is displayed.
a Service meter (a) or clock is displayed in the top
center area of the screen (use [F4] to switch the
display of the service meter and clock).
Display of ending of maintenance a Right end of the screen displays ECO gauge (b)
interval (PC220-Q180-044-K-06-A) (turn on or off the display in the operator mode).
If the check before starting detected a maintenance
item that is near or overdue the set interval, the
maintenance monitor is displayed for 30 seconds to
urge the operator to perform maintenance.
a This screen is displayed only when the
maintenance reminder function is enabled. If the
remaining time of any item is 30 hours or less,
the yellow icon is displayed. If the remaining
time of any item is 0 hour or less, the red icon is
displayed.
30-84 PC210LC-10
Electrical system
When you turn the engine shutdown secondary

switch to the OFF position, the KOMATSU logo
appears once and then the display is switched to
the standard screen.
Selection of auto-deceleration (PC220-AF6C-100-K-

00-A)
While the ordinary screen is displayed, if the auto-
deceleration switch is pressed, large auto-
deceleration monitor (a) is displayed for 2 seconds
and the setting of the auto-deceleration is changed.
a Each time the auto-deceleration switch is
pressed, the auto-deceleration is changed in the
order of [ON] o [OFF] o [ON].
Display of end screen (PC220-Q180-044-K-09-A)
When starting switch is turned to OFF position, the a If the auto-deceleration is set to ON, large
end screen is displayed for 5 seconds. monitor (a) and auto-deceleration monitor (b) are
displayed simultaneously.
a Another message may be displayed on the end
screen due to the message display function of a If the auto-deceleration is set to OFF, auto-
KOMTRAX. deceleration monitor (b) goes off.
Display of operation screen for engine Selection of working mode (PC220-PT5W-100-K-01-A)

shutdown secondary switch (PC220-AKHL-100-K-00-A) Select desired working mode according to the
When you turn the engine shutdown secondary following procedure.
switch to the ON position, the “Engine Shutdown 1. While the standard screen is displayed, press
Secondary Switch Activated“ screen is displayed on the working mode selector switch, and the
every screen except the end screen. working mode selection screen is displayed.
a The engine shutdown secondary switch is a Following figure shows the working mode
provided in the lower L.H. side corner of the selection screen when "with attachment" is
operator's seat. This switch is used to stop the set. (If "with attachment" is not set in service
engine when it does not stop after the starting mode, attachment mode "ATT/P", "ATT/E"
switch is turned to the OFF position. are not displayed.)
PC210LC-10 30-85
Electrical system
2. Operate the function switches or working mode • If an attachment other than the breaker is
selector switch to select the desired working used, the machine may move unexpectedly
mode and enter the selection. or may not operate normally or the hydraulic
Function switch components may be damaged.
• [F3]: Moves to lower item • After the breaker mode is selected, the
• [F4]: Moves to upper item screen to confirm the selection of the breaker
• [F5]: Cancels selection and returns to mode is displayed (The buzzer sounds
standard screen intermittently while this screen is displayed).
• [F6]: Enters selection and returns to standard • If the setting is confirmed on this screen, the
screen screen changes to the standard screen.
Working mode selector switch If "No" is selected: Screen returns to working
• Pressed : Moves to lower item mode selecting screen
• Kept pressed : Enters selection and returns If [Yes] is selected: Working mode is set to
to standard screen breaker mode [B]
a If you do not touch any of the function
switches and working mode selector switch
for 5 seconds, the selection is determined
and the screen changes to the standard
screen.
Selection of travel speed (PC220-C6T7-100-K-00-A)

While the standard screen is displayed, if the travel
speed selector switch is pressed, large travel speed
monitor (a) is displayed for two seconds and the
setting of the travel speed is changed.
3. When the ordinary screen is displayed again,
large working mode monitor (a) is displayed for 2 a Travel speed setting sequentially changes
seconds, and then the setting of the working between [Lo] o [Mi] o [Hi] o [Lo] in this order
mode is changed to the selected mode. every time the switch is pressed.
a When large monitor (a) is displayed, the a When large monitor (a) is displayed, the display
display of working mode monitor (b) is of travel speed monitor (b) is changed, too.
changed, too.
Operation to stop alarm buzzer (PC220-Q576-100-K-

<Precautions for selecting breaker mode [B]> 00-A)
• If breaker mode [B] is selected, both of the While the alarm buzzer is sounding, if the alarm
control of the hydraulic pump and the setting buzzer cancel switch is pressed, the alarm buzzer
of the hydraulic circuit are changed. stops.
30-86 PC210LC-10
Electrical system
a Even if the alarm buzzer cancel switch is

pressed, the screen display does not change.
Operation of windshield wiper (PC220-K751-100-K-00-

A)
While the ordinary screen is displayed, if the wiper
switch is pressed, large wiper monitor (a) is
displayed for 2 seconds and the wiper starts or
stops.
a The window washer does not operate if the
window limit switch is "ON".
a The wiper setting changes sequentially between
[INT] o [ON] o [OFF] o [INT] every time you
press the switch. Operation to display camera mode (PC220-Q16A-
100-K-00-A)
a When the wiper is set to INT or ON, large When [F3] is pressed, the multi-display changes to
monitor (a) is displayed and the display of wiper the camera image (Set the connection of the
monitor (b) is changed at the same time. camera in the service mode).
a If the wiper is set to OFF, large monitor (a) is not
displayed and the wiper monitor disappears.
a Up to three cameras can be connected.

However, if the camera mode is selected, only
the image of camera 1 is always displayed.
Operation of window washer (PC220-K7DA-100-K-00-
A)
While the ordinary screen is displayed, if the
window washer switch is pressed, the washer fluid
is splashed only while the switch is held down.
a Even if the window washer switch is pressed,
the screen display does not change.
Operation of air conditioner/heater (PC220-K500-

100-K-00-A)
While the standard screen is displayed, if the air
conditioner switch is pressed, "Air-conditioner
Setting" screen is displayed.
a While "Air-conditioner Setting" screen is
displayed, if you do not touch any switch for 5 a If any caution occurs in the camera mode, the
seconds, the screen changes to the standard corresponding caution monitor is displayed at
screen. the left top of the screen (excluding the low
hydraulic oil temperature caution).
PC210LC-10 30-87
Electrical system
Check of maintenance information (PC220-Q1C2-

100-K-00-A)
You can check the maintenance information on the
maintenance screen by pressing [F6] while the
maintenance monitor is displayed.
When the maintenance monitor does not appear,
press [F6] and then press [F1] or [F2]. Then make
sure the display is switched to the maintenance
screen.
a If no control lever is operated for 10 seconds

while a failure enough to display user code is
occurring in the camera mode, the screen
returns to the standard screen and displays
information about that failure.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
a As 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side a To reset the remaining time after finishing
of the screen and the image of camera 2 is maintenance, more operations are necessary.
displayed on the right side.
The image of camera 3 is displayed only singly.
a If 2-camera image display operation is made, the
images are displayed frame by frame at intervals
of approximately 1 second on the right and left
side of the screen.
Operation to display clock and service

meter (PC220-Q1MA-100-K-00-A)
While the standard screen is displayed, if [F4] is
pressed, the service meter and the clock are
displayed alternately in section (a).
a When selecting the clock display, perform the
time adjustment, 12-hour or 24-hour display Setting and display of user mode (including
setting, and summer time setting by using the KOMTRAX messages for user) (PC220-Q1C3-100-K-
02-A)
user mode functions.
To enter the user mode, press [F6] to display the
"User Menu" screen while the standard screen is
displayed.
30-88 PC210LC-10
Electrical system
a The User Menu has following menus.

ECO Guidance
Machine setting
KDPF regeneration
Maintenance
Monitor setting
Check mail
[KOMTRAX message]
• There are two types of KOMTRAX message;
one is for the user and the other is for the
technician.
• For user: • Guidance on deterrence of hydraulic relief
It denotes the messages transmitted from the If relieving lasts for 3 or more seconds during
KOMTRAX base station to users. Upon operation, guidance on deterrence of hydraulic
receiving a message, the message monitor is relief is displayed on the monitor.
displayed on the standard screen. Operate this
"Check mail" when viewing contents of a a The lamp for the guidance on deterrence of
message. hydraulic relief goes out automatically after
• For technician: 10 seconds has passed since it appeared, or
It refers to the messages transmitted to the if the function switch [F5] is pressed.
technicians from the KOMTRAX base station.
When a message is received, the standard
screen does not display any information relevant
to the message received. To view contents of a
message, operate "Display service message" of
the service menu in the service mode.
Display of ECO guidance (PC220-Q1L3-100-K-00-A)

When the machine is set in a certain operating
condition, the ECO Guidance screen is displayed
automatically to urge the operator to perform the
energy-saving operation.
a "ECO Guidance" screen is displayed when the
following conditions are met while this display • E-mode recommendation guidance
function is set to enabled in operator mode. If light-load work continues for 10 or more
minutes in P- or ATT/P-mode, E-mode
a Conditions for display:
recommendation guidance is displayed. This
• Idle stop guidance function helps reduce unnecessary fuel
If no lever is operated for a period of at least 5 consumption by alerting the operator to turn on
minutes and the engine keeps running at idle E-mode.
speed during this period, the guidance on idle
stop is displayed on the monitor. This function
helps reduce unnecessary fuel consumption by
alerting the operator to stop the engine while
waiting for the next operation, or during a break.
a The lamp for the idle stop guidance goes out
automatically when the lever operation is
resumed, or if the function switch [F5] is
pressed.
PC210LC-10 30-89
Electrical system
a The lamp for the E-mode recommendation a The lamp for the low fuel level guidance goes
guidance goes out automatically after 10 out automatically after 10 seconds has
seconds has passed since it appeared, or if passed since it appeared, or if the function
the function switch [F5] is pressed. switch [F5] is pressed.
• Travel partial recommendation guidance

If machine travel in the travel mode Hi and the Display of caution monitor (PC220-Q1FC-044-K-00-A)
fuel control dial at MAX continues for 2 or more If an error that is serious enough to display Action
minutes, the travel partial recommendation Level "L01" alarm monitor on the standard screen or
guidance is displayed. When traveling the camera mode screen occurs, a large alarm monitor
machine for a long period of time, moving the is displayed on the screen once and is continuously
fuel control dial from MAX to a lower position shown in window (a).
helps reduce fuel consumption. a On the camera mode screen, the alarm monitor
a The lamp for the travel partial flashes at the left upper of the screen when a
recommendation guidance goes out caution is issued.
automatically after 10 seconds has passed
since it appeared, or if the function switch
[F5] is pressed.
If an error serious enough to display a alarm monitor

of Action Level [L02], [L03] or [L04] occurs, the
alarm monitor is displayed at the center of the
• Low fuel level guidance monitor screen until the error is eliminated.
If the amount of time the machine can be
operated that is projected from the remaining
fuel level and the latest average fuel
consumption drops to less than 8 hours, the low
fuel level guidance is displayed.
30-90 PC210LC-10
Electrical system
Displaying KDPF regeneration (PC200_10-A9H0-251-

K-00-A)
1. KDPF regeneration
k During the KDPF regeneration, the

exhaust temperature may become higher
than that of the former models. To prevent
being burnt, do not stand near the
exhaust pipe. In addition, to prevent a fire,
do not bring any combustible matter near
the exhaust pipe outlet.
k If there is a thatched roof, dead leaves,

paper, or other combustible matter near The KDPF regeneration is performed
the machine, set KDPF regeneration to automatically in the normal state, but the soot
stop to prevent a fire caused by the high- may not be burnt or the filtering function may not
temperature exhaust gas during the KDPF be recovered sufficiently, depending on the
regeneration. For the setting procedure, operating condition. Since KDPF soot
see the Operation and Maintenance accumulation monitor (2) lights up in this case,
Manual. stop the machine in a safe place and perform
the manual stationary regeneration process. For
KDPF (Komatsu Diesel Particulate Filter) is a
the execution procedure, see the Operation and
device used to capture soot in exhaust gas and
Maintenance Manual.
purify the gas. If any soot has accumulated to a
certain level inside the filter, it is burnt
automatically to keep the KDPF performance
high. This purification process is called
"regeneration".
If an operation that may lower the filtering
function of the KDPF has continued for a long
period of time, the regeneration may be
performed to protect the KDPF system,
regardless of the accumulated soot.
2. Manual stationary regeneration

There are 2 levels of monitor displays to request
the manual stationary regeneration, depending
on the degree of emergency.
k If the work is continued while the red

KDPF soot accumulation monitor (2) is
displayed, the KDPF or engine may
encounter a problem. If KDPF soot
During the KDPF regeneration, KDPF accumulation monitor (2) lights up, be
regeneration monitor (1) lights up in the standard sure to perform the manual stationary
screen. regeneration process.
a Even if KDPF regeneration monitor (1) lights 1) When the degree of emergency is low
up, the machine does not need to be stopped If KDPF soot accumulation monitor (2) is
and the operator can continue work normally, yellow (Action level (3): L01), the following
as long as the alarm monitor is not displayed screen is displayed first.
at the center of the standard screen.
PC210LC-10 30-91
Electrical system
k If the work is continued without

performing the manual stationary
regeneration and the soot quantity
exceeds the allowable limit, action
level monitor "L04" lights up and the
machine needs to be repaired.
The action level goes off in 2 seconds and

the following standard screen appears.
a If KDPF soot accumulation monitor (2) is

red, the engine maximum output and
maximum speed are limited to protect the
engine and KDPF system.
If KDPF soot accumulation monitor (2) is red
(Action level (3): L03), the following screen is
displayed.
If the lock lever is set to the LOCK position or

all the work equipment control levers are set
in NEUTRAL, the "KDPF Regeneration"
screen is displayed once for every 2 hours
after the occurrence. However, if the manual
stationary regeneration operation is not
performed, the screen returns to the
standard screen after 30 seconds.
If the lock lever is set to the LOCK position or

all the work equipment control levers are set
in NEUTRAL, the "KDPF Regeneration"
screen is displayed after 3 seconds. Then,
until the manual stationary regeneration
process is performed, the "KDPF
Regeneration" screen or the standard screen
with the alarm monitor lighted is displayed
automatically according to the position of the
lever.
a If KDPF soot accumulation monitor (2) is
yellow, stop the work, and then stop the
machine in a safe place and perform the
manual stationary regeneration process.
2) When the degree of emergency is high
30-92 PC210LC-10
Electrical system
a If KDPF soot accumulation monitor (2)

becomes red, immediately stop the
machine in a safe place and perform the
manual stationary regeneration process.
PC210LC-10 30-93
Electrical system
Display of action level and failure code (PC220-Q1FC-100-K-00-A)

If an abnormality that displays an action level and a a Since “Error List“ cannot be displayed from the
failure code occurs on the standard screen or screen on which the camera mode is displayed,
camera mode screen, the alarm monitor lights up. move to “Error List“ from the standard screen
side.
If the alarm monitor lights up, press function switch

[F5] to display the “Error List“.
• [F1]: Moves selection to next page (screen)
(when displayed)
• [F2]: Moves selection to previous page (screen)
(when displayed)
• [F5]: Returns to the standard screen
On the “Error List“ screen, the following information
is displayed.
(a): Alarm monitor
(b): Action level (3 digits)
(c): Failure code (5 or 6 digits)
(d): Failure code name
(e): Message
(f): Telephone No. (if registered)
a This screen appears only when a trouble (failure
code) for which an action level is set occurs.
a The telephone number is displayed only when
the telephone number is registered in the
service mode.
a If multiple troubles occur simultaneously, all the
codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the "Abnormality Record" in
the service mode, check the details in the
service mode.
a “Error List“ is replaced with the standard screen
automatically after 30 seconds.
30-94 PC210LC-10
Electrical system
a Remedies requested to operator by displayed action levels (The following table is an excerpt from the
"Operation and Maintenance Manual".)
Degree of
Action level Buzzer Alarm monitor Remedy
urgency
Stop immediately and perform
Q checking and maintenance.
High L04 Q
(Continuous) Ask your Komatsu distributor for
testing and repair services.
Stop work, move machine to safe
place, stop it, and perform checking
Q
L03 Q and maintenance.
(Intermittent)
Ask your Komatsu distributor for
testing and repair services.
I Stop the work, and then run the
engine at medium speed with no
Q load or stop it. If the condition is not
L02 Q
(Intermittent) improved, ask your Komatsu
distributor for testing and repair
services.
Some functions are restricted, but
the machine can operate. After
L01 finishing work, perform checking
Low (For 2 seconds ― Q and maintenance.
only) Ask your Komatsu distributor to
perform testing or repairs as
necessary.
PC210LC-10 30-95
Electrical system
Function of checking display of LCD (Liquid

Crystal Display) (PC-Q1LE-100-K-00-A)
While the standard screen is displayed, if the
numeral input switches or function switches are
operated in the following manner, the entire LCD
screen turns white.
• Switch operations (simultaneous): [4] + [F2]
a When finishing the operation of the switches,
release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a To return to the former screen, press any one of
the function switches. Function of Usage Limitation Setting/ Change
Reference: An LCD panel, as one of its
Password (PC220-Q19X-100-K-00-A)
Selecting the Usage Limitation Setting displays the
characteristics, sometimes shows black spots
password input screen when you proceed to setting
(spots that remain unlit) and bright spots (spots that
of the circuit breaker or attachment, or maintenance
do not go off).
resetting. Set the usage limitation according to the
If the number of the bright points and black points following procedure.
does not exceed 10, the LCD panel is not faulty or
1. While the standard screen is displayed, perform
defective.
the following operation by using the numeral
input switches.
• Switch operation (Press the switches in order
while pressing [4])
[4]+[5]o[5]o[5]
a This operation of the switches is not
accepted until 10 minutes elapse after the
starting switch is turned to the ON position.
Function of checking service meter (PC-Q1MB-

100-K-00-A)
When checking the service meter with the starting
switch in the OFF position, operate the numeral
input switches as follows to display only the service
meter section.
• Switch operations (simultaneous): [4] + [1]
a There is some time lag in start of the LCD, so 2. After the “Usage Limitation Password“ screen is
hold down the switches until the service meter is displayed, input the current password by using
displayed. the numeral input switches and confirm it by
a If you release one of the switches, the monitor using the function switch.
goes off. • [F5]: Deletes input numbers/ Returns to
Reference: After the machine monitor is used standard screen
continuously over a long period of time, blue points • [F6]: Enters input password
(points that remain lit) may appear on this screen. It a Default password: [000000]
does not indicate that the LCD panel is faulty or
defective. a When the input password is correct, the
screen changes to the next screen.
30-96 PC210LC-10
Electrical system
a When the input password is incorrect, the

message to request inputting the password
again is displayed.
a The password for the Usage Limitation and

the engine start lock password are not
identical.
3. After the “Usage Limitation Setting“ screen is 4. Changing a password
displayed, select a setting by using the function After the “Usage Limitation New Password
switch. Input“ screen is displayed, input the new
• [F3]: Moves to lower item password by using the numeral input switches
• [F4]: Moves to upper item and confirm it by using the function switch.
• [F5]: Cancels the selection and returns the • [F5]: Deletes input numbers/ Returns the
display to the previous screen display to the preceding screen
• [F6]: Enters selection • [F6]: Enters input password
a Default password: [000000]
a When the input password is correct, the
screen changes to the next screen.
a When the input password is incorrect, the
message to request inputting the password
again is displayed.
a Set a new password of four to six digits (If it
has only three or less digits or has seven or
more digits, it is not accepted).
Selection of use/non-use of Usage limitation

After the “Usage Limitation ON/OFF“ screen is
displayed, select a setting by using the function
switch.
• Non-use: Password input screen is not
displayed
• ON: The password input screen for setting of
the circuit breaker or attachment, or
maintenance resetting appears.
• [F3]: Moves to lower item
• [F4]: Moves to upper item
• [F5]: Cancels the selection and returns the After the “Usage Limitation New Password
display to the previous screen Input“ screen is displayed once more, input the
• [F6]: Enters selection new password for the second time by using the
numeral input switches and confirm it by using
the function switch.
• [F5]: Deletes input numbers/ Returns to
standard screen
• [F6]: Enters input password
PC210LC-10 30-97
Electrical system
a If the input password is different from the one

input before, the message to request
inputting again is displayed.
If the standard screen is displayed after the

screen to notify completion of setting is
displayed, the password is changed successfully.
30-98 PC210LC-10
Electrical system
Service mode (PC220-Q194-100-K-00-A) a The menu items which can be selected in the
To change the mode of the machine monitor to the service menu are as follows (including some
service mode from the operator mode, perform the items which need special operations).
following operation. Monitoring / Pre-defined(PAGE
This operation is always required when you use the 01 30-100)
service mode. 02 Monitoring(PAGE 30-105)
1. Check of screen display and operation of Abnormality record (mechanical
switches systems)(PAGE 30-114)
03
While the standard screen is displayed, perform Abnormality record (electrical
the following operation by using the numeral systems)(PAGE 30-115)
input switches. Maintenance Record(PAGE 30-
04 116)
• Operation of switches (While pressing [4],
press the switches in order): Maintenance Mode Setting
[4]＋[1] o [ 2 ] o [ 3 ] 05
(PAGE 30-117)
a This operation of the switches is accepted Phone number entry(PAGE 30-
06 120)
only while the standard screen is displayed.
Default (Key-on Mode)(PAGE
30-120)
Default value setting (Unit)
07 (PAGE 30-121)
Default (With/Without
Attachment)(PAGE 30-122)
Default (Camera)(PAGE 30-123)
Testing (Cylinder Cut-out
operation)(PAGE 30-124)
Testing (Regeneration for
08 Service)(PAGE 30-125)
Testing (KDPF Memory Reset)
(PAGE 30-127)
2. Selection of service menu Adjustment (Pump Absorption
Torque (F))(PAGE 30-128)
When the "Service Menu" screen is displayed,
the service mode is selected. Select the desired Adjustment (Pump Absorption
service menu by using the function switches or Torque (R))(PAGE 30-128)
numeral input switches. Adjustment (travel low speed
• [F3]: Moves to lower item setting)(PAGE 30-129)
• [F4]: Moves to upper item Adjustment (Attachment Flow
• [F5]: Returns the display to the standard Adjustment)(PAGE 30-130)
screen (operator mode) Adjustment (F pump swash plate
• [F6]: Validates the selection sensor calibration)(PAGE 30-
132)
a If you input a 2-digit code by using the Adjustment (R pump swash plate
numeral input switches, the corresponding 09 sensor calibration)(PAGE 30-
menu is directly selected. This will allow you 137)
to validate the selection using [F6].
Adjustment (Pump calibration:
Matching speed calibration)
(PAGE 30-142)

Matching speed check)(PAGE
30-138)
Restore default value)(PAGE 30-
143)
10 No Injection(PAGE 30-143)
KOMTRAX Settings (Terminal
11 Status)(PAGE 30-144)
PC210LC-10 30-99
Electrical system
KOMTRAX Settings (GPS and

Communication Status)(PAGE
30-145)
KOMTRAX Settings screen
(Modem Status)(PAGE 30-146)
12 Service Message(PAGE 30-146)
30-100 PC210LC-10
Electrical system
Monitoring / Pre-defined (PC220-Q1S1-100-K-00-A)

The machine monitor can monitor the condition of
the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which control them.
In the monitoring / pre-defined, monitoring items
that are used frequently in daily work are selected
beforehand.
1. Selecting the menu
Select "Monitoring / Pre-defined" on the "Service
Menu" screen.
2. Check of monitoring / pre-defined information

After the "Monitoring / Pre-defined" screen is
displayed, you can check the items displayed in
the troubleshooting support by using the function
switches.
• [F1]: Moves to the next page (screen)
• [F2]: Moves to the previous page (screen)
• [F4]: Selects hold or its releasing
(If hold is selected, a diagonal line is
displayed on the HOLD portion)
• [F5]: Returns to service menu screen
a You can select and check any items not
displayed in "Monitoring / Pre-defined" from
the "Monitoring items".
a If the working mode is changed to breaker

mode [B], the screen to confirm the change
of the setting is displayed as in changing the
working mode on the standard screen.
PC210LC-10 30-101
Electrical system
List of monitoring / pre-defined items (SI unit indicates the default values)
Support screen (1/14) Machine basic items
Applicable
No. ID Item name Unit (SI)
equipment
1 01002 Engine speed r/min ENG
2 04107 Coolant temperature °C ENG
3 37212 Engine oil switch ENG
4 18400 Intake temperature °C ENG
5 04401 Hydr. oil temperature °C PUMP
Battery power
6 03203 supply V ENG
Support screen (2/14) Fuel injection

Applicable
equipment
KDOC 1 inlet
2 47300 temperature °C ENG
3 36400 Rail pressure MPa ENG
Rail pressure
4 36200 MPa ENG
command
5 48000 IMV current A ENG
IMV current
6 48001 A ENG
command
Support screen (3/14) EGR,KVGT actuator
Applicable
equipment
2 48100 Turbo speed r/min ENG
3 18100 EGR Valve Position mm ENG
EGR solenoid
4 48600 mA ENG
current
5 48700 KVGT position mm ENG
KVGT solenoid
6 48800 mA ENG
current
Support screen (4/14) Engine temperature-related items
Applicable
equipment
3 04107 Coolant temperature °C ENG
4 18400 Intake temperature °C ENG
5 18500 Charge temperature °C ENG
EGR orifice
Support screen (5/14) Air intake/exhaust pressure, etc.

Applicable
equipment
2 37400 Ambient pressure kPa ENG
3 36500 Charge pressure-A kPa ENG
Exhaust manifold
4 48300 pressure kPa ENG
30-102 PC210LC-10
Electrical system
Support screen (5/14) Air intake/exhaust pressure, etc.

Applicable
equipment
6 48200 Mass air flow kg/min ENG
Support screen (6/14) Post treatment-related items
Applicable
equipment
KDPF outlet
KDPF delta
KDPF 1 outlet
KDOC 1 inlet
KDOC 1 outlet
6 36400 Rail pressure MPa ENG
Support screen (7/14) Engine-related items
Applicable
equipment
2 37212 Engine oil switch ENG
3 48400 Crankcase pressure kPa ENG
KDOC 1 inlet
5 36500 Charge pressure-A kPa ENG
Support screen (8/14) F & R pumps basic items
Applicable
equipment
2 01100 F pump pressure MPa PUMP
3 01101 R pump pressure MPa PUMP
PC-EPC sol current
4 01300 (F) mA PUMP
PC-EPC sol current
5 01302 (R) mA PUMP
Support screen (9/14) F & R pumps application items
Applicable
equipment
F pump
4 01137 dispalcement cc/rev PUMP
R pump
PC210LC-10 30-103
Electrical system
Support screen (10/14) F pump application items

Applicable
equipment
Service pressure
3 01141 MPa PUMP
sensor
PC-EPC sol current
4 01300 (F) mA PUMP
F pump
6 01500 LS-EPC sol current mA PUMP
Support screen (11/14) R pump application items
Applicable
equipment
Service pressure
3 01141 MPa PUMP
sensor
PC-EPC sol current
4 01302 (R) mA PUMP
R pump
6 01500 LS-EPC sol current mA PUMP
Support screen (12/14) PPC pressure
Applicable
equipment
Boom raise PPC
2 07400 pressure MPa PUMP
Boom Lower PPC
3 07500 MPa PUMP
Pressure
Arm Curl PPC
4 07200 MPa PUMP
Pressure
Arm Dump PPC
Applicable
equipment
Swing right PPC
Swing left PPC
Bucket CURL PPC
4 07300 MPa PUMP
Pressure
Bucket DUMP PPC
Applicable
equipment
Travel Fwd LH PPC
30-104 PC210LC-10
Electrical system

Applicable
equipment
Travel Fwd RH PPC
Travel Rev LH PPC
Travel Rev RH PPC
PC210LC-10 30-105
Electrical system
Monitoring (PC220-Q19L-100-K-00-A) a Up to six monitoring items are selectable at a

The machine monitor can monitor the condition of time. However, the items may not be set up
the machine in real time by receiving signals from to six depending on the form of display of the
various switches, sensors, and actuators installed to selected item.
various parts of the machine and the information
from the controllers which is controlling switches,
etc. The monitoring function allows you to select a
desired monitoring item.
1. Selecting menu
Select “Monitoring/Custom“ on “Service Menu“
screen.
3. Deciding monitoring items

After selecting monitoring items, execute
monitoring with the function switch or numeral
input switch.
a Execution with function switch: Double click
or keep pressing [F6] (for approximately 2
seconds).
2. Selecting monitoring item
After the “Monitoring Selection Menu“ screen is a Execution with numeral input switch: Input
displayed, select items to be monitored by using [99999] and press [F6].
the function switches or numeral input switches. a When monitoring only two items, for example,
• [F1]: Moves selection to the left item select them and confirm with [F6]. If [F6] is
• [F2]: Moves selection to the right item pressed once more at this time, monitoring is
• [F3]: Moves selection to the below item executed.
• [F4]: Moves selection to the above item
• [F5]: Clears input numbers/ Returns the a If monitoring items are selected up to the limit
display to the service menu screen number, monitoring is executed
• [F6]: Enters selection automatically.
a In setting of the monitoring, each time

function switch [F2] is pressed, sequential
switching among [ENG] o [KDPF] o
[PUMP] o [MON] o [ENG] takes place in
this order. (Pressing [F1] induces the
sequential switching in the reverse order.)
a Selection with function switches: Select an
applicable equipment by using [F1] or [F2],
select an item by using [F3] or [F4], and then
enter it by using [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is
selected directly. Enter that item by using 4. Performing monitoring
[F6]. After the “Monitoring“ screen is displayed,
perform the necessary operation of the machine
a If the color of the selected box changes from and check the monitoring information.
yellow to red, the selection of the item of that
box is entered. a Monitoring information is indicated by value,
ON/OFF, or special display.
30-106 PC210LC-10
Electrical system
a The unit of display can be selected in SI unit,

metric unit, or inch unit with the Default
function in the service mode.
a When the working mode is changed to

breaker mode [B], the screen to confirm the
change of the setting is displayed as in
5. Holding monitoring information changing the working mode on the standard
You can hold and release holding of the screen.
monitoring information by using the function
switches.
• [F4]: Selects hold or releasing hold
(If the Hold is selected, the HOLD portion is
hatched.)
• [F5]: Returns the display to monitoring
selection menu screen
7. Saving of monitoring item

A function switch lets you save and delete the
selected monitoring item.
• [F1]: MEMORY
• [F2]: CLEAR
6. Changing machine setting mode

To change the setting of the working mode,
travel speed, or auto-deceleration during
monitoring, operate the corresponding switch
under the current condition, and the
corresponding mode is selected.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after
monitoring is finished.
a When you saved a monitoring item, selecting

"Monitoring" again displays the screen that
confirms whether you want to display the
once saved item.
a When an item is saved, it can be displayed
as many times as required unless it is
cleared.
PC210LC-10 30-107
Electrical system
a If another item is saved while having the

previous item saved, the previously saved
item is overwritten by the latest one.
a The saved monitoring item is cleared by
using [F2]. It is also cleared when the
selection is entered by using [F6] in the
following screen.
• KOMTRAX terminal screen
• "With/Without Attachment" screen
• Functional specification screen
• Air conditioner setting screen
30-108 PC210LC-10
Electrical system
Monitoring items table (PC220-Q19L-208-K-00-A)
Monitoring item Unit (Default: SI) Equipment

Code No. (Displayed on screen) in charge Remarks
SI Metric Imperial
01002 Engine speed r/min rpm rpm ENG
04107 Coolant temperature ℃ ℃ °F ENG
48000 IMV current A A A ENG
48001 IMV current command A A A ENG
03203 Battery power supply V V V ENG
37212 Engine oil switch ON • OFF ENG
36400 Rail pressure MPa kg/cm2 psi ENG
37400 Ambient pressure kPa kg/cm2 psi ENG
18400 Intake temperature °C °C °F ENG
18500 Charge temperature °C °C °F ENG
Display in
absolute
value
36500 Charge pressure-A kPa kg/cm2 psi ENG (including
ambient
pressure)
48100 Turbo speed r/min rpm rpm ENG
48200 Mass air flow kg/min kg/min lb/min ENG
Exhaust manifold
48300 kPa kg/cm2 psi ENG
pressure
48400 Crankcase pressure kPa kg/cm 2 psi ENG
18100 EGR Valve Position mm mm in ENG
48500 EGR orifice temperature °C °C °F ENG
48600 EGR solenoid current mA mA mA ENG
48700 KVGT position mm mm in ENG
48800 KVGT solenoid current mA mA mA ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
Throttle position sensor
03000 V V V ENG
volt
04105 Coolant temp sensor volt V V V ENG
Ambient pressure sensor
37401 V V V ENG
volt
18401 Intake temp sensor volt V V V ENG
18501 Charge temp sensor volt V V V ENG
Charge pressure sensor
36501 V V V ENG
volt
36401 Rail pressure sensor volt V V V ENG
Exh manifold press. sens
48301 V V V ENG
volt
Crankcase pressure sens
48401 V V V ENG
volt
EGR valve pos sensor
18101 V V V ENG
volt
EGR orifice temp sens
48501 V V V ENG
volt
48701 KVGT position sensor volt V V V ENG
17500 Engine power mode - ENG
48900 Engine operation mode - ENG
08402 Selection of droop switch - ENG
31701 Throttle Position % % % ENG
31706 Final throttle position % % % ENG
18600 Inject fueling command mg/st mg/st mg/st ENG
PC210LC-10 30-109
Electrical system

SI Metric Imperial
36200 Rail pressure command MPa kg/cm2 psi ENG
37300 Fuel rate (Note 1) l/h l/h gal/h ENG
WIF: Water
18800 Water in fuel ON • OFF ENG
In Fuel
20216 ECM build version - ENG
20217 Calibration data version - ENG
18900 ECM internal temp °C °C °F ENG
20400 ECM S/N - ENG
47000 KDPF outlet pressure kPa kg/cm2 psi KDPF
KDPF out pressure
47001 V V V KDPF
sensor volt
47100 KDPF delta pressure kPa kg/cm2 psi KDPF
KDPF delta press. sensor
47101 V V V KDPF
volt
47300 KDOC 1 inlet temperature °C °C °F KDPF
KDOC 1 inlet temp sens
47301 V V V KDPF
volt
KDOC 1 outlet
47400 temperature °C °C °F KDPF
KDOC 1 outlet temp sens
47401 V V V KDPF
volt
KDPF 1 outlet
47200 temperature °C °C °F KDPF
KDPF 1 outlet temp sens
47201 V V V KDPF
volt
47500 Dozing fuel rate l/h l/h gal/h KDPF
47700 Soot level estimation g/L g/L g/gal KDPF
47800 Ash level estimation g/L g/L g/gal KDPF
2nd Eng. Speed rpm rpm
01601 r/min PUMP
Command
01100 F pump pressure MPa kg/cm2 psi PUMP
01101 R pump pressure MPa kg/cm2 psi PUMP
07400 Boom raise PPC pressure MPa kg/cm2 psi PUMP
Boom Lower PPC kg/cm2 psi
07500 MPa PUMP
Pressure
07200 Arm Curl PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm Dump PPC pressure MPa kg/cm2 psi PUMP
Bucket CURL PPC kg/cm2 psi
07300 MPa PUMP
Pressure
Bucket DUMP PPC
07301 MPa kg/cm2 psi PUMP
pressure
09001 Swing left PPC pressure MPa kg/cm2 psi PUMP
09002 Swing right PPC pressure MPa kg/cm2 psi PUMP
Travel Fwd LH PPC
pressure
Travel Fwd RH PPC
pressure
Travel Rev LH PPC
pressure
Travel Rev RH PPC
pressure
01137 F pump dispalcement cc/rev cc/rev cc/rev PUMP
F pump sw plate sensor
01138 V V V PUMP
volt
01139 R pump dispalcement cc/rev cc/rev cc/rev PUMP
30-110 PC210LC-10
Electrical system

SI Metric Imperial
R pump sw plate sensor
01140 V V V PUMP
volt
04401 Hydr. oil temperature °C °C °F PUMP
01300 PC-EPC sol current (F) mA mA mA PUMP
01302 PC-EPC sol current (R) mA mA mA PUMP
01500 LS-EPC sol current mA mA mA PUMP
Merge-divide sol current
08000 mA mA mA PUMP
main
Merge-divide sol current
08001 mA mA mA PUMP
LS
01700 Attachment sol current mA mA mA PUMP
03200 Battery voltage V V V PUMP
04402 Hydr. temp. sensor volt V V V PUMP
2nd Eng. Speed
01602 % % % PUMP
Command
Main Pump Absorb
13113 Nm kgm lbft PUMP
Torque
15900 Boom Bottom Pressure MPa kg/cm2 psi PUMP
01141 Service pressure sensor MPa kg/cm2 psi PUMP
Swing ON • OFF PUMP
Travel ON • OFF PUMP
Boom Lower ON • OFF PUMP
Pressure
01900 Boom Raise ON • OFF PUMP
Switch 1
Arm curl (IN) ON • OFF PUMP
Arm dump
(OUT) ON • OFF PUMP
Bucket Curl ON • OFF PUMP
Bucket
Dump ON • OFF PUMP
Pressure
01901
Switch 2 Service ON • OFF PUMP
Travel
steering ON • OFF PUMP
Travel
ON • OFF PUMP
Junction
Swing brake ON • OFF PUMP
Merge-
Solenoid ON • OFF PUMP
02300 divider
valve 1
2-stage
ON • OFF PUMP
Relief
Travel
Speed ON • OFF PUMP
Swing
pressure cut ON • OFF PUMP
off
Solenoid Service
02301 ON • OFF PUMP
valve 2 Return
Variable
back press ON • OFF PUMP
Lever Sw. ON • OFF PUMP
Swing
Switch Input Release ON • OFF PUMP
02200
1 SW.
Swing brake
ON • OFF PUMP
SW.
PC210LC-10 30-111
Electrical system

SI Metric Imperial
Model select
ON • OFF PUMP
1
Model select
ON • OFF PUMP
2
Model select
ON • OFF PUMP
Switch Input 3
02201
2 Model select
ON • OFF PUMP
4
Model select
ON • OFF PUMP
5
Overload
ON • OFF PUMP
Alarm
Switch Input Key switch
02202 (ACC) ON • OFF PUMP
3
Switch Input Lock Lever
02203 ON • OFF PUMP
4 SW
Window
ON • OFF PUMP
Switch Input Limit SW.
02204 P Limit SW. ON • OFF PUMP
5
W Limit SW. ON • OFF PUMP
20229 Pump controller Ass'y P/N - PUMP
20403 Pump controller Serial No. - PUMP
20230 Pump controller prog. P/N - PUMP
Pump controller prog. -
20212 PUMP
version
04300 Battery charge volt V V V MON
04200 Fuel level sensor volt V V V MON
Key switch ON • OFF MON
Start ON • OFF MON
Monitor Preheating ON • OFF MON
04500 Input 1 Light ON • OFF MON
Radiator
ON • OFF MON
coolant level
Aircleaner ON • OFF MON
Monitor Eng. oil level ON • OFF MON
04501 Input 2 Battery
charge volt ON • OFF MON
Swing brake
ON • OFF MON
Sw.
Engine
Monitor shutdown
04502 Input 3 ON • OFF MON
secondary
switch
Seat belt
ON • OFF MON
Sw.
F1 ON • OFF MON
F2 ON • OFF MON
Monitor F3 ON • OFF MON
04503 Function
Switches F4 ON • OFF MON
F5 ON • OFF MON
F6 ON • OFF MON
30-112 PC210LC-10
Electrical system

SI Metric Imperial
SW1 ON • OFF MON
SW2 ON • OFF MON
Monitor 1st SW3 ON • OFF MON
04504 & 2nd Row
Switches SW4 ON • OFF MON
SW5 ON • OFF MON
SW6 ON • OFF MON
SW7 ON • OFF MON
SW8 ON • OFF MON
Monitor 3rd SW9 ON • OFF MON
04505 & 4th Row
SW11 ON • OFF MON
SW12 ON • OFF MON
Monitor 5th SW13 ON • OFF MON
04506 Row SW14 ON • OFF MON
20227 Monitor Ass'y P/N - MON
20402 Monitor serial No. - MON
20228 Monitor prog. P/N - MON
20200 Monitor prog. version - MON
55300 Aircon compressor status ON • OFF MON
55000 Aircon outside temp. code - MON
55100 Aircon inside temp. code - MON
55200 Aircon mode data(mon) - MON
Aircon mode data(aircon
55201 - MON
ECU)
Only when
20260 KOMTRAX Ass'y P/N - MON KOMTRAX
is used
Only when
20418 KOMTRAX Serial No - MON KOMTRAX
is used
Only when
20261 KOMTRAX Prog. P/N - MON KOMTRAX
is used
Only when
ID Key Controller Ass'y P/ -
20262 MON ID key is
N
used
Only when
ID key controller Serial -
20419 MON ID key is
No.
used
Only when
ID Key Controller Prog. P/ -
20263 MON ID key is
N
used
a Listing order of monitoring items in table

The monitoring items are listed in the order of display on the Monitoring selection menu screen for
monitoring item selection.
a Unit
The display unit can be set to SI, meter, or inch as required (select a desired unit from "Unit" of "Default").
mg/st in the display unit is an abbreviation for milligram/stroke.
PC210LC-10 30-113
Electrical system
a Equipment in charge
ENG: The engine controller detects monitoring information.
KDPF: Engine controller is in charge of detecting monitoring information.
PUMP: The pump controller detects monitoring information.
MON: The machine monitor detects monitoring information.
Note 1: Fuel Rate (Code No. : 37300) is theoretical fuel consumption ratio. (Since it is a theoretical value,
there is some differences between the actual fuel consumption ratio).
30-114 PC210LC-10
Electrical system
Abnormality record (mechanical (a) Occurrence order of abnormalities from latest

systems) (PC220-Q1S2-100-K-00-A) one/Total number of records
The machine monitor logs the past and currently (b): Failure code
occurring failures classifying them into the (c): Detail of failure
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the mechanical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
a For the failure code list, see "40 Failure code list (when displayed)
for troubleshooting". • [F2] Moves selection to previous page
1. Selecting menu (screen) (when displayed)
Select “Abnormality Record“ on “Service Menu“ • [F5]: Returns the display to "Abnormality
screen. Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a In the mechanical systems abnormality
record screen, up to 50 cases currently
stored are displayed.
a If the number of occurrence is 1 (first
occurrence), the service meter reading at the
first occurrence and that at the last
occurrence are the same.
When the latest service meter reading is
recovered, the value at the recovery time is
2. Selecting sub menu displayed, thus the above readings may not
After the “Abnormality Record“ screen is be the same.
displayed, select “Mechanical Systems“ by using a If [E] is displayed on the left of a failure code,
the function switch or numeral input switches. the abnormality is still occurring or correction
• [F3]: Moves selection to the below item of it is not confirmed.
• [F5]: Returns the display to service menu a For all of the failure codes that the machine
screen monitor can record, see the failure code list.
• [F6]: Enters selection
a When you input a 2-digit code by using the
numeral input switches, the corresponding
item is directly selected. Accordingly, you
may enter the selection by using [F6].
4. Clearing abnormality record

The contents of an abnormality record of the
mechanical system cannot be deleted.
3. Information displayed on "Abnormality Record"

screen
On the “Mechanical Systems“ screen, the
following information is displayed.
PC210LC-10 30-115
Electrical system
Abnormality record (electrical (a) Occurrence order of abnormalities from latest

systems) (PC220-Q1S3-100-K-00-A) one/Total number of records
The machine monitor logs the past and currently (b): Failure code
occurring failures classifying them into the (c): Detail of failure
mechanical system abnormality and electrical (d): Number of occurrences (displayable range:
system abnormality. 0 to 65,535 times)
To check the electrical system abnormality record, (e): Service meter reading at the first occurrence
perform the following procedures. (f): Service meter reading at the last occurrence
a For the failure code list, see "40 Failure code list (when displayed)
for troubleshooting". • [F2] Moves selection to previous page
1. Selecting menu (screen) (when displayed)
Select “Abnormality Record“ on “Service Menu“ • [F3]: Moves selection to the below item
screen. • [F4]: Moves selection to the above item
• [F5]: Returns the display to "Abnormality
Record" screen
a If no abnormality is recorded, "No Error" is
displayed.
a On the electrical systems abnormality record
screen, up to 20 cases currently stored are
displayed.
If the number of abnormality records
increases to 21 or beyond, the latest
occurrence code is displayed and the oldest
one is deleted.
2. Selecting sub menu a If the number of occurrence is 1 (first

After the “Abnormality Record“ screen is occurrence), the service meter reading at the
displayed, select “Electrical Systems“ by using first occurrence and that at the last
the function switch or numeral input switches. occurrence are the same.
• [F3]: Moves selection to the below item a If [E] is displayed on the left of a failure code,
• [F4]: Moves selection to the above item the abnormality is still occurring or correction
• [F5]: Returns the display to service menu of it is not confirmed.
screen
• [F6]: Enters selection a For all of the failure codes that the machine
monitor can record, see the failure code list.
4. Clearing abnormality record

1) While the “Electrical Systems“ screen is
displayed, perform the following operation by
using the numeral input switches.
3. Information displayed on "Abnormality Record"
• Switch operation (Press the switches in
screen
order while pressing [4])
On “Electrical Systems“ abnormality record
[4]+[1]o[2]o[3]
screen, the following information is displayed.
30-116 PC210LC-10
Electrical system
a The following figure shows the screen

when an individual item is cleared (it is
slightly different from the screen when all
the item are cleared at once).
2) Check that the display on the screen

becomes the clear mode, then clear the
individual information one by one or all
together by using the function switches.
a If the screen is set in the clear mode, 4) If the screen to notify completion of clearing
graphic mark [CLEAR] is indicated above is displayed and then the "Electrical
[F2]. Systems" (clear mode) screen is displayed,
• [F2]: Clears all items the clearing of the abnormality record is
• [F3]: Moves selection to the below item completed.
• [F4]: Moves selection to the above item a After a while, the screen returns to the
• [F5]: Returns the display to "Abnormality “Electrical Systems“ abnormality record
Record" screen screen.
• [F6]: Clears items one by one
a To clear items one by one: Select the item
to be cleared with [F3] or [F4] and press
[F6].
a To clear all items together: Press [F2],
and all the items are cleared, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the clearing operation is accepted
but the item is not cleared.
Maintenance Record (PC220-Q19Z-100-K-00-A)

The machine monitor records the maintenance
information of the filters, oils, etc., which are
displayed and checked by the following operations.
When the maintenance is performed, if the data are
reset in the operator mode, the number of the times
of maintenance is recorded in this section.
1. Selecting menu
Select “Maintenance Record“ on “Service Menu“
screen.
3) After the “Electrical Sys. Error Reset“ screen
is displayed, operate the function switches.
• [F5]: Returns to Electrical Systems
abnormality record screen
(clear mode)
• [F6]: Executes clearing
PC210LC-10 30-117
Electrical system
3. Items displayed on Maintenance Record screen

The following information is displayed.
(a): Maintenance items
(b): Number of replacements up to now
(c): Service meter reading (SMR) at the last
replacement
2. Selecting maintenance record item

After the “Maintenance Record“ screen is
displayed, select an item of which the setting is
to be checked by using the function switches or
numeral input switches.
• [F2]: Moves selection to previous page
(screen) Maintenance Mode Setting (PC220-Q1F1-100-K-00-A)
• [F3]: Moves selection to the below item The actuating condition of the maintenance
• [F4]: Moves selection to the above item reminder function in the operator mode can be set
• [F5]: Returns the display to service menu and changed by using this menu.
screen
• To enable or disable the function
a You may enter a 2-digit code by using the • Change set replacement interval (by item)
numeral input switches to select the item of • Initialize all of set change intervals
that code. 1. Selecting menu
Select “Maintenance Mode Setting“ on “Service
Menu“ screen.
a The following items can be selected in the

maintenance record.
2. Selecting sub menu
49 Air cleaner cleaning/change
After the “Maintenance Mode Setting“ screen is
01 Engine oil change displayed, select an item of which the setting is
02 Engine oil filter change to be changed by using the function switches or
03 Fuel main filter change numeral input switches.
41 Fuel pre-filter change • [F1]: Moves selection to next page (screen)
04 Hydraulic oil filter change • [F2]: Moves selection to previous page
05 Hydraulic tank breather change (screen)
07 Damper case oil check and refill • [F3]: Moves selection to the below item
08 Final drive case oil change interval • [F4]: Moves selection to the above item
• [F5]: Returns the display to service menu
09 Machinery case oil change
screen
10 Hydraulic oil change
• [F6]: Enters selection
47 KCCV filter change
48 KDPF filter cleaning
30-118 PC210LC-10
Electrical system

4. Setting of Maintenance Notice Time Setting

After selecting "Maintenance Notice Time
Setting", if the screen is displayed, set with the
function switches.
a The following items can be selected on the

Maintenance Mode Setting screen.
00 Maintenance mode change
49 Air cleaner cleaning/ change Interval
01 Engine oil change interval
02 Engine oil filter change interval
03 Fuel main filter change interval
41 Fuel pre-filter change interval
04 Hydraulic oil filter change interval
05 Hydraulic tank breather change interval
07 Damper case oil check and refill interval
08 Final drive oil change Interval • Default value: Maintenance notice time set
09 Swing machinery oil change interval on the machine monitor (Recommended by
10 Hydraulic oil change interval the manufacturer and not changeable).
• Set value: Maintenance interval that can be
99 Returns all to Default Values
freely set. Maintenance reminder function
3. Setting of maintenance mode change works according to this set time in operator
After selecting “Maintenance Mode Change“ mode (the time increases or decreases in
and the screen is displayed, select the desired multiples of 10 hours).
setting by using the function switches. • [F3]: Decreases set value
• ON: Functions of all maintenance items • [F4]: Increases set value
become effective in operator mode. • [F5] Cancels contents of setting before entry
• OFF: Functions of all maintenance items and returns to the "Maintenance Mode
becomes ineffective in operator mode Change" screen
• [F3]: Moves selection to the below item • [F6]: Enters setting and returns to
• [F4]: Moves selection to the above item Maintenance mode setting screen
• [F5] Cancels selection and returns to the
"Maintenance Mode Change" screen
• [F6]: Enters selection and returns to
a Even if ON/OFF of each item has been set, if
the above setting is changed, it overrides the
individual setting.
PC210LC-10 30-119
Electrical system
5. Setting of each maintenance item • [F5] Cancels contents of setting before entry
Select each maintenance item. After the screen and returns to the "Maintenance Mode
is displayed, set the item by using the function Change" screen
switches. • [F6]: Enters setting and returns to
• ON: Function of the selected individual "Maintenance Mode Change" screen
maintenance item becomes effective in
a When you enter by using [F6] and return to
operator mode.
the "Maintenance Mode Setting" screen by
• OFF: Function of the selected individual
using [F5] , your setting is validated.
maintenance item becomes ineffective in
operator mode. a If the set value of an item of which
• [F3]: Moves selection to the below item maintenance reminder function is set to "ON"
• [F4]: Moves selection to the above item is changed after 1 operating hour or more
• [F5]: Cancels selection and returns to the from the setup, the change is recognized as
"Maintenance Mode Change" screen a reset of the remaining time.
• [F6]: Enters selection and returns to
7. Function to return all of the values to Default

Values
6. Setting of set value of each maintenance item After selecting “All Default Value“ and the
Select the set value of each maintenance item. screen is displayed, select the desired setting by
After the screen is displayed, set the value by using the function switches.
using the function switches.
• If the operation for this function is executed,

• Default value: Maintenance notice time set the set values of all the maintenance items
on the machine monitor (Recommended by are returned to the default values.
the manufacturer and not changeable). • [F5]: Returns the display to "Maintenance
• Set value: Maintenance interval that can be Mode Setting" screen
freely set. Maintenance reminder function • [F6]: Executes initialization
works according to this set time in operator
a A while after [F6] is pressed, the initialization
mode (the time increases or decreases in
completion screen is displayed. Then, when
multiples of 25 hours).
the “Maintenance Mode Setting“ screen is
• [F3]: Decreases set value
displayed, initialization is completed.
• [F4]: Increases set value
30-120 PC210LC-10
Electrical system
Phone number entry (PC220-Q19A-110-K-00-A) a Up to 14 digits can be input from the left.
The telephone number, which is displayed together Input nothing in the surplus places.
with the "Occurred error list" in the operator mode, a If an input numeral is wrong, move the cursor
can be input and changed according to the following (orange background) to that digit and
procedure. overwrite it with the correct numeral.
If a telephone number is not input with this function,
a If [F6] is pressed without inputting a digit,
no telephone number is displayed in the operator
there is not information of telephone No.
mode.
Accordingly, no telephone No. is displayed in
1. Selecting menu the operator mode.
Select “Phone Number Entry“ on the “Service
Menu“ screen.
Default (Key-on Mode) (PC220-Q1F2-100-K-00-A)

2. Registering and changing phone number Use the menu of Default to check or change various
After the “Phone Number Entry“ screen is settings of the machine monitor and machine.
displayed, register or change the phone number
Use the sub menu of "key-on Mode" to set the
by using the function switch or numeral input
working mode selected and displayed on the
switches. machine monitor when the starting switch is turned
• [F2]: Deletes all input digits to ON position.
• [F3]: Moves the input position to the next left
place (if not blank) 1. Selecting menu
• [F4]: Moves the input position to the next Select “Default“ on “Service Menu“ screen.
right place (if not blank)
• [F5]: Resets input digit/Returns the display to
the service menu screen
• [F6]: Validates the entry
PC210LC-10 30-121
Electrical system
• [F6]: Enters selection and returns the display

to Default screen
a Factory default is, "Mode at Previous Key-
off".
a If "With Attachment" is not selected, selection
of the Attachment /P-Mode and Attachment/
E-mode is disabled.
a If you change the setting to "Without
attachment" when Attachment/P-mode [P] or
Attachment/E-mode is selected, Power
mode [P] is displayed when the starting
2. Selecting sub menu switch is turned to the ON position.
After the “Default“ screen is displayed, select a If the engine is stopped with the working
“Key-on Mode“ by using the function switch or mode set to breaker mode [B] in the operator
numeral input switches. mode, Breaker Mode [B] is always displayed
a Select this item similarly to an item on the when the starting switch is turned to ON
“Service Menu“ screen. position, regardless of the above setting.
3. Selecting mode
Default value setting (Unit) (PC220-Q1F3-100-K-00-A)
After the “Key-on Mode“ screen is displayed,
Use the menu of "Default" to check or change
select the mode to be set by using the function
various settings of the machine monitor and
switches.
machine.
• Power mode: [P] is displayed when the
starting switch is set to ON position The unit selecting function is used to select the unit
• Economy mode: [E] is displayed when the of the data to be displayed in monitoring, etc.
starting switch is set to ON position 1. Selecting menu
• Lifting Operation Mode: [L] is displayed when Select “Default“ on “Service Menu“ screen.
the starting switch is turned to ON position.
• Breaker Mode: [B] is displayed when the
starting switch is turned to ON position.
• Attachment/P-mode: [ATT/P] is displayed
when the starting switch is set to the ON
position.
• Attachment/E-mode: [ATT/E] is displayed
when the starting switch is set to the ON
position.
• Mode at Previous Key-off: Final mode in
previous operation is displayed when the
starting switch is turned to ON position.
• [F3]: Moves selection to the below item
• [F4]: Moves selection to the above item 2. Selecting sub menu
• [F5]: Cancels selection and returns the After the “Default“ screen is displayed, select
display to Default screen “Unit“ by using the function switch or numeral
input switches.
30-122 PC210LC-10
Electrical system
a Select this item similarly to an item on the

“Service Menu“ screen.

After the “Default“ screen is displayed, select
3. Selecting unit “With/Without Attachment“ by using the function
After the “Unit“ screen is displayed, select the switch or numeral input switches.
unit to be set by using the function switches. a Select this item similarly to an item on the
• [F3]: Moves selection to the below item “Service Menu“ screen.
• [F5]: Cancels selection and returns the
display to Default screen
• [F6]: Enters selection and returns the display
to Default screen
a Factory default is the “SI Unit”.
3. Selecting With/Without
After the “With/Without Attachment“ screen is
displayed, select a setting by using the function
switch.
• Without Attachment: When attachment is not
installed
• With Attachment: When attachment is
Default (With/Without Attachment) (PC220-Q1F4- installed
100-K-00-A) • [F3]: Moves selection to the below item
Use the menu of Default to check or change various • [F4]: Moves selection to the above item
settings of the machine monitor and machine. • [F5]: Cancels selection and returns the
Use the sub menu of "With/Without Attachment" to display to Default screen
configure attachment setting when the attachment • [F6]: Enters selection and returns the display
is installed or removed. to Default screen
1. Selecting menu a When an attachment is installed, if this
Select “Default“ on “Service Menu“ screen. setting is not configured correctly, the
attachment setting in the operator mode
cannot be performed. As a result, the
attachment may not work normally or the
hydraulic components may be damaged.
PC210LC-10 30-123
Electrical system
• Use: Image from connected camera is

displayed as a normal image.
(as viewed in a mirror, when used for back
monitor)
• Я: Image from connected camera is
displayed as a reverse image (as seen
directly, when used for front or side monitor)
• R: Image from connected camera is
displayed as a normal image (as viewed in a
mirror, when used for back monitor)
• [F5]: Cancels the changes prior to
confirmation
Default (Camera) (PC220-Q1F6-100-K-00-A) and returns to the Default screen
Use the menu of Default to check or change various • [F6]: Enters selection in each line
settings of the machine monitor and machine.
Use the sub menu of "Camera" to configure camera a You cannot switch camera 1 between [Я] and
setting when the camera is installed or removed. [R].
1. Selecting menu a When you enter selection in each line with
Select “Default“ on “Service Menu“ screen. [F6] and return to the "Default" screen with
[F5], your setting is validated.
a When a camera is connected, if it is not set
normally with this function, the graphic mark
of camera is not displayed at [F3] in the
operator mode. Accordingly, the image of the
camera cannot be used.
a When the camera is installed, check that the
right and left portions of the displayed image
are correct.

After the “Default“ screen is displayed, select
“Camera“ by using the function switch or
numeral input switches.
3. Selecting camera setting

After the “Camera“ screen is displayed, select a
setting by using the function switch.
• Not Use: Camera is not used
30-124 PC210LC-10
Electrical system
1. Selecting menu
Select “Diagnostic Tests“ on “Service Menu“
screen.
a If 2 or more cameras are connected, be sure

to set the use of them from camera 1 in
order.
a The simultaneous display function of two After the “Diagnostic Tests“ screen is displayed,
images becomes effective when camera 1 select “Cylinder Cut-out“ using the function
and camera 2 are set for use. switch or numeral input switches.
3. Selecting cylinder to be cut-out

After the “Cylinder Cut-out“ screen is displayed,
select a cylinder to be cut out by using the
function switches.
• [F1]: Moves selection to the left item
• [F2]: Moves selection to the right item
• [F4]: Selects hold or releasing hold
(If the Hold is selected, the HOLD portion is
hatched.)
• [F5]: Returns the display to "Diagnostic
Tests" screen
Testing (Cylinder Cut-out operation) (PC220- • [F6]: Enters selection
AD00-34F-K-00-A)
In the machine monitor, the cylinder cut-out mode a This operation may be performed while the
operation and the KDPF regeneration operation can engine is running.
be executed as well as their cancellation. a When [F6] is pressed, if background (a) of
Cylinder cutout mode operation means to run the the selected cylinder No. becomes white, the
engine with one or more fuel injectors disabled cylinder is cut out.
electrically to reduce the number of effective
a If the machine monitor cuts out a cylinder but
cylinders. This operation is used to identify a
the engine controller cannot cut out that
cylinder that does not output power normally
cylinder, the background (a) of the cylinder
(combustion in it is abnormal).
number becomes yellow.
PC210LC-10 30-125
Electrical system
a One or more cylinders can be cut-out.

a During the Cylinder Cut-out operation, the
auto-deceleration function can be enabled.
When the auto-deceleration is set to ON,
auto-deceleration monitor (b) is displayed.
[Reference]
• If a normally operating cylinder is cut out, the
following phenomena occur.
1) Lowering of engine speed
2) Fuel Inject Command (quantity) increases.
• If the engine is running at near high idle,
4. Releasing cut-out cylinder however, the engine speed may not lower for
When changing a cylinder to be cut out or when the reason of engine control.
Cylinder Cut-Out operation is finished, select a • In this case, lower the engine speed with the
cut-out cylinder to be reset with the function fuel control dial and judge by increase of the
switches. injection rate command.
a This operation may be performed while the Testing (Regeneration for Service) (PC220-A9H0-
engine is running. 252-K-00-A)
a When [F6] is pressed, if background (a) of In the machine monitor, the cylinder cut-out mode
the selected cylinder No. becomes blue, the operation and the KDPF regeneration operation can
cylinder is reset. be executed as well as their cancellation.
Active regeneration for service refers to the method
a If the machine monitor releases a cut-out of burning soot by performing the KDPF
cylinder but the engine controller cannot regeneration, regardless of the soot accumulation.
release the cut-out cylinder, the background
(a) of the cylinder number becomes red. 1. Selecting menu
a The cut-out cylinder mode operation is not screen.
automatically released after the screen
returns to the operator mode. Accordingly, be
sure to perform the releasing operation after
the cylinder cut-out mode operation is
finished.
5. Holding displayed data
Each time [F4] is pressed during the Cylinder
Cut-Out operation, the displayed data is newly
held (c) (the real-time data is kept displayed on
the left side).
While the data is held, if [F4] is pressed, the data
holding function is reset.
a The holding function is available for a
cylinder, regardless of whether it is cut out or 2. Selecting sub menu
not. After the “Diagnostic Tests“ screen is displayed,
select “Regeneration for Service“ by using the
function switch or numeral input switches.
30-126 PC210LC-10
Electrical system
a While the KDPF regeneration status is in the a Before performing the manual stationary
manual stationary regeneration or stopped, regeneration, make sure the surrounding
“Regeneration for Service“ cannot be environment is safe, no people and no
selected. combustibles are in the area. When you
have to move the machine again for the
sake of security, move it to a safe place
and repeat the operation from the start.
a The active regeneration for service
automatically stops in 40 minutes.
However, if the regeneration is started
with the soot accumulation of
approximately 4 g/liter and if the soot
accumulation still remains at above 1.9 g/
liter after 40 minutes from the start, the
operation is switched to the automatic
regeneration. The regeneration is
continued until the soot accumulation
3. Setting regeneration for service decreases to 1.9 g/liter.
When “Regeneration for Service“ screen is
displayed, the following informations are
displayed corresponding to the KDPF
regeneration condition. Set the KDPF
regeneration according to the given messages.
(a): Soot accumulation level
(b): Regenerating condition of KDPF
(c): Selectable items
(d): Message
a The screen displays “Monitoring

Selection Menu“ screen by the following
switch operations while the regeneration
for service is in progress.
• Switch operation (While pressing [4],
press other switches in order): [4] + [1]
o [2] o [3]
To return to the regeneration for
1) KDPF active regeneration (manual stationary service screen from the monitoring
regeneration) screen, press [F5].
Select “Manual Stationary Regeneration“ on For the monitoring procedures, see
“Regeneration for Service“ screen. "Monitoring" of "Service mode".
• [F5]: Returns the display to "Diagnostic 2) Finishing regeneration
Tests" screen After the active regeneration for service is
• [F6]: Executes manual stationary completed, “Regeneration completed“ is
regeneration displayed on the screen.
a Active regeneration for service can be
performed only when the lock lever is in
the LOCK position and the fuel control
dial is the low idle (MIN) position.
PC210LC-10 30-127
Electrical system
3) Stopping of regeneration 2. Selecting sub menu

If [F6] is pressed during manual stationary After the “Diagnostic Tests“ screen is displayed,
regeneration, “Stop manual stationary select “KDPF Memory Reset“ by using the
regeneration?“ is displayed on the screen. function switch or numeral input switches.
Validate the stop by using the function switch.
• [F5]: Does not disable regeneration
(Continue stationary manual
regeneration)
• [F6]: Stops regeneration
3. Setting KDPF Memory Reset

Select an item to be reset, on the “KDPF
Memory Reset“ screen.
Testing (KDPF Memory Reset) (PC220-A9H0-271-K-
00-A) • [F4]: Moves selection to the above item
In the machine monitor, the cylinder cut-out mode • [F5]: Returns the display to "Diagnostic
operation and the KDPF regeneration operation can Tests" screen
be executed as well as their cancellation. • [F6]: Enters selection
KDPF Memory Reset means resetting the KDPF
information stored on the machine. It is performed
when cleaning or replacement of KDPF is done, or
when the engine controller is replaced.
1. Selecting menu
screen.
After “Do you want to reset?“ is displayed,

validate the reset by using the function
switch.
• [F5]: Returns the display to the previous
screen
30-128 PC210LC-10
Electrical system
• [F6]: Executes reset
3. Selecting pump absorption torque setting

After the “Pump Absorption Torque (F)“ screen is
When the reset is finished properly, “Reset
displayed, select the desired value at the right
completed“ is displayed on the screen. If the
side by using the function switches.
reset is not finished properly, “Reset failed“ is
• Set value: For actual torque adjustment
displayed on the screen.
value, see table
a Perform the KDPF replacement reset • [F3]: Increases set value
after replacing the KDPF. • [F4]: Decreases set value
• [F6]: Confirms setting and returns to
a Perform the KDPF cleaning reset after
Adjustment screen
cleaning the KDPF.
a The 3-digit number in the left column do not
a Perform the KDOC replacement reset
change since it is the code of this function.
after replacing the engine controller.
Adjustment (Pump Absorption Torque

(F)) (PC220-C201-27E-K-00-A)
You can make various adjustments related to the
machine with the machine monitor.
The sub menu of Pump Absorption Torque is used
to finely adjust the absorption torque of the
hydraulic pump.
1. Selecting menu
Select “Adjustment“ on “Service Menu“ screen.
a Relationship between set value and torque

adjustment value
Torque adjustment
Code Set Value
value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
After the “Adjustment“ screen is displayed, 006 -19.6 N {-2 kgm}
select “Pump Absorption Torque (F)“ by using 007 -29.4 Nm {-3 kgm}
the function switch or numeral input switches. 008 -39.2 Nm {-4 kgm}
a Select this item similarly to an item on the Adjustment (Pump Absorption Torque
“Service Menu“ screen. (R)) (PC220-C202-27E-K-00-A)
PC210LC-10 30-129
Electrical system
The sub menu of Pump Absorption Torque (R) is a The 3-digit number in the left column do not
used to finely adjust the absorption torque of the change since it is the code of this function.
rear hydraulic pump.
1. Selecting menu
a Relationship between set value and torque

adjustment value
2. Selecting sub menu Torque adjustment

Code Set Value
value
After the “Adjustment“ screen is displayed,
000 +39.2 Nm {+4 kgm}
select “Pump Absorption Torque (R)“ by using
001 +29.4 Nm {+3 kgm}
the function switch or numeral input switches.
002 +19.6 Nm {+2 kgm}
a Select this item similarly to an item on the 003 +9.8 Nm {+1 kgm}
“Service Menu“ screen. 0 Nm {0 kgm}
022 004
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
Adjustment (travel low speed setting) (PC220-

Q1F8-100-K-00-A)
The sub menu of Low Speed is used to finely adjust
the travel speed at Low setting.
1. Selecting menu
3. Selecting pump absorption torque setting Select “Adjustment“ on “Service Menu“ screen.
After the “Pump Absorption Torque (R)“ screen
is displayed, select the desired value at the right
• Set value: For actual torque adjustment
value, see table
Adjustment screen

select “Low Speed“ by using the function switch
or numeral input switches.
30-130 PC210LC-10
Electrical system
3. Selecting travel Low Speed 2. Selecting sub menu

After the “Low Speed“ screen is displayed, After the “Adjustment“ screen is displayed,
select the desired value at the right side by using select “Attachment Flow Adjustment“ by using
the function switches. the function switch or numeral input switches.
• Set value: For actual travel Low speed value,
see table
Adjustment screen
a The 3-digit number in the left column does
not change since it is the code of this
function.
3. Selecting distribution of oil flow

After the “Attachment Flow Adjustment“ screen
is displayed, select the desired value at the right
• Set value: For actual distribution of oil flow,
see table
a Relationship between set value and travel
Low speed value
Adjustment screen
Travel speed at
Code Set Value a The 3-digit number in the left column does
Low
000 3.0 km/h not change since it is the code of this
001 2.8 km/h function.
020
002 3.2 km/h
003 3.4 km/h
Adjustment (Attachment Flow

Adjustment) (PC220-Q1F9-100-K-00-A)
The sub menu of "Attachment Flow Adjustment" is
used to finely adjust the oil flow rate to the
attachment in combined operations.
1. Selecting menu
PC210LC-10 30-131
Electrical system
a Relationship between set value and

distribution of oil flow to attachment
Distribution of flow to
Code Set Value
attachment
000 50%
001 70%
044
002 100%
003 40%
30-132 PC210LC-10
Electrical system
Adjustment (F pump swash plate sensor calibration) (PC220-C3W9-273-K-00-A)

The F pump swash plate sensor calibration sub
menu is used to calibrate the sensor installed on the
actual machine to eliminate deviation of the sensor
signal made when the front pump swash plate
sensor is removed and installed or replaced with
new one.
a The pump swash plate sensor needs to be
calibrated in the following cases.
Calibration Calibra-
of front tion of rear
pump pump
swash swash
plate plate
sensor sensor
Removal and installation
or replacement of front Necessary ―
pump swash plate sensor
Neces-
or replacement of rear ―
sary
pump swash plate sensor
Replacement of main Neces-
Necessary
pump assembly sary
Replacement of pump Neces-
Necessary 1. Preparation for calibration
controller sary
Adjustment and Before starting calibration, set the machine
disassembly of front Necessary ― under the following condition
pump PC valve • Hydraulic oil temperature: 50°C
Adjustment and • Working mode: P mode
Neces- • Travel speed: Hi
disassembly of rear ―
sary
pump PC valve 2. Selecting menu
a Before calibrating the pump swash plate sensor,

Test the pump swash plate sensor to
Check that the pump swash plate sensor is
normal.
a A rough flow of calibration of the pump swash
plate sensor is as follows.
In adjustment menu of service menu

select “Cal F pump swash plate sensor“ by using
the function switch or numeral input switches.
PC210LC-10 30-133
Electrical system
4. Calibration of front pump swash plate sensor for 3) When the speed of the track running idle is
the maximum angle stabilized,
1) After the “Cal F pump swash plate max“ is hold down [F1] of the machine monitor to
displayed, calibrate the front pump swash start calibration.
plate sensor for the maximum angle by A bar is displayed during calibration.
running track idle off the ground and Keep running the track idle until calibration is
operating the function switches. finished.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Enters setting
4) Calibration is finished successfully, "OK" is

displayed for the State of Adjustment to show
that calibration for the maximum angle is
completed.
2) Raise the right track off ground by using the Press [F6] to go to calibration for the
work equipment and move the right travel maximum angle.
lever to the stroke end to run the right track
idle off the ground.
• Fuel control dial: MAX position
• Right travel lever: Full stroke
Travel direction may be set in either of
forward and reverse.
• Swing lock switch may be set in either of
ON and OFF.
Either will do.
k Provide a enough work space to run

the track idle off the ground.
k Be careful about safety around the If calibration is finished unsuccessfully, "NG"

machine while running the track idle is displayed for the State of Adjustment and
off the ground. the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
and remove the cause and repeat calibration.
30-134 PC210LC-10
Electrical system
4) When calibration is finished successfully,

a The calibration value can be initialized by
"OK" is displayed for the State of Adjustment
holding down CLEAR button [F2].
to show that calibration for the minimum
If the calibration value is initialized, angle is completed.
"READY" is displayed for the State of Press [F6] to return to the Adjustment screen.
Adjustment on the screen.
5. Calibration of front pump swash plate sensor for
the minimum angle
1) After the “Cal F pump swash plate sensor
min“ is displayed, set all the levers in neutral
and
perform calibration on the Min. side of the
front pump swash plate sensor by using the
function switches.
[F1]: START
[F2]: CLEAR
[F5]: Returns to the adjustment screen
[F6]: Enters setting
If calibration is finished unsuccessfully, "NG"
is displayed for the State of Adjustment and
the failure cause code is displayed. Referring
to the failure cause codes in Table 1, find out
and remove the cause and press [F6] to
repeat the calibration for the minimum angle.
2) Wait under the following conditions.

• All control levers: NEUTRAL
Fuel control dial may be at any position.
3) Hold down [F1] of the machine monitor to
start calibration.
A bar is displayed during calibration.
Keep all the levers in NEUTRAL until
calibration is finished. a The calibration value can be initialized by
holding down CLEAR button [F2].
When the calibration value is initialized,
"READY" is displayed for the State of
Adjustment on the screen.
PC210LC-10 30-135
Electrical system
Table 1. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
Cause Pump
Calibration Calibration Content Remedies
code Calibration
of swash of swash
plate plate of IT
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Hydraulic oil temperature is Check hydraulic oil
A-2 q q q temperature (Min. 45°C)
low
Check hydraulic oil
temperature (Calibration of
Hydraulic oil temperature is
A-3 q q q swash plate: Max. 85°C,
high
Calibration of pump IT: Max.
55°C)
A-4 q q q Overheating Check for overheating
Pump pressure sensor (F, R) Perform troubleshooting for
A-6 q q q pump pressure sensor
is defective
Pump swash plate (F, R) Perform troubleshooting for
A-7 q q —
sensor is defective pump swash plate sensor
Arm IN PPC pressure sensor Perform troubleshooting for
A-8 — — q
is defective arm IN PPC pressure sensor
— — PC-EPC abnormality Perform troubleshooting for
A-9 q
PC-EPC
CAN communication is
— — defective (engine, monitor, Perform troubleshooting for
A-A q
pump) CAN
Perform troubleshooting for
— — Bucket CURL PPC pressure
A-B q bucket CURL PPC pressure
sensor is defective
sensor
Pump pressure of calibrated Perform troubleshooting for
B-1 q — —
pump is above standard value relief valve and pump
B-3 q q — Lever is not in NEUTRAL Set lever in NEUTRAL
C-1 — q —
pump is below standard value relief valve and pump
C-2 — q — Travel speed setting is not Hi Set travel speed to Hi on
monitor
Fuel control dial is not set to Set fuel control dial to Max.
C-3 — q q MAX position position.
Set travel lever to full stroke
C-4 — q — Both tracks are running and work equipment lever to
neutral.
Check adjustment of service
— — Oil flow from two pumps are (Oil flow is normally divided
C-5 q
not divided during travel single operation)
Travel PPC pressure sensor Perform troubleshooting for
C-6 — q —
abnormality travel PPC
— — Travel PPC pressure is below
C-7 q Set travel lever to full stroke.
standard value
Arm IN when the arm IN circuit
relieved
PPC pressure is below the
E-1 — — q Set arm IN lever to full stroke.
specified level or arm IN
PPC pressure sensor out of
the normal range (*1)
Pump pressure (F, R) is out of Perform troubleshooting for
E-2 — — q standard range relief valve and pump
30-136 PC210LC-10
Electrical system
Object
MIN MAX
Cause Pump
code Calibration
of swash of swash
plate plate of IT
Engine speed is out of Set the engine to Hi idle
E-3 — — q standard range speed.
Engine torque is out of Perform troubleshooting for
E-4 — — q standard range engine and pump
PC-EPC current is out of Perform troubleshooting for
E-5 — — q standard range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
pressure is below standard Set bucket CURL lever to full
E-6 — — q value or bucket CURL PPC stroke.
pressure sensor is out of the
normal range (*1)
Working mode is not set to [P] Set working mode is to [P] or
E-7 — — q or [ATT/P] [ATT/P].
Swing emergency stop switch Set swing emergency stop
E-8 — — q is not set to ON position switch to ON position.
Swing lock switch is not set to Set swing lock switch to ON
E-9 — — q ON position position.
Set air conditioner to OFF
E-A — — q Air conditioner is ON position.
Output voltage of pump swash
FF q q — plate sensor is out of
swash plate sensor
calibration range
KDPF regeneration is
G-1 — — q End KDPF regeneration.
underway
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure codes "DHPAMA" and "DHPBMA").
PC210LC-10 30-137
Electrical system
Adjustment (R pump swash plate sensor

calibration) (PC220-C3WB-273-K-00-A)
1. Preparation for calibration
Before starting calibration, set the machine
under the following condition
• Hydraulic oil temperature: 50°C
2. Selecting menu

select “Cal R pump swash plate sensor“ by
using the function switch or numeral input
switches.
4. Perform the subsequent calibration procedure

according to “Cal F pump swash plate sensor“.
30-138 PC210LC-10
Electrical system
Adjustment (Pump calibration: Matching speed check) (PC220-C200-280-K-00-A)

You can make various adjustments related to the 1. Preparation for calibration
machine with the machine monitor. Before starting calibration, set the machine
The pump calibration function is used to check the under the following condition
matching speed for arm IN relief and bucket CURL • Perform warm-up operation for at least 30
relief and to set the matching speed to the engine minutes
properly when the pump or pump controller is • Hydraulic oil temperature: 50°C
replaced. • Working mode: P mode
a The pump calibration (matching speed • Air conditioner: OFF
calibration) is required in the following cases. 2. Selecting menu
Calibration of
pump
Replacement of engine ―
Replacement of main pump
Necessary
assembly
Replacement of pump controller Necessary
Adjustment and disassembly of
Necessary
front pump PC valve
Adjustment and disassembly of
Necessary
rear pump PC valve
Replacement of main valve ―
Adjustment or replacement of ―
main relief valve
After the “Adjustment“ screen is displayed, input
"40" by using the numeral input switches and
a A rough flow of calibration of the pump is as
press "F6".
follows.
In adjustment menu of service menu a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
replaced, it is not displayed in the menu list.
4. Selection of matching speed check menu

After the “Pump Calibration“ screen is displayed,
select “Matching Speed Check“ by using the
function switch or numeral input switches.
a Select this when it is required to check
abnormality or current condition of the
machine.
Select this item similarly to an item on the
PC210LC-10 30-139
Electrical system
k Secure sufficient area for operation of

the work equipment during testing.
k When operating the work equipment,

secure full safety around the machine.
[Reference]
• The alphabet letter at the right top of the
screen indicates the following condition.
D: Default
F: Adjustment value at shipment from factory
(Factory shipment state (Normal))
U: User calibration value 3) Perform arm IN relief operation. When the
5. Matching speed check (arm IN relief) engine speed is stabilized, hold down [F1] on
the machine monitor to start checking.
1) When the “Matching Speed Check“ screen is During matching speed check, a bar is
displayed, relieve the arm IN circuit and displayed on the screen. Keep relief
check the matching speed by using the operation until the check is finished.
function switch.
[F1]: START
[F5]: Returns to pump calibration screen
4) If the check is normally completed, the result

is displayed.
Press [F6] to go to the bucket CURL relief.
2) Operate the arm control lever or bucket
control lever under the following condition to
check the relief matching.
(Operation)
Operate according to the arm IN relief and
bucket curl relief screen.
a Set bucket CURL relief matching after
completing arm IN relief matching.
Arm lever: IN max. (Operate during arm
IN relief matching)
Bucket lever: CURL max. (Operate during
bucket CURL relief matching)
(Condition)
• Hydraulic oil temperature: 50°C If check is finished unsuccessfully, "NG" is
• Working mode: P mode displayed for the State of check and the
• Fuel control dial: MAX position failure cause code is displayed. Referring to
• Air conditioner: OFF the failure cause codes in Table 2, find out
30-140 PC210LC-10
Electrical system
and remove the cause and repeat matching

speed check.
4) If the check is normally completed, the result

is displayed.
Press [F6] to return to the “Pump Calibration“
6. Matching speed check (Bucket CURL relief)
screen.
1) When the “Matching Speed Check“ screen is
displayed, relieve the bucket CURL circuit
and check the matching speed by using the
function switch.
[F1]: START
[F5]: Returns to arm IN relief screen
If check is finished unsuccessfully, "NG" is

displayed for the State of check and the
failure cause code is displayed. Referring to
the failure cause codes in Table 2, find out
and remove the cause and repeat matching
speed check.
2) Wait under the following conditions.
• Air conditioner: OFF
3) Hold down [F1] of the machine monitor to
start check.
During matching speed check, a bar is
displayed on the screen. Keep relief
operation until the check is finished.
PC210LC-10 30-141
Electrical system
Table 2. Failure cause codes

Calibration failure cause codes (Displayed in descending order of priority)
Object
MIN MAX
Cause Pump
code Calibration
of swash of swash
plate plate of IT
A-1 q q q Engine speed signal is 0 rpm Check that engine is started
Hydraulic oil temperature is Check hydraulic oil
A-2 q q q temperature (Min. 45°C)
low
Check hydraulic oil
temperature (Calibration of
Hydraulic oil temperature is
A-3 q q q swash plate: Max. 85°C,
high
Calibration of pump IT: Max.
55°C)
A-4 q q q Overheating Check for overheating
Pump pressure sensor (F, R) Perform troubleshooting for
A-6 q q q pump pressure sensor
is defective
Pump swash plate (F, R) Perform troubleshooting for
A-7 q q —
sensor is defective pump swash plate sensor
Arm IN PPC pressure sensor Perform troubleshooting for
A-8 — — q
is defective arm IN PPC pressure sensor
— — PC-EPC abnormality Perform troubleshooting for
A-9 q
PC-EPC
CAN communication is
— — defective (engine, monitor, Perform troubleshooting for
A-A q
pump) CAN
— — Bucket CURL PPC pressure
A-B q bucket CURL PPC pressure
sensor is defective
sensor
B-1 q — —
pump is above standard value relief valve and pump
B-3 q q — Lever is not in NEUTRAL Set lever in NEUTRAL
C-1 — q —
pump is below standard value relief valve and pump
C-2 — q — Travel speed setting is not Hi Set travel speed to Hi on
monitor
Fuel control dial is not set to Set fuel control dial to Max.
C-3 — q q MAX position position.
Set travel lever to full stroke
C-4 — q — Both tracks are running and work equipment lever to
neutral.
Check adjustment of service
— — Oil flow from two pumps are (Oil flow is normally divided
C-5 q
not divided during travel single operation)
Travel PPC pressure sensor Perform troubleshooting for
C-6 — q —
abnormality travel PPC
— — Travel PPC pressure is below
C-7 q Set travel lever to full stroke.
standard value
Arm IN when the arm IN circuit
relieved
PPC pressure is below the
E-1 — — q Set arm IN lever to full stroke.
specified level or arm IN
PPC pressure sensor out of
the normal range (*1)
Pump pressure (F, R) is out of Perform troubleshooting for
E-2 — — q standard range relief valve and pump
30-142 PC210LC-10
Electrical system
Object
MIN MAX
Cause Pump
code Calibration
of swash of swash
plate plate of IT
Engine speed is out of Set the engine to Hi idle
E-3 — — q standard range speed.
Engine torque is out of Perform troubleshooting for
E-4 — — q standard range engine and pump
PC-EPC current is out of Perform troubleshooting for
E-5 — — q standard range PC-EPC current
When bucket CURL circuit is
relieved, bucket CURL PPC
pressure is below specified Set bucket CURL lever to full
E-6 — — q value or bucket CURL PPC stroke.
pressure sensor is out of the
normal range (*1)
Working mode is not set to [P] Set working mode is to [P] or
E-7 — — q or [ATT/P] [ATT/P].
Swing emergency stop switch Set swing emergency stop
E-8 — — q is not set to ON position switch to ON position.
Swing lock switch is not set to Set swing lock switch to ON
E-9 — — q ON position position.
Set air conditioner to OFF
E-A — — q Air conditioner is ON position.
Output voltage of pump swash
FF q q — plate sensor is out of
swash plate sensor
calibration range
KDPF regeneration is
G-1 — — q End KDPF regeneration.
underway
(*1) When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the
relief pressure to be 0 MPa {0 kg/cm2}. Accordingly, perform troubleshooting, referring to Troubleshooting
(Failure codes "DHPAMA" and "DHPBMA").

speed calibration) (PC220-C200-270-K-00-A)
1. Preparation for calibration
Before starting calibration, set the machine
under the following condition
• Perform warm-up operation for at least 30
minutes
• Swing emergency stop switch: ON
• Air conditioner: OFF
2. Selecting menu 3. Selecting sub menu
Select “Adjustment“ on “Service Menu“ screen. After the “Adjustment“ screen is displayed, input
"40" by using the numeral input switches and
press "F6".
a Since this function is required only when the
pump is replaced, the PC valve is adjusted or
disassembled, or the pump controller is
replaced, it is not displayed in the menu list.
PC210LC-10 30-143
Electrical system
4. Selecting matching speed calibration menu When [F6] is pressed, if the “Pump Calibration“
After the “Pump Calibration“ screen is displayed, screen is displayed and alphabet letter "D" is
select “Matching Speed Calibration“ by using the indicated at the right top of the screen, initialization
function switch or numeral input switches. is completed.
5. Perform the subsequent calibration procedure

according to “Matching Speed Calibration“. No Injection (PC220-AD00-25L-K-00-A)
If the engine is operated after long storage of the
Adjustment (Pump calibration: Restore machine, it may be worn or damaged because of
default value) (PC200_10-C200-270-K-01-A) insufficient lubrication with oil. To prevent this, the
After the “Pump Calibration“ screen is displayed, machine monitor has a function to crank the engine
select “Restore to Default Setting“ by using the without injecting fuel to lubricate the engine before
function switch or numeral input switches. starting it.
Set the No Injection cranking while the engine is
stopped.
1. Selecting menu
Select “No Injection“ on “Service Menu“ screen.
[F6]: Perform initialization
2. Displaying confirmation screen
30-144 PC210LC-10
Electrical system
When the “No Injection“ screen is displayed, the a This function can be selected even when the
message to ask if no injection cranking should engine is running. However, if you execute
be performed appears. Select the answer by the no injection cranking, a message “The
using the function switch. engine is operating. Please turn the key off
• [F5]: Do not perform (return to Service Menu once.“ is displayed on the screen.
screen)
• [F6]: Executes
Also, if the no injection cranking is operated

when "Check" screen is displayed, the
3. Starting no injection cranking function does not become effective in the
If no injection cranking (no fuel injection to every following case.
cylinder) is enabled, a message to notify that is
• The communication between the monitor
displayed on the screen. Under this condition,
and engine controller is not normal.
crank the engine with the starting motor.
• Perform an engine start operation before
a While the screen is changing to the following the message “No injection is possible“ is
screen, the screen of "Getting Ready." is displayed.
displayed.
a Do not crank the engine for 20 seconds or
longer to protect the starting motor.
KOMTRAX Settings (Terminal Status) (PC220-

Q210-110-K-00-A)
The setting and operating status of KOMTRAX can
4. Finishing no injection cranking be checked by using the menu of "KOMTRAX
After the cranking is over, turn the starting switch Settings".
to the OFF position. "KOMTRAX Settings" is used to check the setting
a You cannot change the screen described condition of the KOMTRAX terminal.
above to another screen. 1. Selecting the menu
5. Prohibiting no injection cranking Select "KOMTRAX Settings" on the "Service
Even if the operator tries to perform the no Menu" screen.
injection cranking while the engine is running,
the message "The engine is operating" is
displayed and the no injection cranking does not
become effective.
PC210LC-10 30-145
Electrical system
KOMTRAX Settings (GPS and Communication

Status) (PC220-Q210-110-K-01-A)
The setting and operating status of KOMTRAX can
be checked by using the menu of "KOMTRAX
Settings".
"GPS & Communication Status" is used to check
the positioning and communication status of the
KOMTRAX terminal.
1. Selecting the menu
Select "KOMTRAX Settings" on the "Service
Menu" screen.
2. Selecting submenu
After the “KOMTRAX Settings” screen is
displayed, select “Terminal Status” with the
function switches or numeral input switches.
a Select this submenu as in the case of
selecting a menu on the "Service Menu"
screen.

After the "KOMTRAX Settings" screen is
displayed, select "GPS & Communication
Status" with the function switches or numeral
input switches.
a Select this sub menu as in the case of
selecting a menu on the "Service Menu"
screen.
3. Contents displayed on the terminal status
screen
On the "Terminal Status" screen, the following
information is displayed.
• Terminal Type: Model name of the
KOMTRAX communication modem
• KOMTRAX Communication : Status of sign-
up test underway
• GMT time: Greenwich Mean Time (add 9
hours to it for Japan time)
• [F5]: Returns the display to the KOMTRAX
settings screen
3. Contents displayed on GPS & Communication

Status screen
On the "GPS & Communication Status" screen,
the following items are displayed.
• Positioning: GPS positioning status
• Communication: Communication
environment and connection status of the
communication modem
• Number of message not yet sent: Number of
mails that are saved on the machine monitor
and have not yet been transmitted
30-146 PC210LC-10
Electrical system
• [F5]: Returns the display to the KOMTRAX

settings screen
3. Details displayed on Modem Status screen

IP addresses (two systems) of the modem are
displayed.
KOMTRAX Settings screen (Modem • [F5]: Returns the display to KOMTRAX
Status) (PC220-Q210-110-K-02-A) settings screen
The setting and operating conditions of KOMTRAX
a An IP address is a unique number assigned
can be checked through the display of KOMTRAX
to each modem that is used when
Settings.
communication between the modem and
Modem information is used to check the IP address server is established.
of the KOMTRAX communication modem.
1. Selection of menu
Select “KOMTRAX Settings“ on “Service Menu“
screen.
Service Message (PC220-Q210-100-K-00-A)

Special messages for the technician sent from the
KOMTRAX base station (a distributor, etc.) can be
2. Selecting sub menu checked with this function.
After the “KOMTRAX Settings“ screen is If a received message includes a setting operation,
displayed, select “Modem Status“ by using the a return mail can be sent by using the numeral input
function switch or numeral input switches. switches as well.
a Select this item similarly to an item on the 1. Selecting menu
“Service Menu“ screen. Select “Service Message“ on “Service Menu“
screen.
PC210LC-10 30-147
Electrical system
a Since this message is special for the

technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
2. Displaying message (read only)

If there is a message, its contents are displayed.
If there is no message, "No message." is
displayed.
• [F5]: Returns the display to Service Menu
screen
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
a Since this message is special for the
technician, the message monitor is not
displayed when it is received with the
machine monitor in the operator mode.
3. Display of message (with return mail function)

If a message provides the Numeric Input line
under the text, input a proper number by using
the numeral input switches and enter it by using
the function switch, and the information is
returned to the KOMTRAX base station.
• [F5]: Returns the display to KOMTRAX
settings screen
• [F6]: Enters and returns input value
a This message is different from that sent to
the operator with the machine monitor in the
operator mode.
30-148 PC210LC-10
Electrical system
Adjusting rearview camera angle (ALL-Q162-001-K-00-A)
a Adjust the camera so that persons in the area a The claw of cover (2) is made of plastic, so
(W) of 1 meter around the rear of the machine is be careful not to break it when removing.
displayed on the machine monitor in the
operator's cab.
2. Remove bolts (3) from 2 places.

3. Remove cover (1).
a Check where and how many shims (6) have
been used.
If the image displayed on the machine monitor is out
of position, remove cover (1) and adjust installation Shims (6) are put on cover (1). Be careful not
angle (A) of the rearview camera. to drop them.
a Angle (A) can be adjusted in the range shown in

the following figure.
Adjusting (PC220-Q162-270-K-01-A)
1. Remove cover (1) by inserting flat-head

screwdriver [1] in the hole in cover (2) and
pressing the internal claw.
4. Loosen camera mounting bolts (4) (at 3 places)

and adjust camera mounting angle (A) so that
corner (B) of mounting bracket (5) is aligned with
horizontal line (C) of the camera.
PC210LC-10 30-149
Electrical system
a Using shims (6), adjust the difference

between the upper and lower clearances
between the counterweight and cover (1) to 2
mm or less.
a Since shim (6) may be caught in cover (1),

insert it from outside to the cover after
inserting the bolt temporarily.
a Machine is displayed partially on the

machine monitor screen.
5. After adjusting, tighten bolts (4).

3 Camera mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
6. Install covers (1) and (2).
30-150 PC210LC-10
Electrical system
Handling voltage circuit of engine controller (PC220-AP40-2A4-K-00-A)
1. Disconnecting or connecting work of the

connector between the engine controller and the
engine must be performed only when the
starting switch and disconnect switch are in the
OFF position and the system operating lamp
goes out.
k Before connecting the wiring harness

connector, be sure to completely remove
sand, dust, water, etc., inside the
connector on the controller side.
2. Perform the measuring operation with the T-
adapter inserted or connected to the connector
between the engine controller and engine when
you perform the troubleshooting.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
PC210LC-10 30-151
Electrical system
Handling battery disconnect switch (PC220-AW1P-100-K-00-A)
1. When the battery disconnect switch is turned to

the OFF position, be sure to remove switch key
(1).
kA hazard can result if an irrelevant person

turns switch key (1) ON carelessly.
2. You can prevent an abnormal end of the
operation due to cut-off of the battery power
supply circuit while the controllers are in
operation by checking the operating status of
each controller with system operating lamp (2).
1) Before cutting off the battery power supply
circuit, turn the starting switch to the OFF
position, and check that system operating
lamp (2) goes out, then turn the battery
disconnect switch to the OFF position.
2) If you turn the battery disconnect switch to
the OFF position (battery power supply
circuit is cut off) while system operating lamp
(2) lights up, Controller data lost error can
occur. Do not operate the battery disconnect
switch as long as system operating lamp (2)
lights up.
3) System operating lamp (2) goes out in 2
minutes longest after the starting switch is
turned to the OFF position.
4) System operating lamp (2) may sometimes
light up while the starting switch is turned to
the OFF position because KOMTRAX
terminal may maintain its communication
under this condition.
5) System operating lamp (2) may look slightly
luminous in the dark after it is turned off. It is
due to the minute leakage of current and not
an abnormal phenomenon.
• After the starting switch is turned to the
OFF position, KOMTRAX terminal
repeats the start and stop to maintain the
periodic communication.
• The start and stop cycle (sleep cycle) of
KOMTRAX terminal varies depending on
the factors including the communication
status and machine stop time. So the
lamp can be lighting as long as
approximately an hour.
6) When you want to cut off the battery circuit
for maintenance but system operating lamp
(2) keeps on lighting up, turn the starting
switch to the ON position once, then turn it to
the OFF position. The lamp will go out in 2
minutes maximum. After system operating
lamp (2) goes out, turn the battery
disconnect switch to the OFF position
immediately.
30-152 PC210LC-10
Electrical system
Testing diodes (ALL-E300-001-P-00-A)
a Test the diode array (8-pin) and the single diode

(2-pin) according to the following procedure.
a The continuity directions of the diode array are
as follows.
2. When using analog tester

1) Selects the resistance range screen.
2) Check the movement of the pointer when
performing the following connection.
1] Apply the red (+) lead of the multimeter to
a The continuity direction of the single diode is the anode (P) side of the diode and apply
indicated on the surface of the diode. the black (-) lead to the cathode (N) side.
Testing (PC220-E300-36J-P-00-A) 2] Apply the red (+) lead of the multimeter to
the cathode (N) side of the diode and
1. When using a digital tester apply the black (-) lead to the anode (P)
1) Select the diode range screen to check the side.
displayed values. 3) Evaluate the condition of the diode by the
a When an ordinary circuit tester is used, movement of the pointer.
the voltage of the internal battery is • The pointer does not move by the above
indicated. 1] connection, but it does by the 2]
2) Apply the red (+) lead of the multimeter to the connection: Normal (however, the
anode (P) side of the diode and apply the movement of the pointer (resistance)
black (-) lead to the cathode (N) side and varies by type of tester, or selection of
check the indicated value. measuring range).
3) Evaluate the condition of the diode by the • The pointer moves by either connection
indicated value. of the above 1], and 2]:
• Indicated value does not change: No Defective (internal short circuit)
continuity (defective) • The pointer moves by neither connection
• Indicated value changes: Continuity the above 1], nor 2]: Defective (internal
(normal) (note) open circuit)
Note: In the case of a silicon diode, a value in
the range from 460 to 600 mV is indicated.
• The indicated value is 0 or approximate
0:
The diode has internal short circuit
(defective).
PC210LC-10 30-153
Pm clinic
Pm clinic (ALL-2160-001-A-00-A)
Pm Clinic service (PC200_10-2160-209-A-00-A)
Model Serial No. Service meter

T PC210LC-10 hours
Customer name Date of check Serviceman
/　　　/
Specifications
Main components Attachment Shoe width
BoomT Standard T
(　　　　　) T Breaker T 600 mm
ArmT Standard T (　　　　　) T (　　　　　　　　) T 700 mm
Bucket T Standard T T (　　　　　　　　) T (　　　　　)
(　　　　　)
Check of oil and coolant level
T Radiator coolant When necessary
T Machinery case oil
T Engine oil T Damper case oil
T (　　　　　　　　)
T Hydraulic oil T Final case oil
Ambient Temperature Height above sea level
°C m
Operator's comment
Visual check result
Mechanical system "Abnormality Record" Electrical system abnormality record

989EKX times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
AA10NX times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
AB00KE times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
B@BAZG times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
B@BAZK times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
B@BCNS times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
B@BCZK times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
B@HANS times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
CA234 times/ 1st at 　 hrs. / last at 　 hrs. times/ 1st at 　 hrs. / last at 　 hrs.
30-154 PC210LC-10
Pm clinic
Highest reading on coolant temperature gauge
Coolant
Engine coolant Color of monitor
temperature
temperature light (a)
gauge level
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 60°C
1 30°C White
Highest reading on hydraulic oil temperature

gauge
Hydraulic oil
Hydraulic oil Color of monitor
temperature
temperature light (a)
gauge level
6 105°C
Red
5 102°C
4 100°C
3 85°C Blue
2 40°C
1 20°C White
PC210LC-10 30-155
Pm clinic
Check items related to engine
30-156 PC210LC-10
Pm clinic
Check items related to oil pressure
PC210LC-10 30-157
Pm clinic
Check sheet (PC200_10-2160-033-A-00-A)
Check sheet (PC210LC-10)

Model Serial No. Service meter Customer name Date of check Inspector
/　　　　/
1. Engine
Testing conditions
Operation of work equipment
Measured value
Auto-deceleration
L.H. knob switch

Fuel control dial
Service limit
Working mode
Check item
Standard
No good
GOOD
Unit
No.
Engine rpm 1,680 to 1,680 to

1 speed 1,820 1,820
All levers in
MAX MPa Min. 0.29 0.25
Engine NEUTRAL
2 speed {kg/cm2} {Min. 3.0} {2.5}
OFF
3 speed 1,100 1,100
All levers in
MIN OFF MPa Min. 0.10 0.07
Engine NEUTRAL
4 speed P
{kg/cm2} {Min. 1.0} {0.7}
5 speed Arm IN to 2,050 2,050
ON hydraulic kPa Max. 0.98 1.96
Blowby
6 MAX relief
pressure {mmH2O} {Max. 100} {200}
Engine All levers in rpm 1,000 to 1,000 to
7 speed ON OFF 1,100 1,100
NEUTRAL
30-158 PC210LC-10
Pm clinic
2. Work equipment speed

Testing conditions
Measured value
Fuel control dial
Service limit
Working mode
Check item
Standard
No good
GOOD
Unit
No.
Work equipment posture,

etc.
Work equipment extended

1 Boom Raise fully second 3.2 to 4.0 Max 4.8
P
second 3.1 to 3.9 Max 4.5
2 Arm IN E second 3.2 to 4.0 Max 4.5
Boom top horizontal
L second 5.8 to 7.2 Max 7.9
3 Arm OUT second 2.4 to 3.0 Max 3.5
Boom top horizontal
4 Bucket Curl second 2.3 to 2.9 Max 3.3
Arm cylinder retracted fully
MAX Work equipment extended
Swing (5 fully 21.7 to
5 turns) second Max 30
26.7
P Swing right and left
48.6 to 48.6 to
LO second
Travel One track raised 59.8 63.8
and run idle 36.7 to 36.7 to
6 (5 turns idle MI second
forward and 44.9 48.9
running)
reverse 27.3 to 27.3 to
HI second
30.3 32.3
3. Hydraulic drift of work equipment
Testing conditions
Mea-
No good
Service
GOOD
No. Check item Fuel Work- Unit Standard sured
Work equipment posture, limit
control ing value
etc.
dial mode
Hydraulic drift
measured at Boom top horizontal, Arm
Engine stop mm/15
1 bucket tooth cylinder retracted fully, Max 600 Max 900
minutes
tip Bucket loaded
PC210LC-10 30-159
Pm clinic
4. Hydraulic circuit
[1] [2] [3] [4] [5]
Testing conditions 60 MPa 60 MPa 60 MPa 60 MPa 6 MPa
{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
cm2} cm2} cm2} cm2} cm2}

Testing tools
L.H. knob switch
No good
Fuel control dial
GOOD
No.
Working mode
R pump main
F pump main
R pump LS
F pump LS
Control
Self-
pressure All levers in — — — —
1 A
reducing NEUTRAL
valve OFF
Main relief
2 valve (low B B B B —
pressure)
Arm OUT relief
Main relief
3 valve (high ON C C C C —-
pressure)
Unload All levers in —-
4 D1 D1 D2 D2
valve NEUTRAL
MAX P Right track run
idle, Lever E1 — E2 - —
moved halfway
5 LS valve
Left track run
idle, Lever - E1 — E2 —
OFF moved halfway
Swing lock
switch ON, — — —
Swing F F
Right swing
motor relief
6
safety Swing lock
valve switch ON, Left — — —
F F
swing relief
30-160 PC210LC-10
Pm clinic
[1] [2] [3] [4] [5]

{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
cm2} cm2} cm2} cm2} cm2}

Testing tools
L.H. knob switch
No good
Fuel control dial
GOOD
No.
Working mode
R pump main
F pump main
R pump LS
F pump LS
Control
Right track
locked ,Right — — — —
G
track forward
relief
Main relief
Right track
valve,
locked , Right — — — —
travel G
track reverse
motor
relief
7 safety MAX P OFF
Left track
valve,
locked, Left — — — —
travel G
track forward
junction
relief
valve
Left track
locked, Left — — — —
G
track reverse
relief
Oil pressure to be checked Unit Standard Service limit
A (Control source
2.93 to 3.43 {30 to 35} 2.75 to 3.43 {28 to 35}
pressure)
B (Work equipment
33.6 to 36.3 {343 to 370} 33.1 to 37.2 {338 to 380}
relief pressure, low)
C (Work equipment
new machine
36.1 to 38.8 {368 to 395} 36.1 to 39.7 {368 to 405}

relief pressure, high) MPa
D (Unload pressure) {kg/ D1 to D2 = 2.5 to 4.5 {26 to 46} D1 to D2 = 2.5 to 4.5 {26 to 46}
E (LS differential cm2}
E1 to E2 = 1.7 to 1.85 {17 to 18.5} E1 to E2 = 1.7 to 1.85 {17 to 18.5}
pressure)
F (Swing relief
27.8 to 30.8 {285 to 315} 27.4 to 31.3 {280 to 320}
pressure)
G (Travel relief
36.7 to 39.7 {375 to 405} 36.7 to 40.2 {375 to 410}
pressure)
* Gauge connection changing work: Exchange hoses of gauges [3] and [4].
PC210LC-10 30-161
Pm clinic
[1] [2] [3a] [4a] [5]

{600 kg/ {600 kg/ {600 kg/ {600 kg/ {60 kg/
No good
Testing cm2} cm2} cm2} cm2} cm2}
GOOD
No.
tools Wor-
Fuel L.H. Operation of
king work F pump R pump F pump R pump
control knob Control
mod- main main servo servo
dial switch equipment
e
Servo Arm OUT H1 H1 H2 H2
8 MAX P OFF —
piston relief
Standard
H (Servo control H1 : H2 = 1 : 0.6

-
pressure) (Oil pressure ratio)
* Gauge connection changing work: Change gauges [3] and [4] to 6 MPa {60 kg/cm2} and exchange
hoses of gauges [3], [4], and [5].
[1] [2] [3b] [4b] [5a]
Testing conditions 60 MPa 60 MPa 6 MPa
6 MPa {60 6 MPa {60
{600 kg/ {600 kg/ {60 kg/
kg/cm2} kg/cm2}
No good
Testing cm2} cm2} cm2}
GOOD
No.
tools Operation
Fuel Work- L.H.
of work F pump R pump F pump (F) R pump
control ing knob (R) LS-EPC
equip- main main
dial mode switch
ment
MIN — — J1 J1 —
PC-EPC(F) P All levers — — J2 J2 —
valve in
9 E — — J3 J3 —
PC-EPC NEU-
(R) valve L TRAL — — J4 J4 —
B — — J5 J5 —
Travel
speed:
LO
Travel — — — — K1
lever in
OFF NEU-
MAX TRAL
Travel
LS-EPC
10 P speed: MI
valve
lever
operated
Travel
speed: HI
lever
operated
30-162 PC210LC-10
Pm clinic

J1 (PC-EPC valve output
Approximately 2.9 {Approximately 30}
pressure 1)
Approximately 0.89 {Approximately 9.1}
pressure 2)
pressure 3)
new machine

MPa Approximately 1.53 {Approximately 15.6}
pressure 4)
{kg/
cm2} Approximately 1.47 {Approximately 15}
pressure 5)
K1 (LS-EPC valve output
pressure 1)
Approximately 1.79 {Approximately 18.2}
pressure 2)
0 {0}
pressure 3)
PC210LC-10 30-163
Pm clinic
30-164 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
40 Troubleshooting
6 40 Troubleshooting
PC210LC-10 40-1
40 Troubleshooting
Table of contents

40 Troubleshooting............................................................................................................................ 40-1
General information on troubleshooting ........................................................................................ 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Testing before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedure for troubleshooting ................................................................... 40-38
Symptom of probable failure and troubleshooting No............................................................. 40-41
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-46
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-59
T-branch box and T-branch adapter table ............................................................................. 40-95
Fuse location table ........................................................................................................... 40-101
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-103
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-106
Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-107
Failure codes table........................................................................................................... 40-108
Troubleshooting by failure code (Display of code) ...................................................................... 40-117
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-117
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-118
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-119
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-120
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-121
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-122
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-123
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-124
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-125
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-126
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-127
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-128
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-129
Failure code [A1U0N3]: KDPF Dry Request (HC Release)................................................... 40-130
Failure code [A1U0N4] KDPF Dry Request (HC Release).................................................... 40-132
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-134
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-136
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-138
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-139
Failure code [B@BCNS] Engine Coolant Overheat ............................................................. 40-140
Failure code [B@BCZK] Radiator Coolant Level Low .......................................................... 40-141
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-143
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-144
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-145
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-147
Failure code [CA131] Throttle Sensor High Error................................................................. 40-149
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-151
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-153
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-155
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-157
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-159
Failure code [CA221] Ambient Press Sens High Error ......................................................... 40-163
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-165
40-2 PC210LC-10
40 Troubleshooting
Table of contents
Failure code [CA234] Eng Overspeed ................................................................................ 40-168

Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-169
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-170
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-171
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-173
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-175
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-188
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-189
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-192
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-194
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-197
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-199
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-201
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-202
Failure code [CA442] Battery Voltage High Error................................................................. 40-204
Failure code [CA449] Rail Press Very High Error................................................................. 40-205
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-206
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-208
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-210
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-211
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-213
Failure code [CA553] Rail Press High Error ........................................................................ 40-215
Failure code [CA559] Rail Press Low Error......................................................................... 40-218
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-220
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-221
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-223
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-225
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-227
Failure code [CA697] ECM Int Temp Sensor High Error ....................................................... 40-229
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-230
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-231
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-233
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-238
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-239
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-241
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-244
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-246
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-248
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-250
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-252
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-254
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-256
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-267
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-268
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-271
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-273
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-275
PC210LC-10 40-3
40 Troubleshooting
Table of contents
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-276
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-278
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-281
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-282
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-283
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-285
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-287
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-288
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-290
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-292
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-294
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-296
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-298
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-301
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-303
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-305
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-306
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-307
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-309
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-311
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-313
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-316
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-317
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-318
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-320
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-322
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-326
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-329
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-332
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-335
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-341
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-347
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-350
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-353
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-357
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-360
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-364
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-368
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-372
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-375
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-379
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-381
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-383
Failure code [D110KB] Battery Relay Output Voltage .......................................................... 40-384
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-386
Failure code [D811MC] KOMTRAX Error............................................................................ 40-389
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-390
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)........................ 40-391
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .......................... 40-393
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-394
Failure code [DA20MC] Pump Controller............................................................................ 40-395
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-396
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-398
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-401
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ........................ 40-403
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ........................... 40-405
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-406
40-4 PC210LC-10
40 Troubleshooting
Table of contents
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-409

Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-410
Failure code [DAF0MC] Monitor Error ................................................................................ 40-411
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-412
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-414
Failure code [DAFGMC] GPS Module Error........................................................................ 40-415
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-416
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor)................................ 40-418
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-419
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-420
Failure code [DAZQKR] CAN2 Discon (AC)........................................................................ 40-421
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-426
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-431
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40-435
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-437
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-438
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-441
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....................................................... 40-444
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-446
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-449
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality....................................... 40-452
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..................................... 40-455
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...................................... 40-458
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-461
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-464
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-467
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-470
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-473
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-476
Failure code [DKR0MA] F pump S/P sensor Abnormality..................................................... 40-479
Failure code [DKR1MA] R pump S/P sensor Abnormality .................................................... 40-481
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-487
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-489
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-491
Failure code [DW45KA] Swing holding brake Sol Open Circuit ............................................. 40-493
Failure code [DW45KB] Swing holding brake Sol Short Circuit ............................................. 40-496
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-499
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-501
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-503
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-505
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-507
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...................................................... 40-509
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-511
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-513
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ................................................. 40-515
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ................................................. 40-517
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-519
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-521
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ......................................................... 40-523
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ......................................................... 40-525
Failure code [DXE0KA] LS-EPC Sol Open Circuit ............................................................... 40-527
Failure code [DXE0KB] LS-EPC Sol Short Circuit ............................................................... 40-529
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................ 40-531
Failure code [DXE4KB] Attachment Flow EPC Short Circuit................................................. 40-533
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ................................................ 40-535
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ................................................ 40-537
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ................................................... 40-539
PC210LC-10 40-5
40 Troubleshooting
Table of contents
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ................................................... 40-541

Failure code [DY20KA] Wiper Working Abnormality ............................................................ 40-543
Failure code [DY20MA] Wiper Parking Abnormality............................................................. 40-545
Failure code [DY2CKB] Washer Drive Short Circuit ............................................................. 40-547
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...................................................... 40-549
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ....................................................... 40-551
Troubleshooting of electrical system (E-mode) .......................................................................... 40-553
E-1 Engine does not start (Engine does not crank) .............................................................. 40-553
E-2 Manual preheating system does not work..................................................................... 40-559
E-3 Automatic preheating system does not work................................................................. 40-562
E-4 Preheating monitor does not light up when preheater is operated ................................... 40-564
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-566
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow.................................................................................... 40-569
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow ............................................................................ 40-570
E-8 Coolant temperature monitor lights up in white while engine is running ........................... 40-571
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................... 40-572
E-10 Charge level monitor lights up while engine is running ................................................. 40-573
E-11 Fuel level monitor lights up in red while engine is running............................................. 40-574
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ......................... 40-575
E-13 Water separator monitor lights up while engine is running ............................................ 40-576
E-14 Coolant temperature monitor lights up in red while engine is running............................. 40-577
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................... 40-578
E-16 Engine oil pressure monitor lights up in red while engine is running .............................. 40-579
E-17 Fuel gauge indicates either full or empty and does not move ........................................ 40-580
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)........................ 40-581
E-19 Coolant temperature gauge indicates either Min. or Max. and does not move ................ 40-582
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor
Max.) ................................................................................................................. 40-583
E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not
move ................................................................................................................. 40-584
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min.
nor Max.) ........................................................................................................... 40-586
E-23 Content of display on machine monitor is different from that of actual machine .............. 40-587
E-24 Machine monitor does not display some items ............................................................ 40-588
E-25 Function switch does not work................................................................................... 40-589
E-26 Automatic preheating system does not work (In cold season)....................................... 40-590
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration
switch is operated ............................................................................................... 40-591
E-28 Auto-deceleration is not actuated or canceled when lever is operated ........................... 40-592
E-29 Working mode selection screen is not diplayed when working mode switch is
operated ............................................................................................................ 40-593
E-30 Engine or hydraulic pump setting does not change when working mode is
changed............................................................................................................. 40-594
E-31 Travel speed monitor does not change when travel speed switch is operated ................ 40-595
E-32 Travel speed does not change while travel speed selection is changed......................... 40-596
E-33 Alarm buzzer does not stop sounding......................................................................... 40-597
E-34 When starting switch is turned to OFF position, service meter is not displayed............... 40-598
E-35 Service mode cannot be selected .............................................................................. 40-599
E-36 Any of work equipment, swing and travel does not work............................................... 40-600
E-37 Any of work equipment, swing and travel cannot be locked .......................................... 40-602
E-38 Machine cannot swing while swing brake cancel switch is canceled ............................. 40-603
E-39 Swing brake does not operate while swing brake cancel switch is locked ...................... 40-605
E-40 One-touch power maximizing function does not work or monitor is not displayed ........... 40-607
E-41 One-touch power maximizing function cannot be canceled .......................................... 40-609
E-42 Travel alarm does not sound when machine travels..................................................... 40-610
E-43 Alarm does not stop sounding while machine is stopped.............................................. 40-611
E-44 Horn does not sound ................................................................................................ 40-612
40-6 PC210LC-10
40 Troubleshooting
Table of contents
E-45 Horn does not stop sounding..................................................................................... 40-614

E-46 Wiper monitor does not light up or go out when wiper switch is operated ....................... 40-615
E-47 Wiper does not operate when wiper switch is operated ................................................ 40-616
E-48 Window washer does not operate when window washer switch is operated................... 40-618
E-49 BOOM LOWER indication is not displayed properly with monitoring function ................. 40-619
E-50 ARM DUMP indication is not displayed properly with monitoring function ...................... 40-620
E-51 ARM IN indication is not displayed properly with monitoring function............................. 40-621
E-52 BOOM RAISE indication is not displayed properly with monitoring function ................... 40-622
E-53 BUCKET CURL indication is not displayed properly with monitoring function ................. 40-623
E-54 BUCKET DUMP indication is not displayed properly with monitoring function ................ 40-624
E-55 SWING indication is not displayed properly with monitoring function ............................. 40-625
E-56 TRAVEL indication is not displayed properly with monitoring function............................ 40-626
E-57 Service is not displayed properly with monitoring function ............................................ 40-627
E-58 Attachment hydraulic circuit cannot be changed.......................................................... 40-630
E-59 KOMTRAX system does not operate normally ............................................................ 40-631
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-633
Information described in troubleshooting table (H-mode) ..................................................... 40-633
System chart for hydraulic system ..................................................................................... 40-634
Failure mode and cause table ........................................................................................... 40-636
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-644
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-647
H-3 All work equipment, swing and travel does not work ...................................................... 40-650
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-651
H-5 Fine control performance or response is poor ............................................................... 40-652
H-6 Boom speed or power is low ....................................................................................... 40-654
H-7 Arm speed or power is low .......................................................................................... 40-658
H-8 Bucket speed or power is low...................................................................................... 40-663
H-9 Work equipment does not move in single operation....................................................... 40-666
H-10 Hydraulic drift of boom is large .................................................................................. 40-667
H-11 Hydraulic drift of arm is large ..................................................................................... 40-668
H-12 Hydraulic drift of bucket is large ................................................................................. 40-669
H-13 Time lag of work equipment is large ........................................................................... 40-670
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-672
H-15 One-touch power maximizing function does not operate .............................................. 40-673
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-674
H-17 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-675
H-18 In combined operations of swing and travel, travel speed drops largely......................... 40-676
H-19 Machine does not travel straight ................................................................................ 40-677
H-20 Travel speed is slow ................................................................................................. 40-680
H-21 Machine is hard to steer or travel power is low ............................................................ 40-682
H-22 Travel speed does not change, or travel speed is too slow or fast ................................. 40-685
H-23 One of tracks does not run ........................................................................................ 40-686
H-24 Upper structure does not swing to the right or left ........................................................ 40-688
H-25 Upper structure swing only to the right or left .............................................................. 40-689
H-26 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-690
H-27 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-691
H-28 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-692
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-693
H-30 Shock is large when upper structure stops swinging.................................................... 40-694
H-31 Large unusual noise is heard when upper structure stops swinging .............................. 40-695
H-32 Swing drift on a slope is large while swing holding brake is applied............................... 40-696
H-33 Swing drift on a slope is large while swing holding brake is released............................. 40-697
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-698
H-35 Oil flow in attachment circuit cannot be controlled ....................................................... 40-699
Troubleshooting of engine (S-mode)......................................................................................... 40-700
PC210LC-10 40-7
40 Troubleshooting
Table of contents
Information mentioned in troubleshooting table (S mode)..................................................... 40-700

S-1 When starting switch is turned to START position, engine does not crank ....................... 40-701
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-702
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-703
S-4 Engine startability is poor ............................................................................................ 40-704
S-5 Engine does not pick up smoothly ............................................................................... 40-706
S-6 Engine stops during operation ..................................................................................... 40-708
S-7 Engine runs rough or is unstable ................................................................................. 40-710
S-8 Engine lacks power .................................................................................................... 40-711
S-9 Exhaust smoke is black (KDPF clogs up early) ............................................................. 40-713
S-10 Engine oil consumption is excessive .......................................................................... 40-715
S-11 Engine oil becomes contaminated early...................................................................... 40-716
S-12 Fuel consumption is excessive .................................................................................. 40-717
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-718
S-14 Engine oil pressure drops ......................................................................................... 40-719
S-15 Fuel is contaminated in engine oil .............................................................................. 40-720
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)................................. 40-721
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-722
S-18 Unusual noise is heard ............................................................................................. 40-723
S-19 Vibration is excessive ............................................................................................... 40-724
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-725
S-21 Active regeneration is executed frequently ................................................................. 40-726
S-22 Active regeneration takes time................................................................................... 40-727
S-23 White smoke is exhausted during active regeneration ................................................. 40-728
40-8 PC210LC-10
40 Troubleshooting
General information on troubleshooting
General information on troubleshooting (ALL-5100-001-A-00-A)
Troubleshooting points (ALL-5130-42A-A-00-A)
(Rev. 2011/09)
k Place the machine on a level ground, and make sure that the frame lock bar, chocks, and parking
brake are applied.
k When performing the operation with two or more service technicians, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
k Ifthe radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k Before disconnecting wiring, remove the key and turn the battery disconnect switch to OFF
position.
k When removing the plug or cap from a component which is under pressure of oil, water, or air,
always release the internal pressure first. When installing measuring equipment, be sure to
connect it properly.
Troubleshooting denotes to locate the primary cause, fix the trouble without delay and prevent its recurrence.
Despite the importance of understanding the structure and operation of the target system in troubleshooting,
you should be aware how interviewing with the operator concerned can facilitate in roughly identifying the
cause of the given undesirable symptom.
1. When performing troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately after any failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the
confidence of the user or operator.
For this reason, when performing troubleshooting, it is necessary to perform thorough prior investigation
and to perform troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before the failure?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1)Is there any sign of irregularities of the machine?
2)Make checks before starting day's work.
3)Make checks of other items.
4)Check other maintenance matters which can be checked externally and are considered to be
necessary.
4. Checking failure
Check the extent of the failure by yourself, and judge whether it is a real failure or a problem with the
method of operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not perform any inspection
or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 to 4 to narrow down the probable causes of
the failure, then use the troubleshooting flowchart to locate the failure exactly.
PC210LC-10 40-9
40 Troubleshooting
a The basic procedure for troubleshooting is as follows.

1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Fixing a trouble in hand does not necessarily prevents its recurrence unless the primary cause is
eliminated. To that end, you must locate and eliminate the primary cause behind the given failure.
40-10 PC210LC-10
40 Troubleshooting
Sequence of events in troubleshooting (ALL-5140-42A-A-00-A)
(Rev. 2011. 7)
PC210LC-10 40-11
40 Troubleshooting
40-12 PC210LC-10
40 Troubleshooting
Testing before troubleshooting (PC220-5150-208-A-00-A)
Judge-
No. Role ment Remedy
value
1 Check for unusual noise and smell - Correct
2 Check for dirt around engine - Remove
3 Check for water leakage around engine - Correct
4 Check for oil leakage around engine - Correct
5 Check for leakage from fuel line - Correct
6 Check of radiator for clogging - Remove
a: Engine, lubricating oil and coolant
7 Check of level and type of fuel - Refilling of oil

8 Check for foreign material in fuel - Clean and drain
9 Check of fuel pre-filter - Replace
10 Check of fuel main filter - Replace
Between
11 Check of level (in oil pan) and type of engine oil Refilling of oil
H and L
Between Refilling of coolant
12 Check of coolant level (in sub tank)
H and L
Air
cleaner
clogging
monitor is
13 Check of air cleaner clogging not Clean or replace
displayed
on
machine
monitor
14 Check for dirt around KDPF - Remove
15 Check for gas leakage around KDPF - Correct
1 Check for unusual noise and smell - Correct
Check for oil leakage -
b: Hydraulic and mechanical equipment
2 Correct
Between
3 Check of hydraulic oil level Refilling of oil
H and L
4 Check of hydraulic oil strainer - Clean and drain
5 Check of hydraulic oil filter - Replace
Between
6 Check of swing machinery case oil level Refilling of oil
H and L
Between Refilling of oil
7 Check of damper case oil level
H and L
8 Check of final drive case oil level - Refilling of oil
from cylinder
9 Air bleeding -
PC210LC-10 40-13
40 Troubleshooting
Judge-
No. Role ment Remedy
value
1 Check of battery terminal for looseness and corrosion - Retighten or replace
2 Check of alternator terminal for looseness and corrosion - Retighten or replace
3 Check of starting motor terminal for looseness and corrosion - Retighten or replace
20 to 30 Charge or replace
4 Check of battery voltage (with engine stopped)
V
Between
5 Check of battery electrolyte level Add or replace
H and L
Check of wiring harness for discoloration, burnt areas and cover
6 peeling - Repair or replace
Check for coming off of wiring harness clamp and sagging of wiring -
7 Correct
harness
c: Electrical parts
8 Check of grounding - Correct

9 Check for loose connector and damaged lock - Repair or replace
10 Check of connector pin for corrosion, bends and deformation - Repair or replace
Dry, clean or
11 Check for water and foreign material in connector -
replace
12 Check of wiring harness for open circuit and short circuit - Repair or replace
13 Check of fuse for blowout and corrosion ― Replace
After few
minutes
Check of alternator voltage (when engine speed is medium or of
14 higher) Replace
operation:
27.5 to
29.5 V
Check of battery relay operation sound (When the starting switch is
15 turned to ON or OFF position) - Replace
16 Check and cleaning of rear view camera - Clean or repair
1 Check of undercarriage - Correct
d: Exterior parts
2 Check of handrails and steps - Correct
3 Check of rear view mirrors - Clean or repair
1 Check of gauges and monitors - Clean or replace

e: Interior parts
2 Check of seat belt - Replace
40-14 PC210LC-10
40 Troubleshooting
Inspection procedure before troubleshooting (ALL-5150-001-A-00-A)
Walk-around check (PC220-5150-289-A-00-A)
Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages
of oil, fuel or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, the wiring harnesses for play, and the hot parts for accumulated dust.
k Accumulated combustibles around hot engine parts such as the engine, KDPF, and turbocharger,
etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and repair any
failures.
a a1 and a2, —, b1, b2, — refer to the symbols in the table on the previous page.
a1. and b1. Check for unusual noise and smell
Check for unusual noise and smell.
Some causes of unusual noise and smell can damage the machine if they are left as they are. Therefore, stop
the machine immediately when you find any abnormality.
a2. Check around engine and dirt removal
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the engine, KDPF, turbocharger, etc.
a3. Check for water leakage around engine
a4. Check for oil leakage around engine
Check any oil leaks from the engine and any water leaks from the cooling system. If any of them is abnormal,
carry out a repair.
a5. Check for leakage from fuel line
Check any fuel leaks and damaged hoses and tubes. If any of them is abnormal, carry out a repair.
a6. Check of radiator and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the radiator.
For removal of dirt from the radiator, see the Operation and Maintenance Manual, "Cleaning and testing of
radiator fins, oil cooler fins, aftercooler fins, fuel cooler fins and air conditioner condenser fins (machine with
the air conditioner)".
a14. Check around KDPF and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around KDPF.
a15. Check around KDPF for gas leakage
Check piping between the turbocharger and KDPF and joints of KDPF for gas leakage (sticking soot, etc.) If
any abnormality is found, repair.
b2. Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage and hoses for cracks and excessive wear, check that the
clearance between them is within the normal range, and then repair any abnormalities.
b3. Check of hydraulic equipment, hydraulic tank, hoses and joints for oil leakage
Check and repair any oil leaks.
c1. Check around battery and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the battery.
c16. Check and cleaning of rear view camera
Check the rear view camera for any defect, and repair any failures.
d1. Check of undercarriage (track, sprocket, idler and guard) for abnormalities, wear, loose bolts and
oil leakage from roller
Repair any abnormalities.
d2. Check of handrails and steps for abnormalities and loose bolts
Repair any abnormalities and retighten any loose bolts.
d3. Check and cleaning of rear view mirrors
Check and repair any abnormalities and breakage of the rear view mirrors.
PC210LC-10 40-15
40 Troubleshooting
Clean the mirror surfaces and adjust their angles so that the operator can see the area behind machine at the
operator's seat.
e1. Check of gauges and monitors for abnormalities
Check the gauges and monitors inside the operator cab. If any of them is abnormal, replace it.
Clean up the surfaces.
e2. Check of seat belt and mounting hardware
Check the hooks, locks and hook fittings for damage. If any of them has a problem, replace.
Testing in accordance with testing procedure (PC200_10-5150-280-A-00-A)
a. Engine, lubricating oil and coolant

a7. Checking of fuel level and type
k Fuel is highly flammable and dangerous.
Never bring flames near fuel.
k When adding fuel, never spill it or let it

overflow.
k Wipe off any spilled fuel. If fuel spills over

soil or sand, remove all the fuel and soil or
sand together.
1. Turn the engine starting switch to the ON

position and check the fuel level with the fuel
gauge (1) on the monitor panel.
After checking, turn the switch back to the OFF
position.
• If the breather hole (3) in the cap is clogged,

the pressure inside the tank goes down and
this may stop supplying the fuel. To prevent
this, clean the breather hole.
2. If fuel is found to be low, open fuel filler cap (F)
on the fuel tank and add fuel through the filler
port to the specified level required for checking
seeing the position of float gauge (G).
3. After adding fuel, push float gauge (G) straight
down with fuel filler cap (F). Be careful not to get
float gauge (G) caught in the tab (2) of fuel filler
cap (F), and tighten fuel filler cap (F) securely.
a8. Checking of foreign material in fuel

1. Open the engine side cover on the rear right of
the machine.
40-16 PC210LC-10
40 Troubleshooting
2. Place a container under drain hose (1) to catch • The water separator forms one unit with fuel
the drained fuel. pre-filter (1).
3. Turn drain valve (2) to the OPEN (O) position 2. It is possible to judge the water level and amount
and drain all the sediment and water of sediment by looking through transparent cap
accumulated at the bottom together with the fuel. (2). If there is any water or sediment collected at
4. When clean fuel comes out, turn drain valve (2) the bottom, place a container to catch the drain
to the CLOSE (S) position. water under drain hose (3).
5. Close side cover. 3. Loosen drain valve (4) to drain the water.
4. When fuel starts to drain from drain hose (3),
tighten drain valve (4) immediately.
a9. Checking of fuel pre-filter

a On this machine, a sensor is installed to
k Immediately after the engine is stopped, its detect if water is accumulated in transparent
parts and oil are still very hot, and may cause cap (2).
burn injury. Accordingly, wait until all parts
have cooled down before starting the work. a When the water separator monitor (5) lights
up in red on the machine monitor, it indicates
k High pressure is generated inside the engine that water is accumulated in transparent cap
fuel piping system when the engine is (2).
running. Stop the engine and wait at least 30
seconds until the inner pressure is released
and then replace the filter .
k Never bring flames near fuel.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu a If the water accumulated in transparent cap
genuine fuel filter cartridge is used, foreign (2) freezes, the water separator monitor may
material may enter and it may cause problems in not light up. After the engine is started, as the
the injection system. Do no use substitute parts. temperature around fuel pre-filter (1)
a During testing or maintenance of the fuel system, increases, the frozen water melt and the
take extreme care not to allow any foreign water separator monitor (5) may suddenly
material to enter the fuel system. If any dust or light up. In cold weather, even when the
other material sticks to any part, wash the part water separator monitor (5) is not lit, drain
thoroughly with clean fuel. the water frequently.
• Prepare a container to receive drained oil. a If the water inside transparent cap (2) freezes,
• Prepare a filter wrench. check that the frozen water has melted
Checking of water separator, and draining of completely, and then drain the water.
water and sediment
1. Open side cover.
PC210LC-10 40-17
40 Troubleshooting
a If transparent cap (2) is dirty or it is difficult to a If the transparent cap is tightened too much,
see the inside, clean transparent cap (2) the O-ring may be damaged, and this may
when replacing fuel pre-filter cartridge (1). cause the leakage of fuel. If it is not tightened
enough, fuel may leak through the gap at the
a When the drain valve (4) has been removed
O-ring. Always observe the specified
during the cleaning operation, coat the O-ring
tightening angle.
with grease and tighten until it contacts the
10.Clean the filter holder, fill the new filter cartridge
bottom.
with clean fuel, apply thin film of oil to the -ring,
Replacement of fuel pre-filter cartridge
then install it to the filter holder.
1. Turn valve (1) at the bottom of the fuel tank to
CLOSE position (S). a When adding fuel, do not remove cap (B) at
the center. Always fill the fuel from the dirty
side of eight small holes (A).
a After adding fuel, remove cap (B) and install
the fuel filter.
a Always fill with clean fuel. Be careful not to let
any dirt or dust get into the fuel. In particular,
center portion is the clean side, so do not
remove cap (B) when adding fuel. Be careful
not to let dirt or dust get into the center clean
side part.
2. Open the engine side cover on the rear right of

the machine.
3. Place a container under the fuel pre-filter
cartridge to catch the fuel.
4. Loosen drain valve (2) to drain water and
sediments from transparent cup (3), and also
drain all the fuel from filter cartridge (4).
5. Remove connector (5). Wrap the removed
connector with a vinyl bag to protect it from fuel,
oil and water.
6. By using the filter wrench, turn transparent cap
(3) to remove it. (This cap is used again.) 11.When installing, tighten it until the O-ring
7. By using the filter wrench, turn filter cartridge (4) contacts the sealing surface of the filter holder,
to remove it. then tighten it 3/4 of a turn.
8. Install the removed transparent cap (3) to the a If the filter cartridge is tightened too much, it
bottom of the new fuel filter cartridge. may be damaged, and may cause the
a When doing this, always replace O-ring (6) leakage of fuel. If it is not tightened enough,
with a new one. fuel may leak through the gap at the O-ring.
Always observe the specified tightening
angle.
a When tightening with a filter wrench, be
extremely careful not to dent or damage it.
12.Check that drain valve (2) is closed securely.
13.Remove the vinyl bag wrapping connector (5),
then connect connector (5).
a If water gets on connector (5), the sensor
may malfunction and the water separator
monitor may light up. When removing
connector (5), be extremely careful not to let
9. When installing, apply thin film of oil to the O-ring, water attach to the connector.
contact it to the sealing surface of filter cartridge
(4), and then tighten it 1/4 to 1/2 turn. a If water attaches to connector (5), dry it
completely before connecting it.
40-18 PC210LC-10
40 Troubleshooting
a10. Checking of fuel main filter

k Immediately after the engine is stopped, its 2. Open the engine side cover on the rear right of
parts and oil are still very hot, and may cause the machine.
burn injury. Accordingly, wait until all parts 3. Place a container under the fuel filter cartridge to
have cooled down before starting the work. catch the fuel.
4. By using the filter wrench, turn filter cartridge (2)
k High pressure is generated inside the engine to remove it.
fuel piping system when the engine is
running. Stop the engine and wait at least 30 a After removing the filter cartridge, fuel drips
seconds until the inner pressure is released from the filter head.
and then replace the filter . In order to prevent fuel from flowing out, be
sure not to leave the machine without the
k Never bring flames near fuel. filter cartridge.
a A special filter with high-efficiency filtering

properties is adopted for Komatsu genuine fuel
filter cartridges. Be sure to use Komatsu
genuine parts when replacing.
a The common rail fuel injection system used on
this machine consists of more precise parts than
those in the conventional injection pump and
nozzles. If any cartridge other than a Komatsu
genuine fuel filter cartridge is used, foreign
material may enter and it may cause problems in
the injection system. Do no use substitute parts. 5. Clean the filter holder, apply the thin film of oil to
a During testing or maintenance of the fuel system, the packing surface of the new filter cartridge,
take extreme care not to allow any foreign then install it to the filter holder.
material to enter the fuel system. If any dust or a Replace inner seal (3) with a new one.
other material sticks to any part, wash the part
thoroughly with clean fuel.
• Prepare a container to receive drained oil.
• Prepare a filter wrench.
1. Turn valve (1) at the bottom of the fuel tank to
CLOSE position (S).
a Do not fill the new filter cartridge with fuel.

a Remove cap (B) on the center, and then
install the filter cartridge.
PC210LC-10 40-19
40 Troubleshooting
foreign material. If any damage or foreign

material is found, replace the cartridge with a
new one, then repeat Steps 5 and after.
a11. Checking of engine oil level (in oil pan) and
type
k Immediately after the engine is stopped, its
parts and oil are still very hot, and may cause
have cooled down before starting the work.
a When checking the oil level after the engine has

been operated, wait for at least 15 minutes after
stopping the engine.
6. When installing, tighten it until the O-ring
contacts the sealing surface of the filter holder, a If the machine is at an angle, make it level
then tighten it 3/4 of a turn. before checking.
a If the filter cartridge is tightened too much, O- a When the ambient temperature is low, water or
ring may be damaged, and may cause the emulsified matter may stick to the dipstick, oil
leakage of fuel. If it is not tightened enough, filler cap, etc. or the drained oil may be milky
fuel may leak through the gap at the O-ring. white because of condensed water vapor in the
Always observe the specified tightening blowby gas. However, if the coolant level is
angle. normal, it is not a problem.
7. Turn valve (1) at the bottom of the fuel tank to 1. Stop the engine.
CLOSE position (S). 2. Open the engine hood.
8. Bleed the air according to the following 3. Pull out dipstick (G) and wipe the oil off of the
procedure. gauge with a cloth.
1) Fill up the fuel tank with fuel (to the level 4. Fully insert dipstick (G) into the dipstick pipe,
where the float is at the highest position). then remove it.
2) Loosen the knob (4) of feed pump, pull it out,
then pump it in and out until the movement
becomes heavy.
• It is not necessary to remove the plugs at
the fuel pre-filter head and fuel main filter
head.
• When the engine runs out of fuel, use the
same procedure to operate the knob (4)
of feed pump and bleed the air.
5. The oil level should be between the H and L

marks on dipstick (G).
If the oil level is below the L mark, add oil
through oil filler port (F).
3) Push in the knob (4) of feed pump and

tighten it.
9. After replacing the filter cartridge, start the
engine and run it at low idle for 10 minutes.
10.Check the filter seal surface for fuel leakage. If
there is any leakage of fuel, check the tightening 6. If the oil is above the H mark, drain the excess
condition of the filter cartridge. If the fuel still engine oil from drain valve (P) at the bottom of
leaks, follow Step 1 to 4 to remove the filter the engine oil pan, then check the oil level again.
cartridge, then check the O-ring for damage or
40-20 PC210LC-10
40 Troubleshooting
7. If oil level is correct, securely tighten the oil filler

cap and close the engine hood.
a12. Checking of coolant level (in sub tank)

k The radiator cap does not need to be opened
for standard checks. When checking the
coolant level, check the sub-tank while the
engine is cool.
k Immediately after the engine is stopped, the

coolant is still very hot and the pressure is
accumulated in the radiator.
If the cap is opened under these conditions,
you may be scalded. If you need to remove a.13 Checking of air cleaner for clogging
the radiator cap, wait until the temperature
k When using compressed air for cleaning, put
drops before you do. Then turn the cap
on personal protective items such as
slowly to release the pressure and remove it
protective eyeglasses, gloves, dust mask,
with care.
etc. to protect yourself from dirt that will fly
1. Open the side cover at the rear left of the out.
machine, and check if the coolant in sub-tank (1)
k When removing the outer element from the
(shown in the figure below) is between the FULL
air cleaner body, do not forcibly pull it out,
and LOW marks. If the coolant level is low, add
otherwise it can be dangerous.
coolant to the FULL level through the filler port of
sub-tank (1). Be careful not to fall from a high location on
2. After refilling with coolant, tighten the cap unsafe scaffolding as a reaction when pulling
securely. out the outer element.
3. If the sub-tank is empty, leakage of coolant is
suspected. Testing
If any abnormality is found in the check for If air cleaner clogging monitor (1) on the monitor
leakage, repair it immediately. If no abnormality panel lights up, clean the air cleaner element.
is found, check the level of the coolant in the
radiator. If it is low, add coolant to the radiator
and then to the sub-tank.
4. Wash the sub-tank (1) if inside of it is too dirty to
check the coolant level.
PC210LC-10 40-21
40 Troubleshooting
a Do not clean the air cleaner element until the air 4. Wipe off the dirt stuck to the inside of the air
cleaner clogging monitor on the monitor panel cleaner body (7) and cover (3) with clean cloth.
lights up. If the element is cleaned frequently
a Do not tap or hit the element against any
before the air cleaner clogging monitor lights up,
other object when cleaning it.
the air cleaner is not able to display its
performance fully, and the cleaning efficiency
goes down.
a Dust attached to the element often drops into
inner element side during cleaning. If performing
checking, cleaning, and maintenance while
engine is running, dust may enter and may
damage the engine. When cleaning, be sure to
stop the engine.
Cleaning of outer element
a Before and after cleaning the element, do not
leave it or keep it under direct sunlight.
a Replace the outer element if it is cleaned six 5. Remove any dirt or dust that is accumulated on
times or used throughout a year. Replace the vacuator valve (4) installed to cover (3).
inner element as well when replacing the outer
element.
a Replace both inner and outer elements when the
air cleaner clogging monitor (1) lights up soon
after installing the cleaned outer element even
though it has not been cleaned six times.
1. Open the side cover at the rear left side of the
machine, and remove three hooks (2) to remove
cover (3).
6. Blow compressed dry air (less than 0.2 MPa

{2.1kg/cm2}) from the inside of the outer element
along the folds.
7. Then blow it from outside along the folds, and
blow it from the inside again.
2. Hold outer element (5), move it lightly up and

down, and right and left, and rotate the element
clockwise and counterclockwise to pull it out.
a Never remove inner element (6). Dusts may
enter in it and it may cause the engine
trouble.
a Do not use a tool such as a screwdriver.
a If small holes or thinner parts are found on
a When outer element (5) is removed, check the element when it is checked by lightening
that the inner element does not come out of inside the element after cleaning, replace the
position and is not at an angle. If it is at angle, element.
push it straight to the end by hand.
3. After removing outer element (5), cover the inner
element (6) with a clean cloth or tape to prevent
dirt or dust from entering.
40-22 PC210LC-10
40 Troubleshooting
8. Remove the cloth or tape covering inner element

(6).
9. Check that there is no dirt or oil stuck to the 2) Hook the tip of hook (2) to the fitting part of
sealing portion of the new element or cleaned the air cleaner body and lock it.
element. Wipe off if any is attached. a When locking the hook (2), do it in
a If the element and O-ring are used again diagonal order (top and bottom, right and
after usage for more than one year, it may left).
cause problems even if they are cleaned. Do a When cover (3) is installed, check that the
not use them. clearance between the air cleaner body
a Do not use the element if its folds or gasket and cover (3) is not too large. If it is too
or seal are damaged. large, install it again.
10.Push the outer element straight into air cleaner
body as moving it the lightly up and down, and
right and left by hand.
a Install it so that the bottom of the air cleaner
element (face where no hole is drilled) (C)
comes to cover (3) end.
If it is installed in wrong direction, it may
cause breakage of the air cleaner element or
serious damage to the engine.
12.Remove one seal from the element whenever

the element is cleaned.
11.Install cover (3) according to the following

procedure.
1) Place cover (3) to the element.
a Always install cover (3) so that vacuator Replacement
(4) sits to the direction below (A). 1. Remove outer element (5) according to
"Cleaning of outer element".
2. Remove inner element (6), then immediately
install the new inner element (6) to air cleaner
body (7).
PC210LC-10 40-23
40 Troubleshooting
a Do not clean and reuse the inner element.

Replace the inner element with a new one at
the same time as you replace the outer
element.
5. Install cover (3) according to "Cleaning of outer

element".
6. Replace seal (9) on the cover (3) with a new
one.
a Install it so that the bottom of the air cleaner

element (face where no hole is drilled) (C)
comes to cover (3) end.
If it is installed in wrong direction, it may
cause breakage of the air cleaner element or
serious damage to the engine.
a If the outer element and cover are installed
while the inner element is not installed
properly, the outer element may be damaged.
Be sure to install them properly.
b. Hydraulic and mechanical equipment

b3. Check of hydraulic oil level
k When removing the oil filler cap, the oil may

spout out. Turn it slowly to release the
internal pressure, then remove it.
3. Push the outer element straight into air cleaner 1. Set the work equipment in the posture shown in
body as moving it the lightly up and down, and the following figure, stop the engine, and then
right and left by hand. check the oil level. Add oil if necessary.
a Install it so that the bottom of the air cleaner a If the work equipment is not in the condition
element (face where no hole is drilled) (C) shown in the following figure, start the engine,
comes to cover (3) end. run it at low idle. Retract the arm and bucket
If it is installed in wrong direction, it may cylinder rods fully, lower the boom, set the
cause breakage of the air cleaner element or bucket teeth in contact with the ground, and
serious damage to the engine. then stop the engine.
4. Replace O-ring (8) for cover (3) with a new one.
40-24 PC210LC-10
40 Troubleshooting
The oil level varies depending on the oil

temperature. Check according to the followings:
• Before starting operation (oil temperature is
10°C to 30°C) : Between H and L marks
• During normal operation (oil temperature is
50°C to 380°C) : Around H mark
b4. Check of hydraulic oil strainer
k When you remove the oil filler cap, oil may

2. Turn the staring switch key to the ON position
within 15 seconds after stopping the engine. spurt out. Be careful to rotate it slowly, and
Move each control lever (for work equipment release inner pressure gradually.
and travel) to the full stroke in all directions to
1. Stop the engine, remove the cap for oil filler port
(F), and release the internal pressure.
3. Open the side cover on the right of the machine,
2. Remove bolts and remove cover (1).
then check sight gauge (G). The oil level should
3. When doing this, the cover (1) may jump out
be between the H and L marks.
under the force of spring (2), so hold the cover
a If the oil level is below the L mark, add oil down as removing the bolts.
through oil filler port (F). 4. Hold the top of rod (3) and pull it up to remove
spring (2) and strainer (4).
a Do not fill the oil beyond the H mark, since it
5. Remove any dirt stuck to strainer (4), then wash
may damage the hydraulic circuit or oil may
it in flushing oil. If strainer (4) is damaged,
spurt out.
replace it with a new one.
a If the oil level exceeds the H mark, stop the 6. To install, insert strainer (4) into protruding part
engine, wait for the hydraulic oil temperature (5) of the tank.
to cool down, and discharge excessive oil 7. Install cover (1) as the protruding part at the
from drain plug (P) under the suction tube. bottom of it holds spring (2), then tighten it with
the bolts. Tighten mounting bolts.
b.5 Check of hydraulic oil filter

k When you remove the oil filler cap, oil may

spurt out. Be careful to rotate it slowly, and
release inner pressure gradually.
1. Set the work equipment in the maintenance

posture shown in the figure on the hard and flat
PC210LC-10 40-25
40 Troubleshooting
ground, lower it to the ground, and stop the

engine.
10.Install oil filler cap (F).

11.To bleed air, run the engine at low idle for 10
minutes.
2. Remove the oil filler cap (F) of hydraulic tank,
12.Stop the engine.
and release the internal pressure.
b6. Check of swing machinery case oil level
1. Pull out dipstick (G) and wipe the oil off of the
gauge with a cloth.
2. Fully insert dipstick (G) into the dipstick pipe.
3. Pull out dipstick (G) and check that the oil level
is between the (H) and (L) marks on the dipstick.
4. If the oil does not reach the (L) mark on dipstick
(G), add oil through oil filler port (F).
5. If the oil level is above the (H) mark on dipstick
3. Remove bolts and remove cover (1).
(G), loosen drain valve (P) and drain the excess
When doing this, the cover (1) may jump out
oil.
under the force of spring (2), so hold the cover
down as removing the bolts. • Set a container to receive the oil under drain
4. After removing spring (2), valve (3) and strainer valve (P) before draining the oil.
(4), remove element (5). 6. After checking oil level or adding oil, insert the
dipstick (G) into the hole and install the cap to oil
• Check the bottom of the filter case for dirt or
filler port (F).
other material, and remove any if found. At
that time, take extreme care for any dirt or
other material not to drop into the hydraulic
tank.
5. Clean the removed parts in flushing oil.
6. Install new element (5).
7. Set strainer (4), valve (3), and spring (2) on the
top of the element.
8. Set cover (1) and install it with mounting bolts
while pressing it by hand.
9. Tighten mounting bolts.
40-26 PC210LC-10
40 Troubleshooting
b8. Check of final drive case oil level

k Oil may spurt out by internal pressure.
Perform removal of the plug from the side,
and release the internal pressure by turning
the plug gradually with care.

• Refill capacity (both right and left): 5.0

• Prepare a handle.
1. Set the TOP mark at the top, and make the line
running on the TOP mark and plug (P)
perpendicular to the ground surface.
2. Place a container under plug (P) to receive the
oil.
3. Remove plugs (P) and (F) with the handle and
drain the oil.
a Check the O-rings attached to the plugs for
damage. If necessary, replace them with new
ones.
4. Tighten plug (P).
5. Add oil through the hole for plug (F).
b7. Check of damper case oil level 6. When oil begins to overflow from the plug (F)
hole, install plug (F).
k Park the machine on a flat ground and stop
the engine. Check the oil level when more 3 Tightening torque of plug (P) and (F)
than 30 minutes passed after stopping the 68.6 ± 9.8 Nm {7 ± 1 kgm}
engine.
k There are 2 plugs, but add oil through the
1. Open the engine side cover on the rear right of one of plugs (F) which is easier to add oil
the machine. and which no internal gears are seen
2. Remove plug (G) and check the oil level. If the from.
oil level is near the bottom of the plug hole, the
oil amount is at a proper level. If the oil amount
is short, remove plug (F) and refill oil through
plug (F) filler port up to the bottom of plug (G)
hole.
a If the oil is excessive, drain it until it reaches
to the specified level. Otherwise it may cause
overheat.
3. Install plugs (G) and (F).
4. Close side cover.
PC210LC-10 40-27
40 Troubleshooting
• Check alternator terminal B (1) for open circuit,

looseness, or corrosion.
c3. Check of starting motor terminal for

looseness and corrosion
• Check starting motor terminals B (1), C (2) for
open circuit, loosening and corrosion.
b9. Bleeding air

• For the bleeding air from the fuel system, see
Testing and adjusting, "Bleeding air from fuel
circuit".
• For the bleeding air from the hydraulic system,
see Testing and adjusting, "Bleeding air from
hydraulic circuit".) c4. Check of battery voltage (with engine
stopped)
c. Electrical parts
c1. Check of battery terminal for looseness and • Check the battery voltage by using the battery
corrosion tester while the engine is stopped.
c5. Check of battery electrolyte level
1. Open the side cover at the rear left side of the
machine, and remove two nuts (1) on the battery Check before operating the machine.
to remove two battery covers (2). k Do not use the battery if the battery
2. Check the battery cable terminals for looseness electrolyte level is below the LOWER LEVEL
and corrosion. line. This will accelerate deterioration of the
inside of the battery and reduce the service
life of the battery. In addition, it may cause an
explosion.
k Since the battery produces combustible gas

that can explode, do not bring any open
flame near it.
k Battery electrolyte is dangerous. Take care

that it does not come in contact with your
eyes or skin. If it does, wash it away with
water and contact your doctor.
c2. Check of alternator terminal for looseness

and corrosion
40-28 PC210LC-10
40 Troubleshooting
a Do not add the battery fluid above the UPPER • When electrolyte level cannot be checked
LEVEL line. If done, the fluid may leak and the through the side face of the battery
coating surface may be damaged or the parts 1. Remove the cap (2) from the top of battery.
may be corroded. (Described above)
2. Observe fluid level port (3), and check the fluid
a To avoid freezing, add the purified water (such
level. If the fluid level is below sleeve (4), always
as a commercial battery fluid) before starting the
add the fluid (such as a commercial battery fluid)
work in the next day.
until it reaches the bottom of sleeve (the UPPER
• When checking the electrolyte level through the LEVEL).
side face of the battery
• (A) Correct level: Since the electrolyte level
1. Wipe and clean the battery surface, especially
reaches to the sleeve bottom, the shape of
around the battery level lines, with a wet cloth,
the electrode plates appears distorted due to
and check to see that the battery fluid is
the surface tension.
between the UPPER LEVEL and LOWER
• (B) Low: Since the electrolyte level does not
LEVEL lines.
reach the sleeve bottom, the shape of the
a Do not clean the battery with a dry cloth electrode plates appears straight.
since static electricity may cause an 3. After adding the refined water, tighten the cap
explosion. (2).
2. If the battery fluid drops below the center

position between the UPPER LEVEL and
LOWER LEVEL lines, remove the cap (2) and a If the fluid exceeds the UPPER LEVEL,
add the refined water (such as a commercial remove the fluid using a dropping pipette or
battery fluid) immediately until the fluid reaches others until the fluid drops to the UPPER
the UPPER LEVEL. LEVEL. When you have removed the fluid
3. After adding the refined water, tighten the cap from the battery, neutralize it with the baking
(2) securely. soda (sodium bicarbonate) and wash it away
with a large quantity of water.
c6. Check of wiring harness for discoloration,
burn and cover peeling
• Check the wiring harness and cables for
discoloration and burn.
a If discolored or burnt, the circuit may be shorted
or grounded.
• Check the wiring harnesses and cables for
damage and peeling of the covers.
• If any abnormality is found, repair or replace the
wiring harness or cables.
c7. Check for coming off of wiring harness
a If the fluid exceeds the UPPER LEVEL, clamp and sagging of wiring harness
remove the fluid using a dropping pipette or • Check wiring harness for sagging and looseness
others until the fluid drops to the UPPER due to coming off of harness clamp
LEVEL. When you have removed the fluid
a In particular, carefully check the wiring harness
from the battery, neutralize it with the baking
around the hot and movable parts.
soda (sodium bicarbonate) and wash it away
with a large quantity of water.
PC210LC-10 40-29
40 Troubleshooting
• If removed from the clamp, secure it with the

clamp.
• Check the connection of ground terminals (T04)

to (T07), (T09) and (T10).
c8. Check of grounding
a Take special care not to cause a loose cable
connection and corrosion.
• Check the connection of ground terminals (60B)
and (T01).
• Open undercover under the engine.

a You can check the connection of engine ground
terminals by removing the under cover of the
engine.
• Check the connection of ground cable (T12) of
• Open the side cover on the rear left of the the engine controller (EC).
machine.
• Check the connection of ground terminal (T08).
40-30 PC210LC-10
40 Troubleshooting
• Cab ground T02 c10. Check the connector pins for corrosion,
a (T02) is not required checking since it is bending and deformation.
connected (T01) and it is located down side of • Disconnect the connectors, and check their pins
rear left inside the cab. for corrosion, bending, sinking than other pins,
and extension of female pins.
• If pins are defective, repair or replace them.
a If the pins are not shiny, apply contact restorer to
them and connect and disconnect the
connectors several times to shine them. (If the
pins do not become shiny, connect and
disconnect the connectors 10 times)
c11. Check of connector for water and foreign
material insertion.
• Disconnect connectors, and check them for
insertion of water or foreign materials.
c9. Check for loose connector and damaged

lock.
• Check the connection of male and female
connectors by pulling them by hand.
• If the connection is loose, secure it.
a If found, the seals may be damaged. Check the

seals for damage.
• If the seal is defective, repair or replace it.
• Dry the inside of the connector with a dryer.
• Check the connectors for unlocking, and check

the lock and connector housing for cracking.
• Check lock screw (L) of engine controller (EC)
for looseness.
a Use a hexagonal wrench with 4 mm width
across flats.
PC210LC-10 40-31
40 Troubleshooting
• A fusible link is a large-capacity fuse.

• If a fuse is corroded and coated with white
powder, or there is any play between the fuse
and fuse holder, replace the fuse.
• Replace each fuse with the one of the same
capacity.
Remove the cover at the rear right of the operator's
seat, and you will see the fuse box.
• Wipe and remove any foreign material with a

cloth or others, and blow the air to clean the
connector.
There are two fusible links (F04) and (F05) you can
see when cover on the air cleaner is removed, and
cover of battery relay is removed.
c12. Check of wiring harness for open or short

circuit
• Check the connection (crimped part) between
connector pins and wiring harness.
• If the line is open as shown as (A), repair or
replace the wiring harness or cables.
c14. Check of alternator voltage (when engine

speed is medium or higher)
1. Open the engine hood.
2. Connect the positive (+) lead of the multimeter to
alternator terminal (B) and connect the negative
(-) lead to the chassis ground.
3. Start and warm up the engine and measure the
voltage while running the engine at a medium or
a higher speed.
• If the voltage is abnormal, repair or replace
• Visually check wiring harnesses for peeling of the alternator.
harness covers and the pins for contact with c15. Check of battery relay operation sound
adjacent pins due to defective crimping. 1. Open the side cover on the left of the machine.
c13. Check of fuse for breakage and corrosion 2. Turn the starting switch to the ON and OFF
positions, and check whether the battery relay
a When replacing a fuse, be sure to turn off the
operation sound is heard or not.
power supply (turn the starting switch to OFF
position) and turn the battery disconnect switch • If the operation sound is not heard, check the
to OFF position. related circuits, referring to the description of
40-32 PC210LC-10
40 Troubleshooting
troubleshooting for E-1 described in the E

mode troubleshooting.
• If the relating circuit is normal, replace the
battery relay.
PC210LC-10 40-33
40 Troubleshooting
Preparation work for troubleshooting of electrical system (ALL-C050-001-K-01-A)
a When carrying out troubleshooting of an electric

circuit related to the machine monitor, engine
controller, pump cont roller, or KOMTRAX
communication MODEM, expose the related
connectors according to the following procedure.
a Disconnect and connect the connectors, which
have a special locking device, according to the
following procedure.
Preparation work (PC220-C050-42C-K-00-A)
1. Machine monitor
1) Remove the screws (three pcs.) mounting
cover (1). 4) Insert or connect troubleshooting T-adapters
in or to connectors CM01, CM02, and CM04
a One of the three screws is covered with on machine monitor (7).
cap (2).
a Disconnect connector P31 of the sunlight
sensor and remove cover (1).
1) Remove the undercover.
a The engine controller is mounted on the
2) Remove a mounting bolt and duct (6).
engine (on the counterweight side).
3) Insert a flat-head screwdriver in slit (3) and
2) Insert or connect troubleshooting T-adapters
pull it up around projection (4) to remove
in or to connectors ECMJ1, ECMJ2, and
cover (5).
CE03 on engine controller (8).
a Connectors are fixed with screw. Loosen
the screws before disconnecting them.
a When returning, tighten the screw to the
specified torque.
3 Screw: 3 ± 1 Nm {0.3 ± 0.1 kgm}
3. Pump controller
40-34 PC210LC-10
40 Troubleshooting
1) Slide the operator's seat and seat stand to a The connectors of the pump controller
the forward end. have a special locking mechanism.
2) Remove the five mounting bolts and cool & Disconnect them according to steps (a) to
hot box (9). (c) and connect them according to steps
(d) to (f) as shown below.
a While removing the cool and hot box,
disconnect the drain hose. Disconnection: (a) Unlock - (b) Slide lever
3) Remove the two mounting bolts, one - (c) Disconnect connector.
fastener, and magazine box (10). Connection: (d) Position connector - (e)
4) Remove the three mounting bolts and cover Slide lever - (f) Lock.
(11).
5) Remove the seven mounting bolts and cover
(14).
4. KOMTRAX communication module

1) Slide the operator's seat and seat stand to
6) Connect test adapters to connectors CP01 the forward end.
and CP02 of pump controller (15). 2) Remove the five mounting bolts and cool &
hot box (9).
a Connect the adapters to only the harness.
a While removing the cool and hot box,
disconnect the drain hose.
3) Remove the two mounting bolts, one
fastener, and magazine box (10).
4) Remove the three mounting bolts and cover
(11).
5) Remove the seven mounting bolts and cover
(14).
6) Connect troubleshooting T-adapters to

connectors CK01 and CK02 of KOMTRAX
communication module (15).
PC210LC-10 40-35
40 Troubleshooting
a Disconnection and connection of connector

The connector of the boost pressure
temperature sensor has a special locking
mechanism. Disconnect it according to steps
(a) - (b), and connect it according to steps (c)
- (d) as shown below.
Disconnection: (a) Unlock - (b) Disconnect
connector.
Connection: (c) Connect connector - (d) Lock.
5. Ambient pressure sensor (AMBAIR

PRESSURE)
Engine Ne speed sensor (Crank sensor)
Engine Bkup speed sensor (Cam sensor)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, engine oil pressure
switch have a special locking device.
a Removal and installation of sensor
Disconnect them in the order of steps (a) –
(c) and connect them in the order of steps (d) A torx wrench is necessary for removal and
– (f) as shown below. installation of the boost pressure
temperature and sensor. See "Tools for
Disconnection: (a) Slide lever - (b) Unlock -
testing, adjusting and troubleshooting".
(c) Disconnect connector.
7. Supply pump IMV solenoid (Fuel regulator)
Connection: (d) Connect connector - (e) Lock
- (f) Slide lever. a Disconnection and connection of connector
The connector of the supply pump IMV
solenoid has a special locking mechanism.
Disconnect it according to steps (a) to (b),
and connect it according to steps (c) to (d) as
shown below.
Disconnection: (a) Unlock - (b) Disconnect
connector.

A deep socket is necessary for removal and
installation of the engine oil pressure switch.
See "Tools for testing, adjusting and
troubleshooting".
6. Boost pressure temperature sensor (BOOST
PRES & IMT)
8. Common rail pressure sensor (Fuel rail

press)
40-36 PC210LC-10
40 Troubleshooting
a Disconnection and connection of connector a Precautions for connecting connector

The connector of the common rail pressure Take care not to connect the connector
sensor has a special locking mechanism. reversely.
Disconnect it according to steps (a) to (b), Engage lock (e) on the wiring harness side
and connect it according to steps (c) to (d) as with triangular projection (f) on the sensor
shown below. side (Do not engage lock (e) with square
Disconnection: (a) Unlock - (b) Disconnect guide (g) on the opposite side of triangular
connector. projection (f)).
9. Engine coolant temperature sensor (Coolant

temp)
a Precautions for disconnecting connector
The direction of the lock on the connector
varies depending on position at which the The connector of the engine coolant
tightening of the sensor has been stopped temperature sensor has a special locking
and the lock may be in a direction in which it mechanism. Disconnect it according to steps
is difficult to unlock (lock faces the engine or (a) to (b), and connect it according to steps
downward). (c) to (d) as shown below.
In this case, pinch the lock in direction (a) by Disconnection: (a) Unlock - (b) Disconnect
bent-longnose pliers [1] (commercially connector.
available), and the lock is unlocked. Connection: (c) Connect connector - (d) Lock.
The lock clicks when it is unlocked, so
disconnect the connector after a click is
heard.

A deep socket is necessary for removal and
installation of the engine coolant temperature
sensor. See Testing and adjusting,
"Troubleshooting tools table".
PC210LC-10 40-37
40 Troubleshooting
Classification and procedure for troubleshooting (PC220-5160-40D-A-00-A)

Classification of troubleshooting
Mode Content
Display of Troubleshooting by failure code
code
E-mode Troubleshooting electrical system
H-mode Troubleshooting hydraulic and mechanical system
S-mode Troubleshooting engine
Procedure for troubleshooting

If a problem occurs in the machine, go to the corresponding troubleshooting section according to the following
procedure.
1. Troubleshooting procedure to be taken when action level and failure code are displayed on
machine monitor:
If an action level and a failure code are displayed on the machine monitor, carry out the troubleshooting for
the corresponding [Display of code] according to the displayed failure code.
a If multiple problems occur simultaneously, all the failure codes for the problems are displayed
repeatedly in order. Record all the failure codes.
2. Troubleshooting procedure to be taken when action level and failure code are not displayed on
normal screen of machine monitor:
Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor. (See [*1])
1) If a code is recorded, carry out troubleshooting for the corresponding [Display of code] according to the
recorded code.
a If an electrical system failure code is recorded, delete all the codes once and reproduce them, and
then see if the trouble is still detected. (See [*2])
a A failure code of the mechanical system cannot be deleted.
a If abnormality related to air conditioner is displayed in electrical system abnormality record, perform
"Check with self-diagnosis" in "Air conditioner".
2) If no failure code is recorded in the abnormality record, a failure that the machine cannot find out by
itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the problem which seems to be a failure again and select the same problem from
the table of "Problem which seems to be failures and troubleshooting Nos.", and then carry out
troubleshooting corresponding to that problem in the [E-mode], [H-mode], or [S-mode].
3. Actions to take after failure is repaired
Referring to following page, delete all failure codes in electrical system abnormality record.
[*1]、[*2]
1. On the normal operation screen, while pressing number key [4] in the panel switch section, press [1], [2],
and [3] in this order.
2. On the service menu screen, press switch [F3] (R) in the panel switch section twice, and then select "03
Abnormality Record".
3. Press switch [F6] in the panel switch section to confirm, and then enter the "Abnormality record" screen.
40-38 PC210LC-10
40 Troubleshooting
4. Press switch [F6] in the panel switch section to confirm, and then enter the "Mechanical system failure
record" screen.
5. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a A failure code of the mechanical system cannot be deleted.
6. Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
7. Similarly to 2 and 3, enter the "Electrical system abnormality record" screen.
8. Press switch [F3] (R) in the panel switch section to check failure codes one by one and take record of all
information of all failure codes.
a If [E] is displayed on the left of a failure code, that failure code is "active" (the failure is still occurring or
normal resetting is not confirmed yet). If [E] is not displayed on the left of a failure code, that failure
code is "non-active" and disappears in the following clearing step. Accordingly be sure to take record
of that failure code.
9. While pressing number key [4] in the panel switch section, press [1], [2], and [3] in this order to enter the
"Clearing mode". (Same as 1)
10.Press switch [F2] (CLEAR) in the panel switch section.
11.Press switch [F6] in the panel switch section to clear all failure codes temporarily.
12.Press switch [F5] (return) in the panel switch section to return to the "Electrical system abnormality record"
screen. Check if there is any failure code still displayed and take record.
13.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
PC210LC-10 40-39
40 Troubleshooting
14.Take record of information of all columns.

a Similarly to the electrical system abnormality record, if "E" is displayed on the left of a failure code, that
failure code is "active"
(the failure is still occurring or normal resetting is not confirmed yet).
15.Press switch [F2] (CLEAR) in the panel switch section to clear all codes temporarily. Check if "Abnormal"
is still displayed and take record. (Same as 10 in [*1] and [*2])
16.Press switch [F5] (return) in the panel switch section to return to the "Abnormality record" screen.
40-40 PC210LC-10
40 Troubleshooting
Symptom of probable failure and troubleshooting No. (PC220-5540-441-A-00-A)
Problem and troubleshooting number

Troubleshooting
No. Problem
Index
Action level, failure code
Action level is displayed on machine monitor. If function key [F5] is pressed,
1 occurring failures list is displayed. Take actions by
The failure code is displayed on the mechanical system abnormality record screen following the
2
failure code.
3 The failure code is displayed on the electrical system abnormality record screen
Troubleshooting
No. Problem
Index
Phenomena related to engine
4 Starting performance is poor. S-4
5 Engine does not start E-1, S-1
6 When starting switch is turned to "START" position, engine is not rotated S-1, E-1
7 Engine is cranked but exhaust gas does not come out S-2
8 Fuel is injected but engine does not start S-3
9 Engine does not pick up smoothly S-5
10 Engine stops during operation S-6, H-2
11 Engine runs rough or is unstable S-7
12 Engine lacks power S-8
13 Exhaust gas color is black (KDPF is prematurely plugged) S-9
14 Oil consumption is increased. S-10
15 Oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive S-12
17 Oil is in coolant (or coolant spurts back or coolant level goes down) S-13
18 Oil pressure drops S-14
19 Fuel in oil S-15
20 Oil is mixed with water (milkiness) S-16
21 Coolant temperature rises too high (overheating) S-17
22 Unusual noise is heard S-18
23 Vibration is excessive S-19
24 Frequency of automatic regeneration is increased S-20
25 A longer time is taken for forced regeneration S-21
26 White smokes are emitted during forced regeneration. S-22
27 Manual preheater does not operate. E-2
28 Automatic preheating function does not work. E-3
29 While preheater is operating, preheating monitor does not light up. E-4
30 Automatic warm-up system does not work (in cold weather). E-26
When auto-decelerator switch is operated, auto-decelerator monitor does not light
31 up or does not go off. E-27
32 Auto-decelerator is not operated or canceled with lever. E-28
Symptom related to work equipment, swing and travel
33 Any of work equipment, swing, and travel does not work. E-36, H-3
34 All of work equipment, swing, and travel mechanism do not lock. E-37
35 Speed or power of all work equipment, swing and travel is low. H-1
36 Engine speed lowers extremely or engine stalls. H-2, S-6
When working mode switch is operated, working mode selection screen is not
37 displayed. E-29
When working mode is changed, setting of engine and hydraulic pump is not
38 changed. E-30
39 Abnormal sound comes out from around hydraulic pump H-4
PC210LC-10 40-41
40 Troubleshooting
Troubleshooting
No. Problem
Index
40 Fine control performance or response is low H-5
Problems related to work equipment
41 Speed or power of boom is low. H-6
42 Speed or power of arm is low. H-7
43 Speed or power of bucket is low H-8
44 Work equipment single operation does not function. H-9
45 Hydraulic drift of boom is large. H-10
46 Hydraulic drift of arm is large. H-11
47 Hydraulic drift of bucket is large. H-12
48 Time lag in work equipment operation is large. H-13
49 When performing hydraulic relief of a work equipment, other work equipment move. H-14
50 Power maximizing function does not work. H-15, E-40
51 Power maximizing function is not reset. E-41
52 When attachment is installed, attachment circuit is not switched to desired one. H-34, E-58
53 Flow rate of attachment circuit cannot be adjusted H-35
Problems related to combined operation
54 Work equipment on large load side moves slower during combined operation H-16
When performing combined operation of swing and boom RAISE , boom RAISE
55 speed is slow. H-17
When performing combined operation of swing and travel , travel speed lowers
56 significantly. H-18
Problems related to travel
57 Machine deviates during travel H-19
58 Travel speed is low H-20
59 Machine is not steered well or steered-travel power is low. H-21
60 Travel speed does not switch or travel speed is too low or high. H-22, E-31, E-32
61 Travel system does not work (only one side) H-23
62 Alarm does not sound during travel. E-42
63 Alarm does not stop sounding while machine is stopped. E-43
Problems related to swing
64 Upper structure swings neither to the right nor left H-24
65 Upper structure does not swing in only one direction H-25
66 Swing acceleration is poor or swing speed is slow in both right and left directions. H-26
Swing acceleration performance is poor or swing speed is slow in only one
67 H-27
direction.
Upper structure overruns excessively when it stops swinging in both right and left
68 H-28
directions.
69 Upper structure overruns excessively when it stops swinging in only one direction. H-29
70 Large shock is made when upper structure stops swinging H-30
71 Large unusual noise is heard when upper structure stops swinging. H-31
72 While swing brake is applied, swing drift on slope is large. H-32
73 While swing brake is released, swing drift on slope is large. H-33
When swing brake cancel switch is set to CANCEL position, machine cannot
74 swing. E-38
When swing brake cancel switch is set to Normal position, swing holding brake
75 does not operate. E-39
Problems related to machine monitor
76 When starting switch is turned to ON position, machine monitor displays nothing E-5
When starting switch is turned to ON position (with engine stopped), engine oil level
77 monitor lights up in red. E-6
When starting switch is turned to ON position (with engine stopped), radiator
78 coolant level monitor lights up in red. E-7
79 Engine coolant temperature monitor lights in white while engine is running. E-8
40-42 PC210LC-10
40 Troubleshooting
Troubleshooting
No. Problem
Index
80 Hydraulic oil temperature monitor lights in white while engine is running. E-9
81 Charge level monitor lights up while engine is running. E-10
82 Fuel level monitor lights up in red while engine is running. E-11
83 Air cleaner clogging monitor lights up in red while engine is running. E-12
84 Water separator monitor lights up while engine is running. E-13
85 Engine coolant temperature monitor lights in red while engine is running. E-14
86 Hydraulic oil temperature monitor lights in red while engine is running. E-15
87 Engine oil pressure monitor lights in red while engine is running. E-16
88 Fuel level gauge keeps indicating minimum or maximum. E-17
Fuel level gauge does not indicate actual fuel level (Indication is not minimum or
89 maximum). E-18
90 Engine coolant temperature gauge keeps indicating minimum or maximum. E-19
Engine coolant temperature gauge does not indicate actual coolant temperature
91 (Indication is not minimum or maximum). E-20
92 Hydraulic oil temperature gauge keeps indicating minimum or maximum. E-21
Hydraulic oil temperature gauge does not indicate actual oil temperature (Indication
93 is not minimum or maximum). E-22
94 Displays on machine monitor are different from those for applicable model. E-23
95 Machine monitor does not display partially. E-24
96 Function switch does not operate E-25
97 Alarm buzzer cannot be canceled E-33
98 When starting switch is in OFF position, service meter is not displayed. E-34
99 Machine monitor cannot be set in service mode E-35
100 Horn does not sound. E-44
101 Horn does not stop sounding. E-45
102 When wiper switch is operated, wiper monitor does not light up or go off. E-46
103 When wiper switch is operated, windshield wiper does not operate. E-47
104 When window washer switch is operated, window washer does not operate. E-48
"Testing and
Air conditioner does not operate normally (including failure code related to air troubleshooting
105 conditioner) procedure" in
Chapter 80
106 Monitoring function does not display lever control signal normally E-49 to E-57
Others
107 KOMTRAX system does not work properly E-59
PC210LC-10 40-43
40 Troubleshooting
Information in troubleshooting table (ALL-5170-421-A-01-A)
(Rev. 2011/12)
a The following information is summarized in the troubleshooting table. Before performing troubleshooting,
understand that information fully.
Action level Failure code
Display on Failure name displayed on the Abnormality Record screen
Display on Failure
machine of the machine monitor
machine monitor
monitor
Detail of Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by
controller the machine monitor or controller
Problem on A problem that appears as a failure on the machine as a result of an action (above) that is
machine performed by the machine monitor or controller.
Related Information on occurred failure or troubleshooting
information
No. Cause Procedure, measuring location, criteria and remarks
1 Defective — <Contents of description>
Open or short circuit in wiring • Procedure
2
harness • Measuring location
Open circuit in wiring harness
a "Between A and B" denotes measuring values such as voltage
3 (wire breakage or defective and resistance between A and B.
contact of connector)
Ground fault in wiring harness a "Between A and ground" means the measurement of voltage,
4 resistance or others between terminal A and the place which has
(contact with ground circuit) a continuity with chassis frame such as unpainted hexagonal
Hot short circuit head bolt or bolt hole which has no rust, etc.
5
(contact with 24 V circuit) • Criteria to judge probable causes (standard value), remarks
<How to use troubleshooting sheet>
• Perform troubleshooting procedures in numerical order.
• If the check result does not meet the criteria, the probable cause
described on the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific
instruction, proceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been
corrected.
<Failures in wiring harness>
Short circuit in wiring harness • Open circuit
6 Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes
into contact with the ground (earth) circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24 V) circuit comes into
contact with the power (24 V) circuit accidentally.
• Short circuit
An independent wire in the harness erroneously comes into contact
with another independent wire.
(poor insulation at connector and others)
40-44 PC210LC-10
40 Troubleshooting

<Precautions for troubleshooting>
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless
otherwise specified.
• When "male" or "female" is not indicated with a connector number,
disconnect the connector, and insert T-adapter between the male
and female connectors.
7 Defective controller • When "male" or "female" is indicated with a connector number,
disconnect the connector, and connect T-adapter to the male or
female connector.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wire indicated first.
• Connect the negative (-) lead to a pin or wire indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to
troubleshooting
• The circuit diagram contains the connector Nos.,
pin Nos., and connector colors related to the
failure.
• The “/“ in a connector number is either:
1) An abbreviation (of more than three letters)
Example: T/C (Torque Converter)
2) Different connector number at male and female
sides
Example: BREAK OUT/E24
• The circuit diagram contains the destination or
source of the branch line in a wiring harness.
• The arrow (io) indicates a rough installation
position on the given machine.
• NO: Normally Open
• NC: Normally Closed
• Signal names such as GND and 24 V are included
in addition to connector numbers at junctions, etc.
in circuit diagrams.
• Except for GND and 24 V, a signal name indicated
at a junction, etc. shows that the wire is connected
to another junction or controller at where the same
signal name is indicated.
PC210LC-10 40-45
40 Troubleshooting
Diagnostic procedure for wiring harness open curcuit of pressure

sensor system (ALL-E720-42A-P-00-A)
a Since the pressure sensor consists not only of resistors but also “electronic circuits“ such as amplifiers, it
may have the differences among the resistances measured and its own polarities. So troubleshooting
must be performed carefully.
Failure codes that require this diagnosis
• CA123: Boost pressure sensor low error
• CA451: Common rail pressure sensor high error
Procedure
1. Measure and record resistance of the pressure sensor unit.
1) Disconnect pressure sensor connector (1) and connect socket (2) to the connector on the sensor side.
2) Measure resistances R1 and R2 between pins.
a If polarities of multimeter probes to apply are reversed, measured values may change. Therefore,
when measuring resistances in steps 1 and 2, apply the multimeter probes to the pressure sensor
connector so that their polarities match those of the sensor.
a If measured value is infinite, measure the resistances with multimeter probes exchanged each
other to reverse their polarities and record the finite value obtained as a measured value.
a Since measured values may disperse, measure several times.
Cause of this dispersion appears to be a charge in a sensor. Repeat steps 1 and 2 several times.
Consider this dispersion when determining whether the wiring harness is open in step 3.
2. Measure and record resistance with the wiring harness between the pressure sensor and engine
controller connected.
1) Since 5 V power supply to the pressure sensor is supplied to other sensors, disconnect other sensor
connectors first. (*)
2) Connect the pressure sensor to be measured, disconnect connector (3) on the engine controller side,
and connect T-adapter (4) to the connector on the wiring harness side.
3) Connect T-box (5) to T-adapter (4) and measure respective pins for resistances R1' and R2'.
3. Determining open circuit
If there is an “apparent difference“ between resistances R1 and R2 measured in step 1 and resistances
R1' and R2' measured in step 2, determine that "wiring harness is open".
a “Apparent difference“ means a difference of 10 or more times.
40-46 PC210LC-10
40 Troubleshooting
Pressure sensor measuring locations and reference values

Measuring location of Internal resistance of
Sensor sensor pins sensor (reference) Remarks
Boost pressure R2: Between (2) and (4) Approx. 100 z Sensor is common to engine
sensor R1: Between (1) and (4) Approx. 200 z models 107 and 114
R2: Between (3) and (1) Approx. 23 kz Sensor is common to engine
Common rail models 107 and 114
pressure sensor R1: Between (1) (+) and If polarities are inverted,
Approx. 10 Mz
(2) (-) resistance is infinite
*: Other connectors to be disconnected when measuring R2' are shown below. (See circuit diagram related to
each failure code)
• When measuring R2' of boost pressure sensor (CA123):
Connectors of common rail pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
• When measuring R2' of common rail pressure sensor (CA451):
Connectors of boost pressure sensor, CAM sensor and water-in-fuel sensor (water separator)
Note the measurements in the table below. (For measuring locations, see the related circuit diagram
described in the troubleshooting page for the failure code.)
Sensor + Wiring
Sensor unit
harness
(Measuring location of Measured value (Measuring location of Measured value
Sensor
pins of sensor side
harness side connector
connector)
of engine controller)
R2': Between (37) and
R2: Between (2) and (4)
Boost pressure (47) (*)
sensor R1': Between (44) and
(47)
R2': Between (37) and
Common rail (47) (*)
pressure sensor R1: Between (1) (+) and R1': Between (47) (+)
(2) (-) and (25) (-)
PC210LC-10 40-47
40 Troubleshooting
Connector list and layout (PC200_10-C050-055-K-00-A)

Layout of connectors
Number
Connector No. Model Equipment name Address
of pins
A13 DT 2 Intermediate connector (boom working lamp) H1
A15 DT 2 Intermediate connector (rear working lamp) I9
Intermediate connector (camera1)[rear monitor
A40 DT 4 camera] K9
A41 DT 4 Intermediate connector (camera2) S1
A42 DT 4 Intermediate connector (camera3) S1
A45 DT 4 Camera1 L8
AB Terminal 2 Alternator (terminal B) AJ8
AC01 YAZAKI 10 Air conditioner unit X5
AC02 SUMITOMO 4 Air conditioner unit X9
AC03 X 1 Air conditioner compressor solenoid clutch AE3
AMB. AIR Ambient pressure sensor
FRAMATOME 3 AE3
PRESSURE
BOOST Boost pressure and temperature sensor
SUMITOMO 4 AJ4
PRESS & IMT
CAM SENSOR FRAMATOME 3 Cam (Bkup) speed sensor AE1
CE03 DRC26 60 Engine controller AE2
CK01 070 18 KOMTRAX terminal X7
CK02 070 12 KOMTRAX terminal X7
CM01 070 18 Machine monitor O5
CM02 070 12 Machine monitor O5
CM04 070 8 Machine monitor (for connecting camera) O5
COOLANT Coolant temperature sensor
DELPHI 2 AE3
TEMP
CP01 AMP 81 Pump controller V9
CP02 AMP 40 Pump controller W9
CRANK Crankshaft (Ne) speed sensor
FRAMATOME 3 AE1
SENSOR
D01 SWP 8 Diode array M9
D02 SWP 8 Diode array N9
D03 SWP 8 Diode array N9
E01 Terminal 1 Electrical air intake heater (ribbon heater) AJ3
E08 DT 2 Intermediate connector (alternator) AJ7
E10 DT 1 Intermediate connector (starting motor) AJ6
E12 SUMITOMO 3 Alternator (terminal L and IG) AJ9
E25 FRAMATOME 4 KDPF pressure sensor AI5
E26 FRAMATOME 4 KDPF temperature sensor AI5
ECM J1[CE01] DRC26 60 Engine controller AI2
ECM J2 [EC2] DRC26 60 Engine controller AJ2
EXHAUST
GAS Exhaust gas temperature sensor
FRAMATOME 2 AG5
TEMPERA-
TURE
EXHAUST Exhaust pressure sensor
FRAMATOME 3 AE5
PRESSURE
F01 ― ― Fuse box T9
F04 L 2 Fusible link (65 A) C7
F05 M 2 Fusible link (30 A) C9
F11 Terminal 1 Slow blow fuse C8
F12 Terminal 1 Slow blow fuse C8
40-48 PC210LC-10
40 Troubleshooting
Number
of pins
FUEL RAIL Common rail pressure sensor
BOSCH 3 AJ4
PRESS
H08 M 4 Intermediate connector (speaker) X4
H09 M 8 Intermediate connector (cab roof) X4
H14 S090 22 Intermediate connector (right console harness) S9
H15 S090 22 Intermediate connector (right console harness) U1
H16 S090 22 Intermediate connector (left console harness) X3
INJECTOR #1 Terminal 2 INJECTOR#1 AE4
INJECTOR #2 Terminal 2 INJECTOR#2 AE5
INJECTOR #3 Terminal 2 INJECTOR#3 AF5
INJECTOR #4 Terminal 2 INJECTOR#4 AG5
INJECTOR #5 Terminal 2 IINJECTOR#5 AH5
INJECTOR #6 Terminal 2 INJECTOR#6 AI5
INJECTOR Intermediate connector (INJECTOR#1 and #2)
DT 4 AE4
CYL 1&2
DT 4 AJ4
CYL 3&4
DT 4 AJ5
CYL 5&6
INLET
METERING BOSCH 2 Supply pump solenoid (IMV) AJ3
VALVE
INTER-
DT 12 Intermediate connector AH5
CONNECT
J01 J 20 Junction connector (black) W3
J02 J 20 Junction connector (pink) W2
J03 J 20 Junction connector (orange) V2
J04 J 20 Junction connector (pink) X3
J05 J 20 Junction connector (pink) X6
J06 J 20 Junction connector (orange) X8
K01 M 2 Resister for PC-EPC valve O8
K02 DT 3 CAN terminating resistor1 AG1
L01 DT 2 Boom working lamp E8
L02 DT 2 R.H. working lamp F2
L03 M 2 Room lamp S9
L05 SWP 2 Intermediate connector (revolving warning lamp) AC8
L09 DT 2 Rear working lamp J9
L15 DT 2 Revolving warning lamp AB9
L19 DT 2 System operating lamp B7
M01B PA 10 Radio U1
M01A ― 3 Radio (AUX jack) ―
M01B M 3 Intermediate connector (AUX) AD2
M01C ― 3 AUX (audio external input) jack AC1
M02 M 2 L.H. speaker AD8
M03 M 2 R.H. speaker AC9
M04 YAZAKI 2 Cigarette lighter S9
M05 M 6 Front window wiper motor O4
M06 YAZAKI 2 Front window washer motor E2
M07 090 2 Horn (treble tone) G1
M08 090 2 Horn (bass tone) G1
M09 M 2 Option power supply connector (1) M5
M10 M 2 Intermediate connector (optional power supply) N5
M11 DT 6 DC/DC converter X6
PC210LC-10 40-49
40 Troubleshooting
Number
of pins
M12 M 2 Option power supply connector (2) X6
M13A M 2 12V power supply socket (1) X8
M13B M 2 12V power supply socket (2) X7
M14 DT 2 Travel alarm K2
Optional power supply connector (continuous
M1A M 2 power supply)[power supply outlet] M5
M35 DT 2 Air suspension system V1
M36 DT 2 Heated seat U1
M40 X 2 Cab left headlamp AB1
M41 X 2 Cab right headlamp Y8
M80 X 3 Bucket quick coupler control box O7
M81 X 2 Bucket quick coupler solenoid valve J2
N08 DT 12 Service connector T9
OEM
CONNECTION FRAMATOME 24 Intermediate connector (engine wiring harness) AI1
[E24]
OIL
PRESSURE FRAMATOME 2 Engine oil pressure switch AE2
SWITCH
P01 AMP 3 Bucket CURL PPC pressure sensor D3
P02 AMP 3 Boom LOWER PPC pressure sensor D3
P03 AMP 3 Left SWING PPC oil pressure sensor D2
P04 AMP 3 Arm IN PPC pressure sensor D3
P05 AMP 3 Bucket DUMP PPC pressure sensor D3
P06 AMP 3 Boom RAISE PPC pressure sensor D2
P07 AMP 3 Right SWING PPC pressure sensor D3
P08 AMP 3 Arm OUT PPC pressure sensor D2
P09 AMP 3 L.H. travel forward PPC pressure sensor P1
P10 AMP 3 L.H. travel reverse PPC pressure sensor Q1
P11 AMP 3 R.H. travel forward PPC pressure sensor P1
P12 AMP 3 R.H. travel reverse PPC pressure sensor P1
Intermediate connector (service PPC oil
P13 X 2 pressure switch) O3
R.H.attachment control pedal forward tilt PPC oil
P14 X 2 pressure switch O3
R.H.attachment control pedal backward tilt PPC
P15 X 2 oil pressure switch O2
L.H.attachment control pedal forward tilt PPC oil
P16 X 2 pressure switch Q1
P17 S090 2 Dual pressure switch V2
P18 090 2 Outer temperature sensor L3
P20 M 3 Fuel control dial P8
P21 DT 2 Fuel level sensor G9
P22 DT 2 Hydraulic oil temperature sensor J9
P23 DT 2 Air cleaner clogging sensor B7
P24 X 2 Coolant level sensor K3
P25 AMP 3 Front pump oil pressure sensor B3
P26 AMP 3 Rear pump oil pressure sensor B3
P27 DT 3 Front pump swash plate sensor H9
P28 DT 3 Rear pump swash plate sensor H9
L.H.attachment control pedal backward tilt PPC
P30 X 2 oil pressure switch R1
P31 050 2 Sunlight sensor O6
40-50 PC210LC-10
40 Troubleshooting
Number
of pins
P44 DT 2 Engine oil level sensor AJ7
P47 DT 2 Water-in-fuel sensor G9
P49 AMP 3 Service oil pressure sensor G9
P55 FRAMATOME 4 MAF sensor C8
P57 FRAMATOME 3 Crankcase pressure sensor K9
R01 Terminal 1 Battery relay (terminal E) B9
R02 Terminal 1 Battery relay (terminal BR) B9
R03 Terminal 1 Battery relay (terminal M) A9
R04 Terminal 1 Battery relay (terminal B) A9
R05 Relay 5 Lamp relay T9
R06 Relay 5 Starting motor cut-off relay (for PPC lock) V9
R07 Relay 5 Starting motor cut-off relay (for personal code) V9
R08 Relay 5 Horn relay U9
R10 Relay 5 Rear working lamp relay U9
R12 Relay 5 Cab headlamp relay T9
Electrical air intake heater (ribbon heater)(coil
R15 Terminal 1 circuit) C8
Electrical air intake heater (ribbon heater)
R16A Terminal 1 (contact circuit) C7
Electrical air intake heater (ribbon heater)
R16B Terminal 1 (contact circuit) C9
R17 DT 2 Safety relay (terminal S and R) C9
R18 Relay 5 Automatic preheating relay W9
R21 Relay 5 Air conditioner compressor solenoid clutch relay W9
R28 Terminal 1 Safety relay (terminal C) A8
R29 Terminal 1 Safety relay (terminal B) A8
S01 ― 5 Starting switch P7
S02 SWP 6 Lamp switch P8
S04 SWP 6 Swing lock switch Q8
S07 SWP 6 Revolving warning lamp switch Q8
S10 Y090 2 Horn switch R1
S11 Y090 2 One-touch power maximizing switch T1
S14 M 3 PPC lock switch U1
S18 SWP 6 Engine shutdown secondary switch T1
S19 DT 2 Seat belt alarm switch S1
S21 ― 12 Emergency pump drive switch O9
S22 ― 4 Swing brake cancel switch O9
Intermediate connector (emergency activation
S25 090 16 switch) O8
S30 S 8 Model Selection connector U9
SB Terminal 2 Starting motor (terminal B) AH6
SC Terminal 1 Starting motor (terminal C) AH5
T01 Terminal 2 Floor frame ground able W2
T02 Terminal 1 Cab ground AD2
T03 Terminal 1 Radio ground cable T1
T04 Terminal 1 Revolving frame ground cable H1
T05 Terminal 1 Revolving frame ground cable I1
T08 Terminal 1 Revolving frame ground cable K3
T09 Terminal 1 Revolving frame ground cable J2
T10 Terminal 1 Revolving frame ground cable J2
PC210LC-10 40-51
40 Troubleshooting
Number
of pins
T12 Terminal 1 Engine controller ground cable L7
TERMINATOR CAN terminating resistor2
DT 3 AI1
PORT
TOOL PORT DT 3 Connector for communication AH1
V01 DT 2 PPC lock solenoid valve C1
V02 DT 2 2-stage relief solenoid valve A1
V03 DT 2 Swing brake solenoid valve C2
V04 DT 2 Travel speed increase solenoid valve A2
V05 DT 2 Travel junction solenoid valve C2
V06 DT 2 Swing cut-off solenoid valve A3
V07 DT 2 Attachment selector solenoid valve A2
V11 DT 2 Front pump PC-EPC valve J9
V12 DT 2 Rear pump PC-EPC valve I9
V19 DT 2 LS-EPC valve L9
V23 DT 2 Merge-divider EPC valve (for main spool) B4
V24 DT 2 Merge-divider EPC valve (for LS spool) C4
V25 DT 2 Variable back pressure solenoid valve B3
V30 DT 2 Attachment oil flow adjustment EPC valve O3
W03 X 2 Window rear limit switch AB9
40-52 PC210LC-10
40 Troubleshooting
Layout of connectors (1/6)
PC210LC-10 40-53
40 Troubleshooting
40-54 PC210LC-10
40 Troubleshooting
PC210LC-10 40-55
40 Troubleshooting
Layout of connectors(4/6)
40-56 PC210LC-10
40 Troubleshooting
PC210LC-10 40-57
40 Troubleshooting
40-58 PC210LC-10
40 Troubleshooting
Connector contact identification (ALL-5310-030-A-00-A)
(Rev. 2009. 04)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
PC210LC-10 40-59
40 Troubleshooting
40-60 PC210LC-10
40 Troubleshooting
PC210LC-10 40-61
40 Troubleshooting
40-62 PC210LC-10
40 Troubleshooting
PC210LC-10 40-63
40 Troubleshooting
40-64 PC210LC-10
40 Troubleshooting
PC210LC-10 40-65
40 Troubleshooting
40-66 PC210LC-10
40 Troubleshooting
PC210LC-10 40-67
40 Troubleshooting
40-68 PC210LC-10
40 Troubleshooting
PC210LC-10 40-69
40 Troubleshooting
40-70 PC210LC-10
40 Troubleshooting
PC210LC-10 40-71
40 Troubleshooting
40-72 PC210LC-10
40 Troubleshooting
PC210LC-10 40-73
40 Troubleshooting
40-74 PC210LC-10
40 Troubleshooting
PC210LC-10 40-75
40 Troubleshooting
40-76 PC210LC-10
40 Troubleshooting
PC210LC-10 40-77
40 Troubleshooting
40-78 PC210LC-10
40 Troubleshooting
PC210LC-10 40-79
40 Troubleshooting
40-80 PC210LC-10
40 Troubleshooting
PC210LC-10 40-81
40 Troubleshooting
40-82 PC210LC-10
40 Troubleshooting
PC210LC-10 40-83
40 Troubleshooting
40-84 PC210LC-10
40 Troubleshooting
PC210LC-10 40-85
40 Troubleshooting
40-86 PC210LC-10
40 Troubleshooting
PC210LC-10 40-87
40 Troubleshooting
40-88 PC210LC-10
40 Troubleshooting
PC210LC-10 40-89
40 Troubleshooting
40-90 PC210LC-10
40 Troubleshooting
PC210LC-10 40-91
40 Troubleshooting
40-92 PC210LC-10
40 Troubleshooting
PC210LC-10 40-93
40 Troubleshooting
40-94 PC210LC-10
40 Troubleshooting
T-branch box and T-branch adapter table (ALL-5330-305-A-00-A)
(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter, while the horizontal
column indicates a part number of harness checker assembly.
T-adapter kit
Identification symbol
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part number Part name
799-601- T-box (for ECONO) 21 q q q q q

2600
799-601- T-box (for MS) 37 q
3100
799-601- T-box (for MS) 37 q
3200
799-601- Plate for MS (14-pin) q
3380
799-601- Adapter for BENDIX (MS) 24 MS-24P q
3410
3420
3430
3440
3450
3460
3510
3520
3530
2910
799-601-
Case q
3470
799-601- Adapter for MIC 5 MIC-5P q q q
2710
799-601- Adapter for MIC MIC-
13 q q q
2720 13P
17 q q q q q q
2730 17P
21 q q q q q q
2740 21P
799-601- Adapter for MIC 9 MIC-9P q q q q
2950
799-601- Adapter for ECONO ECONO
2 q q
2750 2P
3 q q
2760 3P
4 q q
2770 4P
PC210LC-10 40-95
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201

8 q q
2780 8P
12 q q
2790 12P
799-601- Adapter for DLI 8 DLI-8P q q
2810
2820
2830
799-601- Extension cable (ECONO type) ECONO
12 q q q
2840 12P
799-601-
Case q
2850
799-601- q
T-box (for DRC60, ECONO) 60
4350
799-601- q
Case
4360
799-601- Adapter for X (T-adapter) 1 q q
7010
799-601- Adapter for X 2 X2P q q q q
7020
7030
7040
799-601- Adapter for SWP 6 SW6P q q q
7050
799-601- Adapter for SWP 8 SW8P q q q
7060
799-601- Adapter for SWP 12 SW12P q
7310
799-601- Adapter for SWP 14 SW14P q q
7070
799-601- Adapter for SWP 16 SW16P q
7320
799-601- Adapter for M (T-adapter) 1 q q
7080
799-601- Adapter for M 2 M2P q q q q
7090
7110
7120
7130
799-601- Adapter for M 8 M8P q
7340
799-601- Adapter for S 8 S8P q q q q
7140
799-601- Adapter for S (White) 10 S10P q q q q
7150
40-96 PC210LC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601- Adapter for S (Blue) 12 S12P q q q

7160
799-601- Adapter for S (Blue) 16 S16P q q q q
7170
799-601- Adapter for S (White) 16 S16PW q
7330
799-601- Adapter for S (White) 12 S12PW q
7350
799-601- Adapter for AMP040 8 A8P q
7180
799-601- Adapter for AMP040 12 A12P q q
7190
799-601- Adapter for AMP040 16 A16P q q q q
7210
799-601- Adapter for AMP040 20 A20P q q q q
7220
799-601-
Short connector for X 2 q q q q
7230
799-601-
Case q q
7240
799-601-
Case q
7270
799-601- Adapter for 070 10 07-10 q
7510
799-601- Adapter for 070 12 07-12 q
7520
799-601- Adapter for 070 14 07-14 q
7530
799-601- Adapter for 070 18 07-18 q
7540
799-601- Adapter for 070 20 07-20 q
7550
799-601- Adapter for relay 5 REL-5P q
7360
799-601- Adapter for relay 6 REL-6P q
7370
799-601- Adapter for JFC 2 q
7380
799-601- q
Adapter for DTM 2 DTM2 q
9010
799-601- q q q
Adapter for DT 2 DT2 q
9020
799-601- q
9030
799-601- q q q
9040
799-601- q
9050
799-601- q
Adapter for DT (gray) 8 DT8GR q
9060
799-601- q
Adapter for DT (black) 8 DT8B q
9070
PC210LC-10 40-97
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601- q
Adapter for DT (green) 8 DT8G q
9080
799-601- q
Adapter for DT (Brown) 8 DT8BR q
9090
799-601- DT12G- q
Adapter for DT (gray) 12 q
9110 R
799-601- q
Adapter for DT (black) 12 DT12B q
9120
799-601- q
Adapter for DT (green) 12 DT12G q
9130
799-601- q
Adapter for DT (Brown) 12 DT12BR q
9140
799-601- Adapter for HD30-18 8 D18-8 q q
9210
9220
9230
9240
9250
9260
9270
9280
9290
799-601- q
Plate for HD30 (24-pin) q q
9310
799-601- q
T-box (for ECONO) 24 q q
9320
799-601-
Case q
9330
799-601-
Case q
9340
799-601- q
Adapter for DRC 40 DRC-40
9350
799-601- q
Adapter for DRC 24 DRC-24
9360
799-601- Socket for engine (CRI-T2) 2 G q
9410*
Adapter for engine (CRI-T2) q q
799-601- Adapter for engine (CRI-T3)
PFUEL 3 A3
9420
Oil pressure sensor
799-601- Socket for engine (CRI-T2) q q
2 P
9430* Socket for engine(CRI-T3) PCV
799-601- Socket for engine (CRI-T2) 1, 2, 3
3 q
9440*
40-98 PC210LC-10
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
795-799- Socket for engine (HPI-T2) 2 S q

5520*
Socket for engine (HPI-T2) q q
795-799- Socket for engine (CRI-T3) 2 C
5530*
Temperature sensor
795-799- Socket for engine (HPI-T2) q q
2 A
5540* Socket for engine(CRI-T3) TIM
795-799- Cable for engine (HPI-T2) 3 q
5460
5470
5480
799-601- q q
Adapter for engine (140-T3) PIM 4 ITT3N
4110
799-601- Adapter for engine (CRI-T3) NE, q q
3 FCIN
4130 CAM
799-601- Adapter for engine (CRI-T3) q q
3 FCIG
4140 Ambient pressure
3 FCIB
4150 POIL
2 4160
4160 Oil pressure switch
3 4180
4180 PEVA
3 1, 2, 3L
4190* Rail pressure
799-601- Socket for engine (CRI-T3) 1, 2, 3, q q
4
4230* Air intake pressure/temperature 4C
3 1, 2, 3A
4240* PAMB
799-601- q q
Socket for engine (CRI-T3) PIM 3 1, 2, 3B
4250*
799-601- 1, 2, 3, q q
Socket for engine (CRI-T3) G 3
4330* G
2 2, PA
4340* Pump actuator
799-601- Socket for engine (CRI-T3)(95) 1, 2, 3,
4 q
4380* Air intake pressure/temperature 4T
799-601- q q
Adapter for controller (ENG) 4 DTP4
4260
799-601- q
Adapter for controller (ENG) 50 DRC50
4211
799-601- q
Adapter for controller (ENG) 60 DRC60
4220
799-601- Socket for controller (95 ENG) 60 q
4390*
799-601- Box for controller (PUMP) 1-
q
4280* 21
PC210LC-10 40-99
40 Troubleshooting
T-adapter kit
Number of pins
Out of kit
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
799-601- Adapter for controller (HST) 16 HST16A q

9720
799-601- Adapter for controller (HST) 16 HST16B q
9710
799-601- Adapter for controller (HST) 26 HST26A q
9730
2,
799-601- Multi-adapter for pins DT2 to 4
3, q
9890 and DTM2
4
*: Shows not T-adapter but socket.
40-100 PC210LC-10
40 Troubleshooting
Fuse location table (PC200_10-5530-04D-A-00-A)

Connection table of fusible links and fuse boxes
a This connection table shows devices each power of fuse box supplied to. (switched power supply is the
power supply which supplies power when starting switch is ON, and continuous power supply is the power
supply which supplies power when starting switch is OFF and ON.)
a When performing the troubleshooting related to the electrical system, check the fuses and fusible links to
see if the power is supplied properly.
Type of Source of
power Fuse
power Fuse No. Destination of power
supplied to capacity
supply
fuse
Light relay, rear light relay, and cab light relay
PC-EPC (F) solenoid valve and PC-EPC (R) solenoid
valve
[When operating emergency pump drive switch]
1 5A Swing brake solenoid valve
[When operating swing brake cancel switch]
Boom raise throttle EPC valve
[[When operating emergency boom raise throttle cancel
switch]
2 30 A Pump controller (solenoid power supply)
PPC hydraulic lock solenoid valve
3 5A Starting motor cut-off relay (PPC lock)
Fusible link
Switched F04 (65 A) Starting motor cut-off relay (personal code)
power 4 10 A Window washer motor and cigarette lighter
supply 5 10 A Horn, horn relay
6 5A Heater relay and electric air intake heater
7 10 A Revolving warning lamp (if equipped)
Radio, speaker, and left knob switch (pump controller
8 10 A input)
9 20 A Working lamp
10 20 A Air conditioner unit and air conditioner compressor
11 10 A Headlamp
12 10 A Option power supply (1)
Optional power supply (2), 12 V power supply, and air
13 30 A suspension seat with heater
Starting 14 5A Air conditioner controller power supply
switch 15 5A Starting switch, auxiliary engine stop switch
16 10 A Radio backup, room lamp , and system operating lamp
Continu- 17 20 A Machine monitor and pump controller
Fusible link
ous power 18 30 A Engine controller
F05 (30 A)
supply 19 5A Air conditioner controller backup
20 10 A Optional power source (continuous power supply)
PC210LC-10 40-101
40 Troubleshooting
Fusible link position
* There are two fusible links (F04) and (F05) you can find when cover on the air cleaner is removed, and
cover of battery relay is removed.
Fuse box position and No.
40-102 PC210LC-10
40 Troubleshooting
Precautions for KDPF (KCSF and KDOC) Cleaning and

Replacement (PC220-A9H0-2A4-K-00-A)
1. Related information From service menu of machine monitor,
display the "Diagnostic Tests" screen, open
k Since KDPF and KDOC are heated to 500° "KDPF Memory Reset", and then perform
C or above, take care not to get burn "KDOC Cleaning" (reset after KDOC
injury. cleaning).
• Resetting after KDPF (KCSF) change
• Soot accumulation at KCSF inside the KDPF
From service menu of machine monitor,
is classified into 8 levels. The current soot
level can be checked on the machine
"KDPF Memory Reset", and then perform
monitor by selecting the "Diagnostic Test"
"KDPF Change" (resetting after KDPF
screen from the service menu, and then
change).
selecting the "Regeneration for Service"
screen. a When KCSF in KDPF is replaced, always
perform resetting procedures for KDPF
a If the soot accumulation reaches level 4 or 5,
cleaning and KDPF change, and then
failure code [CA2639] is displayed.
perform manual stationary regeneration from
a If the soot accumulation reaches level 6 or 7, "Regeneration for Service" to eliminate
failure code [CA1921] is displayed. moisture from KCSF.
a If the soot accumulation reaches level 8, • Resetting after KDOC change
failure code [CA1922] is displayed. From service menu of machine monitor,
• If the soot accumulation reaches level 8, the
"KDPF Memory Reset", and then perform
KDPF is completely clogged with soot, and
"KDOC Change" (reset after KDOC change).
inspection, cleaning, or replacement is
required. a When KDOC in KDPF is changed, resetting
• Manual stationary regeneration can be procedure for KDOC change must be
performed to burn away soot in the KCSF performed though manual stationary
when the soot accumulation is up to level 7. regeneration is not necessary.
2. When cleaning and replacing KCSF
a At soot accumulation levels 4 to 7, manual
stationary regeneration can also be 1) Regular cleaning at 4500H
performed from the user mode. 1] Check the soot accumulation level. If the
• Procedure of performing manual stationary level is not zero, repeat "Regeneration for
regeneration from Regeneration for Service Service" until the level returns to zero.
2] Stop the engine and wait until the
a When soot accumulation is at level 3 or lower, temperature of piping around the engine
the manual stationary regeneration can be cools down. Remove the KDPF, and then
performed only from "Regeneration for remove the KCSF.
Service". 3] Clean the KCSF by using an ash cleaner,
1) Start the engine. which is equipped at certain workshops.
2) Make sure that machine is in safe condition. (when the removed KCSF is cleaned and
3) From the service menu of the machine reused)
monitor, display the "Diagnostic Tests" 4] Install the cleaned KCSF to the machine.
screen, open "Regeneration for service", and (when the removed KCSF is cleaned and
then perform the "Manual Stationary reused)
Regeneration". 5] Install the replacement KCSF to the
machine (when the KCSF is replaced
a Time required for manual stationary
with a new one).
regeneration depends on the accumulated
6] Turn the starting switch to the ON
soot in KCSF, however, it is estimated as
position. From the KDPF reset screen,
follows.
perform resetting after KDPF cleaning.
• If soot accumulation is level 4: Approx. 40 7] Start the engine and run at low idle to
minutes to 1 hour warm up.
• If soot accumulation is level 5: Approx. 1 to 2 8] Perform regeneration for service.
hours 2) If cracks or damages are found during
• Resetting after KDPF (KCSF) cleaning inspection
PC210LC-10 40-103
40 Troubleshooting
1] Stop the engine and wait until the Case 1-4] From the KDPF reset screen, perform
temperature of piping around the engine resetting after KDPF change.
cools down. Remove the KDPF, and then Case 1-5] Start the engine and run at low idle to
remove the KCSF. warm up.
2] Install the replacement KCSF (new or Case 1-6] Perform Regeneration for Service.
reused) to the machine. (In this case, Regeneration for Service may
3] Turn the starting switch to the ON continue for about 2 hours, since it is set to
position. From the KDPF reset screen, terminate when the soot accumulation drops to 2
perform resetting after KDPF cleaning. g/l.)
4] From the KDPF reset screen, perform Case 1-7] When Regeneration for Service is
resetting after KDPF change. completed, check that failure codes (CA1922,
5] Start the engine and run at low idle to CA1921, and CA2639) are not displayed.
warm up. <Case 2> When Regeneration for Service is
6] Perform regeneration for service. performed (KDPF removal unnecessary)
3) If Soot Level High Error 2 (CA1922) is
a If the following conditions are met, the total
displayed
soot sediment is not beyond the limit (9 g/l),
1] Stop the machine and check that failure but the differential pressure has increased
code (CA1922) is displayed on the due to clogging caused by uneven
machine monitor. accumulation of soot. In this case, actual
2] Check the abnormality record for failure regeneration will not result in abnormal
codes "CA2639: Manual Stationary burning. Regeneration for Service can be
Regeneration Request", "CA1921: KDPF performed safely without replacing the KCSF,
Soot Level High Error 1", and "CA1922: and the KCSF can be continuously used
KDPF Soot Level High Error 2"on the after the regeneration.
machine monitor.
• After checking that no sensor related failures
<Case 1> When KDPF is removed and KCSF is
are present, perform this work if any of the
replaced
following is met.
a If the following conditions are met, soot • Time between activation of "CA2639: Manual
accumulation is beyond the limit to burn Stationary Regeneration Request (L01)" and
away by regeneration. The KDPF must be "CA1921: KDPF Soot Level High Error 1
removed to change the KCSF. (L03)" < 360 sec. (KOMTRAX history) or <
• Time between activation of "CA2639: Manual 0.1 h (Abnormality record screen on monitor)
Stationary Regeneration Request (L01)" and • "Time between activation of "CA1921: KDPF
"CA1921: KDPF Soot Level High Error 1 Soot Level High Error 1 (L03)" and "CA1922:
(L03)" X 360 sec. (KOMTRAX history) or X KDPF Soot Level High Error 2 (L04)" <
0.1 h (Abnormality record screen on monitor) 360sec. (KOMTRAX history) or < 0.1 h
and (Abnormality record screen on monitor)
• Time between activation of "CA1921: KDPF [Contents of work]
Soot Level High Error 1 (L03)" and "CA1922: Case 2-1] Start the engine and run at low idle to
KDPF Soot Level High Error 2 (L04)" X360 warm up. From the KDPF reset screen, perform
sec. (KOMTRAX history) or X 0.1 h resetting after KDPF cleaning.
(Abnormality record screen on monitor) Case 2-2] Perform Regeneration for Service.
[Contents of work] (In this case, Regeneration for Service may
Case 1-1] Stop the engine and wait until the continue for about 2 hours, since it is set to
temperature of piping around the engine cools terminate when the soot accumulation drops to 2
down, then remove KCSF. g/l.)
Case 1-2] Install the replacement KCSF (new or Case 2-3] When Regeneration for Service is
reused). completed, check that failure codes (CA1922,
Case 1-3] Turn the starting switch to the ON CA1921, and CA2639) are not displayed.
position. From the KDPF reset screen, perform 3. When cleaning and replacing KDOC
resetting after KDPF cleaning. 1) If cracks or damages are found during
inspection
a When resetting after KDPF cleaning is
performed, changes in ( ) are reflected. 1] If cracks or damages are found in the
(Soot accumulation amount: 9 g/lo8.1 g/l; KDOC, replace it with a new one.
Action level: L04oL03; Failure code: 2] From the KDPF reset screen, perform
CA1922oCA1921) resetting after KDOC change.
40-104 PC210LC-10
40 Troubleshooting
2) When Regeneration Ineffective (CA1691) is

displayed
1] Stop the machine and check that failure
code (CA1691) is displayed on the
machine monitor.
(CA2637 may be displayed at the same
time.)
2] Check the exhaust gas color.
3] With CA1691 displayed, perform
Regeneration for Service for 40 minutes.
(Since this is done for drying the KDOC,
fuel is not injected during the
regeneration)
4] Stop the engine and wait until the
temperature of piping around the engine
cools down. Remove the KDOC and
check it for cracks or damages.
<Case 1> If cracks or damages are found in
KDOC
Case 1-1] Replace KDOC with a new one.
Case 1-2] From the KDPF reset screen,
perform resetting after KDOC change.
<Case 2> If cracks or damages are not found
in KDOC
Case 2-1] Clean KDOC and reinstall it.
Case 2-2] From the KDPF reset screen,
perform resetting after KDOC cleaning.
Case 2-3] Perform Regeneration for Service
twice for 40 minutes each. (Fuel is injected
during regeneration)
*When performing Regeneration for Service
several times, stop the engine each time
before repeating the regeneration.
Case 2-4] If failure code "CA2637: KDOC
Face Plugging" is displayed after
Regeneration for Service is completed, the
catalyst performance of KDOC is
deteriorated. Replace KDOC with a new one.
PC210LC-10 40-105
40 Troubleshooting
Fabrication of dummy temperature sensor (for KDOC and KDPF

temperature sensors) (HM300-A9J2-304-K-00-A)
• Use this dummy temperature sensor in troubleshooting for KDPF-related failure codes.
• To fabricate dummy temperature sensor, purchase KDPF temperature sensor consolidating box that are
installed on KDPF, and modify it (break up KDPF temperature sensor consolidating box and take out 4-pin
connector section).
• Dummy temperature sensor
40-106 PC210LC-10
40 Troubleshooting
Fabrication of short-circuit connector (for CA1883 and CA3135) (HM300-A9J2-

304-K-01-A)
a KDPF differential pressure sensor is the same as KDPF outlet pressure sensor.
• CA1883 Short-circuit connector for KDPF delta pressure sensor
• CA3135 Short-circuit connector for KDPF outlet pressure sensor
PC210LC-10 40-107
40 Troubleshooting
Failure codes table (PC200LC_10-5520-441-A-00-A)
Failure Applicable History

Failure (Displayed on screen) Action level category Remarks
code component
Failure code [879AKA] A/C Inner Sensor Electrical See
879AKA Open Circuit(PAGE 40-117) MON — Chapter 80,
system
Other items
Failure code [879AKB] A/C Inner Sensor Electrical See
879AKB Short Circuit(PAGE 40-118) MON — Chapter 80,
system
Other items
Failure code [879BKA] A/C Outer Sensor Electrical See
879BKA Open Circuit(PAGE 40-119) MON — Chapter 80,
system
Other items
Failure code [879BKB] A/C Outer Sensor Electrical See
879BKB Short Circuit(PAGE 40-120) MON — Chapter 80,
system
Other items
Failure code [879CKA] Ventilating Sensor Electrical See
879CKA Open Circuit(PAGE 40-121) MON — Chapter 80,
system
Other items
Failure code [879CKB] Ventilating Sensor Electrical See
879CKB Short Circuit(PAGE 40-122) MON — Chapter 80,
system
Other items
Failure code [879DKZ] Sunlight Sensor Electrical See
879DKZ Open or Short Circuit(PAGE 40-123) MON —
system Chapter 80,
Other items
Failure code [879EMC] Ventilation Damper Electrical See
879EMC Abnormality(PAGE 40-124) MON L01 system Chapter 80,
Other items
Failure code [879FMC] Air Mix Damper Electrical See
879FMC Abnormality(PAGE 40-125) MON L01 system Chapter 80,
Other items
Failure code [879GKX] Refrigerant Electrical See
879GKX Abnormality(PAGE 40-126) MON L01 system Chapter 80,
Other items
Failure code [989L00] Engine Controller Electrical
989L00 MON —
Lock Caution1(PAGE 40-127) system
Failure code [989M00] Engine Controller Electrical
989M00 MON —
Failure code [989N00] Engine Controller Electrical
989N00 MON —
Failure code [A1U0N3]: KDPF Dry Request Electrical
A1U0N3 (HC Release)(PAGE 40-130) ENG L01 system
Failure code [A1U0N4] KDPF Dry Request Electrical
A1U0N4 (HC Release)(PAGE 40-132) ENG L03 system
Failure code [AA10NX] Air Cleaner Clogging Electrical
AA10NX (PAGE 40-134) MON L01 system
Failure code [AB00KE] Charge Voltage Low Electrical
AB00KE (PAGE 40-136) MON L03 system
Failure code [B@BAZG] Engine Oil Electrical
B@BAZG ENG L03
Pressure Low(PAGE 40-138) system
Failure code [B@BAZK] Eng Oil Level Low Electrical
B@BAZK MON L01
(PAGE 40-139) system
Failure code [B@BCNS] Engine Coolant Electrical
B@BCNS ENG —
Overheat(PAGE 40-140) system
Failure code [B@BCZK] Radiator Coolant Electrical
B@BCZK MON L01
Level Low(PAGE 40-141) system
Failure code [B@HANS] Hyd Oil Overheat Electrical
B@HANS PUMP L02
Failure code [CA115] Eng Ne and Bkup Electrical
CA115 Speed Sens Error(PAGE 40-144) ENG L04 system
40-108 PC210LC-10
40 Troubleshooting

code component
Failure code [CA122] Chg Air Press Sensor Electrical
CA122 High Error(PAGE 40-145) ENG L03 system
Failure code [CA123] Chg Air Press Sensor Electrical
CA123 Low Error(PAGE 40-147) ENG L03 system
Failure code [CA131] Throttle Sensor High Electrical
CA131 Error(PAGE 40-149) ENG L03 system
Failure code [CA132] Throttle Sensor Low Electrical
Failure code [CA144] Coolant Temp Sens Electrical
Failure code [CA145] Coolant Temp Sens Electrical
Failure code [CA153] Chg Air Temp Sensor Electrical
Failure code [CA154] Chg Air Temp Sensor Electrical
Failure code [CA187] Sensor 2 Supply Volt Electrical
Failure code [CA221] Ambient Press Sens Electrical
Failure code [CA234] Eng Overspeed(PAGE Electrical
CA234 40-168) ENG L02 system
Failure code [CA238] Ne Speed Sensor Electrical
CA238 Supply Volt Error(PAGE 40-169) ENG L01 system
Failure code [CA239] Ne Speed Sens Electrical
CA239 Supply Volt High Error(PAGE 40-170) ENG L01 system
Failure code [CA271] IMV/PCV1 Short Error Electrical
CA271 (PAGE 40-171) ENG L03 system
Failure code [CA272] IMV/PCV1 Open Error Electrical
CA295 In Range Error(PAGE 40-175) ENG L03 system
Failure code [CA322] Inj #1(L#1) Open/ Electrical
CA322 Short Error(PAGE 40-176) ENG L03 system
Failure code [CA343] ECM Critical Internal Electrical
CA343 Failure(PAGE 40-188) ENG L04 system
Failure code [CA351] Injectors Drive Circuit Electrical
Failure code [CA356] Mass Air Flow Sensor Electrical
PC210LC-10 40-109
40 Troubleshooting

code component
Failure code [CA357] Mass Air Flow Sensor Electrical
Failure code [CA428] Water in Fuel Sensor Electrical
Failure code [CA429] Water in Fuel Sensor Electrical
Failure code [CA435] Eng Oil Press Sw Electrical
Failure code [CA441] Battery Voltage Low Electrical
Failure code [CA442] Battery Voltage High Electrical
Failure code [CA449] Rail Press Very High Electrical
Failure code [CA451] Rail Press Sensor Electrical
Failure code [CA452] Rail Press Sensor Low Electrical
Failure code [CA488] Chg Air Temp High Electrical
CA488 Torque Derate(PAGE 40-210) ENG L01 system
Failure code [CA515] Rail Press Sens Sup Electrical
CA515 Volt High Error(PAGE 40-211) ENG L03 system
Failure code [CA516] Rail Press Sens Sup Electrical
CA516 Volt Low Error(PAGE 40-213) ENG L03 system
Failure code [CA553] Rail Press High Error Electrical
Failure code [CA555] Crankcase Press High Electrical
CA555 Error 1(PAGE 40-216) ENG L01 system
Failure code [CA556] Crankcase Press High Electrical
Failure code [CA559] Rail Press Low Error Electrical
Failure code [CA595] Turbo Speed High Electrical
Failure code [CA687] Turbo Speed Low Electrical
Failure code [CA689] Eng Ne Speed Sensor Electrical
Failure code [CA691] Intake Air Temp Sens Electrical
Failure code [CA692] Intake Air Temp Sens Electrical
Failure code [CA697] ECM Int Temp Sensor Electrical
Failure code [CA698] ECM Int Temp Sensor Electrical
Failure code [CA731] Eng Bkup Speed Sens Electrical
CA731 Phase Error(PAGE 40-231) ENG L01 system
Failure code [CA778] Eng Bkup Speed Electrical
CA778 Sensor Error(PAGE 40-233) ENG L01 system
Failure code [CA1117] Persistent Data Lost Electrical
Failure code [CA1664] KDOC Malfunction Electrical
40-110 PC210LC-10
40 Troubleshooting

code component
Failure code [CA1691] Regeneration Electrical
CA1691 Ineffective(PAGE 40-241) ENG L03 system
Failure code [CA1843] Crankcase Press Electrical
CA1843 Sens High Error(PAGE 40-248) ENG L01 system
CA1844 Sens Low Error(PAGE 40-250) ENG L01 system
Failure code [CA1879] KDPF Delta P Electrical
CA1879 Sensor High Error(PAGE 40-252) ENG L03 system
Failure code [CA1881] KDPF Delta P Electrical
CA1881 Sensor Low Error(PAGE 40-254) ENG L03 system
Failure code [CA1883] KDPF Delta P Sens Electrical
CA1883 In Range Error(PAGE 40-256) ENG L03 system
Failure code [CA1921] KDPF Soot Load Electrical
CA1921 High Error 1(PAGE 40-259) ENG L03 system
Failure code [CA1922] KDPF Soot Load Electrical
CA1942 Sens In Range Error(PAGE 40-267) ENG L01 system
Failure code [CA1993] KDPF Delta Electrical
CA1993 Pressure Low Error(PAGE 40-268) ENG L03 system
Failure code [CA2185] Throt Sensor Sup Electrical
CA2185 Volt High Error(PAGE 40-271) ENG L03 system
Failure code [CA2186] Throt Sensor Sup Electrical
CA2186 Volt Low Error(PAGE 40-273) ENG L03 system
Failure code [CA2249] Rail Press Very Low Electrical
Failure code [CA2271] EGR Valve Pos Sens Electrical
Failure code [CA2272] EGR Valve Pos Sens Electrical
Failure code [CA2288] Turbo Speed High Electrical
Failure code [CA2311] IMV Solenoid Error Electrical
Failure code [CA2349] EGR Valve Solenoid Electrical
CA2349 Open Error(PAGE 40-283) ENG L03 system
Failure code [CA2353] EGR Valve Solenoid Electrical
Failure code [CA2357] EGR Valve Servo Electrical
Failure code [CA2373] Exhaust Manifold Electrical
CA2373 Press Sens High error(PAGE 40-288) ENG L03 system
Failure code [CA2374] Exhaust Manifold Electrical
CA2374 Press Sens Low error(PAGE 40-290) ENG L03 system
Failure code [CA2375] EGR Orifice Temp Electrical
Failure code [CA2381] KVGT Pos Sens Electrical
Failure code [CA2382] KVGT Pos Sens Low Electrical
PC210LC-10 40-111
40 Troubleshooting

code component
Failure code [CA2383] KVGT Solenoid Electrical
CA2383 Open Error(PAGE 40-301) ENG L03 system
Failure code [CA2386] KVGT Solenoid Electrical
Failure code [CA2387] KVGT Servo Error Electrical
Failure code [CA2554] Exh Manifold Press Electrical
Failure code [CA2555] Grid Htr Relay Volt Electrical
Failure code [CA2556] Grid Htr Relay Volt Electrical
Failure code [CA2637] KDOC Face Electrical
CA2637 Plugging(PAGE 40-311) ENG L01 system
Failure code [CA2639] Manual Stationary Electrical
CA2639 Regeneration Request(PAGE 40-313) ENG L01 system
Failure code [CA2973] Chg Air Press Electrical
CA2973 Sensor In Range Error(PAGE 40-317) ENG L03 system
Failure code [CA3133] KDPF Outlet Press Electrical
Failure code [CA3251] KDOC Inlet Temp Electrical
Failure code [CA3253] KDOC Temp Error - Electrical
CA3253 Non Regeneration(PAGE 40-329) ENG L03 system
Failure code [CA3254] KDOC Outlet Temp Electrical
Failure code [CA3255] KDPF Temp Error - Electrical
CA3255 Non Regeneration(PAGE 40-335) ENG L03 system
Failure code [CA3256] KDPF Outlet Temp Electrical
CA3313 Sensor Low Error(PAGE 40-347) ENG L03 system
40-112 PC210LC-10
40 Troubleshooting

code component
Failure code [CA3419] Mass Air Flow Electrical
CA3419 Sensor Sup Volt High Error(PAGE 40-379) ENG L03 system
Failure code [CA3421] Mass Air Flow Electrical
CA3421 Sensor Sup Volt Low Error(PAGE 40-381) ENG L03 system
Failure code [CA3741] Rail Press Valve Trip Electrical
Failure code [D110KB] Battery Relay Output Electrical
D110KB Voltage(PAGE 40-384) ENG L01 system
Failure code [D19JKZ] Personal Code Relay Electrical
D19JKZ Abnormality(PAGE 40-386) MON L03 system
Failure code [D811MC] KOMTRAX Error Electrical
D811MC KOMTRAX —
Failure code [D862KA] GPS Antenna Open Electrical
D862KA KOMTRAX —
Circuit(PAGE 40-390) system
Failure code [D8ALKA] System Operating
Electrical
D8ALKA Lamp Disconnection (KOMTRAX)(PAGE 40- KOMTRAX —
system
391)
Failure code [D8ALKB] System Operating
Electrical
D8ALKB Lamp Short Circuit (KOMTRAX)(PAGE 40- KOMTRAX —
system
393)
Failure code [D8AQKR] CAN2 Discon Electrical
D8AQKR MON —
(KOMTRAX)(PAGE 40-394) system
Failure code [DA20MC] Pump Controller Electrical
DA20MC PUMP —
Failure code [DA22KK] Pump Solenoid Electrical
DA22KK Power Low Error(PAGE 40-396) PUMP L03 system
Failure code [DA25KP] 5V Sensor 1 Power Electrical
DA25KP PUMP —
Abnormality(PAGE 40-398) system
Failure code [DA29KQ] Model Selection Electrical
DA29KQ Abnormality(PAGE 40-401) PUMP L01 system
Failure code [DA2LKA] System Operating
Electrical
DA2LKA Lamp Disconnection (Pump Con)(PAGE 40- PUMP —
system
403)
Failure code [DA2LKB] System Operating
Electrical
DA2LKB Lamp Short Circuit (Pump Con)(PAGE 40- PUMP —
system
405)
Failure code [DA2QKR] CAN2 Discon Electrical
DA2QKR (Pump Con)(PAGE 40-406) MON L03 system
Failure code [DA2RKR] CAN1 Discon Electrical
DA2RKR (Pump Con)(PAGE 40-409) MON L03 system
Failure code [DAF0MB] Monitor ROM Electrical
DAF0MB MON —
Abnormality(PAGE 40-410) system
Failure code [DAF0MC] Monitor Error(PAGE Electrical
DAF0MC MON —
40-411) system
Failure code [DAF8KB] Camera Power Electrical
DAF8KB Supply Short Circuit(PAGE 40-412) MON L03 system
Failure code [DAF9KQ] Model Selection Electrical
DAF9KQ Abnormality(PAGE 40-414) MON L03 system
Failure code [DAFGMC] GPS Module Error Electrical
DAFGMC KOMTRAX —
Failure code [DAFLKA] Operating Lamp Electrical
DAFLKA MON —
Open Circuit(Monitor)(PAGE 40-416) system
Failure code [DAFLKB] System Operating Electrical
DAFLKB MON —
Lamp Short Circuit (Monitor)(PAGE 40-418) system
PC210LC-10 40-113
40 Troubleshooting

code component
Failure code [DAFQKR] CAN2 Discon Electrical
DAFQKR (Monitor)(PAGE 40-419) KOMTRAX —
system
Failure code [DAZ9KQ] A/C Model Selection Electrical
DAZ9KQ Abnormality(PAGE 40-420) MON —
system
Failure code [DAZQKR] CAN2 Discon (AC) Electrical
DAZQKR (PAGE 40-421) MON L01 system
Failure code [DB2QKR] CAN2 Discon Electrical
DB2QKR (Engine Con)(PAGE 40-426) MON L03 system
Failure code [DB2RKR] CAN1 Discon Electrical
DB2RKR (Engine Con)(PAGE 40-431) MON L04 system
Failure code [DGH2KB] Hyd Oil Sensor Electrical
DGH2KB Short(PAGE 40-435) PUMP L01 system
Failure code [DHA4KA] Air Cleaner Clog Electrical
DHA4KA Sensor Open Circuit(PAGE 40-437) MON L01 system
Failure code [DHPAMA] F Pump Press Electrical
DHPAMA Sensor Abnormality(PAGE 40-438) PUMP L01 system
Failure code [DHPBMA] R Pump Press Electrical
DHPBMA Sensor Abnormality(PAGE 40-441) PUMP L01 system
Failure code [DHS3MA] Arm IN PPC Sen. Electrical
DHS3MA Abnormality(PAGE 40-444) PUMP L01 system
Failure code [DHS4MA] Bucket Curl PPC Electrical
DHS4MA Press Sensor Abnormality(PAGE 40-446) PUMP L01 system
Failure code [DHS8MA] Boom Raise PPC Electrical
Failure code [DHS9MA] Boom LOWER Electrical
Failure code [DHSAMA] Swing RH PPC Electrical
DHSAMA Press Sensor Abnormality(PAGE 40-455) PUMP L01 system
Failure code [DHSBMA] Swing LH PPC Electrical
DHSBMA Press Sensor Abnormality(PAGE 40-458) PUMP L01 system
Failure code [DHSCMA] Arm Dump PPC Electrical
DHSCMA Press Sensor Abnormality(PAGE 40-461) PUMP L01 system
Failure code [DHSDMA] Bucket Dump PPC Electrical
DHSDMA Press Sensor Abnormality(PAGE 40-464) PUMP L01 system
Failure code [DHSFMA] Travel Fwd LH PPC Electrical
DHSFMA Press Sensor Abnormality(PAGE 40-467) PUMP L01 system
Failure code [DHSGMA] Travel Fwd RH
Electrical
DHSGMA PPC Press Sensor Abnormality(PAGE 40- PUMP L01 system
470)
Failure code [DHSHMA] Travel Rev LH PPC Electrical
DHSHMA Press Sensor Abnormality(PAGE 40-473) PUMP L01 system
Failure code [DHSJMA] Travel Rev RH PPC Electrical
DHSJMA Press Sensor Abnormality(PAGE 40-476) PUMP L01 system
Failure code [DKR0MA] F pump S/P sensor Electrical
DKR0MA Abnormality(PAGE 40-479) PUMP L01 system
Failure code [DKR1MA] R pump S/P sensor Electrical
DKR1MA Abnormality(PAGE 40-481) PUMP L01 system
Failure code [DR21KX] Camera 2 Picture Electrical
DR21KX Rev. Drive Abnormality(PAGE 40-483) PUMP L01 system
Failure code [DR31KX] Camera 3 Picture Electrical
DR31KX Rev. Drive Abnormality(PAGE 40-485) PUMP L01 system
Failure code [DV20KB] Travel Alarm Short Electrical
DV20KB Circuit(PAGE 40-487) PUMP L01 system
Failure code [DW43KA] Travel Speed Sol Electrical
DW43KA Open Circuit(PAGE 40-489) PUMP L01 system
40-114 PC210LC-10
40 Troubleshooting

code component
Failure code [DW43KB] Travel Speed Sol Electrical
DW43KB Short Circuit(PAGE 40-491) PUMP L01 system
Failure code [DW45KA] Swing holding brake Electrical
DW45KA Sol Open Circuit(PAGE 40-493) PUMP L03 system
Failure code [DW45KB] Swing holding brake Electrical
DW45KB Sol Short Circuit(PAGE 40-496) PUMP L03 system
Failure code [DW91KA] Travel Junction Sol Electrical
DW91KA Open Circuit(PAGE 40-499) PUMP L01 system
Failure code [DW91KB] Travel Junction Sol Electrical
DW91KB Short Circuit(PAGE 40-501) PUMP L01 system
Failure code [DWA2KA] Attachment Sol Electrical
DWA2KA Open Circuit(PAGE 40-503) PUMP L03 system
Failure code [DWA2KB] Attachment Sol Electrical
DWA2KB Short Circuit(PAGE 40-505) PUMP L03 system
Failure code [DWK0KA] 2-Stage Relief Sol Electrical
DWK0KA Open Circuit(PAGE 40-507) PUMP L01 system
Failure code [DWK0KB] 2-stage Relief Sol Electrical
DWK0KB Short Circuit(PAGE 40-509) PUMP L01 system
Failure code [DWK2KA] Variable Back Electrical
DWK2KA Press Sol Open Circuit(PAGE 40-511) PUMP L01 system
Failure code [DWK2KB] Variable Back Electrical
DWK2KB Press Sol Short Circuit(PAGE 40-513) PUMP L01 system
Failure code [DWK8KA] Swing Press C/O Electrical
DWK8KA Sol Open Circuit(PAGE 40-515) PUMP L01 system
Failure code [DWK8KB] Swing Press C/O Electrical
DWK8KB Sol Short Circuit(PAGE 40-517) PUMP L01 system
Failure code [DXA8KA] PC-EPC (F) Sol Electrical
DXA8KA Open Circuit(PAGE 40-519) PUMP L03 system
Failure code [DXA8KB] PC-EPC (F) Sol Electrical
DXA8KB Short Circuit(PAGE 40-521) PUMP L03 system
Failure code [DXA9KA] PC-EPC (R) Sol Electrical
DXA9KA Open Circuit(PAGE 40-523) PUMP L03 system
Failure code [DXA9KB] PC-EPC (R) Sol Electrical
DXA9KB Short Circuit(PAGE 40-525) PUMP L03 system
Failure code [DXE0KA] LS-EPC Sol Open Electrical
DXE0KA Circuit(PAGE 40-527) PUMP L01 system
Failure code [DXE0KB] LS-EPC Sol Short Electrical
DXE0KB Circuit(PAGE 40-529) PUMP L01 system
Failure code [DXE4KA] Attachment Flow Electrical
DXE4KA EPC Open Circuit(PAGE 40-531) PUMP ―
system
Failure code [DXE4KB] Attachment Flow Electrical
DXE4KB EPC Short Circuit(PAGE 40-533) PUMP ―
system
Failure code [DXE5KA] Merge-divide Main Electrical
DXE5KA Sol Open Circuit(PAGE 40-535) PUMP L01 system
Failure code [DXE5KB] Merge-divide Main Electrical
DXE5KB Sol Short Circuit(PAGE 40-537) PUMP L01 system
Failure code [DXE6KA] Merge-divide LS Sol Electrical
DXE6KA Open Circuit(PAGE 40-539) PUMP L01 system
Failure code [DXE6KB] Merge-divide LS Sol Electrical
DXE6KB Short Circuit(PAGE 40-541) PUMP L01 system
Failure code [DY20KA] Wiper Working Electrical
DY20KA Abnormality(PAGE 40-543) PUMP ―
system
Failure code [DY20MA] Wiper Parking Electrical
DY20MA Abnormality(PAGE 40-545) PUMP ―
system
Failure code [DY2CKB] Washer Drive Short Electrical
DY2CKB Circuit(PAGE 40-547) PUMP ―
system
PC210LC-10 40-115
40 Troubleshooting

code component
Failure code [DY2DKB] Wiper Drive (Fwd) Electrical
DY2DKB Short Circuit(PAGE 40-549) PUMP ―
system
Failure code [DY2EKB] Wiper Drive (Rev) Electrical
DY2EKB Short Circuit(PAGE 40-551) PUMP ―
system
a In this table, failure codes are arranged in the order of characters from numeric to alphabetic character.
a Applicable component is the controller or machine monitor which checks the system.
MON: Machine monitor
ENG: Engine controller
PUMP: pump
KOMTRAX: KOMTRAX terminal
a The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
a History category means the classification of either electrical system or mechanical system which is used
for storage in the Failure History of the service menu.
For details, see "Troubleshooting by failure code (Display of code)".
40-116 PC210LC-10
40 Troubleshooting
Troubleshooting by failure code (Display of code)
Troubleshooting by failure code (Display of code) (ALL-3840-001-A-00-A)
Failure code [879AKA] A/C Inner Sensor Open Circuit (PC220-879AKA-441-A-00-A)
See ”Failure code [879AKA] A/C Inner Sensor Open

Circuit” of Section 80 Appendix.
a Since connector of inside air temperature sensor
cannot be disconnected while air conditioner is
mounted on machine, air conditioner controller
or air conditioner unit must be replaced.
PC210LC-10 40-117
40 Troubleshooting
Failure code [879AKB] A/C Inner Sensor Short Circuit (PC220-879AKB-441-A-00-A)
See "Failure code [879AKB] A/C Inner Sensor Short

Circuit" of Section 80 Appendix.
a Since connector of inside air temperature sensor
40-118 PC210LC-10
40 Troubleshooting
Failure code [879BKA] A/C Outer Sensor Open Circuit (PC220-879BKA-441-A-00-A)
See "Failure code [879BKA] A/C Outer Sensor

Open Circuit" of Section 80 Appendix.
PC210LC-10 40-119
40 Troubleshooting
Failure code [879BKB] A/C Outer Sensor Short Circuit (PC220-879BKB-441-A-00-A)
See "Failure code [879BKB] A/C Outer Sensor

Short Circuit" of Section 80 Appendix.
40-120 PC210LC-10
40 Troubleshooting
Failure code [879CKA] Ventilating Sensor Open Circuit (PC220-879CKA-441-A-00-A)
See Chapter 80, Other items "Failure code

[879CKA] Ventilating Sensor Open Circuit".
a Since connector of ventilating sensor
(evaporator temperature sensor) cannot be
disconnected while air conditioner is mounted
on machine, air conditioner controller or air
conditioner unit must be replaced.
PC210LC-10 40-121
40 Troubleshooting
Failure code [879CKB] Ventilating Sensor Short Circuit (PC220-879CKB-441-A-00-A)
See "Failure code [879CKB] Ventilating Sensor

Short Circuit" of Section 80 Appendix.
a Since connector of ventilating sensor
(evaporator temperature sensor) cannot be
disconnected while air conditioner is mounted
on machine, air conditioner controller or air
conditioner unit must be replaced.
40-122 PC210LC-10
40 Troubleshooting
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit (PC220-879DKZ-441-A-

00-A)
See "Failure code [879DKZ] Sunlight Sensor Open

or Short Circuit" of Section 80 Appendix.
PC210LC-10 40-123
40 Troubleshooting
Failure code [879EMC] Ventilation Damper Abnormality (PC220-879EMC-441-A-00-A)
See "Failure code [879EMC] Ventilation Damper

Abnormality" of Section 80 Appendix.
a Since connector of vent changeover servomotor
40-124 PC210LC-10
40 Troubleshooting
Failure code [879FMC] Air Mix Damper Abnormality (PC220-879FMC-441-A-00-A)
See "Failure code [879FMC] Air Mix Damper

a Since the connector of air mix servo motor can
not be disconnected as long as it is installed on
the machine, change air conditioner controller or
air conditioner unit.
PC210LC-10 40-125
40 Troubleshooting
Failure code [879GKX] Refrigerant Abnormality (PC220-879GKX-441-A-00-A)
See "Failure code [879GKX] Refrigerant

40-126 PC210LC-10
40 Troubleshooting
Failure code [989L00] Engine Controller Lock Caution1 (PC200-989L00-400-A-00-A)
Action Engine controller lock caution 1

Failure code
level Failure
- (Machine monitor system)
989L00
Details of • Engine controller is locked (factor 1).
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Problem on • Engine cannot be started.
machine
• If this failure code appears after machine monitor is replaced, user password must be
Related changed to one before replacement.
information • Method of reproducing failure code: Turn starting switch to ON position.
Defective machine This failure may be caused by replacement of machine monitor.
1
monitor
PC210LC-10 40-127
40 Troubleshooting
Failure code [989M00] Engine Controller Lock Caution2 (PC200-989M00-400-A-00-A)

Failure code
level Failure
989M00
Details of Engine controller is locked (factor 2).
failure
Problem on • Engine cannot be started.
machine
• If this failure code appears after machine monitor is replaced, user password must be
Related changed to one before replacement.
Defective machine This failure may be caused by replacement of machine monitor.
1
monitor
If this failure code appears while machine monitor is not replaced, machine
Defective machine monitor may be defective. (Since this is an internal defect, troubleshooting cannot
2
monitor be performed.)
40-128 PC210LC-10
40 Troubleshooting
Failure code [989N00] Engine Controller Lock Caution3 (PC200-989N00-400-A-00-A)

Failure code
level Failure
989N00
Details of • Engine controller is locked (factor 3).
failure
Action of • Tries automatic recovery.
Problem on
machine
Related • Method of reproducing failure code: This failure code cannot be reproduced because of
information automatic recovery.
Defective engine If this failure code appears repeatedly, engine controller may be defective. (Since
1 this is an internal defect, troubleshooting cannot be performed.)
controller
PC210LC-10 40-129
40 Troubleshooting
Failure code [A1U0N3]: KDPF Dry Request (HC Release) (PC400-A1U0N3-400-A-Z0-A)
Action level Failure code KDPF dry request (HC release)

Failure
L01 A1U0N3 (Engine controller system)
Detail of • Unburned fuel remains in KCSF due to long operation of engine at low idle.
failure
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
k Since the temperature of the KDPF and KDOC will become higher than 500 °C , take
care not to get burn injury.
• Signal voltage from KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47301(V))
• Temperature sensed by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C ))
• Signal voltage from KDOC outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
• Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
• Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
Related function. (Code: 47200 (°C ))
information • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
engine running at idle (without regenerating KDPF) are all approx. 100 to 250 °C and
temperature differences among them are approx. 10 °C (KDOC inlet temperature>KDOC
outlet temperature>KDPF outlet temperature).
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approx. 250 to 400 °C , and KDOC outlet temperature and KDPF outlet
temperature reach to approx. 450 to 550 °C .
• If there is a significant difference between KDOC inlet temperature and KDOC outlet
temperature when KDPF is completely cool or engine is running at idle (without
regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet temperature
sensor, whichever is suspected to be defective, judging from KDPF outlet temperature.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
• Method of reproducing failure code: Turn starting switch to ON position.
1. See descriptions of wiring harness and connectors in "c: Electrical
equipment" in "Checks before troubleshooting" of "General
Defective wiring harness information on troubleshooting", and check it.
1 2. Turn starting switch to ON position.
connector
If this failure code does not appear, harness connector is defective.
a If this failure code appears, perform the following.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is displayed, perform
2 temperature sensor troubleshooting for it.
40-130 PC210LC-10
40 Troubleshooting

1. Turn starting switch to ON position.
2. Monitor signal voltages from KDOC inlet temperature sensor and
KDPF outlet temperature sensor, and note down the temperature
values of each sensor at their initial condition and during manual
stationary regeneration (see "Related information").
3. Make sure that machine is in safe condition.
4. From service menu of machine monitor, select "Diagnostic Tests"
screen, open "0 Regeneration for Service", and then execute
Soot accumulation in KCSF "Manual Statonary Regeneration" (manual stationary regeneration
3
inside KDPF. will be completed in approx. 40 minutes).
If this failure code is not displayed after manual stationary regeneration
is completed, cause is soot accumulation.
a If another failure code is displayed during manual stationary
regeneration, perform troubleshooting for it.
a If failure code [CA2639] is displayed after manual stationary
regeneration is completed, perform troubleshooting for it.
4 Defective engine controller If this failure code is displayed and no failure is found by above checks,
engine controller is defective. (Since this is an internal defect,
troubleshooting cannot be performed.)
a Turn starting switch to ON position and check that failure code [CA2639] is not displayed.
PC210LC-10 40-131
40 Troubleshooting
Failure code [A1U0N4] KDPF Dry Request (HC Release) (PC400-A1U0N4-400-A-Z0-A)
Action level Failure code KDPF dry request 2 (HC release)

Failure
L03 A1U0N4 (Engine controller system)
Detail of • Unburned fuel remains in KCSF because engine has been run at low idle or low load for a
failure long time.
Action of Requests manual stationary regeneration (fuel drying) to operator.
controller Or, informs that manual stationary regeneration (fuel drying) is in progress.
Problem on Machine comes into same state as that of automatic regeneration.
machine (When machine is in safe condition, engine speed is limited to approximately 1,000 rpm.)
k Since the temperature of the KDPF and KDOC will become higher than 500 °C , take
care not to get burn injury.
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature with
engine running at idle (without regenerating) are all approx. 100 to 250 °C and
Related temperature differences among them are approx. 10 °C (KDOC inlet temperature>KDOC
information outlet temperature>KDPF outlet temperature).
• When manual stationary regeneration is performed as an action taken for A1U0N3 or
A1U0N4, dosing fuel is not injected. Therefore, KDOC inlet, KDOC outlet, and KDPF
outlet temperatures will be around 250 to 400 °C .
• In other cases than the above, when active regeneration (manual stationary regeneration)
is in progress, the KDOC inlet temperature will be approx. 250 to 400 °C , and the KDOC
outlet temperature and KDPF outlet temperature will both be approx. 450 to 550 °C .
• It takes about 40 minutes to perform active regeneration (manual stationary
regeneration).
• If there is a significant difference between the KDOC inlet temperature and KDOC outlet
temperature when the KDPF is completely cool or engine running at idle (not
regenerating), replace the KDOC inlet temperature sensor or the KDOC outlet
temperature sensor, whichever is suspected to be abnormal, judging by the KDPF outlet
temperature reading.
• KDOC inlet temperature sensor connecter label "TEMP1" is indicated on KDPF
temperature sensor consolidating box in black embossed letters (same for KDOC outlet
temperature sensor connector label "TEMP2" and KDPF outlet sensor connector label
"TEMP3").
1. Perform manual stationary regeneration by following the instructions
Performing manual stationary on the monitor.
1
regeneration (to dry KCSF) If this failure code is cleared after regeneration is performed, repair is
complete.
connector
40-132 PC210LC-10
40 Troubleshooting

3 temperature sensor troubleshooting for it.
4 Defective engine controller If this failure code appears and no failure is found by above checks,
a Turn the starting switch ON and make sure that this failure code and code [A1U0N3] are not displayed.
PC210LC-10 40-133
40 Troubleshooting
Failure code [AA10NX] Air Cleaner Clogging (PC400-AA10NX-400-A-Z0-A)
Action level Failure code Air cleaner clogging

Failure
L01 AA10NX (Machine monitor system)
Detail of • Air cleaner clogging switch signal voltage was not 1 V or less while engine was running,
failure and machine monitor detected clogging of air cleaner (open of switch contacts).
Action of • Displays air cleaner clogging monitor in red on machine monitor.
controller
Problem on • If machine is operated as it is, engine may be damaged.
machine
• Input state (ON/OFF) from air cleaner clogging switch can be checked by using
Related monitoring function.
information (Code 04501: Monitor Input 2)
• Method of reproducing failure code: Start engine.
Clogged air cleaner (when Air cleaner may be clogged. Check it for clogging and then clean or
1 system is normal) replace if clogged.
1. Turn starting switch to OFF position.
3. Start engine
Defective air cleaner clogging
2 switch (Internal open circuit) When air cleaner is
Max. 1 z
Resis- Between P23 (male) normal *1
tance (1) and (2) When air cleaner is
clogged *2 Min. 1 Mz

Open circuit in wiring harness 2. Disconnect connectors CM02 and P23, and connect T-adapters to
each female side.
3 (wire breakage or defective Between CM02 (female) (4) and P23 (female)
contact of connector) Resis- (1) Max. 1 z
tance
Between P23 (female) (2) and ground Max. 1 z
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine
4 Defective machine monitor When air cleaner is
Max. 1 V
Between CM02 (4) and normal
Voltage
CM01 (3) When air cleaner is
clogged 7 to 11 V
• Air cleaner suction resistance

*1: Max. -3,430 Pa {-350 mmH2O}
*2: -7,470 ± 490 Pa {-762 ± 50 mmH2O}
40-134 PC210LC-10
40 Troubleshooting
Circuit diagram related to air cleaner clogging
PC210LC-10 40-135
40 Troubleshooting
Failure code [AB00KE] Charge Voltage Low (PC200-AB00KE-400-A-00-A)
Action Charging voltage is low

Failure code
level Failure
(Machine monitor system)
L03 AB00KE
Details of • While engine is running, machine monitor checks signal voltage from alternator and
failure determines that charge voltage is low (below 7.8 V).
• Displays charge level monitor red on machine monitor.
Action of • Even if cause of failure disappears, machine does not become normal until starting switch
controller is turned to OFF position.
Problem on • If machine is operated as it is, battery may not be charged.
machine
• Signal voltage of alternator can be checked with monitoring function. (Code: 04300
Related Charge voltage)
information • Method of reproducing failure code: Starting engine.
Loose alternator 1. Turn starting switch to OFF position.
1 terminal or open 2. Check terminal.
circuit at terminal
Defective 2. Insert T-adapters into connector E12.
generation by
2 alternator (when a Connector E08 may be used for diagnosis.
system works 3. Starting engine.
properly) Between E12 (1) Engine speed:
and ground Medium or higher
Defective wiring 2. Insert T-adapters into connector CM01.
3 harness or machine 3. Start engine.
monitor
Voltage Between CM01 (16) and ground 20 to 30 V
Open circuit in a If no failure is found by check on cause 2, this check is not required.
wiring harness 1. Turn starting switch to OFF position.
4 (wire breakage or 2. Disconnect connectors CM01 and E12, and connect T-adapters to each female
defective contact of side.
connector) Between CM01 (female) (16) and E12
Resistance (female) (1) Max. 1 z
a If no failure is found by check on cause 2, this check is not required.

Ground fault in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors CM01 and E12, and connect T-adapters to either
5 (contact with GND female side.
circuit) Between CM01 (female) (16) and
Resistance ground, or E12 (female) (1) and ground Min. 1 Mz
Defective machine If no failure is found by above checks, machine monitor is defective. (Since this is
6 an internal defect, troubleshooting cannot be performed.)
monitor
40-136 PC210LC-10
40 Troubleshooting
Circuit diagram related to charging
PC210LC-10 40-137
40 Troubleshooting
Failure code [B@BAZG] Engine Oil Pressure Low (PC220_10-BaBAZG-400-A-01-A)
Action
Failure code Abnormally low engine oil pressure
level Failure (Engine controller system)
L03 B@BAZG
Details of • While engine is running, engine controller detects engine oil pressure drop (sensor
failure contact is closed) from signal voltage of engine oil pressure switch.
• Displays engine oil pressure monitor yellow on machine monitor.
Action of • If cause of failure disappears, machine becomes normal by itself.
controller • Limits engine output and allows engine to run.
Problem on • If machine is operated as it is, engine may be damaged.
machine • Engine output decreases.
• Signal from engine oil pressure switch is input to engine controller. If engine oil pressure
Related switch is closed (turned ON) while engine is running, engine controller transmits this
information signal to machine monitor to display this failure code.
• Method of reproducing failure code: Starting engine.
Lowered engine oil Engine oil pressure may be low. Check it and fix if it is low.
pressure (when
1 system works
properly)
If no failure is found by above checks, engine oil pressure monitor system may be
defective. Perform troubleshooting in E-mode.
Defective engine oil • E-14 Coolant temperature monitor lights up in red while engine is running
pressure monitor (PAGE 40-577)
2
system • E-15 Hydraulic oil temperature monitor lights up in red while engine is running
(PAGE 40-578)
• E-16 Engine oil pressure monitor lights up in red while engine is running(PAGE
40-579)
40-138 PC210LC-10
40 Troubleshooting
Failure code [B@BAZK] Eng Oil Level Low (PC400-BaBAZK-400-A-Z0-A)
Action level Failure code Engine oil level low

Failure
L01 B@BAZK (Machine monitor system)
Detail of • While engine is running, signal voltage from engine oil level switch is not below 1 V, so
failure machine monitor determines that engine oil level is low (oil level switch is open).
Action of • Displays engine oil level monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may seize up.
machine
• Input (ON/OFF) from engine oil level switch can be checked by using monitoring function.
Related (Code 04501: Monitor Input 2)
information • Method of reproducing failure code: Start engine
Low engine oil level
1 Check engine oil level. If it is low, remove cause.
(when system is normal)
Defective engine oil level 1. Turn starting switch to OFF position.
sensor 2. Disconnect connector P44 and connect T-adapter to male side.
2
(internal defect) Resis- Between P44 (male) (1) and ground
Max. 1 z
tance
Open circuit in wiring harness 2. Disconnect connectors CM02 and P44, and connect T-adapters to
3 (wire breakage or defective each female side.
contact of connector) Resis- Between CM02 (female) (2) and P44 (female)
(1) Max. 1 z
tance
If no failure is found by above checks, machine monitor is defective.
• Reference
2. Disconnect connectors CM01 and CM02 and connect T-adapters to
4 Defective machine monitor each female side.
Between CM02 (female) (2) and CM01 (female)
Voltage Max. 1 V
(3)
Circuit diagram related to engine oil level
PC210LC-10 40-139
40 Troubleshooting
Failure code [B@BCNS] Engine Coolant Overheat (PC220_10-BaBCNS-400-A-01-A)
Action Engine coolant overheats

Failure code
level Failure
B@BCNS (Engine controller system)
L02
Details of • While engine is running, engine controller detects overheating of engine coolant from
failure signal voltage of engine coolant temperature sensor.
• Displays engine coolant temperature monitor red on machine monitor.
• If cause of failure disappears, machine becomes normal by itself.
Action of • Limits engine output and allows engine run.
controller • Stops regeneration control.
• Closes EGR valve (depending on coolant temperature).
Problem on • If machine is operated as it is, engine may seize up.
machine
• Signal of engine coolant temperature sensor is input to engine controller and then data is
transmitted to machine monitor through CAN communication system.
Related • Engine coolant temperature can be checked with monitoring function.
information (Code: 04107 Engine coolant temperature)
Overheating of Engine coolant may overheat. Check it and remove cause if it overheats.
engine coolant
1 (when system is
normal)
If no failure is found by above checks, engine coolant temperature gauge system
may be defective. Perform the following troubleshooting described in E-mode
Defective engine troubleshooting section.
coolant
2 temperature gauge • E-19 Coolant temperature gauge indicates either Min. or Max. and does not
system move(PAGE 40-582)
• E-20 Coolant temperature gauge indicates incorrect temperature (indicates
neither Min. nor Max.)(PAGE 40-583)
40-140 PC210LC-10
40 Troubleshooting
Failure code [B@BCZK] Radiator Coolant Level Low (PC220_10-BaBCZK-400-A-01-A)
Action Engine coolant level is low

Failure code
level Failure
B@BCZK (Machine monitor system)
L01
• While starting switch is at ON position (with engine stopped) or engine is running, radiator
Details of coolant level switch signal voltage does not remain below 1 V. So machine monitor
failure determines that engine coolant level is low (sensor contact is open).
Action of • Displays radiator coolant level monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may overheat.
machine
• Input (ON/OFF) from radiator coolant level switch can be checked by using monitoring
Related function.
information (Code: 04500 Monitor input 1)
Lowered radiator Coolant level in radiator sub tank may be low. Check it and add coolant if it is low.
coolant level (when
1 system works
properly)
Defective coolant 2. Disconnect connector P24 and connect T-adapters to male side.
2 level switch Between FULL and
(internal defect) Between P24 Max. 1 z
Resistance LOW lines
(male) (1) and (2)
Below LOW line Min. 1 Mz
Open circuit in 2. Disconnect connectors CM02 and P24, and connect T-adapters to each female
wiring harness side.
3 (wire breakage or
defective contact of a Add coolant.
connector) Between CM02 (female) (3) and P24
• Reference
Defective machine 3. Turn starting switch to ON position.
4
monitor
Between FULL and
Max. 1 V
Between CM02 (3) LOW lines
Voltage
and CM01 (3) Min. 7 to 11 V
Below LOW line
PC210LC-10 40-141
40 Troubleshooting
Circuit diagram related to radiator coolant level switch
40-142 PC210LC-10
40 Troubleshooting
Failure code [B@HANS] Hyd Oil Overheat (PC220_10-BaHANS-400-A-01-A)
Action Hydraulic oil overheat

Failure code
level Failure
B@HANS (Pump controller system)
L02
Details of • While engine is running, pump controller determines that hydraulic oil overheats (above
failure approx. 105°C) from signal voltage of hydraulic oil temperature sensor.
Action of • Displays hydraulic oil temperature monitor red on machine monitor.
Problem on • If machine is operated as it is, hydraulic components may be damaged.
machine
• Signal of hydraulic oil temperature sensor is input to pump controller and then data is
transmitted to machine monitor through CAN communication system.
• Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401 Hydraulic oil temperature)
Related • Refer to following troubleshooting described in E mode troubleshooting section.
information
• E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not move
• E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates
neither Min nor Max)
Overheating of Hydraulic oil may overheat. Check it and remove cause if it overheats.
hydraulic oil (when
1 system works
properly)
Defective hydraulic If no failure is found by above checks, hydraulic oil temperature gauge system
2 oil temperature may be defective. Perform troubleshooting for failure code [DGH2KB].
gauge system
PC210LC-10 40-143
40 Troubleshooting
Failure code [CA115] Eng Ne and Bkup Speed Sens Error (PC200-CA115-400-A-00-A)
Action Engine Ne and Bkup speed sensor error

Failure code
level Failure
(Engine controller system)
L04 CA115
Details of • Signals from both engine Ne speed sensor and engine Bkup speed sensor are abnormal.
failure
controller
Problem on • Engine stops.
machine • Engine does not start.
Related • Method of reproducing failure code: Start engine.
information
Defective contact of Connectors of Ne speed sensor and Bkup speed sensor may be connected
1 defectively (or to wrong connection). Check them.
sensor connector
Defective Ne speed Perform troubleshooting for failure code [CA689].
2 sensor system
Defective Bkup Perform troubleshooting for failure code [CA778].
3 speed sensor
system
Defective engine If no failure is found by above checks, engine controller is defective. (Since this is
controller
40-144 PC210LC-10
40 Troubleshooting
Failure code [CA122] Chg Air Press Sensor High Error (D65-CA122-400-A-Z0-A)
Action
Failure code Charge pressure sensor high error
level Failure
L03 CA122
Detail of • High voltage is detected in pressure signal circuit of charge (boost) pressure &
failure temperature sensor.
• Takes it that charge pressure is at calculated value and allows engine to run.
Action of • Restricts engine output and allows engine to run.
controller • Closes EGR valve.
• Stops regeneration control by KDPF.
Problem on • Engine output lowers.
machine
• Input voltage from charge (boost) pressure sensor can be checked with monitoring
function.
(Code: 36501 (V))
• Charge (boost) pressure sensed by charge (boost) pressure sensor can be checked with
Related
monitoring function.
information
(Code: 36500 (kPa))
• If sensor connector is disconnected, code [CA123] for "Low Error" is displayed, even in
normal condition.
information on troubleshooting", and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector If this failure code does not appear, wiring harness connector is
defective.
Defective sensor power If failure code [CA187] or [ CA227] is also displayed, perform
2 troubleshooting for it first.
source 2 circuit
2. Disconnect connector BOOST PRESS & IMT.
If failure code changes from [CA122] to [CA123] ,boost pressure sensor
is defective.
a Failure code [CA153] for temperature sensor is displayed at the
Defective boost pressure & same time.
3 temperature sensor Ignore this failure code since it appears because of disconnection of
sensor.
• Reference
2. Insert T-adapter in connector ECM J1.
Sensor 0.3 to 4.7
Voltage Between ECM J1 (15) and (59)
output V
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
4 Short circuit in wiring harness connect T-adapter to female side of ECM J1.
Resis- Between ECM J1 (female) (15) and (60) Min. 100
tance kz
PC210LC-10 40-145
40 Troubleshooting

Hot short circuit in wiring 2. Disconnect connector BOOST PRESS & IMT, and connect T-
harness adapter to connector ECM J1.
5 3. Turn starting switch to ON position (with connector BOOST PRESS
(contact with 24 V circuit) & IMT disconnected).
Voltage Between ECM J1 (15) and (59) Max. 1 V
If no failure is found by above checks, engine controller is defective.
6 Defective engine controller
(Since this is internal defect, troubleshooting cannot be performed.)
Circuit diagram related to boost pressure sensor
40-146 PC210LC-10
40 Troubleshooting
Failure code [CA123] Chg Air Press Sensor Low Error (D65-CA123-400-A-Z0-A)
Action
Failure code Charge air pressure sensor low error
level Failure
L03 CA123
Detail of • Low voltage is detected in pressure signal circuit of charge (boost) pressure &
failure temperature sensor.
• Takes it that charge pressure is at calculated value and allows engine to run.
Problem on
• Engine output lowers.
machine
• Input voltage from charge (boost) pressure sensor can be checked with monitoring
function.
(Code: 36501 (V))
• Charge (boost) pressure sensed by charge (boost) pressure sensor can be checked with
Related (Code: 36500 (kPa))
• Since troubleshooting "socket" for this sensor features female connector only, it is not
usable for checking open circuit in wiring harness and voltage at sensor connector (not
designed for T-adapter).
• If sensor connector is disconnected, this failure code is displayed.
connector
Defective power supply
system of charge pressure If failure code [CA187] or [CA227] is also displayed, perform
2 sensor (boost pressure troubleshooting for it first.
sensor)
2. Disconnect connectors CAM SENSOR, AMB. AIR PRESSURE,
BOOST PRESS & IMT, and ECM J1.
3 Short circuit in wiring harness 3. Connect T-adapter to female side of ECM J1.
Resis- Between ECM J1 (female) (15) and (59) Min. 100 kz

tance Between ECM J1 (female) (15) and (60) Min. 100 kz
Ground fault of wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
4 harness (contact with ground connect T-adapter to female side of ECM J1.
circuit) Resis- Between ECM J1 (female) (15) and ground Min. 100 kz
tance Between ECM J1 (female) (60) and ground Min. 100 kz
If no failure is found by the above checks, there may be open circuit in
5 Open circuit in wiring harness
wiring harness. (*)
a If causes 1 to 5 are not cause for failure and check result of cause 6
is abnormal, sensor is defective.
Defective boost pressure and
temperature sensor 1. Turn starting switch to OFF position.
6 (improper input voltage to 2. Insert T-adapter in connector ECM J1.
engine controller) 3. Turn starting switch to ON position.
Sensor
Voltage Between ECM J1 (15) and (59) 0.3 to 4.7 V
output
PC210LC-10 40-147
40 Troubleshooting

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
Circuit diagram related to boost pressure sensor
40-148 PC210LC-10
40 Troubleshooting
Failure code [CA131] Throttle Sensor High Error (PC200-CA131-400-A-00-A)
Action Throttle sensor high error

Failure code
level Failure
L03 CA131
Details of • High voltage appears in signal circuit of fuel control dial.
failure
• Uses throttle value obtained before failure detection and allows engine to run if failure is
Action of detected with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after detecting
failure.
Problem on • Engine speed cannot be controlled by using fuel control dial.
machine
• Signal voltage of fuel control dial can be checked with monitoring function.
Related (Code: 03000 Fuel control dial voltage)
1. Perform checkup referencing descriptions of wiring harness and connectors in
"c: Electrical equipment"of "Checks before troubleshooting" in "General
Defective wiring information on troubleshooting".
1
harness connector 2. Turn starting switch to ON position.
If this failure code disappears, wiring harness connector is defective.
Defective throttle If failure code [CA2185] or [CA2186] is also displayed simultaneously, perform
2 sensor power troubleshooting for it first.
supply system
Defective fuel 2. Disconnect connector P20 and connect T-adapters to male side.
3 control dial (throttle Between P20 (male)(1) and (3) 4.0 to 6.0 kz
sensor) Resistance Between P20 (male)(2) and (3) 0.25 to 5.0 kz
Between P20 (male)(1) and (2) 0.25 to 5.0 kz
Open circuit or 2. Disconnect connector CE03 and connect T-adapters to female side.
4 short circuit in
wiring harness Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
Resistance
Between CE03 (female) (41) and (51) 0.25 to 5.0 kz
Short circuit in 2. Disconnect connectors CE03 and P20, and connect T-adapters to either
5 wiring harness female side.
Between CE03 (female) (41) and (42), or
Resistance between P20 (female) (1) and (2) Min. 100 kz
Hot short circuit in 1. Turn starting switch to OFF position.

wiring harness 2. Disconnect connector P20 and connect T-adapters to female side.
6 (contact with 24 V 3. Turn starting switch to ON position.
circuit) Voltage Between P20 (female) (2) and ground Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
• Reference
2. Insert T-adapters into connector CE03.
Defective engine 3. Turn starting switch to ON position.
7
controller 4. Operate fuel control dial and perform troubleshooting.
Between CE03 (41)
Power supply 4.75 to 5.25 V
and (42)
Voltage
Between CE03 (41)
Sensor output 0.5 to 4.5 V
and (51)
PC210LC-10 40-149
40 Troubleshooting
Circuit diagram related to throttle sensor
40-150 PC210LC-10
40 Troubleshooting
Failure code [CA132] Throttle Sensor Low Error (PC200-CA132-400-A-00-A)
Action Throttle sensor low error

Failure code
level Failure
L03 CA132
Details of • Low voltage appears in signal circuit of fuel control dial.
failure
• Uses throttle value obtained before failure detection and allows engine to run if failure is
Action of detected with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after detecting
failure.
machine
• Signal voltage of fuel control dial can be checked with monitoring function.
Related (Code: 03000 Fuel control dial voltage)
harness connector
Defective throttle If failure code [CA2185] or [CA2186] is also displayed simultaneously, perform
2 sensor power troubleshooting for it first.
supply system
Defective fuel 2. Disconnect connector P20 and connect T-adapters to male side.
3 control dial (throttle Between P20 (male)(1) and (3) 4.0 to 6.0 kz
sensor) Resistance Between P20 (male)(2) and (3) 0.25 to 5.0 kz
Between P20 (male)(1) and (2) 0.25 to 5.0 kz
Open circuit or 2. Disconnect connector CE03 and connect T-adapters to female side.
4 short circuit in
wiring harness Between CE03 (female) (41) and (42) 4.0 to 6.0 kz
Resistance
Between CE03 (female) (41) and (51) 0.25 to 5.0 kz
Open circuit in 2. Disconnect connectors CE03 and P20, and connect T-adapters to each female
5 (wire breakage or Between CE03 (female) (42) and P20
(female) (1) Max. 1 z
defective contact of
connector) Between CE03 (female) (51) and P20
Between CE03 (female) (41) and P20

2. Disconnect connectors CE03 and P20, and connect T-adapters to either
Short circuit in female side.
6 wiring harness Between CE03 (female) (41) and (51), or
between P20 (female) (2) and (3) Min. 100 kz
Resistance
Between CE03 (female) (41) and (42), or Min. 100 kz
between P20 (female) (1) and (3)
PC210LC-10 40-151
40 Troubleshooting

2. Disconnect connectors CE03 and P20, and connect T-adapters to either
Ground fault in female side.
harness Between ground and wiring harness
7 between CE03 (female) (51) and P20 Min. 100 kz
(Contact with GND (female) (2)
circuit) Resistance
Between ground and wiring harness
between CE03 (female) (42) and P20 Min. 100 kz
(female) (1)
If no failure is found by above checks, engine controller is defective. (Since this is
• Reference
2. Insert T-adapters into connector CE03.
Defective engine 3. Turn starting switch to ON position.
8
controller 4. Operate fuel control dial and perform troubleshooting.
Between CE03 (41)
Power supply 4.75 to 5.25 V
and (42)
Voltage
Between CE03 (41)
Sensor output 0.5 to 4.5 V
and (51)
40-152 PC210LC-10
40 Troubleshooting
Failure code [CA144] Coolant Temp Sens High Error (D61-CA144-400-A-Z0-A)
Action level Failure code Coolant temperature sensor high error

Failure
L01 CA144 (Engine controller system)
Detail of • High voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run.
controller
Problem on • Engine does not start easily at low temperature.
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function (Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked with
monitoring function. (Code: 04107 (°C))
Related • Method of reproducing failure code: Turn starting switch to ON position.
information • This failure code is displayed if temperature sensor connector is disconnected.
• Because troubleshooting "socket" for this sensor features female connector only, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed for T-adapter).
1
defective.
a If this failure code appears, perform following.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side.
a If coolant temperature sensor has resistance of 700 z to 37 kz with
coolant temperature above 0 °C , regard coolant temperature sensor
Defective coolant as normal.
2 temperature sensor 0 °C 30 to 37 kz
Between COOLANT TEMP (male) 9.3 to 10.7
25 °C
Resis- (A) and (B) kz
tance a Coolant temperature 50 °C 3.2 to 3.8 kz
-Resistance characteristics 80 °C 1.0 to 1.3 kz
95 °C 700 to 800 z
2. Disconnect connector ECM J1 and connect T-adapter to female side
of connector.
Open or short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in kz
resistance characteristics table of coolant
temperature sensor of cause 2.
If no failure is found in above checks, engine controller is defective.
PC210LC-10 40-153
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-154 PC210LC-10
40 Troubleshooting
Failure code [CA145] Coolant Temp Sens Low Error (D61-CA145-400-A-Z0-A)
Action level Failure code Coolant temperature sensor low error

Failure
Detail of • Low voltage is detected in engine coolant temperature sensor signal circuit.
failure
Action of • Sets coolant temperature to fixed temperature (100 °C ),and allows engine to run.
controller
machine • Overheat prevention function does not work.
• Signal voltage from engine coolant temperature sensor can be checked with monitoring
function (Code: 04105 (V)).
• Temperature sensed by engine coolant temperature sensor can be checked with
Related monitoring function. (Code: 04107 (°C))
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA144] for "High Error" is displayed.
1
defective.
2. Disconnect connector COOLANT TEMP, and connect socket to male
side of connector.
a If coolant temperature sensor has resistance of 700 z to 37 kz with
coolant temperature above 0 °C , regard coolant temperature sensor
as normal.
Defective coolant 0 °C 30 to 37 kz
2 temperature sensor Between COOLANT TEMP (male) 9.3 to 10.7
(A) and (B) 25 °C
kz
50 °C 3.2 to 3.8 kz
Resis- a Coolant temperature
-Resistance characteristics 80 °C 1.0 to 1.3 kz
tance
95 °C 700 to 800 z
All coolant
Between (B) and ground tempera- Min. 100 kz
ture range
of connector.
Short circuit in wiring Between ECM J1 (female) (14) and (13)
3 (coolant temperature: Min. 0 °C )
harness
Resis- 700 z to 37
tance a Resistance is the same as that shown in kz
resistance characteristics table of coolant
temperature sensor of cause 2.
Ground fault in wiring 2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect
4 harness (contact with ground T-adapters to female side of ECM J1.
circuit) Resis- Between ECM J1 (female) (14) and ground
Min. 100 kz
tance
PC210LC-10 40-155
40 Troubleshooting
Circuit diagram related to coolant temperature sensor
40-156 PC210LC-10
40 Troubleshooting
Failure code [CA153] Chg Air Temp Sensor High Error (D65-CA153-400-A-Z0-A)
Action level Failure code Charge (Air) temperature sensor High error.
Failure
Detail of • High voltage is detected in charge (boost) temperature sensor signal circuit.
failure
• Takes it that charge temperature (boost temperature) is at calculated value and allows
engine to run.
Action of • Closes EGR valve.
controller • Restricls engine output and allows engine to run.
• Stops KDPF regeneration control.
machine • Engine output lowers.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function (Code: 18501 (V)).
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 ( °C ))
information • Because troubleshooting "socket" for this sensor features female connector only, it is not
connectable to female connector of sensor wiring harness, and thus not usable for
checking open circuit (not designed for T-adapter).
• This failure code is displayed if temperature sensor connector is disconnected.
1
defective.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to
male side of connector.
a If temperature sensor has resistance of 80 z to 48 kz , regard charge
temperature sensor as normal.
Defective charge -40 °C 41 to 48 kz
2 temperature sensor -20 °C 14 to 16 kz
Between BOOST PRESS & IMT 0 °C 5.4 to 6.1 kz
Resis- (male) (3) and (4) 30 °C 1.6 to 1.8 kz
tance a Charge temperature 560 to 600
60 °C
-Resistance characteristics kz
90 °C 230 to 250 z
130 °C 80 to 90 z
of connector.
3
harness
Resis- a Use Temperature-Resistance 80 z to 48
tance characteristics table for troubleshooting on kz
cause 2.
PC210LC-10 40-157
40 Troubleshooting
Circuit diagram related to boost temperature sensor
40-158 PC210LC-10
40 Troubleshooting
Failure code [CA154] Chg Air Temp Sensor Low Error (D65-CA154-400-A-Z0-A)
Action level Failure code Charge (boost) temperature sensor signal voltage is too low.
Failure
Detail of • Low voltage is detected in charge (boost) temperature sensor signal circuit.
failure
• Takes it that charge temperature (boost temperature) is at calculated value and allows
engine to run.
controller • Restricts engine output and allows engine to run.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked with monitoring function (Code: 18501 (V)).
Related checked with monitoring function. (Code: 18500 ( °C ))
• If temperature sensor connector is disconnected, this failure code is not displayed but
failure code [CA153] for "High Error" is displayed.
1
defective.
2. Disconnect connector BOOST PRESS & IMT, and connect socket to
male side of connector.
a If charge temperature sensor has resistance of 80 z to 48 kz ,
regard charge temperature sensor as normal.
-40 °C 41 to 48 kz
Defective charge -20 °C 14 to 16 kz
2 temperature sensor Between BOOST PRESS & IMT 0 °C 5.4 to 6.1 kz
(male) (3) and (4) 30 °C 1.6 to 1.8 kz
Resis- a Charge temperature 560 to 600
tance 60 °C
-Resistance characteristics kz
90 °C 230 to 250 z
130 °C 80 to 90 z
Between BOOST PRESS & IMT Whole
(male) (3) and ground range Min. 100 kz

of connector.
3
harness
Resis- a Use Temperature-Resistance 80 z to 48
tance characteristics table for troubleshooting on kz
cause 2.
Ground fault in wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and
4 harness (contact with ground connect T-adapter to female side of ECM J1.
circuit) Resis- Between ECM J1 (female) (5) and ground
Min. 100 kz
tance
PC210LC-10 40-159
40 Troubleshooting
Circuit diagram related to boost temperature sensor
40-160 PC210LC-10
40 Troubleshooting
Failure code [CA187] Sensor 2 Supply Volt Low Error (PC200LC_10-CA187-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
Detail of • Low voltage appears in sensor power supply 2 (5 V) circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor and allows engine to run taking it that
ambient pressure is at fixed value (52.44 kPa {0.53 kg/cm2}).
• Ignores signals from boost pressure sensor and allows engine to run taking it that boost
Action of pressure is at calculated value.
controller • Ignores signals from crankcase pressure sensor and allows engine to run taking it that
crankcase pressure is at fixed value (0 kPa).
• Closes EGR valve.
• Limits engine output and allows engine to run.
Problem on • Engine output decreases.
machine
information
connector
If this failure code disappears, harness connector is defective.
a If this failure code appears, perform following checks.
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine
wiring harness is defective.
a Other failure codes (many codes) are also displayed. They are
generated because of disconnection of connector. Ignore failure
Defective sensor or wiring codes other than [CA187].
2 Sensor and wiring
harness Connector
harness
Cam (Bkup speed)
CAM SENSOR
sensor
Boost pressure sensor BOOST PRESS & IMT
Connector
Ambient pressure
AMB. AIR PRESSURE
sensor
Crankcase pressure
P57
sensor
Engine harness ECM J1
If failure codes other than this code are displayed, perform
3 Defective relevant system
troubleshooting for them.
2. Disconnect connector ECM J1 and connect T-adapters to male side.
4 Defective engine controller 3. Turn starting switch to ON position with connector ECM J1
disconnected.
Voltage Between ECM J1 (male) (60) and (59) 4.75 to 5.25
V
PC210LC-10 40-161
40 Troubleshooting
Circuit diagram related to sensor power supply 2 circuit
40-162 PC210LC-10
40 Troubleshooting
Failure code [CA221] Ambient Press Sens High Error (D65-CA221-400-A-Z0-A)
Action
Failure code Ambient Pressure Sensor High Error
level Failure
L03 CA221
Detail of • High voltage appears in signal circuit of ambient pressure sensor.
failure
• Takes it that ambient pressure is at fixed value of 52.44 kPa (0.53 kg/cm 2) and allows
engine to run.
Action of • Limits engine output and allows engine to run.
machine
• Input voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function. (Code: 37400 (kPa))
1 Defective harness connector 2. Turn starting switch to ON position.
2 supply 1 circuit troubleshooting for it first.
2. Disconnect connector AMB. AIR PRESSURE.
If failure code [CA221] changes to [CA222], sensor is defective.
Defective ambient pressure • Reference
3
sensor 1. Turn starting switch to OFF position.
2. Insert T-adapters in connector ECM J1.
Sensor 0.5 to 4.5
output V
2. Disconnect connectors ECM J1 and AMB AIR PRESSURE, and
4 Short circuit in wiring harness connect T-adapters to either female side.
Resis- Between ECM J1 (60) and (16), or between Min. 100
tance AMB. AIR PRESSURE (female) (1) and (3) kz
2. Disconnect connector AMB. AIR PRESSURE.
Hot short circuit in wiring 3. Connect T-adapters to female side of connector AMB. AIR
harness (contact with 24 V PRESSURE or insert T-adapters into connector ECM J1.
5
circuit) 4. Turn starting switch to ON position with connector AMB AIR
PRESSURE disconnected.
Between ECM J1 (16) and (59), or between
Voltage Max. 1 V
AMB. AIR PRESSURE (female) (3) and (2)
(Since this is an internal defect, troubleshooting cannot be performed.)
PC210LC-10 40-163
40 Troubleshooting
Circuit diagram related to ambient pressure sensor
40-164 PC210LC-10
40 Troubleshooting
Failure code [CA222] Ambient Press Sens Low Error (D65-CA222-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of ambient pressure sensor.
failure
• Takes it that ambient pressure is at fixed value of 52.44 kPa (0.53 kg/cm2) and allows
engine to run.
machine
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
Related function.
information (Code: 37400 (kPa))
• This failure code appears if sensor connector is disconnected.
If failure code [CA187] or [ CA227] is also displayed, perform
troubleshooting for it first.
Defective ambient pressure 2. Disconnect connector AMB. AIR PRESSURE and connect T-
2 sensor power supply circuit adapters to female side.
Power
Between AMB. AIR PRESSURE 4.75 to
Voltage supply
(female) (1) and (2) 5.25 V
input
2. Disconnect connectors AMB AIR PRESSURE and ECM J1, and
connect T-adapters to either female side.
a If power supply input is normal in check on
cause 2, this check is not required. Between Max. 10 z
Open circuit in wiring harness ECM J1 (female) (60) and AMB. AIR
3 (wire breakage or defective PRESSURE (female) (1)
contact of connector) Resis-
a If power supply input is normal in check on
tance
cause 2, this check is not required. Between Max. 10 z
ECM J1 (female) (59) and AMB. AIR
PRESSURE (female) (2)
Between ECM J1 (female) (16) and AMB. AIR
PRESSURE (female) (3) (sensor output) Max. 10 z
PC210LC-10 40-165
40 Troubleshooting

Ground fault in wiring harness 2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and
4 connect T-adapters to either female side.
(contact with ground circuit)
Resis- Between ground and ECM J1 (female) (16) or Min. 100
tance AMB. AIR PRESSURE (female) (3) kz
2. Disconnect connectors ECM J1 and AMB. AIR PRESSURE, and
5 Short circuit in wiring harness connect T-adapters to either female side.
Resis- Between ECM J1 (16) and (60), or between Min. 100
tance AMB. AIR PRESSURE (female) (2) and (3) kz
Defective ambient pressure 3. Turn starting switch to ON position.
6
sensor
Sensor 0.5 to 4.5
output V
Circuit diagram related to ambient pressure sensor
40-166 PC210LC-10
40 Troubleshooting
Failure code [CA227] Sensor 2 Supply Volt High Error (D65-CA227-400-A-Z0-A)
Action level Failure code Sensor 2 Supply Voltage High Error

Failure
Detail of • High voltage appears in sensor power supply 2 circuit.
failure
• Ignores signals from Bkup speed sensor and controls engine by using Ne speed sensor
signals.
• Ignores signals from ambient pressure sensor and allows engine to run taking it that
ambient pressure is at fixed value (52.44 kPa {0.53 kg/cm2}).
• Ignores signals from boost pressure sensor and allows engine to run taking it that boost
Action of pressure is at calculated value.
controller • Ignores signals from crankcase pressure sensor and allows engine to run taking it that
crankcase pressure is at fixed value (0 kPa).
machine
information
Abnormally high sensor
1 Perform same troubleshooting as that for failure code [CA187].
power supply 2 voltage
PC210LC-10 40-167
40 Troubleshooting
Failure code [CA234] Eng Overspeed (PC200-CA234-400-A-00-A)
Action Engine overspeed

Failure code
level Failure
L02 CA234
Details of • Engine speed is over the operating range.
failure
Action of • Limits fuel injection rate until engine speed lowers to operating range.
controller
Problem on • Engine speed fluctuates.
machine
• Engine speed can be checked with monitoring function.
Related (Code: 01002 Engine speed)
information • Method of reproducing failure code: Start the engine and run at high idle.
Use of improper Fuel used may be improper. Check it.
1
fuel
Defect in related If another failure code is displayed, carry out troubleshooting for it.
2 system
3 Improper fuel Machine may be used improperly. Instruct operator on proper way to use.
controller
40-168 PC210LC-10
40 Troubleshooting
Failure code [CA238] Ne Speed Sensor Supply Volt Error (D65-CA238-400-A-Z0-A)
Action
Failure code Ne Speed Sensor Supply Voltage Error
level Failure
L01 CA238
Detail of • Low voltage appears in power supply circuit of engine Ne speed sensor.
failure
Action of • Controls engine by using signals from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup (CAM) speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
machine • Engine starting performance becomes deteriorated
• Engine hunts.
information
2. Disconnect connector CRANK SENSOR, and turn starting switch to
ON position.
2 Defective sensor If this failure code is not displayed, crank sensor is defective.
codes other than [CA238].
2. Disconnect harness connector ECM J1 and turn starting switch to
ON position.
3 Defective wiring harness If this failure code is not displayed, engine wiring harness is defective.
4 Defective engine controller 3. Turn starting switch to ON position with engine wiring harness
disconnected.
V
Circuit diagram related to Ne speed sensor
PC210LC-10 40-169
40 Troubleshooting
Failure code [CA239] Ne Speed Sens Supply Volt High Error (PC220_10-CA239-400-A-
00-A)
Action Ne speed sensor supply voltage high error
Failure code
level Failure
L01 CA239
Details of • High voltage appears in power supply circuit of engine Ne speed sensor.
failure
Action of • Controls engine with signal from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup speed sensor is also defective).
machine • Engine startability becomes poor.
• Engine hunts.
information
harness connector
If this failure code does not appear, wiring harness connector is defective.
a If this failure code is displayed, implement the following.
2. Disconnect connector CRANK SENSOR, and turn starting switch to ON
2 Defective sensor
position.
If this failure code is not displayed, sensor is defective.
2. Disconnect wiring harness ECM J1 and turn starting switch to ON position.
Defective wiring If this failure code is not displayed, engine wiring harness is defective.
3
harness
a Many other failure codes appear at same time because of disconnection of
connector. Ignore failure codes other than [CA239].
Defective engine
4 3. Turn starting switch to ON position with engine wiring harness connector
controller
disconnected.
Voltage Between ECM J1 (male) (36) and (37) 4.75 to 5.25 V
Circuit diagram related to Ne speed sensor
40-170 PC210LC-10
40 Troubleshooting
Failure code [CA271] IMV/PCV1 Short Error (D65-CA271-400-A-Z0-A)
Action level Failure code IMV/PCV1 Short Error

Failure
Detail of • Short circuit is detected in drive circuit of supply pump actuator (IMV).
failure
Action of • None in particular.
controller
• Engine speed does not increase from low idle speed.
machine • Common rail fuel pressure rises above command value.
information
Defective supply pump 2. Disconnect connector INLET METERING VALVE.
actuator
If failure code changes from [CA271] to [CA272] , supply pump actuator
is defective.
2. Disconnect connector ECM J1 and connect T-adapters to female
Short circuit or ground fault in side.
3 wiring harness Between ECM J1 (female) (30) and (40) 1 to 5 z
Resis-
tance Between ECM J1 (female) (30) and ground Min. 100
kz
4 Short circuit in wiring harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
connect T-adapters to female side of ECM J1.
Resis- Between ECM J1 (female) (30) and (40) Min. 100
tance kz
2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
Ground fault in wiring harness
5 connect T-adapters to female side of ECM J1.
Between ECM J1 (female) (30) and ground Min. 100
Resis- kz
tance Between ECM J1 (female) (40) and ground Min. 100
kz
PC210LC-10 40-171
40 Troubleshooting
Circuit diagram related to IMV/PCV1
40-172 PC210LC-10
40 Troubleshooting
Failure code [CA272] IMV/PCV1 Open Error (D65-CA272-400-A-Z0-A)
Action level Failure code IMV/PCV1 Open Error

Failure
Detail of • Open circuit is detected in drive circuit of supply pump actuator.
failure
Action of None in particular.
controller
Problem on • Engine runs but its speed does not stabilize.
machine • Common rail fuel pressure rises above command value.
Related • Since female connector alone is provided for "socket" used for troubleshooting of this
information sensor, it is not connectable to female connector on sensor wiring harness side and thus
not usable for check of open circuit (not designed as T-adapter).
2. Disconnect connector INLET METERING VALVE.
Defective supply pump Between INLET METERING VALVE (male) (1)
2 1 to 5 z
actuator Resis- and (2)
tance Between INLET METERING VALVE (male) (1)

Open circuit or ground fault 2. Disconnect connector ECM J1 and connect T-adapters to female
3 in wiring harness side.
Resis- Between ECM J1 (female) (30) and (40)
1 to 5 z
tance
Ground fault in wiring 1. Turn starting switch to OFF position.
4 harness 2. Disconnect connectors ECM J1 and INLET METERING VALVE, and
(contact with ground circuit) connect T-adapters to female side of ECM J1.
Resis- Between ECM J1 (female) (30) and ground Min. 100 kz
2. Disconnect connector INLET METERING VALVE.
3. Insert T-adapters into connector ECM J1.
Hot short circuit in wiring 4. Turn starting switch to ON position (with connector INLET
5 harness METERING VALVE connected) and start measurement after at least
(contact with 24 V circuit) one minute.
a Average voltage is displayed because of PWM control.
Voltage Between ECM J1 (30) and (40) Max. 3 V
PC210LC-10 40-173
40 Troubleshooting
Circuit diagram related to IMV/PCV1
40-174 PC210LC-10
40 Troubleshooting
Failure code [CA295] Ambient Press Sens In Range Error (WA380_7-CA295-400-A-Z0-A)
Action level Failure code Ambient Pressure Sensor In Range Error

Failure
Detail of • Output value from ambient pressure sensor is out of normal range.
failure
• Takes it that ambient pressure is at fixed value of 52.44 kPa (0.53 kg/cm 2) and allows
engine to run.
machine
(Code: 37401 (V))
Related • Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
information function.
(Code: 37400 (kPa))

Defective ambient pressure
1 Perform troubleshooting for failure codes [CA221] and [CA222].
sensor system
PC210LC-10 40-175
40 Troubleshooting
Failure code [CA322] Inj #1(L#1) Open/Short Error (D65-CA322-400-A-Z0-A)
Action level Failure code Injector #1(L#1) Open/Short Error

Failure
Detail of • Open or short circuit is detected in drive circuit of No. 1 injector.
failure
controller
Problem on • Engine runs with poor combustion or hunts.
Related • While engine is running normally, approx. 65 V of pulse voltage is supplied to injector (+)
information side. Because it is pulse voltage, it cannot be measured by using multimeter.
2. Disconnect connector INJECTOR CYL 1 & 2 and connect T-adapters
to male side.
2 Defective No. 1 injector Between INJECTOR CYL 1 & 2 (male) (3)
Max. 2 z
Resis- and (4)
tance Between INJECTOR CYL 1 & 2 (male) (3)

Open circuit or ground fault in
3 side.
wiring harness
Resis- Between ECM J1 (female) (48) and (58) Max. 2 z
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
4 (wire breakage or defective connect T-adapters to each female side.
contact of connector) Between ECM J1 (female) (48) and
Max. 2 z
Resis- INJECTOR CYL 1 & 2 (female) (3)
tance Between ECM J1 (female) (58) and
INJECTOR CYL 1 & 2 (female) (4) Max. 2 z

5 harness 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and
(contact with ground circuit) connect T-adapters to either female side.
Resis- Between ground and ECM J1 (female) (48)
or INJECTOR CYL 1 & 2 (female) (3) Min. 100 kz
tance
40-176 PC210LC-10
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
a Check by using multimeter in continuity mode.
Short circuit in wiring harness No continuity
6 Between ECM J1 (female) (48) and each pin
other than pin (48) (No sound is
heard)
Continuity
No continuity
Between ECM J1 (female) (58) and each pin
heard)
Defective injector of other If failure codes of other injectors are displayed, perform troubleshooting
7 cylinder for them first.
Defective injector harness of If failure codes of other injectors are displayed, perform troubleshooting
8 other cylinder for them first.
Circuit diagram related to injector #1
PC210LC-10 40-177
40 Troubleshooting
Action level Failure code Injector #5(L#5) Open /Short Error

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (4)

3 side.
wiring harness
4 (wire breakage or defective connect T-adapters to either female side.
Max. 2 z

tance
40-178 PC210LC-10
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and
heard)
Continuity
No continuity
heard)
PC210LC-10 40-179
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (4)

3 side.
wiring harness
Max. 2 z

tance
40-180 PC210LC-10
40 Troubleshooting

heard)
Continuity
No continuity
heard)
PC210LC-10 40-181
40 Troubleshooting
Action level Failure code Injector #6(#6) Open/Short Error

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Max. 2 z

tance
40-182 PC210LC-10
40 Troubleshooting

heard)
Continuity
No continuity
heard)
PC210LC-10 40-183
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
Max. 2 z

tance
40-184 PC210LC-10
40 Troubleshooting

2. Disconnect connectors ECM J1 and INJECTOR CYL1 & 2, and
heard)
Continuity
No continuity
heard)
PC210LC-10 40-185
40 Troubleshooting

Failure
failure
controller
to male side.
Max. 2 z
Resis- and (2)

3 side.
wiring harness
Max. 2 z

tance
40-186 PC210LC-10
40 Troubleshooting

heard)
Continuity
No continuity
heard)
PC210LC-10 40-187
40 Troubleshooting
Failure code [CA343] ECM Critical Internal Failure (PC220_10-CA343-400-A-01-A)
Action ECM critical internal failure

Failure code
level Failure
L04 CA343
Details of • Memory or power supply circuit in engine controller is defective.
failure
controller
Problem on • Engine may stop during operation or may not be able to start.
machine
• Power supply voltage of engine controller can be checked with monitoring function.
Related (Code: 03203 Battery Voltage)
information • Method of reproduc failure code: Starting engine.
Defect in related If another failure code is displayed, carry out troubleshooting for it.
1 system
Internal defect of Perform troubleshooting for failure code [CA441].
2 engine controller
40-188 PC210LC-10
40 Troubleshooting
Failure code [CA351] Injectors Drive Circuit Error (PC200-CA351-400-A-00-A)
Action Injector drive circuit error

Failure code
level Failure
L03 CA351
Details of • There is error in drive power circuit of injector.
failure
controller
• Exhaust gas becomes black.
Problem on • Combustion becomes irregular.
• Stopped engine cannot be started.
Related • Power supply voltage of engine controller can be checked by using monitoring function.
information (Code: 03203 (V))
Defective related If another failure code is displayed, perform troubleshooting for it, too.
1 system
Defective power Perform troubleshooting for failure code [CA441].
2 supply voltage
system
PC210LC-10 40-189
40 Troubleshooting
Failure code [CA352] Sensor 1 Supply Volt Low Error (D65-CA352-400-A-Z0-A)
Action level Failure code Sensor 1 Supply Voltage Low Error

Failure
Detail of • Low voltage appears in sensor power supply 1 (5 V) circuit.
failure
• Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits
Action of engine output.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run..
machine
information
2. Disconnect following connectors one by one and turn starting switch
to ON position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is not displayed, disconnected sensor or engine
harness is defective.
Defective sensor or wiring
2 a Other failure codes (many codes) are also displayed. They are
harness
Exhaust manifold pressure sensor EXHAUST PRESSURE
EGR valve lift sensor SEGR
Connector
KVGT position sensor SVGT
Engine harness ECM J2
If failure codes other than this code are displayed, perform
3 Defective relevant system
troubleshooting for them.
4 Defective engine controller 3. Turn starting switch to ON position with connector ECM J2
disconnected.
V
40-190 PC210LC-10
40 Troubleshooting
Circuit diagram related to sensor power supply 1 circuit
PC210LC-10 40-191
40 Troubleshooting
Failure code [CA356] Mass Air Flow Sensor High Error (PC200LC_10-CA356-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor High Error
Failure
Detail of • High frequency is input to mass air flow sensor signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
Related • Mass air flow sensor and intake air temperature sensor are integrated.
Defective sensor power If failure code [CA3419] or [CA3421] is also displayed, perform
2 supply system troubleshooting for it first.
Defective mass air flow 2. Disconnect connector P55.
3 sensor 3. Turn starting switch to ON position.
(internal defect) If this failure code changes to [CA357], mass air flow sensor is
defective.
1. Be ready with starting switch at OFF position.
2. Disconnect connector P55, and connect T-adapters to female side.
Defective sensor power
supply system
Power Approx. 12
Voltage Between P55 (female) (2) and (3)
supply V
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
contact of connector) a To check open circuit in GND line
Resis- Between ECM J1 (female) (22) and P55
tance
2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
female side of ECM J1.
6 Short circuit in wiring harness
Resis- Between ECM J1 (female) (23) and each pin Min. 100
tance other than pin (23) kz
40-192 PC210LC-10
40 Troubleshooting
Circuit diagram related to mass air flow sensor
PC210LC-10 40-193
40 Troubleshooting
Failure code [CA357] Mass Air Flow Sensor Low Error (PC200LC_10-CA357-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Low Error
Failure
Detail of • Low frequency is input to mass air flow sensor signal circuit.
failure
• Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
• Since sensor output is 5 V pulse voltage, it cannot be measured by using multimeter.
• Mass air flow sensor and intake air temperature sensor are integrated.
Related • If sensor connector is disconnected, both this failure code and failure code [CA691] are
information displayed.
2 supply system troubleshooting for it first.
Defective mass air flow 2. Replace mass air flow sensor.
(internal defect) If this failure code does not appear, original mass air flow sensor is
defective.
2. Disconnect connector P55, and connect T-adapters to female side.
supply system
Power Approx. 12
supply V
each female side.
a If no failure is found by check on cause 4,
this check is not required. Max. 10 z
Open circuit in wiring harness Between ECM J1 (female) (21) and P55
5 (wire breakage or defective (female) (2)
tance
Between ECM J1 (female) (22) and P55
(female) (3)

Ground fault in wiring harness either female side.
6
(contact with ground circuit) Min. 100
Resis- Between ground and ECM J1 (female) (23) or
P55 (female) (1) kz
tance
40-194 PC210LC-10
40 Troubleshooting

Resis- Between ECM J1 (female) (23) and each pin Min. 100
tance other than pin (23) kz
Hot short circuit in wiring 2. Disconnect connector P55, and connect T-adapters to female side.
8 harness 3. Turn starting switch to ON position.
(contact with 24 V circuit) a Ignore displayed failure codes.
Voltage Between P55 (female) (1) and (3) Max. 1 V
PC210LC-10 40-195
40 Troubleshooting
Failure code [CA386] Sensor 1 Supply Volt High Error (D65-CA386-400-A-Z0-A)
Action level Failure code Sensor 1 Supply Voltage High Error

Failure
Detail of • High voltage appears in sensor power supply 1 circuit.
failure
• Ignores signals from exhaust manifold pressure sensor, closes EGR valve, and limits
Action of engine output.
controller • Ignores signals from EGR valve lift sensor and KVGT position sensor, takes it that they
remain at values before failure detection, and allows engine to run..
machine
information
Abnormally high sensor
1 Perform troubleshooting for failure code [CA352].
supply voltage
40-196 PC210LC-10
40 Troubleshooting
Failure code [CA428] Water in Fuel Sensor High Error (PC300-CA428-400-A-Z0-A)
Action level Failure code Water-in-fuel sensor high error

Failure
Detail of • High voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with
information (Code: 18800)
1
defective.
Defective water-in-fuel sensor 2. Disconnect connector P47 and connect T-adapters to male side.
2 installed to fuel pre-filter a If water is in water separator, drain it.
Resistance Between P47 (male) (1) and (2) 10 to100 kz
Short circuit or ground fault in 2. Disconnect connector ECM J1 and connect T-adapter to female
3 wiring harness side of connector.
Between ECM J1 (female) (24) and (32)
Resistance (Water sensor resistance) 10 to100 kz
a If no failure is found in checks on cause 3, this check is not required.

1. Be ready with starting switch to OFF position.
Open circuit in wiring harness 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to
contact of connector) Between ECM J1 (female) (32) and P47
Resistance

5 Short circuit in wiring harness a Check with multimeter in continuity mode.
No continuity
Between ECM J1 (female) (24) and every
Continuity (no sound is
pin other than (24)
heard.)
PC210LC-10 40-197
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-198 PC210LC-10
40 Troubleshooting
Failure code [CA429] Water in Fuel Sensor Low Error (PC300-CA429-400-A-Z0-A)
Action level Failure code Water-in-fuel sensor low error

Failure
Detail of • Low voltage appears in signal circuit of water-in-fuel sensor installed to fuel pre-filter.
failure
controller
Problem on • Water separator monitor is not displayed correctly.
machine
• Signal (ON/OFF) from water-in-fuel sensor of fuel pre-filter can be checked with
information (Code: 18800)
1
defective.
2. Disconnect connector P47 and connect T-adapters to male side.
Defective water-in-fuel
2 sensor installed to fuel pre- a If water is in water separator, drain it.
filter Between P47 (male) (1) and (2) 10 to100
Resis- kz
tance Between P47 (male) (1) and ground Min. 100 kz
Short circuit or ground fault in of connector.
3 wiring harness Between ECM J1 (female) (24) and (32) 10 to100
Resis- (water-in-fuel sensor resistance) kz
tance
Between ECM J1 (female) (32) and ground Min. 100 kz
1. Be ready with starting switch to OFF position.
4 Short circuit in wiring harness a Check with multimeter in continuity mode.

No
Between ECM J1 (female) (24) and every pin continuity
Continuity
other than (24) (no sound
is heard.)
a If no failure is found in checks on cause 3, this check is not required.
5 harness (contact with ground 2. Disconnect connectors ECM J1 and P47, and connect T-adapters to
circuit) either female side.
P47 (female) (1) Min. 100 kz
tance
PC210LC-10 40-199
40 Troubleshooting
Circuit diagram related to water-in-fuel sensor
40-200 PC210LC-10
40 Troubleshooting
Failure code [CA435] Eng Oil Press Sw Error (PC200-CA435-400-A-00-A)
Action Engine oil pressure switch error

Failure code
level Failure
L01 CA435
Details of • Abnormality is detected in signal circuit of engine oil pressure switch.
failure
controller
Problem on • Engine protection function based on engine oil pressure does not work.
machine • Engine oil pressure monitor is not displayed correctly.
• Method of reproducing failure code: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is closed (turned ON) when oil pressure is low (when engine is
stopped), but is opened (turned OFF) when high (when engine is running).
Related • To generate this failure code, engine controller checks if engine oil pressure switch is
information closed (ON), that is, if signal voltage is zero only when engine is stopped.
• When engine is running, failure of engine oil pressure switch is shown by failure code
[B@BAZG].
1
harness connector 2. Turn starting switch to ON position.
Defective engine oil 2. Disconnect connector OIL PRESSURE SWITCH and connect T-adapters to
2 pressure switch male side.
Between OIL PRESSURE SWITCH
Resistance (male) (1) and ground Max. 10 z

Open circuit or
2. Disconnect connector ECM J1 and connect T-adapters to female side.
3 short circuit in
wiring harness Between ECM J1 (female) (31) and
Resistance ground Max. 10 z
controller
Circuit diagram related to engine oil pressure switch
PC210LC-10 40-201
40 Troubleshooting
Failure code [CA441] Battery Voltage Low Error (PC200-CA441-400-A-00-A)
Action Battery voltage low error

Failure code
level Failure
L04 CA441
Details of • Low voltage appears in controller power supply circuit.
failure
Action of • Takes power voltage to be at fixed value (24 V) and allows engine to run.
controller
Problem on • Engine stops.
machine • Engine startability is poor.
• Method of reproducing failure code: Starting switch: ON
Related • Power supply voltage of engine controller can be checked with moniitoring funtion.
information (Code: 03203(V))
Loose or corroded Battery cable terminal may be loose or corroded. Check it.
1 battery terminal
Loose terminal or 1. Starting switch: OFF
2 partial open circuit Check terminals of alternator, battery relay, ground terminal (T12), etc.
at terminal
See descriptions of wirings harness and connectors in "c: Electrical equipment" in
Defective wiring
3 "Checks before troubleshooting" of "General information on troubleshooting", and
harness connector
check them.
1. Starting switch: OFF
Improper battery 2. Perform troubleshooting with starting switch at OFF position and at engine
4 voltage cranking.
Voltage Between battery terminals (+) and (-). 20 to30 V
2. Insert T-adapter into connector E12.
5 Defective alternator 3. Start engine (Engine speed: Middle or faster).
Voltage Between E12 (1) and ground 27.5 to 29.5 V
controller
40-202 PC210LC-10
40 Troubleshooting
Circuit diagram related to engine controller power supply
PC210LC-10 40-203
40 Troubleshooting
Failure code [CA442] Battery Voltage High Error (PC200-CA442-400-A-00-A)
Action Battery voltage high error

Failure code
level Failure
L04 CA442
Details of • High voltage (about 36 V or higher) appears in controller power supply circuit.
failure
Action of • Takes it that power supply voltage is at fixed value (24 V) and allows engine to run.
controller
Problem on • Engine continues to run normally, but it may stop during running or may not be able to
machine restart.
Related • Power supply voltage of engine controller can be checked with monitoring function.
information (Code: 03203 (V))
High battery Perform troubleshooting for failure code [CA441].
1 voltage
40-204 PC210LC-10
40 Troubleshooting
Failure code [CA449] Rail Press Very High Error (WA380_7-CA449-400-A-Z0-A)
Action level Failure code Rail Pressure Very High Error

Failure
Detail of • Excessively high pressure is developed in common rail circuit.
failure
controller
Problem on • Engine sounds become louder under no load or light load.
• Common rail pressure can be checked with monitoring function.
Related (Code: (36400 Common rail pressure)
information • Method of reproducing failure code: Start engine.
Defective relevant system If other failure codes are also displayed, perform troubleshooting for
1
them.
Air may be in low-pressure circuit. Check it according to following
procedure.
2 Air in low-pressure circuit 1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel pre-filter.
3. Check leaking level of fuel and air from pressure pickup plug hole.
a For check of pressure in fuel return circuit, see Testing and adjusting,
Defective fuel return circuit "Testing fuel pressure".
3 equipment Pressure in Max. 18.6 kPa
fuel return At low idle or during cranking {max. 0.19 kg/
circuit cm2}
Defective common rail
pressure sensor system
a For check of fuel leakage from pressure limiter, see Testing and
adjusting, "Testing fuel delivery rate, return rate and leakage".
5 Defective pressure limiter Leakage
from At low idle (for 30 seconds) Max. 8 ml
pressure
limiter
6 Defective supply pump If no failure is found by above checks, supply pump may be defective.
PC210LC-10 40-205
40 Troubleshooting
Failure code [CA451] Rail Press Sensor High Error (WA380_7-CA451-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of common rail pressure sensor.
failure
controller
Problem on
• Engine speed or output decreases.
machine
• Engine does not start.
• Signal voltage from common rail pressure sensor can be checked with monitoring
function.
(Code: 36401 Common rail pressure sensor voltage)
• Pressure sensed by common rail pressure sensor can be checked with monitoring
function.
Related (Code: 36400 (MPa))
• This failure code appears if common rail pressure sensor connector is disconnected.
• Since female connector alone is provided for "socket" used for troubleshooting of this
sensor, it is not usable for check of open circuit in wiring harness and voltage at sensor
connector (.not designed as T-adapter).
If failure code [CA515] or [CA516] is also displayed, perform
2 pressure sensor power
supply system
2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
3 Short circuit in wiring harness 3. Connect T-adapters to female side of ECM J2.
Min. 100 kz
tance
2. Disconnect connector FUEL RAIL PRESS and insert T-adapters into
connector ECM J2.
Hot short circuit in wiring 3. Turn starting switch to ON position (with connector FUEL RAIL
4 harness PRESS disconnected).
(contact with 24 V circuit) a Pin (31) of ECM J2 is connected to 5 V circuit via resistor inside
engine controller.
Voltage Between ECM J2 (21) and (44) 4.75 to 5.25
V
If no failure is found by above checks, wiring harness probably has open
5 Open circuit in wiring harness
circuit. (*)
a If no failure is found by checks on cases 1 to 5 and failure is found by
check on cause 6, sensor is defective.
6 pressure sensor (defective 1. Turn starting switch to OFF position.
input voltage to engine 2. Insert T-adapters in connector ECM J2.
controller) 3. Turn starting switch to ON position.
Sensor 0.2 to 4.8 V
output
40-206 PC210LC-10
40 Troubleshooting

*: See "Troubleshooting method for open circuit in wiring harness of pressure sensor system" of "General
information on troubleshooting".
Circuit diagram related to common rail pressure sensor
PC210LC-10 40-207
40 Troubleshooting
Failure code [CA452] Rail Press Sensor Low Error (WA380_7-CA452-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of common rail pressure sensor.
failure
controller
Problem on • Engine speed or output decreases.
machine • Engine does not start.
function.
(Code: 36401 Common rail pressure sensor voltage)
Related function.
information (Code: 36400 (MPa))
• If sensor connector is disconnected even in normal condition, failure code [CA451] for
"High Error" is generated instead of this code.
2 pressure sensor power supply
system
2. Disconnect connector FUEL RAIL PRESS.
If failure code [CA452] changes to [CA451], sensor is defective.
Defective common rail • Reference
3 pressure sensor 1. Turn starting switch to OFF position.
Sensor
output 0.2 to 4.8 V
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
4 (contact with ground circuit) connect T-adapters to female side of ECM J2.
Resistance Between ECM J2 (female) (44) and ground Min. 100 kz
2. Disconnect connectors FUEL RAIL PRESS and ECM J2.
3. Connect T-adapters to female side of ECM J2.
Resistance Between ECM J2 (female) (21) and (44) Min. 100 kz
40-208 PC210LC-10
40 Troubleshooting
PC210LC-10 40-209
40 Troubleshooting
Failure code [CA488] Chg Air Temp High Torque Derate (D65-CA488-400-A-Z0-A)
Action level Failure code Chg Air Temp High Torque Derate
Failure
Detail of • Temperature signal from boost pressure & temperature sensor exceeds upper limit of
failure control temperature.
controller
machine
• Boost temperature can be checked with monitoring function.
Related (Code: 18500 Boost temperature)
Aftercooler cooling performance may be degraded. Check for following
points:
Drop of cooling performance
1 • Defective fan rotation
of aftercooler
• Insufficient cooling air
• Clogged aftercooler fins
Unusual rise of turbocharger Outlet temperature of turbocharger may be unusually high. Check
2 outlet temperature related parts.
Defective boost temperature
sensor system
40-210 PC210LC-10
40 Troubleshooting
Failure code [CA515] Rail Press Sens Sup Volt High Error (WA380_7-CA515-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
controller
machine
function.
(Code: 36401 (V))
Related function.
Defective common rail If this failure code disappears, sensor is defective.
2 pressure sensor
codes other than this code.
2. Disconnect connector ECM J2.
If this failure code does not appear, wiring harness may be defective.
3 Defective wiring harness Perform following troubleshooting.
Hot short circuit in wiring
4 harness
(contact with 24 V circuit) 4. Turn starting switch to ON position.
Voltage Between ECM J2 (31) and (21) 4.75 to 5.25
V
5 Defective engine controller 3. Turn starting switch to ON position.
V
PC210LC-10 40-211
40 Troubleshooting
40-212 PC210LC-10
40 Troubleshooting
Failure code [CA516] Rail Press Sens Sup Volt Low Error (WA380_7-CA516-400-A-Z0-A)
Action level Failure code Rail Pressure Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in common rail pressure sensor power supply (5 V) circuit.
failure
controller
machine
function.
(Code: 36401 (V))
Related function.
Defective common rail 3. Turn starting switch to ON position.
2 pressure sensor If this failure code disappears, sensor is defective.
(internal defect) a Other failure codes (many codes) are also displayed. They are
If this failure code does not appear, wiring harness may be defective.
3 Defective wiring harness Perform following troubleshooting.
4 harness 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
Resis- Between ECM J2 (female) (31) and ground
Min. 100 kz
tance
Short circuit in wiring harness
5 2. Disconnect connectors ECM J2 and FUEL RAIL PRESS, and
Resis- Between ECM J2 (female) (21) and (31) Min. 100 kz
tance
PC210LC-10 40-213
40 Troubleshooting

6 Defective engine controller 3. Turn starting switch to ON position.
V
40-214 PC210LC-10
40 Troubleshooting
Failure code [CA553] Rail Press High Error (D65-CA553-400-A-Z0-A)
Action
Failure code Rail Press High Error
level Failure
L01 CA553
Detail of • Excessively high pressure trouble (1) has occurred in the common rail circuit.
failure
controller
Problem on • Engine noise becomes louder at no or light load.
Related (Code 36400: Common rail pressure)
1 Defect in related system If another failure code is displayed, perform troubleshooting for it.
Connection of ground terminals may be defective. Check the following
terminals.
Defective connection of • Ground terminal of machine ((–) terminal of battery)
2 ground terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
3 Perform troubleshooting for failure code [CA451], [CA452]
PC210LC-10 40-215
40 Troubleshooting
Failure code [CA555] Crankcase Press High Error 1 (PC220_10-CA555-400-A-00-A)
Action Crankcase pressure high error 1

Failure code
level Failure
L01 CA555
Details of • Crankcase pressure high error (level 1) is detected.
failure
controller
Problem on
machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401 (V))
Related • Pressure from crankcase pressure sensor can be checked with monitoring function.
Clogged KCCV Replace KCCV filter.
1
filter
When KCCV filter is replaced, if this failure code does not disappear and emulsion
Blocked KCCV gas
2 is recognized inside KCCV, blowby gas piping of KCCV may be clogged with
piping
emulsion. Perform troubleshooting for coolant leakage.
Defective Sensor system may be defective. Perform troubleshooting for failure codes
3 crankcase pressure [CA1843] and [CA1844].
sensor
40-216 PC210LC-10
40 Troubleshooting
Failure code [CA556] Crankcase Press High Error 2 (PC220_10-CA556-400-A-00-A)
Action Crankcase pressure high error 2

Failure code
level Failure
L03 CA556
Details of • Crankcase pressure high error (level 2) is detected.
failure
controller
machine
(Code: 48401 (V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
1
filter
Blocked KCCV gas
piping
sensor
When KCCV filter is replaced, if failure code of crankcase pressure high error does
Increase of blowby not disappear and failure code of crankcase pressure high errors is displayed in
4 gas short period, engine may be seized or turbocharger may have trouble. Perform
troubleshooting for mechanical system.
PC210LC-10 40-217
40 Troubleshooting
Failure code [CA559] Rail Press Low Error (WA380_7-CA559-400-A-Z0-A)
Action level Failure code Rail Pressure Low Error

Failure
Detail of • Common rail pressure low error occurs in common rail circuit.
failure
controller
• Engine does not start or engine is hard to start.
Problem on • Exhaust gas color becomes black.
Related (Code: (36400 Common rail pressure)
1 Improper fuel Fuel used may be improper. Check it.
Check fuel leakage to outside.
2 Fuel leakage to outside
(Visually check it while running engine at low idle.)
a See "Note 1" for troubleshooting.
a For check of pressure in low-pressure fuel circuit, see Testing and
adjusting, "Testing fuel pressure".
Negative pressure
at fuel supply Max. -40.7 kPa
Defective low-pressure circuit pump inlet (outlet At high idle
{max.-305 mmHg}
3 side of fuel pre-
devices
filter)
207 to 500 kPa
During cranking
{2.11 to 5.1 kg/cm2}
Inlet pressure of
207 to 650 kPa
fuel main filter
At high idle {2.11 to 6.63 kg/
cm2}
a For check of fuel leakage from pressure limiter, see Testing and
4 Defective pressure limiter adjusting, "Testing fuel delivery rate, return rate and leakage".
Leakage from
At low idle (for 30 seconds) Max. 8 ml
pressure limiter
a For check of fuel return rate from injector, see Testing and adjusting,
"Testing fuel delivery rate, return rate and leakage".
Defective injector During cranking
5 (Including high-pressure (Min. 150 rpm, for 30 Max. 45 ml
piping in cylinder head) Return rate from seconds)
injector
At low idle
Max. 125 ml
(For 30 sec)
a For check of fuel return rate from supply pump, see Testing and
adjusting, "Testing fuel delivery rate, return rate and leakage".
During cranking
6 Defective supply pump (Min. 150 rpm, for 30 Max. 575 ml
Return rate from seconds)
supply pump
At low idle
Max. 575 ml
(For 30 sec)
40-218 PC210LC-10
40 Troubleshooting
Note 1: Check following points when performing troubleshooting of low-pressure circuit devices.
1) Volume of remaining fuel
2) Clogging of fuel tank breather
3) Fuel leakage from low-pressure fuel piping and clogging of piping
4) Clogging of fuel pre-filter
5 Clogging of fuel main filter
6) After clogging of filters, etc. is removed, if this failure code does not disappear, replace fuel filter.
Reference
High pressure pipe from common rail is connected to injector via inlet connector (11) in cylinder head.
Since inlet connector (11) is tightened with retainer (10), retighten retainer (10).
3 retainer (10) : 50 ± 4 Nm {5 ± 0.4 kgm}
Width across flats 24 mm
PC210LC-10 40-219
40 Troubleshooting
Failure code [CA595] Turbo Speed High Error 2 (PC220_10-CA595-400-A-00-A)
Action Turbocharger speed high error 2

Failure code
level Failure
L01 CA595
Details of • Turbocharger speed is too high.
failure
controller
machine
• Speed detected by turbocharger speed sensor can be checked with monitoring function.
Related (Code: 48100 (rpm))
Increase in Turbocharger speed may be high. Check it.
1 turbocharger speed
Defective Check turbocharger since it may have trouble.
2 turbocharger
Defective If no failure is found by check on cause 1, turbocharger speed sensor system may
3 turbocharger speed be defective. Perform troubleshooting for failure code [CA687].
sensor
40-220 PC210LC-10
40 Troubleshooting
Failure code [CA687] Turbo Speed Low Error (D65-CA687-400-A-Z0-A)
Action level Failure code Turbocharger Speed Low Error

Failure
Detail of • Turbocharger rotates at abnormally low speed.
failure
Action of • Takes it that turbocharger speed is at calculated speed and allows engine to run.
controller
Problem on
machine
• Speed sensed by turbocharger speed sensor can be checked with monitoring function.
1 Defective turbocharger Turbocharger may be defective. Check it.
Defective turbocharger speed 2. Disconnect connector VGT_REV and connect T-adapters to female
3 sensor side.
(internal defect) Resis- Between VGT_REV (female) (1) and (2) 600 to 1,600
tance z
Open or short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector ECM J2 and connect T-adapters to female
4 (short circuit, wire breakage side.
or defective contact of Resis- Between ECM J2 (female) (32) and (33) 600 to 1,600
connector) tance z
2. Disconnect connectors ECM J2 and VGT_REV, and connect T-
Ground fault in wiring harness adapters to either female side.
5 Resis- Between ground and ECM J2 (female) (32)
(contact with ground circuit) Min. 100 kz
tance or VGT_REV (female) (1)
or VGT_REV (female) (2) Min. 100 kz
tance
Short circuit in wiring harness 2. Disconnect connectors ECM J2 and VGT_REV, and connect T-
6 adapters to either female side.
Resis- Between ECM J2 (female) (32) and (33), or
between VGT_REV (female) (1) and (2) Min. 100 kz
tance
Defective installation of Turbocharger speed sensor may be installed incorrectly (loose fitting) or
7 sensor or defective speed speed sensor parts (internal parts of KVGT) may be defective (due to
sensing part thermal deformation). Check them.
PC210LC-10 40-221
40 Troubleshooting
Circuit diagram related to turbocharger speed sensor
40-222 PC210LC-10
40 Troubleshooting
Failure code [CA689] Eng Ne Speed Sensor Error (WA380_7-CA689-400-A-Z0-A)
Action level Failure code Engine Ne Speed Sensor Error

Failure
Detail of • Engine Ne speed sensor signal is abnormal.
failure
Action of • Runs engine by using signals from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup (CAM) speed sensor is also defective).
Problem on • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
machine • Engine starting performance becomes deteriorated
• Engine hunts.
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• Speed sensor detects passing of slot on speed sensing wheel, which is installed to inner
surface on vibration damper, to measure crankshaft speed.
Defective Ne speed sensor If failure code [CA238] or [CA239] is also displayed, perform
2 power supply system troubleshooting for it first.
Breakage or improper
Engine Ne speed sensor may be broken or installed improperly
3 installation (loosened) of
(loosened). Check it.
engine Ne speed sensor
2. Disconnect connector CRANK SENSOR and connect T-adapters to
female side.
Defective Ne speed sensor
power supply input
Power
Between CRANK SENSOR
Voltage supply 4.75 to 5.25
(female) (1) and (2) V
input
2. Disconnect connectors ECM J1 and CRANK SENSOR and connect
T-adapters to each female side.
this check is not required.
Max. 10 z
Open circuit in wiring harness Between ECM J1 (female) (36) and
5 (wire breakage or defective CRANK SENSOR (female) (1)
tance
Max. 10 z
Between ECM J1 (female) (37) and
CRANK SENSOR (female) (2)
Between ECM J1 (female) (26) and CRANK Max. 10 z
SENSOR (female) (3)
PC210LC-10 40-223
40 Troubleshooting

2. Disconnect connectors ECM J1 and CRANK SENSOR and connect
6 Short circuit in wiring harness Between ECM J1 (female) (26) and (36) or
Min. 100 kz
Resis- CRANK SENSOR (female) (1) and (3)
tance Between ECM J1 (female) (26) and (37) or
CRANK SENSOR (female) (2) and (3) Min. 100 kz

Ground fault in wiring 2. Disconnect connectors ECM J1 and CRANK SENSOR and connect
7 harness T-adapters to female side of ECM J1 or CRANK SENSOR.
(contact with ground circuit) Resis- Between ground and ECM J1 (female) (26) or
CRANK SENSOR (female) (3) Min. 100 kz
tance
Hot short circuit in wiring 2. Disconnect connector CRANK SENSOR and connect T-adapters to
harness female side of CRANK SENSOR.
(contact with 24 V circuit)
Between CRANK SENSOR (female) (3) and
Voltage Max. 1 V
ground
Damage or loose mounting of
9 Check speed sensing wheel.
speed sensing wheel
If no failure is found by above checks, Ne speed sensor is defective.
10 Defective Ne speed sensor
Circuit diagram related to engine Ne speed sensor
40-224 PC210LC-10
40 Troubleshooting
Failure code [CA691] Intake Air Temp Sens High Error (PC200LC_10-CA691-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor High Error
Failure
Detail of • High voltage is detected in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Mass air flow sensor and intake temperature sensor are integrated.
• Signal voltage from intake air temperature sensor can be checked with monitoring
function. (Code: 18401 (V))
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
information function. (Code: 18400 (°C))
• If sensor connector is disconnected, this failure code is displayed together with failure
code [CA357].
1
defective.
Defective intake temperature -30 °C 25 to 28 kz
2 sensor Between P55 (male) (4) and (3) 0 °C 5.5 to 6.1 kz
(internal defect) Resis-
tance a Intake temperature - resistance 25 °C 1.9 to 2.1 kz
characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Open or short circuit in wiring 2. Disconnect connector ECM J1 and connect T-adapter to female side
harness of connector.
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
and defective contact of tance kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Hot short circuit in wiring 2. Disconnect connector P55.
harness 3. Insert T-adapters to connector ECM J1, or connect T-adapters to
4
female side of connector P55.
(Contact with 24 V circuit)
Between ECM J1 (6) and (22) or between
Voltage Max. 5.25 V
P55 (4) (female) (4) and (3)
a Check with multimeter in continuity mode.
Resis- Between ECM J1 (female) (6) and each pin
other than (6) Min. 100 kz
tance
PC210LC-10 40-225
40 Troubleshooting
Circuit diagram related to intake temperature sensor
40-226 PC210LC-10
40 Troubleshooting
Failure code [CA692] Intake Air Temp Sens Low Error (PC200LC_10-CA692-400-A-Z0-A)
Action level Failure code Intake Air Temperature Sensor Low Error
Failure
Detail of • Low voltage error is detected in signal circuit of intake air temperature sensor.
failure
Action of • Takes it that intake temperature is at fixed value (25 °C ) and allows engine to run.
controller
Problem on
machine
• Signal voltage from intake air temperature sensor can be checked with monitoring
Related • Temperature sensed by intake air temperature sensor can be checked with monitoring
• Mass air flow sensor and intake temperature sensor are integrated.
1
defective.
2. Disconnect connector P55.
If this failure code changes to failure code [CA691], intake air
temperature sensor is defective.
•
• Reference
Defective intake temperature
2 sensor
(internal defect)
-30 °C 25 to 28 kz
Between P55 (male) (4) and (3) 0 °C 5.5 to 6.1 kz
25 °C 1.9 to 2.1 kz
Resis- a Intake temperature - resistance
tance characteristics 40 °C 1.1 to 1.2 kz
100 °C 180 to 185 z
Between P55 (male) (4) and Whole
ground (sensor body) range Min. 100 kz
Open or short circuit in wiring 2. Disconnect connector ECM J1 and connect T-adapter to female side
harness of connector.
3 (short circuit, wire breakage Resis- Between ECM J1 (female) (6) and (22) 180 z to 28
and defective contact of tance kz
connector) a Use Intake temperature - Resistance characteristics table for
troubleshooting on cause 2.
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
4 either female side.
P55 (female) (4) Min. 100 kz
tance
5 Short circuit in wiring harness female side of ECM J1.
a Check with multimeter in continuity mode.
PC210LC-10 40-227
40 Troubleshooting

Resis- Between ECM J1 (female) (6) and each pin
other than (6) Min. 100 kz
tance
Circuit diagram related to intake temperature sensor
40-228 PC210LC-10
40 Troubleshooting
Failure code [CA697] ECM Int Temp Sensor High Error (PC220_10-CA697-400-A-00-A)
Action ECM internal temperature sensor high error

Failure code
level Failure
L01 CA697
Details of • High voltage appears in signal circuit of engine controller internal temperature sensor.
failure
controller
Problem on
machine
• Temperature sensed by internal temperature sensor of engine controller can be checked
Related with monitoring function.
information (Code: 18900 (°C))
Unsuitable use of Check whether controller is used in a high-temperature environment.
1
controller
controller
PC210LC-10 40-229
40 Troubleshooting
Failure code [CA698] ECM Int Temp Sensor Low Error (PC220_10-CA698-400-A-00-A)
Action ECM internal temperature sensor low error

Failure code
level Failure
L01 CA698
Details of • Low voltage appears in signal circuit of engine controller internal temperature sensor.
failure
controller
Problem on
machine
• Temperature sensed by internal temperature sensor of engine controller can be checked
Related with monitoring function.
information (Code: 18900 (°C))
Unsuitable use of Check whether controller is used in a low-temperature environment.
1
controller
controller
40-230 PC210LC-10
40 Troubleshooting
Failure code [CA731] Eng Bkup Speed Sens Phase Error (WA380_7-CA731-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Phase Error
Failure
Detail of • Phase error occurs between signals of engine Ne speed sensor and engine Bkup speed
failure sensor.
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
• Engine can not start or engine is hard to start.
Problem on • Idle speed is unstable.
machine • Exhaust gas color becomes black.
information
Damaged engine Ne speed Engine Ne speed sensor may be damaged. Check it.
1
sensor
Damaged engine Bkup speed Engine Bkup speed sensor may be damaged. Check it.
2
sensor
Speed sensing wheel on crankshaft side may be installed improperly
or damaged. Check it according to following procedure.
1. Align paint mark (M1) of damper with mounting bolt (M2) of
Improper installation or damper.
3 damage of speed sensing a No.1 cylinder is not at its compression top dead center with
wheel on crankshaft side damper at that position (approximately 76 to 88 degrees before
to compression top dead center).
2. Installation is correct if center of slot (WS) of speed sensing wheel
is positioned under top surface (M2) of Ne speed sensor.
Speed detection ring on camshaft side may be installed improperly or
damaged. Check it according to following procedure.
Improper installation or 1. Set No. 1 cylinder to compression top dead center (align stamping
4 damage of speed sensing ring mark).
on camshaft side 2. Remove Bkup speed sensor.
3. Installation is correct if twin groove (single rib) (B) of speed sensing
ring is visible through sensor mounting hole (H).
Defective timing adjustment of Timings of crankshaft and camshaft may not be matched each other.
5
crankshaft and camshaft Check them.
Ground terminals may be connected defectively. Check following
terminals :
Defective connection of ground • Ground terminal of machine ((-) terminal of battery)
6
terminal • Ground terminal of engine
• Ground terminal of engine controller
• Ground terminal of starting motor
PC210LC-10 40-231
40 Troubleshooting
40-232 PC210LC-10
40 Troubleshooting
Failure code [CA778] Eng Bkup Speed Sensor Error (WA380_7-CA778-400-A-Z0-A)
Action level Failure code Engine Bkup Speed Sensor Error

Failure
Detail of • Engine Bkup speed (cam) sensor signal is abnormal.
failure
Action of • Continues to control engine by using engine Ne speed sensor signal.
controller
Problem on • Engine starting performance becomes deteriorated
• Since interior portion of speed sensor is configured with hall sensor and electronic circuit
rather than coil, measurements of speed sensor resistance by using mulitimeter cannot
Related be used to determine whether sensor is normal or not.
information • Since speed sensor output is pulse voltage of 5 V in normal state, multimeter is not usable
for measurement.
• This speed sensor detects groove in speed sensing ring, which is installed to camshaft, to
measure camshaft speed.
equipment" in "Checks before troubleshooting" of "General information
Defective harness on troubleshooting", and check it.
connector
2 supply 2 circuit troubleshooting for it first.
Breakage or improper
installation (loosened) of Engine Bkup speed sensor may be broken or installed improperly
3 engine Bkup speed (loosened). Check it
(cam) sensor
2. Disconnect connector CAM SENSOR , and connect T-adapters to
female side.
Defective engine Bkup
4 speed sensor power
supply input Power 4.75 to 5.25
Between CAM SENSOR (female) (1) and (2)
supply V
Voltage Between CAM SENSOR (female) (1) and (2) 4.75 to 5.25
V
2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
Open circuit in wiring adapters to each female side.
harness Between ECM J1 (female) (60) and CAM SENSOR
5 (wire breakage or
defective contact of Resis- Between ECM J1 (female) (59) and CAM SENSOR
connector) Max. 10 z
tance (female) (2)
Between ECM J1 (female) (9) and CAM SENSOR

2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
adapters to either female side.
Short circuit in wiring
6 Between ECM J1 (female) (9) and (60) or between
harness Min. 100 kz
Resis- CAM SENSOR (female) (1) and (3)
tance Between ECM J1 (female) (9) and (59) or between Min. 100 kz
CAM SENSOR (female) (2) and (3)
PC210LC-10 40-233
40 Troubleshooting

harness 2. Disconnect connectors ECM J1 and CAM SENSOR, and connect T-
7 adapters to either female side.
(contact with ground
circuit) Resis- Between ground and ECM J1 (female) (9) or CAM
Min. 100 kz
tance SENSOR (female) (3)
Hot short circuit in wiring 2. Disconnect connector CAM SENSOR , and connect T-adapters to
8 harness (contact with 24 female side.
V circuit) 3. Turn starting switch to ON position.
Voltage Between CAM SENSOR (female) (3) and ground Max. 1 V
Loosened camshaft Remove engine Bkup speed (cam) sensor, and check ring through hole (H).
9 speed sensing ring a If speed sensing ring (B) is loosened, see "Reference".
If no failure is found by above checks, engine Bkup speed (cam) sensor is
Defective engine Bkup defective.
10 speed (cam) sensor
Defective engine If no failure is found by above checks, engine controller is defective.
11
controller (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to engine Bkup speed sensor
40-234 PC210LC-10
40 Troubleshooting
PC210LC-10 40-235
40 Troubleshooting
• Reference
Check of camshaft ring for looseness
Remove front cover and check camshaft ring for looseness.
a See Disassembly and assembly, "Removal and installation of engine front seal".
a Prepare front seal, liquid gasket LG-7 and front seal tool (795–799–6400)) beforehand.
Removal
1. Remove fan and fan belt, For details, see Disassembly and assembly, "Removal and installation of engine
front seal".
2. Remove damper assembly (1).
(DP): Dowel pin
3. Remove front cover (2).

4. Remove front seal (3).
(RING): Ring
40-236 PC210LC-10
40 Troubleshooting
5. Check that mounting bolt (4) of camshaft ring (5) is not loosened.
3 Mounting bolt (4):
10 ± 2 Nm {0.98 ± 0.2 kgm}
(DP): Dowel pin
Installation
a See figures shown in removal procedure section.
1. Install front cover (2).
2 Front cover:
Liquid gasket (LG-7)
2. See Disassembly and assembly, "Removal and installation of engine front seal".
1) install front cover (3).
2) Install dowel pin (DP), and install damper assembly.
3) Install fan belt, and install the fan.
4) Install the cooling system assembly.
PC210LC-10 40-237
40 Troubleshooting
Failure code [CA1117] Persistent Data Lost Error (PC400-CA1117-400-A-Z0-A)
Action level Failure code Persistent Data Lost Error

Failure
Detail of
• Internal defect occurred in controller.
failure
controller
• Engine continues to run normally, but it may stop during running or may not be able to
Problem on start if it is stopped.
machine • Engine controller cannot store internal data correctly.
Related • Since the engine controller internal data (KDPF related, etc.) may be lost, appropriate
information actions must be taken after the system recovers from the error.
Since the power supply circuit may be defective, carry out
1 Defective power supply circuit
troubleshooting for failure code [CA441].
Improper operation of battery Battery disconnect switch may have been operated improperly.
2
disconnect switch
Actions to be
taken after See "How to perform regeneration for service" section.
recovery from
error
40-238 PC210LC-10
40 Troubleshooting
Failure code [CA1664] KDOC Malfunction (PC200LC_10-CA1664-400-A-Z0-A)
Action level Failure code KDOC Malfunction

Failure
• During KDPF regeneration, KDOC inlet temperature sensor and KDOC outlet
Detail of temperature sensor indicate similar values (temperature difference is approximately within
failure 10°C).
• Closes EGR valve
Action of • Stops KDPF regeneration control.
controller
a You can cancel above measures by "turning starting switch to OFF position once, then
turning starting switch to ON position" after failure code is generated.
machine
k Since KDPF and KDOC are heated to 500°C or above, take care not to get burn
injury.
function. (Code: 47300 (°C))
Related • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
information engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
difference between these temperatures is approx. 10°C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When active regeneration (manual stationary regeneration) is in progress, KDOC inlet
temperature is approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet
temperature are approx. 450 to 550°C.
• KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
letters is seen on KDPF temperature sensor consolidating box (KDOC outlet temperature
sensor connector label "TEMP2" and KDPF outlet sensor connector label "TEMP3" are
shown similarly to "TEMP1").
• As to procedure for accessing KDPF temperature sensor, see 50 Disassembly and
assembly, "Removal and installation of KDPF assembly" and "Disassembly and assembly
of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to the
OFF position. So when you restart engine, wait one minute minimum before turning
starting switch to the ON position again.
• When this failure code appears, perform troubleshooting according to following work flow.
A. Identification of cause and repair
Machine O
operation for B. Machine operation for clearing failure code
clearing
failure code a This failure code does not disappear by simply turning starting switch to ON position from
OFF position after repair. You must perform machine operation for clearing failure code
after repair trouble.
Defective KDOC inlet If failure code [CA3313], [CA3314], or [CA3315] is also displayed,
1 temperature sensor perform troubleshooting for [CA3313], [CA3314], or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is also displayed,
2 temperature sensor perform troubleshooting for [CA3316], [CA3317], or [CA3318].
PC210LC-10 40-239
40 Troubleshooting

Defective wiring harness equipment" in "Checks before troubleshooting" of "General
3
connector information on troubleshooting", and check it and fix trouble as
needed.
KDOC outlet temperature sensor, and note signal voltages from
respective temperature sensors in initial condition (see Related
information).
4. Disconnect either connector TEMP1 or TEMP2.
4 Short circuit in wiring harness 5. Turn starting switch to ON position.
KDOC outlet temperature sensor, and note second signal voltages
from respective temperature sensors (see Related information).
If second signal voltages sensed by KDOC inlet temperature sensor and
KDOC outlet temperature sensor do not change notably (almost same
as first signal voltages), check wiring harness for short circuit
(troubleshooting for failure codes [CA3313] and [CA3316]).
5 Defective KDOC 1. Check that KDPF is installed to exhaust system.

2. Check that KDOC is installed to KDPF.
B. Machine operation for clearing failure code
1. Turn starting switch from OFF position to ON position.
2. Start engine and run it at low idle (with no load) for approximately 1 minute.
3. Use monitoring function to display KDOC inlet and outlet temperatures.
a To clear this failure code, KDOC inlet temperature must be 250°C or higher.
4. Use work equipment to raise either track off ground.
5. Set swing lock switch to ON position and working mode to P-mode.
6. Run that track idle off ground for continuous 15 minutes with fuel control dial at MAX position and travel
speed at Hi setting.
If failure code disappears after steps 1 to 6 are implemented, repair work is complete.
a When service tool "INSITE" is available, you can clear every failure code by executing "Reset All Faults"
command.
For how to use "INSITE", see "INSITE" operation manual.
If this failure code appears again after above procedures are
6 Defective engine controller implemented, engine controller is defective.
Circuit diagram related to KDOC and KDPF temperature sensors
40-240 PC210LC-10
40 Troubleshooting
Failure code [CA1691] Regeneration Ineffective (PC200LC_10-CA1691-400-A-Z0-A)
Action level Failure code Regeneration Ineffective

Failure
• KDOC efficiency (catalyst action) is degraded. (Soot trapped in KCSF does not burn
Detail of sufficiently because the KDOC outlet temperature does not rise enough. During
failure regeneration, KDOC inlet temperature is normally approx. 250 to 400°C, and KDOC outlet
temperature is normally approx. 450 to 550°C.)
controller • Stops KDPF regeneration control.
machine
injury.
function. (Code: 47400 (°C)
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
engine is at idle (KDPF regeneration is not executed) are approx. 100 to 250°C, and
Related • When manual stationary regeneration (normal) is in progress, KDOC inlet temperature is
information approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet temperature are
approx. 450 to 550°C.
• When manual stationary regeneration without injecting dosing fuel (KDOC drying) is in
progress, KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature are all approx. 250 to 400°C.
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
a When soot accumulation is at level 3 or lower, the manual stationary regeneration can be
performed only from "Regeneration for Service".
3. From service menu of machine monitor, select "Diagnostic Tests", open "02 Regeneration
for Service", and then perform "Manual Stationary Regeneration (manual stationary
regeneration will be completed in approx. 40 minutes).
PC210LC-10 40-241
40 Troubleshooting
a Failure code [CA2637] may be displayed at the same time, however, perform
troubleshooting for this failure code [CA1691].
Related • Method of reproducing failure code:
information When KDOC is changed, there is no need to check completion of repair.
When KDOC is not changed, start engine and turn manual stationary regeneration switch
ON. (See cause 6.)
• If there is a significant difference between KDOC outlet temperature
Defective KDOC outlet and KDOC inlet temperature and KDPF outlet temperature when
1 temperature sensor KDPF is completely cool or engine running at idle (not regenerating),
replace KDOC outlet temperature sensor.
1. Rapidly accelerate engine from low idle to high idle two times, and
then keep engine running at high idle for five seconds.
• If excessive black smoke is exhausted when accelerating engine or
running it at high idle, perform troubleshooting for "S-9 KDPF gets
2 Unusual exhaust gas color
clogged in a short time".
a It does not matter that black smoke particles are exhausted during
engine acceleration but are not exhausted during running at high
idle.
a Dry KDOC.
KDPF outlet temperature sensor, note temperature values from each
Defective KDOC sensor with KDPF under initial condition and during manual
3 stationary regeneration, and check that KDOC outlet temperature
(KDOC drying)
sensor is normal. (See "Related information".)
3. Perform manual stationary regeneration. (See "Related
information".)
a Since this is for drying KDOC, dosing fuel is not injected during
regeneration.
k Perform after KDPF and KDOC are sufficiently cooled.
1. Remove KDPF.
Defective KDOC 2. Remove KDOC.
4 (dirty or cracked or damaged 3. Blow air from KDOC outlet side to clean ceramic surfaces inside
KDOC surface) KDOC.
4. Check ceramic inside KDOC for cracks.
If cracks are found in KDOC, KDOC is defective (replace KDOC).
a Perform the following regardless whether KDOC is replaced or not.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
a When reset after KDOC change is performed, failure codes
5 Reset after KDOC change [CA1691] and [CA2637] will not be displayed. At that time, remedy of
not injecting dosing fuel when the failure code is displayed is
released.
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
manual stationary regeneration.
40-242 PC210LC-10
40 Troubleshooting

a Perform this troubleshooting when KDOC is not changed.
KDPF outlet temperature sensor, note temperature values from each
sensor with KDPF under initial condition and during manual
stationary regeneration, and check that KDOC outlet temperature
sensor is normal. (See "Related information".)
Defective KDOC 3. Perform manual stationary regeneration. (See "Related
information".)
6 (degraded KDOC catalyst 4. Turn starting switch to OFF position.
action) 5. Start engine and perform manual stationary regeneration again.
(Check whether failure code [CA2637] is displayed or not.)
a Check that failure code is not displayed and finish troubleshooting.
a If failure code [CA2637] is displayed after manual stationary
regeneration is completed, KDOC is defective (catalyst action of
KDOC is degraded. Change KDOC).
a When KDOC is changed, perform troubleshooting for cause 5 again.
PC210LC-10 40-243
40 Troubleshooting
Failure code [CA1695] Sensor 5 Supply Volt High Error (PC220_10-CA1695-400-A-00-A)
Action
Failure code
level Failure Sensor power supply 5 high error
L03 CA1695
Details of • High voltage appears in 5 V power supply for KDPF differential pressure sensor and
failure KDPF outlet pressure sensor.
• Takes it that KDPF outlet pressure sensor is at fixed value (0 kPa {0 kg/cm 2}) and allows
engine to run.
• Takes it that KDPF delta pressure sensor value is at recommended value (or at 0 kPa {0
Action of kg/cm2}).
• Limits engine output and allows engine run.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
1. Perform checkup referencing the descriptions of wiring harness and
connectors in "c: Electrical equipment"of "Checks before troubleshooting" in
Defective wiring "General information on troubleshooting".
harness connector
Defective KDPF
2. Disconnect connector E25.
delta pressure
2 (outlet pressure)
sensor a Ignore displayed failure codes other than this one.
(internal defect) If this failure code does not appear, KDPF delta pressure (outlet pressure) sensor
is defective.
wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to either
circuit) Between CE03 ground and (female) (52)
Resistance or E25 (female) (4) Min. 100 kz

Short circuit in 2. Disconnect connectors CE03 and E25, and connect T-adapters to female side
4 wiring harness of connector CE03.
Between CE03 (female) (52) and each
Resistance pin other than (52) Min. 100 kz

3. Insert T-adapters into connector CE03 or connect T-adapters to female side of
Defective engine connector E25.
5
controller 4. Turn starting switch to ON position.
Between CE03 (52) and (43), or
between E25 (female) (4) and (1)
40-244 PC210LC-10
40 Troubleshooting
Circuit diagram related to KDPF differential pressure sensor and KDPF

outlet pressure sensor
PC210LC-10 40-245
40 Troubleshooting
Failure code [CA1696] Sensor 5 Supply Volt Low Error (PC220_10-CA1696-400-A-00-A)
Action
Failure code
level Failure Sensor power supply 5 low error
L03 CA1696
Details of • Low voltage appears in 5 V power supply for KDPF delta pressure sensor and KDPF
failure outlet pressure sensor.
• Takes it that KDPF outlet pressure sensor is at fixed value (0 kPa {0 kg/cm 2}) and allows
engine to run.
• Takes it that KDPF delta pressure sensor value is at recommended value (or at 0 kPa {0
Action of kg/cm2}) and allows engine to run.
machine
Related • KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
1. Perform checkup referencing the descriptions of wiring harness and
connectors in "c: Electrical equipment"of "Checks before troubleshooting" in
Defective wiring "General information on troubleshooting".
harness connector
Defective KDPF
delta pressure
2 (outlet pressure)
sensor a Ignore displayed failure codes other than this one.
(internal defect) If this failure code does not appear, KDPF delta pressure (outlet pressure) sensor
is defective.
Short circuit in 2. Disconnect connectors CE03 and E25, and connect T-adapters to female side
3 wiring harness of connector CE03.
Between CE03 (female) (52) and each
Resistance pin other than (52) Min. 100 kz

3. Insert T-adapters into connector CE03 or connect T-adapters to female side of
Defective engine connector E25.
4
controller 4. Turn starting switch to ON position.
Between CE03 (52) and (43), or
between E25 (female) (4) and (1)
40-246 PC210LC-10
40 Troubleshooting
Circuit diagram related to KDPF differential pressure sensor and KDPF

outlet pressure sensor
PC210LC-10 40-247
40 Troubleshooting
Failure code [CA1843] Crankcase Press Sens High Error (PC200LC_10-CA1843-400-A-Z0-

A)
Action level Failure code Crankcase Pressure Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of crankcase pressure sensor.
failure
Action of • Takes it that crankcase pressure is at fixed value (approximately 0 kPa) and allows engine
controller to run.
Problem on
machine
(Code: 48401(V))
Related • Pressure sensed by crankcase pressure sensor can be checked with monitoring function.
2 supply circuit troubleshooting for it first.
Defective crankcase 2. Disconnect connector P57.
3 pressure sensor 3. Turn starting switch to ON position.
(internal defect) If failure code [CA1843] changes to [CA1844], crankcase pressure
sensor is defective.
Open circuit in wiring harness each female side.
4 (wire breakage or defective
Resis- Between ECM J1 (female) (59) and P57 (male)
(2) Max. 10 z
tance
5 Short circuit in wiring harness either female side.
tance
Hot short circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connector P57 and connect T-adapters to female side.
Voltage Between P57 (female) (3) and (2) Max. 1 V
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
Sensor
output
40-248 PC210LC-10
40 Troubleshooting
Circuit diagram related to crankcase pressure sensor
PC210LC-10 40-249
40 Troubleshooting
Failure code [CA1844] Crankcase Press Sens Low Error (PC200LC_10-CA1844-400-A-00-

A)
Action level Failure code Crankcase pressure sensor low error

Failure
Detail of • Low voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of • Set crankcase pressure to the fixed value (approx. 0 kPa), and run engine.
controller
Problem on
machine
(Code: 48401(V))
Related • Crankcase pressure sensed by crankcase pressure sensor can be checked with
information monitoring function. (Code: 48400 (MPa))
connector
Defective sensor power 1. Turn starting switch to OFF position.

2 supply system 2. Disconnect connector P57 and connect T-adapters to female side.
Power 4.75 to 5.25
supply V
2. Disconnect connectors ECM J1 and P57 and connect T-adapters to
each female side.
a If any failure is found in harness, disconnect connector OEM
CONNECTION and check further to determine which is defective;
engine harness or chassis harness.
Open circuit in wiring harness a If no failure is found by check on cause 2,

Resis- this check is not required.
3 (wire breakage or defective Max. 10 z
tance Between ECM J1 (female) (60) and P57
(female) (1)
Resis- this check is not required.
Max. 10 z
tance Between ECM J1 (female) (59) and P57
(female) (2)
Resis- Between ECM J1 (female) (3) and P57
tance
40-250 PC210LC-10
40 Troubleshooting

either female side.
Ground fault in wiring
4 harness a If any failure is found in harness, disconnect connector OEM
(contact with ground circuit) CONNECTION and check further to determine which is defective;
engine harness or chassis harness.
Resis- Between ECM J1 (female) (3) or P57 (female)
(3) and ground Min. 100 kz
tance
tance
Defective crankcase 2. Insert T-adapters into connector P57.
6 pressure sensor (internal 3. Turn starting switch to ON position.
defect) Sensor
Voltage Between P57 (female) (3) and (2) 0.3 to 4.7 V
output
• Reference
7 Defective engine controller 1. Turn starting switch to OFF position.
2. Insert T-adapters into connector J1.
Sensor
output
Circuit diagram related to crankcase pressure sensor
a Connector PPCV is dummy (no sensor is connected to it).
PC210LC-10 40-251
40 Troubleshooting
Failure code [CA1879] KDPF Delta P Sensor High Error (PC200LC_10-CA1879-400-A-Z0-A)
Action level Failure code KDPF delta pressure sensor high error
Failure
Detail of • High voltage appears in KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure is at recommended value and allows engine to run.
(If another failure code is also generated, controller may run engine using delta pressure
Action of of 0 kPa.)
machine
k Since the temperature of the KDPF will become higher than 500 °C , take care not to
get burn injury.
• KDPF delta pressure sensor and KDPF outlet pressure sensor are integrated.
Related • If failure code [CA1695] is not displayed but failure code [CA3133] is displayed, GND line
information may have open circuit (defective connection of connector).
• Signal voltage from KDPF delta pressure sensor can be checked with monitoring function.
(Code: 47101(V))
• Delta pressure sensed by KDPF delta pressure sensor can be checked with monitoring
function. (Code: 47100 (kPa))
connector
If failure code [CA1695] or [CA1696] is displayed, perform
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25 V
Defective KDPF delta If failure code changes to [CA1881], KDPF delta pressure sensor is
3 pressure sensor defective.
a If this failure code is still displayed, the wiring harness or engine
controller is defective.
a Ignore other displayed failure codes.
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to
4 each female side.
(wire breakage or defective
contact of connector) a To check for open circuit in GND line
Resis- Between CE03 (female) (43) and E25
tance
40-252 PC210LC-10
40 Troubleshooting

2. Disconnect connectors CE03 and E25, and connect T-adapters to
female side of connector CE03.
5 a Check by using multimeter in continuity mode.
harness
No continuity
Between CE03 (female) (55) and each other
Continuity (No sound is
pin
heard)
Circuit diagram related to KDPF delta pressure sensor
PC210LC-10 40-253
40 Troubleshooting
Failure code [CA1881] KDPF Delta P Sensor Low Error (PC200LC_10-CA1881-400-A-Z0-A)
Action level Failure code KDPF deltal pressure sensor low error
Failure
Detail of • Low voltage appears in the KDPF delta pressure sensor signal circuit.
failure
• Takes it that KDPF delta pressure is at recommended value and allows engine to run.
(If another failure code is also generated, controller may run engine using delta pressure
Action of of 0 kPa.)
machine
k Since the temperature of the KDPF will become higher than 500 °C , take care not to
get burn injury.
• If failure code [CA1696] is not displayed but failure code [CA3134] is displayed, the
Related sensor connector may be disconnected or an open circuit (poor connection in connector)
information is suspected in the 5 V line.
• This failure code is displayed if the sensor connector is disconnected.
(Code: 47101(V))
• Differential pressure sensed by KDPF delta pressure sensor can be checked with
monitoring function. (Code: 47100 (kPa))
connector
If failure code [CA1695] or [CA1696] is displayed, perform
2 supply system 2. Disconnect connector E25 and connect T-adapters to female side.
Voltage Between E25 (female) (4) and (1) 4.75 to 5.25
V
each female side.
Open circuit in wiring harness Between CE03 (female) (43) and E25
tance
Between CE03 (female) (52) and E25
(female) (4)
40-254 PC210LC-10
40 Troubleshooting

Ground fault in wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapters to
Resis- Between CE03 (female) (55) or E25 (female)
Min. 100 kz
tance (2) and ground
female side of connector CE03.
5 Short circuit in wiring harness a Check by using multimeter in continuity mode.
No continuity
Continu- Between CE03 (female) (55) and each other
ity pin (No sound is
heard)
Defective KDPF delta 2. Insert T-adapter into connector E25.
6 pressure 3. Turn starting switch to ON position.
PC210LC-10 40-255
40 Troubleshooting
Failure code [CA1883] KDPF Delta P Sens In Range Error (PC200LC_10-CA1883-400-A-

Z0-A)
Action level Failure code KDPF Delta Pressure Sensor In Range Error
Failure
Detail of • Signal voltage from KDPF delta pressure sensor is out of range. (Signal voltage from
failure sensor is within "operating" range.)
• Takes it that KDPF delta pressure is at estimated value and allows engine to run.
(If another failure code is also generated, controller may use delta pressure of 0 kPa to
run engine.)
machine
k Since KDPF is heated to 500°C or above, take care not to get burn injury.
(Code: 47101 (V))
Related function. (Code: 47400 (°C))
information • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• Temperature sensed by torque converter oil temperature sensor can be checked with
monitoring function. (Code: 30100 (°C))
a Use "Short-circuit connector: 799T-601-4611".
• As to procedure for accessing KDPF delta pressure sensor, wiring harness, and tube, see
50 Disassembly and assembly, "Removal and installation of KDPF assembly" and
"Disassembly and assembly of KDPF".
• Engine controller stops approximately 30 seconds after starting switch is turned to OFF
position. So when you restart engine, wait 1 minute minimum before turning starting
switch to ON position again.
Machine O
clearing
troubleshooting for [CA1695] or [CA1696] first.
1 supply system 2. Disconnect connector E25 and connect T-adapter to female side.
40-256 PC210LC-10
40 Troubleshooting

2
needed.
If failure code [CA1881] is not displayed, wiring harness or engine
a Perform check on cause 2 again.
Defective wiring harness or 1. Turn starting switch to OFF position.

3 engine controller 2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (2) of
connector E25).
Defective KDPF delta a If failure codes [CA1881] and [CA1879] are displayed in check on
4 pressure sensor cause 3, KDPF delta pressure sensor is defective.
each female side.
tance
(female) (4)

Ground fault in wiring 2. Disconnect connectors CE03 and E25, and connect T-adapter to
6 harness either female side.
(contact with ground circuit) Resis- Between ground and CE03 (female) (55) or
E25 (female) (2) Min. 100 kz
tance
2. Disconnect connectors CE03 and E25, and connect T-adapter to
female side of CE03.
Between CE03 (female) (55) and No continuity (no sound
Continuity
each pin other than pin (55) is heard)
PC210LC-10 40-257
40 Troubleshooting

1. Remove KDPF delta pressure sensor tube.
2. Clean KDPF delta pressure sensor tube to clear clogging.
3. Check KDPF delta pressure sensor tube for cracks and damage.
4. Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Defective KDPF delta
8 pressure sensor tube • Reference
How to check KDPF delta pressure sensor tube for clogging
2. Monitor delta pressure sensed by KDPF delta pressure sensor on
monitoring screen of machine monitor.
Code 47,100 (kPa) 0 ± 3 (kPa)
k Place the machine on a level ground.
1. Turn starting switch to ON position and leave it in that position for 1 minute. (In order to allow engine
controller to determine drift of voltage when starting switch is turned to ON position)
4. After finishing warm-up operation, set swing lock switch to OFF position, working mode to P-mode, and
fuel control dial to MAX position.
5. Perform arm IN relief for 40 seconds.
a Take care not to overheat hydraulic oil.
a If failure code disappears, repair is complete.
6. If failure code still remains displayed, repeat above step 5 three times.
a If failure code disappears, repair is complete.
command.
40-258 PC210LC-10
40 Troubleshooting
Failure code [CA1921] KDPF Soot Load High Error 1 (PC200LC_10-CA1921-400-A-Z0-A)
Action level Failure code KDPF Soot Load High Error 1

Failure
• Soot accumulation of KDPF reaches level 6 or 7. As much soot is accumulated in KCSF,
Detail of the user is requested to perform "Manual Stationary Regeneration" immediately.
failure (If soot accumulation reaches level 8, KDPF must be replaced.)
controller • Disables automatic regeneration but allows manual stationary regeneration.
machine
k Since KDOC and KDPF are heated to 500°C or above, take care not to get burn
injury.
(Code: 47101 (V))
Related difference between these temperatures is approx. 10°C. (KDOC inlet temperature >
information KDOC outlet temperature > KDPF outlet temperature)
• When the active regeneration (the manual stationary regeneration) is in progress, KDOC
inlet temperature is approx. 250 to 400°C, and KDOC outlet temperature and KDPF outlet
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
a Time required for the manual stationary regeneration depends on the accumulated soot in
KCSF, however, it is estimated as follows.
• If soot accumulation is level 4: Approx. 40 minutes to 1 hour
• If soot accumulation is level 5: Approx. 1 to 2 hours
• If soot accumulation is level 6 or 7: Approx. 1 to 3 hours
• If soot accumulation is level 8: The manual stationary regeneration can not be performed.
PC210LC-10 40-259
40 Troubleshooting
Factors for excessive soot accumulation

1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that leads to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
Related and perform the regeneration.
information a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
(For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
a If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for it first.
a If failure code [CA1922] has been displayed originally, it changes to [CA1921] during
troubleshooting process of [CA1922]. In such case, refer to failure code [CA1922].
• Method of reproducing failure code: Turn starting switch to the ON position.
1. Check if the regeneration stop button is pressed down from the
machine monitor.
a If the regeneration stop button is pressed down, release it.
4. Perform manual stationary regeneration from user mode.
a When the manual stationary regeneration is finished correctly, the
Excessive KDPF (KCSF) repair is completed.
1
soot accumulation level
a If the regeneration does not complete within 3 hours, perform the
troubleshooting of [CA2639].
a Check that failure code is not displayed after manual stationary
regeneration is completed.
a If failure code [CA1922] or [CA2639] is displayed after manual
stationary regeneration is completed, proceed to checks on
cause 2.
a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
a For check of the exhaust gas color, see "30 Testing and adjusting",
"Testing exhaust gas color".
a When checking the exhaust gas color, perform the "Regeneration
Disable" from the machine monitor.
2 Unusual exhaust gas color then keep engine running at high idle for 5 seconds.
idle.
a Check that no failure code appears.
40-260 PC210LC-10
40 Troubleshooting

a When you finish the check of the exhaust gas color, release
"Regeneration Disable".
PC210LC-10 40-261
40 Troubleshooting
Failure code [CA1922] KDPF Soot Load High Error 2 (PC200LC_10-CA1922-400-A-Z0-A)
Action level Failure code KDPF Soot Load High Error 2

Failure
• Soot accumulation in KDPF is very high, and machine must be stopped and performed
Detail of maintenance immediately.
failure • Soot accumulation reaches level 8 (KDPF is completely clogged with soot).
controller • Disables the automatic regeneration and the manual stationary regeneration.
machine
injury.
(Code: 47101 (V))
Related function. (Code: 47100 (kPa))
information • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when
• Soot accumulation in KDPF is classified into 8 levels. Current soot accumulation level can
be checked on machine monitor by selecting the "02 Regeneration for Service" screen.
• The manual stationary regeneration can be performed for removing soot when soot
accumulation is up to level 7.
• If soot accumulation reaches level 8, failure code [CA1922] is displayed. At this level, the
KDPF is completely clogged with soot, and inspection, cleaning, or replacement is
required.
40-262 PC210LC-10
40 Troubleshooting
Factors for excessive soot accumulation
1. Engine runs with light loads and cannot keep exhaust gas temperature high enough to
burn soot in KDPF.
• If temperature of the gas entered into after-treatment system (KDPF) is low, a large
amount of soot may accumulate.
• To avoid the soot accumulation in KDPF, the engine must run under high load.
2. Engine has failure that lead to excessive black smoke.
3. "Regeneration Disable" is set from the screen monitor.
• Even if the soot is accumulated, regeneration does not start automatically.
You must move the machine to a safe place to release the "Regeneration Disable",
and perform the regeneration.
a Releasing method of "Regeneration Disable"
Select the "Cancel of Regeneration Disable" from the ”KDPF Regeneration” screen and
execute.
Related
information (For details, see Operation and Maintenance Manual, "Operation", "Handling KDPF",
"Operation procedure of KDPF Regeneration Disable".)
• Procedure of performing the manual stationary regeneration from the "Regeneration for
Service".
performed only from the "Regeneration for Service".
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"Regeneration for Service", and then perform the "Manual Stationary Regeneration".
a Resetting after KDPF cleaning
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Cleaning" (reset after KDPF cleaning).
a Resetting after KDPF change
From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"KDPF Memory Reset", and then perform "KDPF Change" (resetting after KDPF change).
a When KCSF in KDPF is changed, always perform resetting procedures for KDPF cleaning
and KDPF change, and then perform the "Manual Stationary Regeneration" from the
"Regeneration for Service" to eliminate moisture from KCSF.
PC210LC-10 40-263
40 Troubleshooting

Increase of soot machine monitor.
1 accumulation due to a If the regeneration stop button is pressed down, release it.
"Regeneration Disable"
a After releasing the "Regeneration Disable", proceed to checks on
causes 2 and after.
• Check the abnormality record.
1. Turn starting switch to the ON position.
2. From the machine monitor, displays the abnormality record screen
and check the history of failure codes CA2639, CA1921 and
CA1922.
Interval between failure code CA2639 and CA1921
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
and
Interval between failure code CA1921 and CA1922
X360 sec (KOMTRAX history) or X0.1 h (Monitor history screen)
[When above conditions are satisfied]
a As much soot is accumulated, KDPF regeneration can not be
performed.
1. Replace the KCSF or the KDPF.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
Defective KDPF (KCSF)
2 procedure after KDPF cleaning, and perform the reset after KDPF
(change KCSF) cleaning again.
3. Reset the KDPF after its change (see "Related information").
4. Perform checks on causes 4 to 7 (When KDPF is changed, this is not
needed.)
7. Perform regeneration for service.
repair is completed.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
[When above conditions are not satisfied]
(When the actual soot accumulation is less than the displayed value)
Proceed to checks on cause 3 and after.
40-264 PC210LC-10
40 Troubleshooting

a When the actual soot accumulation is less than the displayed value
on the machine monitor
1. Proceed to checks on cause 4 to 7.
2. Turn the starting switch to the ON position, and perform the reset
after KDPF cleaning (see "Related information").
a Check that failure code [CA1922] is changed to [CA1921].
a If the failure code [CA1922] continues, check the resetting
procedure after KDPF cleaning, and perform the reset after KDPF
cleaning again.
Defective KDPF (KCSF) 5. Perform manual stationary regeneration from user mode.
3 (abnormal condition of soot
accumulation) a When the manual stationary regeneration is finished correctly, the
a If failure code [CA1922] is displayed again within 1 hour after
starting the manual stationary regeneration, perform Step 2 and 3
again.
a If failure code [CA1922], [CA1921] or [CA2639] is displayed after
manual stationary regeneration is completed, perform checks on
cause 8.
4 temperature sensor troubleshooting for [CA3313], [CA3314], or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] is displayed, perform
5 temperature sensor troubleshooting for [CA3316], [CA3317], or [CA3318].
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform
6 temperature sensor troubleshooting for [CA3316], [CA3321] or [CA3322].
2. Monitor differential pressure sensed by KDPF differential pressure
sensor on monitoring screen of machine monitor.
Code 47,100 (kPa) 0 ± 3 (kPa)
a If the differential pressure is outside of the above range, perform the
Defective KDPF differential following.
7 pressure sensor
1. Remove KDPF differential pressure sensor tube.
(including sensor tubes) 2. Clean KDPF differential pressure sensor tube to clear clogging.
a If the KDPF differential pressure sensor tube is not clogged,
perform the following.
3. Perform for "Short circuit in wiring harness" of failure code [CA1881]
or [CA1883]. (If no short circuit occurs, replace the KDPF differential
pressure sensor.)
PC210LC-10 40-265
40 Troubleshooting

a If failure code [CA1921], or [CA2639] is displayed after manual
stationary regeneration is completed, perform following.
8 Unusual exhaust gas color then keep engine running at high idle for 5 seconds.
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
40-266 PC210LC-10
40 Troubleshooting
Failure code [CA1942] Crankcase Press Sens In Range Error (PC220_10-CA1942-

400-A-00-A)
Action Crankcase pressure sensor in range error
Failure code
level Failure
L01 CA1942
Details of • Signal voltage from crankcase pressure sensor is out of normal range.
failure
controller
Problem on
machine
(Code: 48401 (V))
Related • Pressure from crankcase pressure sensor can be checked with monitoring function.
sensor
2
filter
Blocked KCCV gas
piping
When KCCV filter is replaced, if failure code of crankcase pressure high error does
Increase of blowby not disappear and failure code of crankcase pressure high errors is displayed in
4 gas short period, engine may be seized or turbocharger may have trouble. Perform
troubleshooting for mechanical system.
PC210LC-10 40-267
40 Troubleshooting
Failure code [CA1993] KDPF Delta Pressure Low Error (PC200LC_10-CA1993-400-A-Z0-A)
Action level Failure code KDPF Delta Pressure Low Error

Failure
Detail of • Signal voltage from KDPF delta pressure sensor is lower than threshold value.
failure
controller
machine
(Code: 47101 (V))
information • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
O
Machine B. Machine operation for clearing failure code
operation for
clearing a This failure code does not disappear by simply turning starting switch to ON position from
failure code OFF position after repair. You must perform machine operation for clearing failure code
a In machine operation for clearing failure code, "dummy temperature sensor: 799T-601-
4680" is used.
40-268 PC210LC-10
40 Troubleshooting

Defective KDPF delta If failure code [CA1879], [CA1881], or [CA1883] is displayed, perform
1 pressure sensor troubleshooting for [CA1879], [CA1881], or [CA1883] first.
1. Turn starting switch to OFF position once, and then turn it to ON
position.
2. Check whether failure codes other than [CA1993] are generated.
3. Start engine and accelerate it suddenly from low idle to full speed
two times, then run it at full speed for 5 seconds. During above
operation, check exhaust gas color at exhaust pipe when engine
2 KCSF abnormality 1 accelerates suddenly and runs at full speed.
4. If black smoke is exhausted from exhaust pipe in above step 3,
KCSF is abnormal. Check whether KCSF is installed. If yes, check
KCSF for damage and foreign material in it, and fix trouble as
needed.
a If black smoke is not exhausted, proceed to checks on causes 3 and
after.
Perform following checks.
1. Check whether KDPF delta pressure sensor tube is installed.
2. Check whether KDPF delta pressure sensor tube is connected
Defective KDPF delta correctly.
3 pressure sensor tube 3. Remove KDPF delta pressure sensor tube and check it for clogging,
cracks, and damage.
4. Check both ends of KDPF delta pressure sensor tube for loose
connection.

2. Disconnect connector E26 and install dummy temperature sensor to female side.
5. After finishing warm-up operation, set swing lock switch to OFF position and working mode to P-mode.
6. Perform arm IN relief for continuous 1 minute.
a Take care not to overheat hydraulic oil.
a If failure code disappears after implementing steps 1 to 6, repair work is complete.
a If failure code still remains displayed, repeat above step 6 three times.
8. Remove dummy temperature sensor and restore connector connection.
command.
If this failure code is still displayed after above procedures are
implemented, remove KDPF and check whether KCSF is installed. If
yes, check KCSF for damage and foreign material in it, and fix trouble as
4 KCSF abnormality 2 needed.
After repair trouble, implement above "B. Machine operation for clearing
failure code".
PC210LC-10 40-269
40 Troubleshooting
40-270 PC210LC-10
40 Troubleshooting
Failure code [CA2185] Throt Sensor Sup Volt High Error (PC400-CA2185-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in throttle sensor power supply (5 V) circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
machine
information
N- Procedure, measuring location, criteria and remarks
Cause
o.
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2185].
2. Disconnect connectors CE03 and P20, and connect T-adapter to
3 female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
2. Disconnect connector P20, and connect T-adapter to female side.
Voltage Between P20 (female) (1) and ground 4.75 to 5.25 V
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
PC210LC-10 40-271
40 Troubleshooting
40-272 PC210LC-10
40 Troubleshooting
Failure code [CA2186] Throt Sensor Sup Volt Low Error (PC400-CA2186-400-A-Z0-A)
Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in throttle sensor power supply (5 V) circuit.
failure
• Uses throttle value obtained before failure detection to run engine if failure is detected
Action of with starting switch at ON position.
controller • Uses full throttle value to run engine if starting switch is set to ON position after failure
detection.
machine
information
Cause
o.
Defective wiring harness on troubleshooting", and check it.
connector
2. Disconnect connector P20, and turn starting switch to ON position.
Defective throttle sensor
2 (fuel control dial) If this failure code disappears, throttle sensor is defective.
a Other failure codes are also displayed. They are generated because of
disconnection of connector. Ignore failure codes other than [CA2186].
Ground fault in wiring 2. Disconnect connectors CE03 and P20, and connect T-adapter to either
3 harness female side.
(contact with ground circuit) Resis- Between ground and CE03 (female) (42) or P20
Min. 1 Mz
tance (female) (1)
2. Disconnect connectors CE03 and P20, and connect T-adapter to
Short circuit in wiring female side of CE03.
harness
Resis- Between CE03 (female) (42) and each pin other
Min. 1 Mz
tance than pin CE03 (female) (42)
If no failure is found by above checks, engine controller is defective. (Since
this is an internal defect, troubleshooting cannot be performed.)
• Reference
Power
Voltage Between CE03 (42) and (41)
supply 4.75 to 5.25 V
PC210LC-10 40-273
40 Troubleshooting
40-274 PC210LC-10
40 Troubleshooting
Failure code [CA2249] Rail Press Very Low Error (PC200LC_10-CA2249-400-A-Z0-A)
Action level Failure code Rail Pressure Very Low Error

Failure
Detail of • Supply pump does not feed fuel (level 2).
failure
controller
machine
• Signal voltage from common rail pressure sensor can be checked by using monitoring
Related • Common rail pressure sensed by common rail pressure sensor can be checked with
information monitoring function. (Code: 36400 (MPa))
Supply pump pressure low Perform troubleshooting for failure code [CA559].
1
error
PC210LC-10 40-275
40 Troubleshooting
Failure code [CA2271] EGR Valve Pos Sens High Error (D65-CA2271-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of EGR valve lift sensor.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Position sensed by EGR valve lift sensor can be checked with monitoring function.
information (Code: 18100 (mm))
Defective sensor power If failure code [CA352] or [CA386] is displayed, perform troubleshooting
2 supply circuit for [CA352] or [CA386] first.
Defective EGR valve lift 2. Disconnect connector SEGR.
(internal defect) If failure code [CA2271] changes to [CA2272], EGR valve lift sensor is
defective.
2. Disconnect connector INTER-CONNECT.
If failure code [CA2271] changes to [CA2272], connector box is
Defective connector box
4 defective.
(internal short circuit)
a EGR solenoid failure code [CA2349], KVGT sensor failure code
[CA2382], and KVGT solenoid failure code [CA2383] are also
displayed. They are generated because of disconnection connector
INTER-CONNECT. Ignore these failure codes.
2. Disconnect connectors INTER-CONNECT and SEGR, and connect
Open circuit in connector box T-adapters to INTER-CONNECT male side and SEGR female side.
Resis- Between INTER-CONNECT (male) (4) and
SEGR (female) (B) Max. 10 z
tance
2. Disconnect connectors ECM J2 and INTER-CONNECT, and
Open circuit in wiring harness connect T-adapters to each female side.
6 (wire breakage or defective a To check open circuit in GND line
contact of connector) a If no failure is found by check on cause 2, this check is not required.
Resis- Between ECM J2 (female) (47) and INTER-
CONNECT (female) (4) Max. 10 z
tance
40-276 PC210LC-10
40 Troubleshooting

Between ECM J2 (female) (30) and (59) or
Resis- between INTER-CONNECT (female) (3) and Min. 100
tance (5) kz

harness 2. Disconnect connector SEGR and connect T-adapters to female side.
Voltage Between SEGR (female) (C) and (B) Max. 1 V
• Reference
Sensor 1.0 to 4.0
output V
Circuit diagram related to EGR valve lift sensor
PC210LC-10 40-277
40 Troubleshooting
Failure code [CA2272] EGR Valve Pos Sens Low Error (D65-CA2272-400-A-Z0-A)
Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of • Low voltage appears in signal circuit of EGR valve lift sensor.
failure
machine
• Signal voltage from EGR valve lift sensor can be checked with monitoring function.
(Code: 18101 (V))
Related • Position sensed by EGR valve lift sensor can be checked with monitoring function.
If failure code [CA352] or [CA386] is displayed, perform troubleshooting
for [CA352] or [CA386] first.
2 2. Disconnect connector SEGR and connect T-adapters to female side.
supply circuit
Between SEGR (female) (A) and Power 4.75 to 5.25
Voltage
(B) supply V
T-adapters to INTER-CONNECT male side and SEGR female side.
this check is not required. Between INTER- Max. 10 z
Open circuit in connector box CONNECT (male) (3) and SEGR (female)
3 (wire breakage or defective (A).
tance
this check is not required. Between INTER- Max. 10 z
CONNECT (male) (4) and SEGR (female)
(B).
Between INTER-CONNECT (male) (5) and
SEGR (female) (C) Max. 10 z

Ground fault in connector T-adapters to INTER-CONNECT male side and SEGR female side.
4 box Between ground and INTER-CONNECT
Min. 100 kz
(contact with ground circuit) Resis- (male) (5) or SEGR (female) (C)
tance Between ground and INTER-CONNECT
(male) (3) or SEGR (female) (A) Min. 100 kz
40-278 PC210LC-10
40 Troubleshooting

Short circuit in connector box T-adapters to INTER-CONNECT male side and SEGR female side.
5 Between INTER-CONNECT (male) (4) and
(internal short circuit) Min. 100 kz
Resis- (5), or between SEGR (female) (B) and (C)
tance Between INTER-CONNECT (male) (3) and
(4), or between SEGR (female) (A) and (B) Min. 100 kz

2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
Open circuit in wiring Max. 10 z
harness Between ECM J2 (female) (30) and
6 INTER-CONNECT (female) (3)
tance
Max. 10 z
INTER-CONNECT (female) (4)
Between ECM J2 (female) (59) and INTER-

2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
Ground fault in wiring T-adapters to each female side.
7 harness Between ground and ECM J2 (female) (59) or
Min. 100 kz
(contact with ground circuit) Resis- INTER-CONNECT (female) (5)
tance Between ground and ECM J2 (female) (30) or
INTER-CONNECT (female) (3) Min. 100 kz

2. Disconnect connectors ECM J2 or INTER-CONNECT, and connect
Between ECM J2 (female) (47) and (59) or
8 between INTER-CONNECT (female) (4) and Min. 100 kz
harness
Resis- (5)
between INTER-CONNECT (female) (3) and Min. 100 kz
(4)
2. Insert T-adapters into connector SEGR.
Defective EGR valve lift
9 sensor a Sensor voltage is measured with wiring harness connected.
(internal defect) Accordingly, if voltage is abnormal, check harness connector for
failure, and then determine whether sensor is defective or not.
Sensor
Voltage Between SEGR (C) and (B) 1.0 to 4.0 V
output
10 Defective engine controller (Since this is an internal defect, troubleshooting cannot be performed.)
PC210LC-10 40-279
40 Troubleshooting
Circuit diagram related to EGR valve lift sensor
40-280 PC210LC-10
40 Troubleshooting
Failure code [CA2288] Turbo Speed High Error 1 (D65-CA2288-400-A-Z0-A)
Action level Failure code Turbocharger Speed High Error 1

Failure
Detail of • Turbocharger runs at abnormally high speed.
failure
controller
machine
• Speed sensed by turbocharger speed sensor can be checked with monitoring function.
Increased turbocharger
1 Turbocharger speed may increase abnormally high. Check it.
speed
2 Defective turbocharger Turbocharger may be defective. Check it.
If no failure is found by check on cause 1, turbocharger speed sensor
Defective turbocharger speed system may be defective. Perform troubleshooting for failure code
3
sensor [CA687].
PC210LC-10 40-281
40 Troubleshooting
Failure code [CA2311] IMV Solenoid Error (PC200-CA2311-400-A-00-A)
Action IMV solenoid error

Failure code
level Failure
L03 CA2311
Details of • Resistance of supply pump actuator circuit is abnormally high or low.
failure
controller
machine
information
Malfunction of IMV Perform troubleshooting for failure codes [CA271] and [CA272].
1
solenoid
40-282 PC210LC-10
40 Troubleshooting
Failure code [CA2349] EGR Valve Solenoid Open Error (D65-CA2349-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Open Error

Failure
Detail of • Open circuit is detected in EGR valve solenoid drive circuit.
failure
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
Related (Code: 48600 (mA))
1. See descriptions of wiring harness and connectors in "c:
Electrical equipment" in "Checks before troubleshooting" of
"General information on troubleshooting", and check it.
Defective EGR valve solenoid 2. Disconnect connector EGR-SOL and connect T-adapters to
2 male side.
Between EGR-SOL (male) (1) and
Resistance (2) 5 to 10 z

2. Disconnect connector ECM J2 and connect T-adapters to
Open circuit or short circuit in female side.
3 wiring harness a To measure resistance of EGR valve solenoid
Resistance (16) 5 to 10 z

2. Disconnect connectors ECM J2 and EGR-SOL, and connect
Ground fault in wiring harness T-adapters to either female side.
4
(contact with ground circuit) Between ground and ECM J2
Resistance (female) (6) or EGR-SOL (female) Min. 100 kz
(1)
a If no failure is found by check on cause 3, this check is not
required.
Open circuit in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT,
5 (wire breakage or defective contact and connect T-adapters to INTER-CONNECT male side and
of connector) EGR-SOL female side.
Between INTER-CONNECT (male)
(1) and EGR-SOL (female) (1) Max. 10 z
Resistance
Between INTER-CONNECT (male)
(2) and EGR-SOL (female) (2) Max. 10 z

required.
Ground fault in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT,
6 and connect T-adapters to INTER-CONNECT male side or
EGR-SOL female side.
Between ground and INTER-
Resistance CONNECT (male) (1) or EGR-SOL Min. 100 kz
(female) (1)
PC210LC-10 40-283
40 Troubleshooting

required.
Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
7 (wire breakage or defective contact connect T-adapters to each connector.
of connector) Between ECM J2 (female) (6) and
INTER-CONNECT (female) (1) Max. 10 z
Resistance
INTER-CONNECT (female) (2) Max. 10 z

required.
Ground fault in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
8
(contact with ground circuit) connect T-adapters to each female side.
Between ground and ECM J2
Resistance (female) (6) or INTER-CONNECT Min. 100 kz
(female) (1)
2. Disconnect connectors ECM J2 and EGR-SOL, and connect
T-adapters to female side of ECM J2.
No continuity
Between EGR J2 (female) (6) and
each pin other than pin (6)
heard)
If no failure is found by above checks, engine controller is
10 Defective engine controller defective. (Since this is an internal defect, troubleshooting cannot
be performed.)
Circuit diagram related to EGR valve solenoid
40-284 PC210LC-10
40 Troubleshooting
Failure code [CA2353] EGR Valve Solenoid Short Error (D65-CA2353-400-A-Z0-A)
Action level Failure code EGR Valve Solenoid Short Error

Failure
Detail of
• Short circuit is detected in EGR valve solenoid drive circuit.
failure
machine
• Signal current to EGR valve lift solenoid can be checked with monitoring function.
Defective EGR valve 2. Disconnect connector EGR-SOL and connect T-adapters to male
2 solenoid side.
(internal short circuit) Resis- Between EGR-SOL (male) (1) and (2)
5 to 10 z
tance
Open or short circuit in wiring side.
3
harness a To measure resistance of EGR valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and EGR-SOL, and connect T-
4 harness adapters to either female side.
EGR-SOL (female) (1) Min. 100 kz
tance
Ground fault in connector box 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and
5 connect T-adapters to INRER-CONNECT male side and EGR-SOL
female side.
Resis- Between ground and INTER-CONNECT
(male) (1) or EGR-SOL (female) (1) Min. 100 kz
tance
6 harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
(contact with ground circuit) T-adapters to each female side.
tance
PC210LC-10 40-285
40 Troubleshooting

2. Disconnect connectors ECM J2 and EGR-SOL, and connect T-
adapters to female side of ECM J2.

No
Between EGR J2 (female) (6) and each pin continuity
Continuity
other than pin (6) (No sound
is heard)
Circuit diagram related to EGR valve solenoid
40-286 PC210LC-10
40 Troubleshooting
Failure code [CA2357] EGR Valve Servo Error (D65-CA2357-400-A-Z0-A)
Action level Failure code EGR Valve Servo Error

Failure
Detail of • EGR valve servo error occurs.
failure (EGR lift sensor sends back EGR valve position value that differs from command value.)
Action of • Does not supply current to EGR valve (closes EGR valve).
machine
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Related Position (mm))
1
them.
a For testing of EGR valve drive pressure, see Testing and adjusting,
Insufficient EGR valve drive "Measuring EGR valve and KVGT oil pressure".
2 pressure
If EGR valve drive pressure is abnormal, perform checks on causes 3
and 4.
a For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
3 system (main circuit) If engine oil pressure is not normal, perform troubleshooting (S mode)
for mechanical system. (S-14 Engine oil pressure drops)
Defective oil pump for EGR Oil pump or relief valve for EGR valve circuit may be defective. Check
4
valve them.
Defective hydraulic piping for Hydraulic piping of EGR valve circuit may be defective. Check it.
5
EGR valve
Defective return hydraulic
6 Return hydraulic piping for EGR valve circuit may be defective. Check it.
piping for EGR valve
7 Defective EGR valve EGR valve may have mechanical trouble. Check it.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If no failure is found by checks on causes 1 to 8, engine controller is
9 Defective engine controller defective.
PC210LC-10 40-287
40 Troubleshooting
Failure code [CA2373] Exhaust Manifold Press Sens High error (D65-CA2373-400-
A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of exhaust manifold pressure sensor.
failure
• Takes it that exhaust manifold pressure is at calculated value and allows engine to run.
machine
• Signal voltage from exhaust manifold pressure sensor can be checked with monitoring
function.
(Code: 48301 (V))
Related • Pressure sensed by exhaust manifold pressure sensor can be checked with monitoring
(Code: 48300 (MPa))
Defective boost pressure 2. Disconnect connector EXHAUST PRESSURE.
(internal defect) If failure code [[CA2373] changes to [CA2374], exhaust manifold
pressure sensor is defective.
Short circuit in wiring harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
4 (Short circuit between wiring connect T-adapters to each female side.
harnesses) Resis- Between ECM J2 (34) and (30), or between Min. 100
tance EXHAUST PRESSURE (female) (3) and (1) kz
Hot short circuit in wiring 2. Disconnect connector EXHAUST PRESSURE and connect T-
harness adapters to female side.
Between EXHAUST PRESSURE (female) (3)
Voltage Max. 1 V
and (2)
• Reference
Sensor 0.2 to 4.7
output V
40-288 PC210LC-10
40 Troubleshooting
Circuit diagram related to exhaust manifold pressure sensor
PC210LC-10 40-289
40 Troubleshooting
Failure code [CA2374] Exhaust Manifold Press Sens Low error (D65-CA2374-400-
A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor Low Error
Failure
Detail of • Low voltage appears in signal circuit of exhaust manifold pressure sensor.
failure
machine
function.
(Code: 48301 (V))
(Code: 48300 (MPa))
Defective sensor power 2. Disconnect connector EXHAUST PRESSURE and connect T-
2 supply circuit adapters to female side.
Between EXHAUST PRESSURE Power 4.75 to 5.25
Voltage
(female) (1) and (2) supply V
2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
connect T-adapters to each female side.
Open circuit in wiring harness Between ECM J2 (30) and EXHAUST
PRESSURE (female) (1) Max. 10 z
contact of connector) Resis- Between ECM J2 (female) (47) and EXHAUST
tance
Between ECM J2 (female) (34) and EXHAUST

2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
Ground fault in wiring connect T-adapters to either female side.
4 harness Between ground and ECM J2 (female) (34) or
Min. 100 kz
(contact with ground circuit) Resis- EXHAUST PRESSURE (female) (3)
tance Between ground and ECM J2 (female) (30) or
EXHAUST PRESSURE (female) (1) Min. 100 kz

Short circuit in wiring harness 2. Disconnect connectors ECM J2 and EXHAUST PRESSURE, and
5 (Short circuit between wiring connect T-adapters to either female side.
harnesses) Resis- Between ECM J2 (34) and (47), or between Min. 100 z
tance EXHAUST PRESSURE (female) (2) and (3)
40-290 PC210LC-10
40 Troubleshooting

Defective exhaust manifold 2. Insert T-adapter to connector ECM J2
6 pressure sensor 3. Turn starting switch to ON position.
(internal defect) Between EXHAUST PRESSURE (female) (3)
and (2)
Circuit diagram related to exhaust manifold pressure sensor
PC210LC-10 40-291
40 Troubleshooting
Failure code [CA2375] EGR Orifice Temp Sens High Error (D65-CA2375-400-A-Z0-A)
Action level Failure code EGR Orifice Temperature Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of EGR orifice temperature sensor.
failure
• Runs engine by setting EGR orifice temperature to calculated value.
machine
• Signal voltage from EGR orifice temperature sensor can be checked with monitoring
function.
(Code: 48501 (V))
Related • Temperature sensed by EGR orifice temperature sensor can be checked with monitoring
(Code: 48500 (°C))
2. Disconnect connector EXHAUST GAS TEMPERATURE and
connect T-adapters to male side.
760 to 880
-30 °C
kz
380 to 515
0 °C
kz
155 to 225
25 °C
kz
Defective EGR orifice
Between EXHAUST GAS 21 to 29
2 temperature sensor (internal 80 °C
defect) TEMPERATURE (male) (1) and (2) kz
Resis- 900 to
tance 200 °C
1050 z
150 to 200
300 °C
z
400 °C 40 to 56 z
500 °C 15 to 22 z
Between EXHAUST GAS
Whole Min. 100
TEMPERATURE (male) (2) and
range kz
ground (sensor body)
Open or short circuit in wiring 2. Disconnect connector ECM J2 and connect T-adapters to female
harness side.
3 (short circuit, wire breakage a Use Temperature-Resistance characteristics table of EGR orifice
or defective contact of temperature sensor that is used for check on cause 2 as resistance
connector) criteria.
Resis- Between ECM J2 (female) (18) and (48) 15 z to
tance 880 kz
40-292 PC210LC-10
40 Troubleshooting

Hot short circuit in wiring 2. Disconnect connector EXHAUST GAS TEMPERATURE and
harness connect T-adapters to female side.
Between EXHAUST GAS TEMPERATURE Max. 5.25
Voltage
(female) (1) and (2) V
Circuit diagram related to EGR orifice temperature sensor
PC210LC-10 40-293
40 Troubleshooting
Failure code [CA2376] EGR Orifice Temp Sens Low Error (PC220_10-CA2376-400-A-00-A)
Action EGR orifice temperature sensor low error

Failure code
level Failure
L03 CA2376
Details of • Low voltage error is detected in EGR orifice temperature sensor signal circuit.
failure
• Runs engine by setting EGR orifice temperature to the calculated value.
machine
• Voltage sensed by EGR orifice temperature sensor can be checked using monitoring
function.
(Code: 48501 (V))
Related • Temperature sensed by EGR orifice temperature sensor can be checked using
information monitoring function.
(Code: 48500 (°C))
1. See descriptions of harness and connectors in "c: Electrical equipment" of
Defective wiring "Checks before troubleshooting" in "General information on troubleshooting",
1
harness connector and check them.
Defective EGR 1. Turn starting switch to OFF position.
orifice temperature 2. Disconnect connector EXHAUST GAS TEMPERATURE.
(internal defect) If this failure code changes to failure code [CA2375], EGR orifice temperature
• Reference
2. Disconnect connector EXHAUST GAS TEMPERATURE and connect T-
adapter to male side.
-30°C 760 to 880 kz
0°C 380 to 515 kz
Between 25°C 155 to 225 kz
Defective EGR EXHAUST GAS 80°C 21 to 29 kz
orifice temperature TEMPERATURE 200°C 900 to 1050 z
3 sensor (male) (1) and (2) 300°C 150 to 200 z
(internal defect) 400°C 40 to 56 z
Resistance
500°C 15 to 22 z
Between
EXHAUST GAS
TEMPERATURE
Whole range Min. 100 kz
(male) (2) and
ground (sensor
body)
Open circuit or 1. Turn starting switch to OFF position.
short circuit in 2. Disconnect connector ECM J2 and connect T-adapter to female side.
wiring harness
4 a Resistance is the same as that given in temperature-resistance characteristics
(short circuit, open
circuit or defective table of EGR orifice temperature sensor that has bee used to check cause 3.
connector contact) Resistance Between ECM J2 (female) (18) and (48) 15 z to 880 kz
harness 2. Disconnect connectors ECM J2 and EXHAUST GAS TEMPERATURE, and
5
(Contact with GND connect T-adapters to either female side.
circuit)
40-294 PC210LC-10
40 Troubleshooting

ground, or between EXHAUST GAS
Resistance TEMPERATURE (female) (2) and Min. 100 kz
ground
controller
Circuit diagram related to EGR orifice temperature sensor
PC210LC-10 40-295
40 Troubleshooting
Failure code [CA2381] KVGT Pos Sens High Error (D65-CA2381-400-A-Z0-A)
Action level Failure code KVGT Position Sensor High Error

Failure
Detail of • High voltage appears in signal circuit of KVGT position sensor.
failure
• Closes EGR valve and opens KVGT fully.
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position sensed by KVGT position sensor can be checked with monitoring function.
Defective KVGT position 2. Disconnect connector SVGT.
(internal defect) a If failure code [CA2381] changes to [CA2382], KVGT position sensor
is defective.
2. Disconnect connector INTER-CONNECT.
If failure code [CA2381] changes to [CA2382], connector box is
Defective connector box defective.
4
(internal short circuit) a EGR solenoid failure code [CA2349], EGR sensor failure code
[CA2272], and KVGT solenoid failure code [CA2383] are also
displayed.
Ignore these failure codes since they are generated because of
disconnection of connector INTER-CONNECT.
2. Disconnect connectors INTER-CONNECT and SVGT and connect T-
Open circuit in connector box adapters to INTER-CONNECT male side and SVGT female side.
SVGT (female) (B) Max. 10 z
tance
Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
tance
40-296 PC210LC-10
40 Troubleshooting

Short circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and
7 (Short circuit between wiring
harnesses) Between ECM J2 (female) (30) and (38) or
Resis- between INTER-CONNECT (female) (8) and Min. 100
tance (10) kz

harness 2. Disconnect connector SVGT and connect T-adapters to female side.
Voltage Between SVGT (female) (C) and (B) Max. 1 V
• Reference
Sensor 1.0 to 4.0
output V
Circuit diagram related to KVGT position sensor
PC210LC-10 40-297
40 Troubleshooting
Failure code [CA2382] KVGT Pos Sens Low Error (D65-CA2382-400-A-Z0-A)
Action level Failure code KVGT Position Sensor Low Error

Failure
Detail of • Low voltage appears in signal circuit of KVGT position sensor.
failure
machine
• Signal voltage from KVGT position sensor can be checked with monitoring function.
(Code: 48701 (V))
Related • Position sensed by KVGT position sensor can be checked with monitoring function.

2 supply circuit 2. Disconnect connector SVGT and connect T-adapters to female side.
Between SVGT (female) (A) and Power 4.75 to
Voltage
(B) supply 5.25 V
2. Disconnect connectors INTER-CONNECT and SVGT, and connect
Open circuit in connector box T-adapters to INRER-CONNECT male side and SVGT female side.
3 (wire breakage or defective Between INTER-CONNECT (male) (8) and
SVGT (female) (A) Max. 10 z
SVGT (female) (B) Max. 10 z
tance
Between INTER-CONNECT (male) (10) and
SVGT (female) (C) Max. 10 z

2. Disconnect connectors INTER-CONNECT and SVGT, and connect
Ground fault in connector box T-adapters to INRER-CONNECT male side or SVGT female side.
4 Between ground and INTER-CONNECT (male) Min. 100
Resis- (10) or SVGT (female) (C) kz
tance Between ground and INTER-CONNECT (male) Min. 100
(8) or SVGT (female) (A) kz
40-298 PC210LC-10
40 Troubleshooting

2. Disconnect connectors INTER-CONNECT and SVGT,and connect
Short circuit in connector box T-adapters to INRER-CONNECT male side or SVGT female side.
5 Between INTER-CONNECT (male) (9) and Min. 100
Resis- (10), or between SVGT (female) (B) and (C) kz
tance Between INTER-CONNECT (male) (8) and (9), Min. 100
or between SVGT (female) (A) and (B) kz
Open circuit in wiring harness connect T-adapters to each female side.
6 (wire breakage or defective Between ECM J2 (female) (30) and INTER-
tance
Between ECM J2 (female) (38) and INTER-

Ground fault in wiring harness connect T-adapters to each female side.
7 Between ground and ECM J2 (female) (38) or Min. 100
Resis- INTER-CONNECT (female) (10) kz
tance Between ground and ECM J2 (female) (30) or Min. 100
INTER-CONNECT (female) (8) kz
Short circuit in wiring harness Between ECM J2 (female) (47) and (38) or
8 (Short circuit between wiring between INTER-CONNECT (female) (9) and Min. 100
kz
harnesses) Resis- (10)
between INTER-CONNECT (female) (8) and Min. 100
(9) kz

2. Insert T-adapters into connector SVGT.
Defective KVGT position
9 sensor a Sensor voltage is measured with wiring harness connected.
(internal defect) Accordingly, if voltage is abnormal, check harness connector for
failure, and then determine whether sensor is defective or not.
Sensor 1.0 to 4.0
Voltage Between SVGT (C) and (B)
output V
PC210LC-10 40-299
40 Troubleshooting
Circuit diagram related to KVGT position sensor
40-300 PC210LC-10
40 Troubleshooting
Failure code [CA2383] KVGT Solenoid Open Error (D65-CA2383-400-A-Z0-A)
Action level Failure code KVGT Solenoid Open Error

Failure
Detail of • Open circuit is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function. (Code: 48800
Related (mA))
Defective KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapters to male
2 side.
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
3
harness a To measure resistance of KVGT valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
VGT-SOL (female) (1) Min. 100 kz
tance
2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
Open circuit in connector box connect T-adapters to INRER-CONNECT male side and VGT-SOL
5 (wire breakage or defective female side.
contact of connector) Between INTER-CONNECT (male) (6) and
Max. 10 z
Resis- VGT-SOL (female) (1)
tance Between INTER-CONNECT (male) (7) and
VGT-SOL (female) (2) Max. 10 z

Ground fault in connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
6 connect T-adapters to INRER-CONNECT male side or VGT-SOL
female side.
Resis- Between INTER-CONNECT (male) (6) or VGT-
SOL (female) (1), and ground. Min. 100 kz
tance
PC210LC-10 40-301
40 Troubleshooting

Open circuit in wiring harness 2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect
7 (wire breakage or defective T-adapters to each female side.
contact of connector) Between ECM J2 (female) (10) and INTER-
Max. 10 z
Resis- CONNECT (female) (6)
tance Between ECM J2 (female) (20) and INTER-

tance
2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-

No
Between ECM J2 (female) (10) and each pin continuity
Continuity
is heard)
Circuit diagram related to KVGT solenoid
40-302 PC210LC-10
40 Troubleshooting
Failure code [CA2386] KVGT Solenoid Short Error (D65-CA2386-400-A-Z0-A)
Action level Failure code KVGT Solenoid Short Error

Failure
Detail of
• Short circuit is detected in KVGT solenoid drive circuit.
failure
machine
• Signal current to KVGT solenoid can be checked with monitoring function.
Defective KVGT solenoid 2. Disconnect connector VGT-SOL and connect T-adapters to male
2 side.
Resis- Between VGT-SOL (male) (1) and (2)
5 to 10 z
tance
3
harness a To measure resistance of KVGT valve solenoid
5 to 10 z
tance
Ground fault in wiring 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-
VGT-SOL (female) (1) Min. 100 kz
tance
Ground fault in connector box 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and
5 connect T-adapters to INTER-CONNECT male side or VGT-SOL
female side.
Resis- Between INTER-CONNECT (male) (6) or VGT-
SOL (female) (1), and ground. Min. 100 kz
tance
tance
PC210LC-10 40-303
40 Troubleshooting

2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-

No
Between ECM J2 (female) (10) and each pin continuity
Continuity
is heard)
Circuit diagram related to KVGT solenoid
40-304 PC210LC-10
40 Troubleshooting
Failure code [CA2387] KVGT Servo Error (WA380_7-CA2387-400-A-Z0-A)
Action level Failure code KVGT Servo Error

Failure
• KVGT servo error occurs.
Detail of failure (KVGT position sensor sends back KVGT position value that differs from command
value.)
machine
information
1
them.
For testing of KVGT drive pressure, see Testing and adjusting,
Insufficient KVGT drive "Measuring EGR valve and KVGT oil pressure".
2 pressure a If KVGT drive pressure is abnormal, perform checks on causes 4
and 5.
For testing of KVGT control pressure, see Testing and adjusting,
Insufficient KVGT control "Testing EGR valve and KVGT oil pressure".
3 pressure
a If KVGT control pressure is abnormal, replace EPC valve for KVGT.
For check of engine oil pressure, see Testing and adjusting, "Testing
Defective engine oil pressure engine oil pressure".
4 system (main circuit)
If engine oil pressure is abnormal, perform troubleshooting (S mode) for
mechanical system. (S-14 Engine oil pressure lowers.)
5 Defective oil pump for KVGT Oil pump or relief valve for KVGT circuit may be defective. Check them.
Defective hydraulic piping for Hydraulic piping of KVGT circuit may be defective. Check it.
6
KVGT
Defective return hydraulic
7 piping for KVGT Return hydraulic piping of KVGT circuit may be defective. Check it.
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged
8 Defective KVGT after performing regeneration for service, KVGT is defective.
(Since the time required for manual stationary regeneration depends on
the accumulated soot level, see failure code CA2639. )
Defective KVGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
9
sensor
PC210LC-10 40-305
40 Troubleshooting
Failure code [CA2554] Exh Manifold Press Sens In Range Error (D65-CA2554-400-
A-Z0-A)
Action level Failure code Exhaust Manifold Pressure Sensor In Range Error
Failure
Detail of • Signal voltage output from exhaust manifold pressure sensor is out of normal range.
failure
machine
function.
(Code: 48301 (V))
(Code: 48300 (MPa))
• Method of reproducing failure code: Turn starting switch to ON position, or start engine
and run engine at high idle.
Blocked piping of exhaust Exhaust manifold pressure sensor piping may be blocked. Check piping
1 manifold pressure sensor for clogging.
Defective exhaust manifold Exhaust manifold pressure sensor system may be defective. Perform
2 pressure sensor troubleshooting for failure codes [CA2373] and [CA2374].
40-306 PC210LC-10
40 Troubleshooting
Failure code [CA2555] Grid Htr Relay Volt Low Error (PC200LC_10-CA2555-400-A-Z0-A)
Action level Failure code Grid Heater Relay Voltage Low Error
Failure
Detail of • Open circuit is in preheat relay drive circuit (primary circuit).
failure
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
checked with monitoring function. (Code: 18500 (°C))
• Method of reproducing failure code: Turn starting switch to ON position (boost
temperature: Max. -4 °C).
• Troubleshooting of this failure code covers circuits from engine controller to primary circuit
Related (coil) of preheat relay R18.
information • For troubleshooting of heater relay and secondary circuit of preheat relay R18, see
following E-mode troubleshooting.
• E-2 Manual preheating system does not work
• E-3 Automatic preheating system does not work
• E-4 While preheating is working, preheating monitor does not light up
connector
2. Disconnect relay R18, and connect T-adapter to male side.
Resis- Between R18 (male) (1) and (2)
200 to 400 z
tance
2 Defective preheat relay R18
2. Replace relay R18 with another one.
If this failure code disappears, original preheat relay R18 is defective.
Open or short circuit in wiring 2. Disconnect connector CE03, and connect T-adapter to female side.
3
harness Resis- Between CE03 (female) (4) and (13)
200 to 400 z
tance a Coil resistance of relay R18
2. Disconnect connector CE03 and relay R18, and connect T-adapter
4 Open circuit in wiring harness to each female side.
Between CE03 (female) (4) and R18 (female)
Max. 10 z
Resis- (1)
tance Between CE03 (female) (13) and R18
PC210LC-10 40-307
40 Troubleshooting
Circuit diagram related to intake air heater relay
40-308 PC210LC-10
40 Troubleshooting
Failure code [CA2556] Grid Htr Relay Volt High Error (PC200LC_10-CA2556-400-A-Z0-A)
Action level Failure code Grid Heater Relay Voltage High Error
Failure
Detail of • Short circuit is in preheat relay drive circuit (primary circuit).
failure
controller
Problem on • Intake air heater does not work in auto preheating mode (resulting in degraded startability
machine and emission of white smoke at low temperatures).
checked with monitoring function. (Code: 18500 (°C))
• Method of reproducing failure code: Turn starting switch to ON position (boost
temperature: Max. -4 °C).
• Troubleshooting of this failure code covers circuits from engine controller to primary circuit
Related (coil) of preheat relay R18.
information • For troubleshooting of heater relay and secondary circuit of preheat relay R18, see
following E-mode troubleshooting.
• E-2 Manual preheating system does not work
• E-3 Automatic preheating system does not work
• E-4 While preheating is working, preheating monitor does not light up
connector
2. Disconnect relay R18, and connect T-adapter to male side.
200 to 400 z
tance
2 Defective preheat relay R18
2. Replace relay R18 with another one.
If this failure code disappears, original preheat relay R18 is defective.
3 Ground fault in wiring harness to either female side.
Resis- Between ground and CE03 (female) (4) or
R18 (female) (1) Min. 100 Kz
tance
to female side of CE03.
No continuity
Between CE03 (female) (4) and each pin
other than pin (4)
heard)
PC210LC-10 40-309
40 Troubleshooting
Circuit diagram related to intake air heater relay
40-310 PC210LC-10
40 Troubleshooting
Failure code [CA2637] KDOC Face Plugging (PC200LC_10-CA2637-400-A-Z0-A)
Action level Failure code KDOC Face Plugging

Failure
• KDOC face is plugged.
1. The KDOC surface is contaminated due to the operating conditions, and the catalytic
Detail of efficiency has dropped (clean the DOC).
failure 2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or
dropped efficiency due to damage (Replace KDOC with a new or used one.)
Action of • Closes EGR valve
controller • Stops fuel dosing.
Problem on • None in particular
machine
k Since temperature of the turbocharger exhaust connector, KDOC and KDPF

exceeds 500 °C, take care not to get burn injury.
a When KDOC in KDPF is changed, perform reset procedure for KDOC change and then
finish repair.
• Procedure of performing manual stationary regeneration from Regeneration for Service.
performed only from "Regeneration for Service".
Related 1. Start the engine.
information 2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display the "Diagnostic Tests" screen, open
"02 Regeneration for service", and then perform the "Manual Stationary
Regeneration".
• If the KDOC efficiency is still low, this failure code [CA2637] may be displayed repeatedly
and failure code [CA1691] indicating the poor regeneration may be displayed.
<How to clear failure code>
• Start the engine and perform the warm-up operation, then operate the machine under
normal conditions for approximately 3 hours.
(If the exhaust gas temperature is high, this operation time can be reduced.)
1 Defective KVGT If failure code [CA238*] is displayed, troubleshoot for it first.
If failure code [CA227*], [CA23**] or others is displayed, troubleshoot for
2 Defective EGR valve
it first.
1. Remove turbocharger exhaust connector.
Defective turbocharger 2. Check for oil or fuel inside turbocharger exhaust connector.
3
exhaust connector • If contaminated, troubleshoot for failure codes [CA227*], [CA23**],
etc., relating to the EGR valve and KVGT.
Defective exhaust connector Check exhaust system between turbocharger and KDPF for damage of
4 and ducts connected to the connector and ducts, and for loose connection.
KDPF
then keep engine running at high idle for 5 seconds.
• If excessive black smoke is exhausted when running the engine at
high idle, troubleshoot for "S-9 KDPF gets clogged in a short time".
5 Unusual exhaust gas color
idle.
PC210LC-10 40-311
40 Troubleshooting

1. Remove KDPF.
2. Remove KDOC.
• Check KDOC for cracks (replace KDOC if cracks are found).
• Check whether more than 50% of KDOC inlet surface is plugged with
6 Defective KDOC soot or not.
(KDOC cleaning)
a When KDOC is replaced, perform check on cause 7. And when
cleaning of KDOC is done, perform checks on causes 7 and 8.
1. Install KDOC and KDPF.
3. From service menu of machine monitor, display the "Diagnostic
Tests" screen, open "03 KDPF Memory Reset", and then perform "03
KDOC Change" (reset after KDOC change).
7 Reset after KDOC change
a Check that reset after KDOC change is completed successfully (by
reset count). If not, perform troubleshooting again.
a When KDOC is replaced, finish troubleshooting without performing
1. Perform manual stationary regeneration from Regeneration for
Service.
3. Repeat the "Regeneration for service" (to check the repair
Performing manual stationery completion).
8 regeneration
a If failure code [CA2637] is displayed after you have completed the
"Regeneration for Service", the KDOC efficiency has dropped.
Replace the KDOC and perform reset after KDOC change (see
Cause 7).
a Operate the machine approximately 3 hours and check that this failure code is not displayed.
40-312 PC210LC-10
40 Troubleshooting
Failure code [CA2639] Manual Stationary Regeneration Request (PC200LC_10-

CA2639-400-A-Z0-A)
Action level Failure code Manual Stationary Regeneration Request

Failure
The "Manual Stationary Regeneration Request" prompts operator to forcibly perform the
Detail of "Manual Stationary Regeneration", which is more effective to remove soot, because soot
failure accumulation in the KCSF of KDPF has exceeded level for the automatic regeneration.
• Soot accumulation reaches level 4 or 5.
Action of
• Normal control
controller

machine
injury.
• KVGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
Related temperature are approx. 450 to 550°C.
information • KDOC inlet temperature sensor connector label "TEMP1" expressed in black embossed
• How to perform the manual stationary regeneration
3. From the service menu of the machine monitor, display the "Diagnostic Tests" screen,
open "Regeneration for Service", and perform the "Manual Stationary Regeneration".
a While the regeneration for service is in progress, the “monitoring” screen is displayed by
performing the switch operation: keep pressing numeral input switch [4] and sequentially
press [1], [2] and [3] in order.
(For detail, see Testing and adjusting “Regeneration for service ” . )
a If this failure code is still displayed after several hours have passed after the manual
stationary regeneration, perform the following troubleshooting procedures.
PC210LC-10 40-313
40 Troubleshooting
a If another failure code is displayed (including when the manual stationary regeneration is
in progress), perform troubleshooting for it first.
40-314 PC210LC-10
40 Troubleshooting

machine monitor.
If the regeneration stop button is pressed down, release it.
Increase of soot 3. Make sure that machine is in safe condition.
1 accumulation due to 4. Start the engine, and perform the manual stationary regeneration
"Regeneration Disable" from user mode.
a If the regeneration does not complete within 3 hours, proceed to
checks on cause 2 and after.
• If there is a significant difference between KDOC inlet temperature
Defective KDOC inlet and KDOC outlet temperature when KDPF is completely cool or
2 temperature sensor engine running at idle (not regenerating), replace KDOC inlet
temperature sensor.
KVGT may have mechanical failure. Check it.
If values of KDOC inlet temperature: approximately 250°C or below and
KVGT solenoid current: approximately 1000 mA remain unchanged after
3 Defective KVGT performing regeneration for service, KVGT is defective.
(The time required for the manual stationary regeneration depends on
the accumulated soot level. See "Related information".)
Defective KDPF (KDOC, 1. Perform the troubleshooting "S-22 Active regeneration takes time" of
4 KCSF) S mode.
a If failure code [CA2639] is displayed after the manual stationary
regeneration is completed, perform the following.
then keep engine running at high idle for 5 seconds.
5 Unusual exhaust gas color • If excessive black smoke is exhausted when accelerating engine or
running it at high idle, troubleshoot for "S-9 KDPF gets clogged in a
short time".
a When black smoke particles are exhausted during engine
acceleration, if it disappears with engine at high idle, the exhaust gas
color is judged as normal.
PC210LC-10 40-315
40 Troubleshooting
Failure code [CA2961] EGR Orifice Temp High Error 1 (PC220_10-CA2961-400-A-00-A)
Action EGR orifice temperature high error 1

Failure code
level Failure
L03 CA2961
Details of • Output signals from the EGR temperature sensor exceeds upper temperature control limit
failure and indicates a value out of normal range.
controller
machine
• Signal voltage of EGR orifice temperature sensor can be checked with monitoring
function.
(Code: 48501 (V)
Related • Temperature sensed by the EGR orifice temperature sensor can be checked with
information monitoring function.
(Code: 48500 (°C))
• This failure code is displayed if the sensor connector is disconnected.
• Method of reproducing failure code: Starting switch: ON
Defect in related If another failure code is indicated, carry out troubleshooting for it.
1 system
EGR gas EGR gas temperature may be abnormally high. Perform troubleshooting.
2 temperature rise
Defective EGR EGR orifice temperature sensor system may be defective. Carry out
3 orifice temperature troubleshooting for failure codes [CA2375] and [CA2376].
sensor
40-316 PC210LC-10
40 Troubleshooting
Failure code [CA2973] Chg Air Press Sensor In Range Error (D65-CA2973-400-A-Z0-A)
Action level Failure code Charge Air Pressure Sensor In Range Error
Failure
Detail of • Output signal from boost pressure sensor is out of normal range.
failure
• Takes it that boost temperature is at calculated value and allows engine to run.
machine
• Signal voltage from boost pressure sensor can be checked with monitoring function.
(Code: 36501 (V))
Related • Pressure sensed by boost pressure sensor can be checked with monitoring function.
Defective boost pressure Boost pressure sensor system may be defective. Perform
1 troubleshooting for failure codes [CA122] and [CA123].
sensor
PC210LC-10 40-317
40 Troubleshooting
Failure code [CA3133] KDPF Outlet Press Sens High Error (PC200LC_10-CA3133-400-A-
Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor High Error
Failure
Detail of • High voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF delta pressure is at estimated value (gauge pressure) and allows
Action of engine to run.
controller (Controller may use 0 kPa (gauge pressure) to run engine if another failure code is also
displayed.)
Problem on
• None
machine
• If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, GND
Related circuit probably has open circuit (defective contact of connector).
information • Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring

connector
Defective KDPF outlet If this failure code changes to [CA3134], KDPF outlet pressure sensor is
3 pressure sensor defective.
a If this failure code remains displayed, wiring harness or engine
Open circuit in wiring 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors CE03 and E25, and connect T-adapter to
4 each female side.
Resis- Between CE03 (female) (43) and E25 Max. 1 z
tance (female) (1)
40-318 PC210LC-10
40 Troubleshooting

harness
No continuity
other than pin (58)
heard)
Circuit diagram related to KDPF outlet pressure sensor
PC210LC-10 40-319
40 Troubleshooting
Failure code [CA3134] KDPF Outlet Press Sens Low Error (PC200LC_10-CA3134-400-A-
Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
Detail of • Low voltage appears in signal circuit of KDPF outlet pressure sensor.
failure
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
displayed.)
Problem on
• None
machine
• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V circuit probably has open circuit (defective
Related contact of connector).
information • This failure code appears if sensor connector is disconnected.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
• Delta pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
Cause
o.
connector
Defective sensor power supply 1. Turn starting switch to OFF position.
2 system
2. Disconnect connector E25 and connect T-adapter to female side.
each female side.
tance
(female) (4)

Ground fault in wiring harness 2. Disconnect connectors CE03 and E25, and connect T-adapter to
Min. 1 Mz
tance E25 (female) (3)
40-320 PC210LC-10
40 Troubleshooting

Cause
o.
No continuity
Continu- Between CE03 (female) (58) and each pin
ity other than pin (58) (No sound is
heard)
Defective KDPF outlet pressure 2. Insert T-adapter into connector E25.
sensor
PC210LC-10 40-321
40 Troubleshooting
Failure code [CA3135] KDPF Outlet Press Sens In Range Error (PC200LC_10-
CA3135-400-A-Z0-A)
Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
Detail of • Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage from sensor is within "operating" range.)
• Takes it that KDPF outlet pressure is at estimated value (gauge pressure) and allows
Action of engine to run
displayed.)
Problem on
• None
machine
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring
• Outlet pressure sensed by KDPF outlet pressure sensor can be checked with monitoring
a Use "Short-circuit connector: 799T-601-4670" (its wiring is not identical with that of "Short-
circuit connector: 799-601-4611).
O
operation for
4680" is used.
2 information on troubleshooting", and check it and fix trouble as
connector
needed.
40-322 PC210LC-10
40 Troubleshooting

Defective wiring harness or If failure code [CA3134] is not displayed, wiring harness or engine
3 engine controller controller is defective.
2. Disconnect connector E25 and connect short-circuit connector to
female side.
a To connect 5 V line to signal line (to short pin (4) to pin (3) of
Defective wiring harness or connector E25).
3 engine controller 3. Turn starting switch to ON position.
Defective KDPF outlet a If failure codes [CA3134] and [CA3133] are displayed in check on
4 pressure sensor cause 3, KDPF outlet pressure sensor is defective.
each female side.
tance
(female) (4)

Ground fault in wiring 2. Disconnect connectors EC3 and E25, and connect T-adapter to
6 harness either female side.
(contact with ground circuit) Resis- Between ground and CE03 (female) (58) or
E25 (female) (3) Min. 100 kz
tance

Continuity is heard)
PC210LC-10 40-323
40 Troubleshooting

1.Remove KDPF delta pressure sensor tube.
2.Clean KDPF delta pressure sensor tube to clear clogging.
3.Check KDPF delta pressure sensor tube for cracks and damage.
4.Install KDPF delta pressure sensor tube with both tube ends
connected securely.
Defective KDPF delta
8 • Reference
pressure sensor tube
How to check KDPF delta pressure sensor tube for clogging
2. Monitor outlet pressure sensed by KDPF outlet pressure sensor on
monitoring screen of machine monitor.
Code 47,000 (kPa) 0 ± 3 (kPa)

5. Referring to Related information, display KDOC inlet and outlet temperatures and KDPF outlet
temperature.
6. After finishing warm-up operation, set swing lock switch to OFF position and working mode to P-mode.
7. Perform arm IN relief for continuous 40 seconds.
a If failure code disappears after implementing steps 1 to 7, repair work is complete.
command.
40-324 PC210LC-10
40 Troubleshooting
PC210LC-10 40-325
40 Troubleshooting
Failure code [CA3251] KDOC Inlet Temp High Error (PC200LC_10-CA3251-400-A-Z0-A)
Action level Failure code KDOC Inlet Temperature High Error

Failure
Detail of • KDOC inlet temperature remains at high level.
failure
controller • You can cancel above measures by "turning starting switch to OFF position once, then
machine
injury.
Related • Temperature sensed by KDPF outlet temperature sensor can be checked with monitoring
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
of KDPF".
Machine O
clearing
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is also displayed,
1 temperature sensor perform troubleshooting for [CA3313], [CA3314] or [CA3315] first.
2
needed.
40-326 PC210LC-10
40 Troubleshooting

2. Disconnect connectors CE03 and TEMP1 (KDOC inlet temperature
sensor), and connect T-adapter to female side of CE03.
Continuity
2. Use monitoring function to display signal voltages and temperatures
from KDOC inlet temperature sensor, KDOC outlet temperature
sensor, and KDPF outlet temperature sensor on screen.
3. Run engine at idle for 10 minutes.
4. Note temperature values (after checking that they are stabilized).
5. Monitor temperature from each sensor.
Defective KDOC inlet
4 temperature sensor If temperature of any temperature sensor fluctuates 24°C or greater,
regard that temperature sensor as defective.
a If none of temperature sensor values changes more than 24°C,
problem is not in sensor system. Perform checks on causes 5 and
after.
a If another failure code appears with engine running at idle, perform
Check intake system hoses, clamps, and tubes for damage and
5 Malfunction of intake system
loosening. Repair as necessary. (Repair intake air leaks.)
Perform cylinder cutout mode operation to identify disabled cylinder (see
6 Defective injector
Testing and adjusting, "Handling of cylinder cutout mode operation).
2. Check for oil or fuel inside turbocharger exhaust connector.
Oil leak into turbocharger • If oil or fuel is found, visually check for oil leaks from EGR valve and
7
exhaust connector turbocharger. Repair if any failure is found.
a Wipe off oil and fuel from piping.
Check exhaust system between turbocharger and KDPF for oil or fuel
leaking in.
Oil leak into exhaust
8 connector and ducts leading • Wipe off oil or fuel if found.
to KDPF a If trace of oil or fuel leakage into KDPF is found, check KDPF, and
clean or replace it as necessary.
If failure code disappears, repair is complete.
command.
PC210LC-10 40-327
40 Troubleshooting
40-328 PC210LC-10
40 Troubleshooting
Failure code [CA3253] KDOC Temp Error - Non Regeneration (PC200LC_10-CA3253-

400-A-Z0-A)
Action level Failure code KDOC Temperature Error - Non Regeneration

Failure
Detail of • KDOC outlet temperature remains at high level when active regeneration is not
failure performed.
controller
machine
injury.
Related function. (Code: 47201 (V))
2. Since cylinders other than disabled cylinder increase their fuel injection to compensate
for torque drop, exhaust temperature may rise and KDOC inlet temperature high error
may be generated.
of KDPF".
O
operation for
4680" is used.
Defective KDOC inlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure
1 temperature sensor code [CA3251] (causes related to sensor and wiring harness).
Defective KDOC outlet Perform checks on causes 1 and 3 to 5 of troubleshooting for failure
2 temperature sensor code [CA3254] (causes related to sensor and wiring harness).
3 Defective KDOC 1. Remove KDPF.

2. Remove KDOC.
PC210LC-10 40-329
40 Troubleshooting

a When KDOC in KDPF is replaced, perform reset procedure for
KDOC change and then finish troubleshooting without performing
(See check on cause 7 of failure code [CA2637])
soot or not.
(KDOC cleaning)
2. Start engine and run it at low idle for approximately 15 minutes.
• If failure code disappears, repair is complete.
If failure code is not cleared, perform following steps.
a If failure code remains uncleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 4 and 6 are required to satisfy temperature
requirements.
• KDOC inlet temperature X 200°C
• KDOC outlet temperature X 200°C
3. Use monitoring function to display KDOC inlet and outlet temperatures.
6. Run that track idle off ground for 3 minutes with fuel control dial at MAX position and travel speed at Hi
setting.
• After above steps are implemented, if failure code is not cleared because of low ambient temperature
(at -20°C level), perform following steps.
8. Disconnect connector E26 (in KDPF temperature sensor consolidating box) and install dummy
temperature sensor to wiring harness side.
10.Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
11.Start engine and run it at low idle (with no load) for approximately 15 minute.
If failure code disappears after implementing steps 7 to 11, repair work is complete.
12.Turn engine starting switch to OFF position.
13.Remove dummy temperature sensor to restore connector connection.
command.
40-330 PC210LC-10
40 Troubleshooting
PC210LC-10 40-331
40 Troubleshooting
Failure code [CA3254] KDOC Outlet Temp High Error 1 (PC200LC_10-CA3254-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature High Error 1

Failure
Detail of • KDOC outlet temperature remains at high level.
failure
controller
machine
injury.
of KDPF".
Machine O
clearing
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
connector
needed.
40-332 PC210LC-10
40 Troubleshooting

2. Disconnect connectors CE03 and TEMP2 (KDOC outlet temperature
Continuity
Defective KDOC outlet
after.
7
leaking in.
1. Remove KDPF.
2. Remove KDOC.
a When KDOC of KDPF is replaced, perform reset procedure for
KDOC change and then finish troubleshooting without performing
9 Defective KDOC manual stationary regeneration (see check on cause 7 of failure
code [CA2637]).
soot or not.
(KDOC cleaning)
PC210LC-10 40-333
40 Troubleshooting

4. End regeneration for service.
(Perform regeneration for service for 15 minutes and more from its start.)
If failure code disappears when regeneration for service is ended, repair is complete.
command.
40-334 PC210LC-10
40 Troubleshooting
Failure code [CA3255] KDPF Temp Error - Non Regeneration (PC200LC_10-CA3255-

400-A-Z0-A)
Action level Failure code KDPF Temperature Error - Non Regeneration

Failure
Detail of • KDPF outlet temperature remains at high level when active regeneration is not performed.
failure
controller
machine
injury.
of KDPF".
O
operation for
4680" is used.
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is also displayed,
2
needed.
2. Disconnect connectors CE03 and TEMP3 (KDPF outlet temperature
Continuity is heard)
PC210LC-10 40-335
40 Troubleshooting

Defective KDPF outlet 5. Monitor temperature from each sensor.
• If none of temperature sensor values changes more than 24°C,
after.
• If another failure code appears with engine running at idle, perform
2. Check inside of turbocharger exhaust connector for adhesion of oil
Oil leak into turbocharger and fuel.
7 • If oil or fuel is found, visually check for oil leaks from EGR valve and
exhaust connector
turbocharger. Repair if any failure is found.
leaking in.
Oil leak into exhaust • Wipe off oil or fuel if found.
8 connector and ducts leading
40-336 PC210LC-10
40 Troubleshooting

1. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
a If failure code remains uncleared after above steps 1 and 2 are implemented, following temperature
requirements are included in clearing condition. Steps 3 and 4 are required to satisfy temperature
requirements.
• KDOC outlet temperature X 200 °C
• KDPF outlet temperature X 200 °C
3. Use monitoring function to display KDOC inlet and KDPF outlet temperatures.
6. Run that track idle off ground for continuous 3 minutes with fuel control dial at MAX position and travel
speed at Hi setting.
• After above steps are implemented, if failure code is not cleared because of low ambient temperature
(at -20°C level), perform following steps.
8. Disconnect connector E26 (in KDPF temperature sensor consolidating box) and install dummy
temperature sensor to wiring harness side.
10.Monitor KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature, and check
that each temperature ranges from approximately 560 to 590°C. For details, see Related information.
11.Start engine and run it at low idle (with no load) for approximately 15 minute.
If failure code disappears after implementing steps 7 to 11, repair work is complete.
12.Turn engine starting switch to OFF position
13.Remove dummy temperature sensor to restore connector connection.
command.
PC210LC-10 40-337
40 Troubleshooting
Failure code [CA3256] KDPF Outlet Temp High Error 1 (PC200LC_10-CA3256-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature High Error 1

Failure
Detail of • KDPF outlet temperature remains at high level.
failure
controller
machine
injury.
of KDPF".
Machine O
clearing
2
needed.
40-338 PC210LC-10
40 Troubleshooting

Between CE03 (female) (54) and each pin No continuity (no sound
other than pin (54) is heard)
Defective KDPF outlet 5. Monitor temperature from each sensor.
after.
exhaust connector
leaking in.
4. End regeneration for service.
(Perform regeneration for service for 15 minutes and more from its start.)
If failure code disappears when regeneration for service is ended, repair is complete.
command.
PC210LC-10 40-339
40 Troubleshooting
40-340 PC210LC-10
40 Troubleshooting
Failure code [CA3311] KDOC Outlet Temp High Error 2 (PC200LC_10-CA3311-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature High Error 2

Failure
Detail of • KDOC outlet temperature remains extremely high relative to KDOC inlet temperature.
failure
controller
machine
injury.
Related • Temperature sensed by KDOC outlet temperature sensor can be checked with monitoring
of KDPF".
OFF position. So when you restart engine, wait 1 minute minimum before turning starting
switch to the ON position again.
Machine O
operation for C. Machine operation for confirming completion of repair
clearing
failure code a This failure code disappears when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
Defective KDOC outlet If failure code [CA3316], [CA3317], or [CA3318] appears, perform
1 temperature sensor troubleshooting for [CA3316], [CA3317] or [CA3318] first.
2
needed.
2. Disconnect connectors CE03 and TEMP2 (KDOC outlet temperature
Continuity
PC210LC-10 40-341
40 Troubleshooting

Defective KDOC outlet 5. Monitor temperature from each sensor.
after.
exhaust connector
leaking in.
C. Machine operation for confirming completion of repair
a Failure code disappears once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3316] KDOC Outlet Temp Sens Low Error
• [CA3317] KDOC Outlet Temp Sens High Error
40-342 PC210LC-10
40 Troubleshooting
PC210LC-10 40-343
40 Troubleshooting
Failure code [CA3312] KDPF Outlet Temp High Error 2 (PC200LC_10-CA3312-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature High Error 2

Failure
Detail of • KDPF outlet temperature remains at very high level.
failure
controller
machine
injury.
of KDPF".
Machine O
operation for C. Machine operation for confirming completion of repair
clearing
failure code a This failure code disappears when starting switch is turned from OFF position to ON
position after repair. However, following machine operation must be done to confirm
completion of repair.
See descriptions of wiring harness and connectors in "c: Electrical
Defective wiring harness equipment" in "Checks before troubleshooting" of "General information
2
connector on troubleshooting", and check it and fix trouble as needed.
40-344 PC210LC-10
40 Troubleshooting

Continuity
Defective KDPF outlet
after.
7
leaking in.
C. Machine operation for confirming completion of repair
a Failure code disappears once when starting switch is turned from OFF position to ON position. Check
that cleared failure code is not generated again when engine runs at low idle.
a If this failure code appears when starting switch is turned to ON position but engine is not started, perform
troubleshooting for following failure codes, too, after finishing troubleshooting and repair for this code.
• [CA3319] KDPF Outlet Temp Sens Low Error
• CA3321] KDPF Outlet Temp Sens High Error
PC210LC-10 40-345
40 Troubleshooting
40-346 PC210LC-10
40 Troubleshooting
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error (PC200LC_10-CA3313-400-A-
Z0-A)
Action level Failure code KDOC Inlet Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in KDOC inlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor, too, controller takes it that
Action of KDOC inlet temperature is at default value (250°C) and allows engine to run.)
controller • Closes EGR valve
machine
injury.
Related
information
• If sensor connector is disconnected or open circuit occurs, this failure code does not
appear but failure code [CA3314] for "High Error" appears.
To avoid error due to improper operation, start and run engine at idle for 1 minute. If this
failure code is cleared, repair is complete.
connector
PC210LC-10 40-347
40 Troubleshooting

2. Disconnect TEMP1 (KDOC inlet temperature sensor).
If this failure code changes to [CA3314], KDOC inlet temperature
a If this failure code still remains displayed, wiring harness or engine
• Reference
Defective KDOC inlet 1. Turn starting switch to OFF position.
2 temperature sensor 2. Disconnect connector TEMP1 and connect T-adapter to female
side.
-10°C 33 to 65 kz
Between TEMP1 (female) 0°C 25 to 47 kz
(1) and (2) 50°C 7.8 to 12.2 kz
Resis-
tance
700°C 64 to 69 z
Ground fault in wiring harness 1. Turn starting switch to OFF position.
(contact with ground circuit) 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter
3 (including wiring harness in to female side of CE03 or male side of TEMP1.
KDPF temperature sensor Resis- Between ground and CE03 (female) (45) or
Min. 100 Kz
consolidating box) tance TEMP1 (male) (1)
2. Disconnect connectors CE03 and TEMP 1, and connect T-adapter
Short circuit in wiring harness to female side of CE03.
(including wiring harness in
KDPF temperature sensor
consolidating box) No continuity
heard)
a If no failure is found by checks on causes 3 and 4, this check is not
required.
2. Disconnect connector E26 and connect T-adapter to male side.
3. Disconnect connectors TEMP1, TEMP2, and TEMP3.
Defective KDPF temperature a If no failure is found by check on cause 3,
5 sensor consolidating box this check is not required. Min. 100 Kz
Between E26 (male) (3) and ground
Resis-
tance a If no failure is found by check on cause 4,
this check is not required. Min. 100 Kz
Between E26 (male) (3) and each pin other
than pin (3)
required.
6 2. Disconnect connectors CE03 and E26, and connect T-adapter to
either female side.
Min. 100 Kz
40-348 PC210LC-10
40 Troubleshooting

required.
7 Short circuit in wiring harness female side of CE03.
No continuity
heard)
2. If this failure code appears, perform procedure for <How to clear
Defective engine controller failure code> in "Related information".
8
If this failure code is still displayed and no failure is found by above
checks, engine controller is defective. (Since this is an internal defect,
PC210LC-10 40-349
40 Troubleshooting
Failure code [CA3314] KDOC Inlet Temp Sens High Error (PC200LC_10-CA3314-400-A-Z0-
A)
Action level Failure code KDOC Inlet Temperature Sensor High Error
Failure
Detail of • High voltage appears in KDOC inlet temperature sensor circuit.
failure
machine
injury.
Related
information
• If failure codes [CA3317] and [CA3319] are also displayed, connector in KDPF
temperature sensor consolidating box may be disconnected or probably has open circuit
(defective contact of connector) in ground line.
connector
40-350 PC210LC-10
40 Troubleshooting

2. Disconnect connector TEMP1 (KDOC inlet temperature sensor)
and connect T-adapter to male side.
3. Connect T-box to T-adapter and connect pins (1) and (2) of T-box
with jumper cable.
a To connect ground line to signal line
If this failure code changes to [CA3313] , KDOC inlet temperature
Defective KDOC inlet a If this failure code remains displayed, wiring harness or engine
2 temperature sensor controller is defective.
• Reference
2. Disconnect connector TEMP1 and connect T-adapter to female
side.
-10°C 33 to 65 kz
Between TEMP1 (female) 0°C 25 to 47 kz
Resis- (1) and (2) 50°C 7.8 to 12.2 kz
tance a Temperature-Resistance 100°C 3.2 to 4.5 kz
700°C 64 to 69 z
harness 2. Disconnect connector CE03, and connect T-adapter to female
side.
3 (including wiring harness in Between CE03 (female) (45) and (19)
KDPF temperature sensor Resis-
64 z to 65 kz
consolidating box) tance a Use above Temperature-Resistance
characteristics as resistance criteria.
Open circuit in wiring harness required.
(wire breakage or defective 1. Turn starting switch to OFF position.
contact of connector) 2. Disconnect connectors CE03 and TEMP1, and connect T-adapters
4 to female side of CE03 and male side of TEMP1.
KDPF temperature sensor Between CE03 (female) (45) and TEMP1
Max. 10 z
consolidating box) Resis- (male) (1)
tance Between CE03 (female) (19) and TEMP1
(male) (2) Max. 10 z

2. Disconnect connectors CE03 and TEMP 1, and connect T-adapter
5 (including wiring harness in
heard)
a If no failure is found by checks on causes 3 to 5, this check is not
required.
Defective KDPF temperature 3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect
6 sensor consolidating box T-adapter to male side of TEMP1.
a If no failure is found by check on cause 3
Resis- or 4, this check is not required. Max. 10 z
tance Between E26 (male) (2) and TEMP1 (male)
(2)
PC210LC-10 40-351
40 Troubleshooting

or 4, this check is not required. Max. 10 z
Between E26 (male) (3) and TEMP1 (male)
(1)
than pin (3)
a If no failure is found by check on cause 3 or 4, this check is not
required.
Open circuit in wiring harness 2. Disconnect connectors CE03 and E26, and connect T-adapter to
contact of connector) Between CE03 (female) (45) and E26
Max. 10 z
Resis- (female) (3)
tance Between CE03 (female) (19) and E26

required.
No continuity
heard)
9
40-352 PC210LC-10
40 Troubleshooting
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error (PC200LC_10-CA3315-
400-A-Z0-A)
Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
• Difference between temperature sensed by KDOC inlet temperature sensor and that by
Detail of KDOC outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
machine
injury.
Related • Signal voltage from KDPF outlet temperature sensor can be checked with monitoring
information function. (Code: 47201 (V))
of KDPF".
O
operation for
4680" is used.
Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform
1 temperature sensor troubleshooting for it first.
PC210LC-10 40-353
40 Troubleshooting

2
needed.
2. Disconnect TEMP1 (KDOC inlet temperature sensor).

3 engine controller 2. Disconnect connector TEMP1 and connect T-adapter to male side.
with jumper cable.
Open circuit in wiring harness 1. Turn starting switch to OFF position.
2. Disconnect connectors CE03 and TEMP1, and connect T-adapters
to female side of CE03 and male side of TEMP1.
4 Between CE03 (female) (45) and TEMP1
(including wiring harness in Max. 10 z
Resis- (male) (1)
consolidating box) Max. 10 z
(male) (2)
harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to
(contact with ground circuit) female side of CE03 or male side of TEMP1.
5
KDPF temperature sensor TEMP1 (male) (1) Min. 100 Kz
tance
consolidating box)
Short circuit in wiring harness 2. Disconnect connectors CE03 and TEMP1, and connect T-adapter to
(including wiring harness in female side of CE03.
6
KDPF temperature sensor a Check by using multimeter in continuity mode.
consolidating box) Between CE03 (female) (45) and No continuity (no sound
Continuity
40-354 PC210LC-10
40 Troubleshooting

3. Disconnect connectors TEMP1, TEMP2, and TEMP3, and connect
T-adapter to male side of TEMP1.
(2)

7 sensor consolidating box this check is not required. Max. 10 z
Resis- (1)
tance
than pin (3)
Open circuit in wiring 2. Disconnect connectors CE03 and E26, and connect T-adapter to
harness each female side.
8
(wire breakage or defective Between CE03 (female) (45) and E26
contact of connector) Max. 10 z
Resis- (female) (3)

9 harness 2. Disconnect connectors CE03 and E26, and connect T-adapter to
(contact with ground circuit) either female side.
Min. 100 Kz
Continu- Between CE03 (female) (45) and No continuity (no sound is
ity each pin other than pin (45) heard)
Open or short circuit in wiring
2. Disconnect connector CE03, and connect T-adapter to female side.
harness
Between CE03 (female) (45) and (19)
KDPF temperature sensor Resis- a Use Temperature-Resistance 64 z to 65 kz
consolidating box) tance characteristics shown below as resistance
criteria.
PC210LC-10 40-355
40 Troubleshooting

a When failure codes [CA3314] and [CA3313] are displayed in check
on cause 3 and no failure is found by checks on causes 2 and 4 to 10,
and if failure is found by check on cause 11, KDOC inlet temperature
• Reference
Defective KDOC inlet -10°C 33 to 65 kz
12 temperature sensor
0°C 25 to 47 kz
Between TEMP1 (female) (1) and 7.8 to 12.2
50°C
Resis- (2) kz
tance 3.2 to 4.5
a Temperature-Resistance 100°C
kz
characteristics 200 to 240
400°C
z
700°C 64 to 69 z
setting.
command.
40-356 PC210LC-10
40 Troubleshooting
Failure code [CA3316] KDOC Outlet Temp Sens Low Error (PC200LC_10-CA3316-400-A-
Z0-A)
Action level Failure code KDOC Outlet Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in KDOC outlet temperature sensor circuit.
failure
• Uses KDOC inlet temperature for KDOC outlet temperature to run engine.
(If failure is detected in KDOC inlet temperature sensor, too, controller takes it that KDOC
Action of outlet temperature is at default value (250°C) and allows engine to run.)
machine
injury.
Related
information
connector
PC210LC-10 40-357
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).
If this failure code changes to [CA3317] , KDOC outlet temperature
• Reference
Defective KDOC outlet 1. Turn starting switch to OFF position.
2 temperature sensor 2. Disconnect connector TEMP2 and connect T-adapter to female
side.
-10°C 33 to 65 kz
Between TEMP2 (female) (1) 0°C 25 to 47 kz
and (2) 50°C 7.8 to 12.2 kz
Resis-
tance
700°C 64 to 69 z
(contact with ground circuit) 2. Disconnect connectors CE03 and TEMP2, and connect T-adapter
3 (including wiring harness in to female side of CE03 or male side of TEMP2.
Min. 100 Kz
consolidating box) tance TEMP2 (male) (1)
2. Disconnect connectors CE03 and TEMP2, and connect T-adapter
heard)
required.
5 sensor consolidating box this check is not required. Min. 100 Kz
Resis-
than pin (1)
Min. 100 Kz
40-358 PC210LC-10
40 Troubleshooting

No continuity
heard)
If this failure code appears, perform procedure for <How to clear
8
PC210LC-10 40-359
40 Troubleshooting
Failure code [CA3317] KDOC Outlet Temp Sens High Error (PC200LC_10-CA3317-400-
A-Z0-A)
Action level Failure code KDOC Outlet Temperature Sensor High Error
Failure
Detail of • High voltage appears in KDOC outlet temperature sensor circuit.
failure
machine
injury.
connector
40-360 PC210LC-10
40 Troubleshooting

2. Disconnect KDOC outlet temperature sensor (connector TEMP2)
and connect T-adapter to female side.
with jumper cable.
If this failure code changes to [CA3316], KDOC outlet temperature
Defective KDOC outlet a If this failure code remains displayed, wiring harness or engine
• Reference
side.
-10°C 33 to 65 kz
Between TEMP2 (female) (1) and 0°C 25 to 47 kz
Resis- (2) 50°C 7.8 to 12.2 kz
700°C 64 to 69 z
harness 2. Disconnect connector CE03, and connect T-adapter to female side.
a Use above Temperature-Resistance 64 z to 65 kz
consolidating box) tance
(wire breakage or defective 2. Disconnect connectors CE03 and TEMP2, and connect T-adapters
contact of connector) to female side of CE03 and male side of TEMP2.
4
(including wiring harness in Between CE03 (female) (48) and TEMP2
KDPF temperature sensor Max. 10 z
Resis- (male) (1)
consolidating box) tance Between CE03 (female) (19) and TEMP2

2. Disconnect connectors CE03 and TEMP2, and connect T-adapter to
Short circuit in wiring harness female side of CE03.
other than pin (48)
heard)
PC210LC-10 40-361
40 Troubleshooting

required.
a If no failure is found by check on cause
3 or 4, this check is not required. Max. 10 z
Defective KDPF temperature Between E26 (male) (2) and TEMP2 (male)
6 sensor consolidating box (2)
Resis- 3 or 4, this check is not required. Max. 10 z
(1)
5, this check is not required. Min. 100 Kz
than pin (1)
required.
Max. 10 z
Resis- (female) (1)

No continuity
other than pin (48)
heard)
9
40-362 PC210LC-10
40 Troubleshooting
PC210LC-10 40-363
40 Troubleshooting
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error (PC200LC_10-
CA3318-400-A-Z0-A)
Action level Failure code KDOC Outlet Temperature Sensor In Range Error.
Failure
• Difference between temperature sensed by KDOC outlet temperature sensor and that by
Detail of KDOC inlet temperature sensor differs from expected value.
machine
injury.
of KDPF".
O
operation for
4680" is used.
Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform
connector
needed.
40-364 PC210LC-10
40 Troubleshooting

2. Disconnect TEMP2 (KDOC outlet temperature sensor).

3 engine controller 2. Disconnect connector TEMP2 and connect T-adapter to male side.
with jumper cable.
female side of CE03 and male side of TEMP2.
Resis- (male) (1)
(male) (2)
5
Resis- Between ground and CE03 (female) (48) or Min. 100
KDPF temperature sensor TEMP2 (male) (1)
tance Kz
consolidating box)
6
Continuity
Between E26 (male) (2) and TEMP2 (male) (2)

7 this check is not required. Max. 10 z
sensor consolidating box
Between E26 (male) (1) and TEMP2 (male) (1)
Resis-
tance a If no failure is found by check on cause 5, Min. 100
this check is not required. Kz
this check is not required. Min. 100
Between E26 (male) (1) and each pin other Kz
than pin (1)
PC210LC-10 40-365
40 Troubleshooting

contact of connector) Between CE03 (female) (48) and E26 (female)
Max. 10 z
Resis- (1)
tance Between CE03 (female) (19) and E26 (female)
(2) Max. 10 z

Resis- Between ground and CE03 (female) (48) or Min. 100
tance E26 (female) (1) Kz
Continuity
harness
KDPF temperature sensor Resis- a Use Temperature-Resistance 64 z to 65
consolidating box) tance characteristics shown below as resistance kz
criteria.
and if failure is found by check on cause 11, KDOC outlet
temperature sensor is defective.
• Reference
Defective KDOC outlet -10°C 33 to 65 kz
0°C 25 to 47 kz
50°C
Resis- (2) kz
tance 3.2 to 4.5
kz
400°C
z
700°C 64 to 69 z
40-366 PC210LC-10
40 Troubleshooting

setting.
command.
PC210LC-10 40-367
40 Troubleshooting
Failure code [CA3319] KDPF Outlet Temp Sens High Error (PC200LC_10-CA3319-400-A-
Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
Detail of • High voltage appears in KDPF outlet temperature sensor circuit.
failure
• Uses KDOC outlet temperature for KDPF outlet temperature to run engine.
(If failure is detected in KDOC outlet temperature sensor, controller takes it that KDPF
machine
injury.
connector
40-368 PC210LC-10
40 Troubleshooting

2. Disconnect KDPF outlet temperature sensor (connector TEMP3)
and connect T-adapter to female side.
with jumper cable.
If this failure code changes to [CA3321], KDPF outlet temperature
Defective KDPF outlet a If this failure code remains displayed, wiring harness or engine
• Reference
side.
-10°C 33 to 65 kz
Resis- (2) 50°C 7.8 to 12.2 kz
700°C 64 to 69 z
harness 2. Disconnect connector CE03, and connect T-adapter to female side.
a Use above Temperature-Resistance 64 z to 65 kz
(wire breakage or defective 2. Disconnect connectors CE03 and TEMP3, and connect T-adapters
contact of connector) to female side of CE03 and male side of TEMP3.
4
(including wiring harness in Between CE03 (female) (54) and TEMP3
KDPF temperature sensor Max. 10 z
Resis- (male) (1)
consolidating box) tance Between CE03 (female) (19) and TEMP3

other than pin (54)
heard)
PC210LC-10 40-369
40 Troubleshooting

required.
or 4, this check is not required. Max. 10 z
Defective KDPF temperature Between E26 (male) (2) and TEMP3 (male)
6 sensor consolidating box (2)
Resis- or 4, this check is not required. Max. 10 z
(1)
than pin (4)
required.
Max. 10 z
Resis- (female) (4)

No continuity
other than pin (54)
heard)
9
40-370 PC210LC-10
40 Troubleshooting
PC210LC-10 40-371
40 Troubleshooting
Failure code [CA3321] KDPF Outlet Temp Sens Low Error (PC200LC_10-CA3321-400-A-
Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
Detail of • Low voltage appears in KDPF outlet temperature sensor circuit.
failure
machine
injury.
connector
40-372 PC210LC-10
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).
If this failure code changes to [CA3319], KDPF outlet temperature
• Reference
Defective KDPF outlet 2. Disconnect connector TEMP3 and connect T-adapter to female
2 temperature sensor side.
-10°C 33 to 65 kz
0°C 25 to 47 kz
50°C
(2) kz
Resis- 3.2 to 4.5
tance kz
400°C
z
700°C 64 to 69 z
Between TEMP3 (female) (1) and ground Min. 1 Mz
(contact with ground circuit) 2. Disconnect connectors CE03 and TEMP3, and connect T-adapters
3 (including wiring harness in to female side of CE03 and male side of TEMP3.
TEMP3 (male) (1) Min. 1 Mz
(including wiring harness in a Check by using multimeter in continuity mode.
4
KDPF temperature sensor No
consolidating box) Between CE03 (female) (54) and each pin continuity
Continuity
is heard)
required.
5 sensor consolidating box this check is not required. Min. 1 Mz
Resis-
this check is not required. Min. 1 Mz
than pin (4)
E26 (female) (4) Min. 1 Mz
tance
PC210LC-10 40-373
40 Troubleshooting

No
Between CE03 (female) (54) and each pin continuity
Continuity
is heard)
8
40-374 PC210LC-10
40 Troubleshooting
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error (PC200LC_10-
CA3322-400-A-Z0-A)
Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
Detail of • Temperature sensed by KDPF outlet temperature sensor differs from expected value.
machine
injury.
of KDPF".
O
operation for
4680" is used.
Defective KDPF outlet If failure code [CA3313] or [CA3314] is displayed, perform
Defective wiring harness
2 equipment" in "Checks before troubleshooting" of "General
connector
PC210LC-10 40-375
40 Troubleshooting

2. Disconnect TEMP3 (KDPF outlet temperature sensor).

3 engine controller 2. Disconnect TEMP3 and connect T-adapter to female side.
with jumper cable.
2. Disconnect connectors CE03 and TEMP3, and connect T-adapters
to female side of CE03 and male side of TEMP3.
Resis- (male) (1)
(male) (2)
5
KDPF temperature sensor TEMP3 (male) (1) Min. 100 Kz
tance
consolidating box)
6
Continuity
(2)

7 sensor consolidating box this check is not required. Max. 10 z
Resis- (1)
tance
than pin (4)
40-376 PC210LC-10
40 Troubleshooting

Max. 10 z
Resis- (female) (4)

E26 (female) (4) Min. 100 Kz
tance
Continuity
harness
KDPF temperature sensor Resis- a Use Temperature-Resistance
64 z to 65 kz
consolidating box) tance characteristics shown below as
resistance criteria.
if failure is found by check on cause 11, KDOC inlet temperature
• Reference
Defective KDPF outlet 2. Disconnect connector TEMP3 and connect T-adapter to female side.
-10°C 33 to 65 kz
Resis- (2) 50°C 7.8 to 12.2 kz
700°C 64 to 69 z
PC210LC-10 40-377
40 Troubleshooting

setting.
command.
40-378 PC210LC-10
40 Troubleshooting
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error (PC200LC_10-
CA3419-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage High Error
Failure
Detail of • High voltage appears in power supply (12 V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures that are similar to those for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
information
Defective mass air flow 3. Turn starting switch to ON position.
2 sensor If this failure code does not appear, MAF sensor is defective.
(internal defect)
3 Defective wiring harness If this failure code does not appear, wiring harness is defective.
4 Defective engine controller Approx. 12
Voltage Between ECM J1 (male) (21) and (22)
V
PC210LC-10 40-379
40 Troubleshooting
40-380 PC210LC-10
40 Troubleshooting
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error (PC200LC_10-
CA3421-400-A-Z0-A)
Action level Failure code Mass Air Flow Sensor Supply Voltage Low Error
Failure
Detail of • Low voltage appears in power supply (12V) circuit of mass air flow sensor.
failure
a If signal voltage of mass air flow sensor becomes abnormal, controller takes following
measures that are similar to those for failure codes [CA356] and [CA357].
Action of • Takes it that mass air flow is at fixed value (10 kg/min) and allows engine to run.
machine
information
Defective mass air flow 3. Turn starting switch to ON position.
2 sensor If this failure code does not appear, MAF sensor is defective.
(internal defect)
Defective wiring harness or
3 If this failure code does not appear, wiring harness is defective.
connector
Ground fault in wiring harness 2. Disconnect connectors ECM J1 and P55, and connect T-adapters to
P55 (female) (2) Min. 1 Mz
tance
Resis- Between ECM J1 (female) (21) and (22) or
between P55 (female) (2) and (3) Min. 1 Mz
tance
6 Defective engine controller Approx. 12
Voltage Between ECM J1 (male) (21) and (22)
V
PC210LC-10 40-381
40 Troubleshooting
40-382 PC210LC-10
40 Troubleshooting
Failure code [CA3741] Rail Press Valve Trip Error (D65-CA3741-400-A-Z0-A)
Action
Failure code Common rail pressure limiter valve is open.
level Failure
L03 CA3741
Failure • Engine controller determines that common rail pressure limiter valve opens.
Action of • Lowers set value of common rail pressure.
controller
Problem on • Engine output lowers. Engine may not start again.
machine
function.
(Code: 36401 (V))
Related • Pressure sensed by common rail pressure sensor can be checked with monitoring
(Code: 36400 (MPa))
Common rail pressure limiter
1 Perform troubleshooting for failure code [CA449].
valve is open.
PC210LC-10 40-383
40 Troubleshooting
Failure code [D110KB] Battery Relay Output Voltage (PC220_10-D110KB-400-A-01-A)
Action Short circuit in battery relay output circuit

Failure code
level Failure
(Pump controller system)
L01 D110KB
Details of • Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
failure
• Stops 24 V output to battery relay primary circuit (coil side).
Problem on • Writing data into ROM (non-volatile memory) of each controller may fail.
machine
• As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
be measured at pump controller connector.
Related • Output state (ON/OFF) to battery relay can be checked with monitoring function.
information (Code: 03700 Controller output 1)
• Method of reproducing failure code: For 0.5 seconds after turning starting switch from ON
to OFF position.
Defective battery 1. Turn starting switch to OFF position.
relay
1
(internal open Continuity Between terminal RE and terminal BR Continuity
circuit)
2. Disconnect negative battery cable (in order to prevent short circuit).
3. Disconnect terminals R01 and R02, and connectors D01, H15 and CP02.
Ground fault in
Between terminal R02 (BR) and ground Min. 1 Mz
wiring harness
2 (contact with GND Between ground and terminal R02
circuit) (harness side), D01 (female) (1), or D01 Min. 1 Mz
Resistance (female) (2)
Between ground and CP02 (female)
(108) or between D01 (female) (5) Min. 1 Mz
If no failure is found by above checks, pump controller is defective.
• Reference
Pump controller 2. Insert T-adapters into connector D01.
defective.
4. Measure voltage during 4 to 7 seconds after turning starting switch from ON to
OFF position.
Voltage Between D01 (5) and ground 20 to 30 V
40-384 PC210LC-10
40 Troubleshooting
Circuit diagram related to battery relay
PC210LC-10 40-385
40 Troubleshooting
Failure code [D19JKZ] Personal Code Relay Abnormality (PC200LC_10-D19JKZ-400-A-

Z0-A)
Action level Failure code Personal Code Relay Abnormality

Failure
L03 D19JKZ (Machine monitor system)
Detail of • Disconnection or short circuit was detected in primary coil side of personal code relay
failure circuit.
• None in particular (when open circuit is detected).
• Shuts of power supply to personal code relay (when short circuit is detected).
Action of • If cause of failure disappears, machine becomes normal by itself (when open circuit is
machine detected).
monitor • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position (when short circuit is detected).
Problem on
machine
• This failure code is displayed only when engine lock function is enabled.
• Method of reproducing failure code: Turn starting switch ON (Disconnection). Trouble
Related cannot be reproduced on machine (Short circuit).
information • Troubleshooting for this failure code covers circuit starting from No. 3 fuse of fuse box
F01, through primary (coil) circuit of personal code relay R07, to machine monitor.
Defective No. 3 of fuse F01
1 If fuse is blown, circuit probably has ground fault.
(3rd from right top)
2. Disconnect relay R07, and connect T-adapters to male side.
200 to 600 z
tance
Defective personal code relay
2 1. Turn starting switch to OFF position.
R07
2. Replace relay R07 with preheater relay R18.
If this failure code disappears, original personal code relay R07 is
defective.
2. Remove fuse No. 3 of fuse box F01 (3rd fuse from the right top).
3. Disconnect connectors CM01 and S14, and connect T-adapter to
Open circuit or short circuit or
3 female side of CM01.
ground fault in wiring harness
Between F01-3 and CM01 (female) (6) 200 to 600 z
Resis-
Between F01-3 or CM01 (female) (6) and
tance Min. 1 Mz
ground
4 Open circuit in wiring harness 3. Disconnect connector CM01 and relay R07, and connect T-adapters
to each female side.
Between F01-3 and R07 (female) (1) Max. 1 z
Resis-
Between R07 (female) (2) and CM01
tance Max. 1 z
(female) (6)
3. Disconnect connector CM01 and relay R07, and connect T-adapters
5 Ground fault in wiring harness to either female side.
Between F01-3 or R07 (female) (1) and
Min. 1 Mz
Resis- ground
tance Between R07 (female) (2) and ground, or
between CM01 (female) (6) and ground Min. 1 Mz
40-386 PC210LC-10
40 Troubleshooting

3. Disconnect connectors CM01 and relay R07, and connect T-adapter
to female side of connector CM01.
No continuity
Between CM01 (female) (6) and each pin
other than pin (6)
heard)
If no failure is found by above checks, machine monitor (KOMTRAX
Defective machine monitor
7 portion) is defective. (Since this is an internal defect, troubleshooting
(KOMTRAX section)
cannot be performed.)
PC210LC-10 40-387
40 Troubleshooting
Circuit diagram related to personal code relay
40-388 PC210LC-10
40 Troubleshooting
Failure code [D811MC] KOMTRAX Error (PC220_10-D811MC-400-A-00-A)
Action KOMTRAX malfunctions.

Failure code
level Failure
— (KOMTRAX system)
D811MC
Details of
• Malfunction of KOMTRAX
failure
Action of
controller
Problem on • KOMTRAX system does not work properly.
machine
information
Malfunction of Defective KOMTRAX (Since this is an internal defect, troubleshooting cannot be
1 performed.)
KOMTRAX
PC210LC-10 40-389
40 Troubleshooting
Failure code [D862KA] GPS Antenna Open Circuit (PC200-D862KA-400-A-00-A)
Action GPS Antenna Open Circuit

Failure code
level Failure
－ (KOMTRAX system in machine monitor)
D862KA
Details of • Open circuit is in GPS antenna circuit.
failure
Problem on • GPS positioning cannot work.
machine
information
Defective GPS Probable causes are defective GPS antenna, open circuit or short circuit in
1 antenna or antenna antenna cable, and defective connection of antenna cable connector (GPS).
cable
Figure of structure
40-390 PC210LC-10
40 Troubleshooting
Failure code [D8ALKA] System Operating Lamp Disconnection

(KOMTRAX) (PC300-D8ALKA-400-A-Z0-A)
Action level Failure code Open circuit in system operating lamp
Failure
— D8ALKA (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at about 5 V or below for about 3 seconds after starting switch is
failure turned to ON position, during which KOMTRAX outputs no current to system operating
lamp.
controller
• While system operating lamp lights up, battery disconnect switch must not be turned to
Problem on OFF position. Turning battery disconnect switch to OFF position may destroy data stored
machine in KOMTRAX memory.
• Although KOMTRAX is not able to light system operating lamp, no trouble will result
unless battery disconnect switch is turned to OFF position.
Related • As long as system operating lamp is lit, output circuit voltage remains at Low level.
information • No controllers output current to system operating lamp for about 3 seconds after starting
switch is turned to ON position. This allows KOMTRAX to detect open circuit in system
operating lamp circuit.
Defective fuse No. 16 in fuse a If room lamp lights up, this check is not required.
1
box F01 When fuse is blown, circuit may have ground fault.
Open circuit in wiring harness 2. Remove fuse No. 16 of fuse box F01.
2 (wire breakage or defective 3. Disconnect connector CK01 and connect T-adapters to female side.
contact of connector) Resis- Between CK01 (15) and fuse F01 -16
Max. 1 z
tance
2. Remove fuse No. 16 of fuse box F01.
Ground fault in wiring harness 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19.
3 (contact with ground circuit) Connect T-adapters to female side of connector CK01.
Resis- Between CK01 (female) (15) and ground
Min. 1 Mz
tance
If no failure is found by above checks, KOMTRAX terminal is defective.
4 KOMTRAX terminal defective
PC210LC-10 40-391
40 Troubleshooting
Circuit diagram related to system operating lamp
40-392 PC210LC-10
40 Troubleshooting
Failure code [D8ALKB] System Operating Lamp Short Circuit

(KOMTRAX) (PC300-D8ALKB-400-A-Z0-A)
Action level Failure code Short circuit in system operating lamp
Failure
— D8ALKB (KOMTRAX system)
• KOMTRAX determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while KOMTRAX outputs current to system
failure operating lamp.
controller
machine in KOMTRAX memory.
Related • Although KOMTRAX is not able to light system operating lamp, no trouble will result
information unless battery disconnect switch is turned to OFF position.
• As long as system operating lamp is lit, output circuit voltage remains at Low level.

1 Short circuit in wiring harness 3. Disconnect connectors CM01, CP02, CK01, CE03, and L19.
Connect T-adapters to female side of connector L19.
Resis- Between L19 (female) (1) and (2)
Min. 1 Mz
tance
If no failure is found by above checks, KOMTRAX terminal is defective.
2 Defective KOMTRAX terminal
PC210LC-10 40-393
40 Troubleshooting
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) (PC220_10-D8AQKR-400-A-00-A)
Action CAN communication-2 line of KOMTRAX terminal is

Failure code
level Failuredisabled
- D8AQKR (Detected by machine monitor) (Machine monitor system)
Details of • Machine monitor does not recognize KOMTRAX terminal through CAN communication-2
failure line (KOMNET/c).
Action of
controller
Problem on
machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Machine monitor uses five different failure codes, [DA2QKR], [DB2QKR], [D8AQKR],
[DAZQKR] and [DAFQKR], to indicate CAN communication failure through CAN 2 line.
When all of these five failure codes are displayed, ground fault, short circuit or hot short
circuit in wiring harness (CAN communication line). Since air conditioner is also operated
Related through CAN communication, you must, in such case, check from air conditioner screen
information whether air conditioner is operable (ON/OFF and air flow of air conditioner).
a Even when this failure code is displayed on monitor screen, air conditioner may remain
operable. If air conditioner is operable, there is no possibility of ground fault, short circuit
or hot short circuit in wiring harness (CAN communication line)
• Since power to each controller and machine monitor is supplied directly from battery, they
receive power even while starting switch is at OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
Defective power Perform troubleshooting for "E-59" of E-mode.
1 supply to
KOMTRAX terminal
Defective CAN Perform checks on causes 4 to 9 of troubleshooting for [DB2QKR].
2 communication 2
line
Defective If no failure is detected by above checks, KOMTRAX terminal is defective.
3
KOMTRAX terminal (Since this is an internal defect, troubleshooting cannot be performed.)
40-394 PC210LC-10
40 Troubleshooting
Failure code [DA20MC] Pump Controller (PC220_10-DA20MC-400-A-00-A)
Action Malfunction of pump controller

Failure code
level Failure
- (Pump controller system)
DA20MC
Details of • Malfunction of pump controller
failure
Action of
controller
Problem on • Pump controller does not operate normally
machine
information
Malfunction of If machine operates normally, replacement is not necessary.
1 pump controller
PC210LC-10 40-395
40 Troubleshooting
Failure code [DA22KK] Pump Solenoid Power Low Error (PC200-DA22KK-400-A-00-A)
Action Pump solenoid power supply voltage low error

Failure code
level Failure
L03 DA22KK
Details of • Solenoid power supply voltage of controller is below 20 V.
failure
• Stops generation of failure codes (open circuit and short circuit) for all solenoid systems
Action of while this failure code is active.
Problem on • No solenoid valve is energized properly, so machine does not work properly.
machine
Related be measured at pump controller connector.
information • If failure code [D110KB] is displayed, perform troubleshooting for it first.
Defective fusible If fusible link or fuse is blown, circuit probably has ground fault. (See Cause 5.)
1 link F04 or fuse No.
2 of fuse box F01
Dropped battery
2 2. After measuring voltage, measure it again when starting engine.
voltage
Voltage Between battery (+) and ground 20 to 30 V
1. Turn starting switch to OFF position and disconnect ground cable.
2. Disconnect connector CP02 and connect T-adapters to female side.
Defective wiring 3. Connect ground cable and turn starting switch to ON position.
3
harness
Between ground and each of CP02
Voltage 20 to 30 V
(116), (118) and (121)
Open circuit in 2. Remove fusible link F04 and fuse (2) in fuse box F01.
wiring harness 3. Disconnect connector CP02 and connect T-adapters to female side.
4 (wire breakage or Between F01-2 and each of CP02
defective contact of (female) (116), (118) and (121) Max. 1 z
connector)
Resistance Between F01-1A and F04 (male) (2) Max. 1 z
Between F04 (male) (1) and terminal
Max. 1 z
R03
2. Remove fusible link F04 and fuse (2) in fuse box F01.
Ground fault in 3. Disconnect connector CP02 and connect T-adapters to female side.
wiring harness
5 Between ground and each of CP02
(contact with GND (female) (116), (118) and (121), or F01-2 Min. 1 Mz
circuit)
Between ground and F01-1A or F04
Resistance Min. 1 Mz
(male) (2)
Between ground and F04 (male) (1) or
Min. 1 Mz
terminal R03
Defective pump If no falure is found by above checks, pump controller is defective. (Since this is an
6 internal defect, troubleshooting cannot be performed.)
controller.
40-396 PC210LC-10
40 Troubleshooting
Circuit diagram related to solenoid power supply
PC210LC-10 40-397
40 Troubleshooting
Failure code [DA25KP] 5V Sensor 1 Power Abnormality (PC200LC_10-DA25KP-400-A-Z0-A)
Action level Failure code 5V Sensor 1 Power Abnormality.

Failure
– DA25KP (Pump controller system)
Detail of • Voltage of 5V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
failure
• Stops output of power from 5V sensor power supply output 1.
• Signals of pressure sensors and jet sensor (differential pressure sensor) are not input
normally.
• Error codes for failures in pressure sensors and jet sensor (differential pressure sensor)
Problem on are also displayed.
machine • Travel and work equipment speeds are slow.
• Automatic travel speed selector function does not work (pump pressure sensor system).
• Auto-decelerator function remains activated or fine control performance of work
equipment is poor.
information
2. Disconnect following sensors one by one, and turn starting switch to
ON position for each troubleshooting.
a If this failure code disappears, disconnected sensor is defective.
a Since connector is disconnected, other failure codes appear.
Ignore all displayed failure codes other than this.
3. After each troubleshooting, turn starting switch to OFF position.
Sensor Connector
Bucket CURL pressure sensor P01
Boom LOWER pressure sensor P02
Swing (L) pressure sensor P03
Defective pressure sensor Arm IN pressure sensor P04
1 Bucket DUMP pressure sensor P05
Boom RAISE pressure sensor P06
Swing (R) pressure sensor P07
Arm OUT pressure sensor P08
L.H. travel FORWARD pressure sensor P09
L.H. travel REVERSE pressure sensor P10
R.H. travel FORWARD pressure sensor P11
RH. travel REVERSE pressure sensor P12
F pump pressure sensor P25
R pump pressure sensor P26
F pump swash plate sensor P27
R pump swash plate sensor P28
Service pressure sensor (dummy) P49
a To measure voltage before controller stops output of power.
Hot short circuit in wiring
harness 2. Disconnect connectors P01 to P12, P25 to P28, and P49.
2 3. Connect T-adapters to female side of connector P01.
(contact with 24 V circuit) 4. Turn starting switch to ON position (with connector disconnected).
Voltage Between P01 (female) (3) and ground 4.5 to 5.5
V
40-398 PC210LC-10
40 Troubleshooting

Ground fault in wiring harness 2. Disconnect connectors CP01, P01 to P12, and P49.
3 (contact with ground circuit) 3. Connect T-adapter to female side of connector CP01.
Resis- Between CP01 (female) (6) and ground
Min. 1 Mz
tance
4 Defective pump controller
PC210LC-10 40-399
40 Troubleshooting
Circuit diagram related to 5 V sensor power supply 1 circuit
40-400 PC210LC-10
40 Troubleshooting
Failure code [DA29KQ] Model Selection Abnormality (PC200LC_10-DA29KQ-400-A-Z0-A)
Action level Failure code Model selection abnormality

Failure
L01 DA29KQ (Pump controller system)
Detail of • Model code signal for model which is not registered in controller is input.
failure
• Controls machine taking it that machine is default model (PC200 standard specification
Action of machine).
controller • Even if cause of failure disappears, machine does not become normal until starting switch
is turned to OFF position.
Problem on • No problem appears if machine is PC200 standard specification machine.
machine • Overheat may occur on Colorado specification machine.
• Pat number of pump controller assembly can be checked with monitoring function.
(Code: 20229 Assembly part number (pump controller))
• Signal status (ON/OFF) of model selection signal can be checked by using monitoring
function.
(Code: 02201 Switch Input 2)
a PC210LC-10
Related
information Model select 1: OFF
Model select 2: ON
Model select 3: ON
Model select 4: OFF
Model select 1: ON
Pump controller with wrong 1. Use monitoring function to display assembly part number and check
1 part number whether it is identical to that listed in Parts book.
2. Disconnect connector S30 and connect T-adapters to female side.
Between S30 (female) (1) and (2) Min. 1 Mz
Defective model selection Between S30 (female) (1) and (8) Min. 1 Mz
2 connector (internal open Between S30 (female) (3) and (4) Min. 1 Mz
circuit or short circuit) Resis- Between S30 (female) (4) and (7)
Min. 1 Mz
tance
Between S30 (female) (2) and (3) Max. 1 z
Open circuit in wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
3 (wire breakage or defective Between CP01 (female) (21) and ground Max. 1 z
contact of connector) Resis- Between CP01 (female) (40) and ground
Max. 1 z
tance
Between CP01 (female) (58) and ground Max. 1 z
PC210LC-10 40-401
40 Troubleshooting

2. Disconnect connectors CP01 and S30, and insert T-adapter into
4 Short circuit in wiring harness connector S30.
Resis- Between CP01 (female) (59) and (21) Min. 1 Mz
tance Between CP01 (female) (77) and (21) Min. 1 Mz
Ground fault in wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
5 (contact with ground circuit) Resis- Between CP01 (female) (59) and ground Min. 1 Mz
tance Between CP01 (female) (77) and ground Min. 1 Mz
Circuit diagram related to model selection (PC210LC–10)
40-402 PC210LC-10
40 Troubleshooting
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump

Con) (PC300-DA2LKA-400-A-Z0-A)
Failure
— DA2LKA (Pump controller system)
• Pump controller determines that system operating lamp circuit is open because voltage of
Detail of output circuit remains at about 5 V or below for about 3 seconds after starting switch is
failure turned to ON position, during which pump controller outputs no current to system
operating lamp.
controller
machine in pump controller memory.
• Although pump controller is not able to light system operating lamp, no trouble will result
switch is turned to ON position. This allows pump controller to detect open circuit in
system operating lamp circuit.
1
box F01 When fuse is blown, circuit probably has ground fault.
Open circuit in wiring harness 2. Remove fuse No. 16 of fuse box F01.
2 (wire breakage or defective 3. Disconnect connector CM01 and connect T-adapters to female side.
contact of connector) Resis- Between CP02 (female) (100) and F01-16
Max. 1 z
tance
3 (contact with ground circuit) Connect T-adapters to female side of connector CP02.
Resis- Between CP02 (female) (100) and ground
Min. 1 Mz
tance
PC210LC-10 40-403
40 Troubleshooting
40-404 PC210LC-10
40 Troubleshooting
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump

Con) (PC300-DA2LKB-400-A-Z0-A)
Failure
— DA2LKB (Pump controller system)
• Pump controller determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while pump controller outputs current to system
failure operating lamp.
controller
machine in pump controller memory.
Related • Although pump controller is not able to light system operating lamp, no trouble will result
Min. 1 Mz
tance
PC210LC-10 40-405
40 Troubleshooting
Failure code [DA2QKR] CAN2 Discon (Pump Con) (PC200LC_10-DA2QKR-400-A-Z0-A)
Action level Failure code CAN2 Disconnection (Pump Con)

Failure
L03 DA2QKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication 2 line
failure (KOMNET/c).
Action of
• Holds information at the time of occurrence of failure.
controller
• Information to be obtained from pump controller is not displayed or special function that
Problem on uses information from pump controller does not work. Or received data (failure codes,
machine monitoring codes, etc. transmitted from pump controller) is no longer updated.
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is displayed, pump controller
may be defective.
• Machine monitor uses four failure codes, [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR], to indicated failure in CAN communication through CAN 2 line. When all of
these failure code are displayed simultaneously on screen, ground fault, short circuit, or
hot short circuit may occur in wiring harness (CAN communication line). Since air
conditioner is also controlled through CAN communication, check whether air conditioner
is operated (ON/OFF and air flow adjustment) on air conditioner screen.
Related • This code appears even when pump controller power supply is shut off.
information
a If ID controller is not installed, failure code [F7FQKR] is not generated. Therefore, failures
in CAN communication through communication 2 line are indicated with failure codes
[DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR].
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected to continuous power supply,
they receive continuous power even while starting switch is at OFF position.
using multimeter.
2. Disconnect fusible link F05 and connect T-adapters to female side.
1 Defective fusible link F05 Resis- Between F05 (female) (1) and (2)
Max. 1 z
tance
a If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in fuse
2 2. Remove fuse No. 17 in fuse box F01.
box F01
When fuse is blown, circuit may have ground fault.
a Check ground terminal T04 for looseness and rust.
Improper power supply to 2. Disconnect connector CP01 and connect T-adapters to female side.
3 pump controller 3. Turn starting switch to ON position.
Voltage
40-406 PC210LC-10
40 Troubleshooting

1. Turn starting switch to OFF position, and set battery disconnect
switch to OFF position.
Open circuit in wiring harness 2. Remove fuse No. 17 in fuse box F01.
3. Disconnect fusible link F05 and connector CP01, and connect T-
4 (wire breakage or defective adapters to each female side.
Between terminal R04 and F05 (female) (1) Max. 1 z
Resis- Between F05 (female) (2) and F01-16D Max. 1 z
tance Between F01-17 and CP01 (female) (1) Max. 1 z
Between F01-17 and CP01 (female) (4) Max. 1 z
Defective CAN Perform checks on cause 4 to 9 in troubleshooting for failure code
5 [DB2QKR].
communication 2 line
7 Defective machine monitor
PC210LC-10 40-407
40 Troubleshooting
Circuit diagram related to pump controller power supply
40-408 PC210LC-10
40 Troubleshooting
Failure code [DA2RKR] CAN1 Discon (Pump Con) (PC200LC_10-DA2RKR-400-A-Z0-A)
Action level Failure code CAN1 Disconnection (Pump Con)

Failure
L03 DA2RKR (Detected by machine monitor) (Machine monitor system)
Detail of • Machine monitor does not recognize pump controller through CAN communication line 1
failure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Information to be obtained from pump controller is not displayed or special function that
uses information from pump controller does not work. Or received data is no longer
updated.
Problem on • Pump control is disabled.
machine • Hydraulic oil temperature gauge needle goes off on machine monitor screen.
• Wiper operation is disabled.
• Washer operation is disabled.
• Flow control of attachment hydraulic line is disabled.
switch is received.
• If any of failure codes [DY20KA], [DY20MA] or [DW43KA] is also displayed, pump
controller may be defective.
• Machine monitor indicates CAN communication failure with failure codes [DA2RKR] or
[DB2RKR]. If failure code [DB2RKR] is also displayed, wiring harness (CAN
Related communication line) may have ground circuit, short circuit, or hot short circuit.
information • Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is connector "B_RES". (Connector "B_RES" is not on CAN communication 1 line but
connected to it via connector "J2").
• Since each controller and machine monitor are connected to continuous power supply,
they receive continuous power even while starting switch is at OFF position.
using multimeter.
• This code appears even when pump controller power supply is shut off.
Defective pump controller Perform checks on causes 1 to 4 in troubleshooting for failure code
1 power supply system [DA2QKR].
Defective CAN Perform checks on causes 2 to 8 in troubleshooting for failure code
2 communication 1 system [DB2RKR].
PC210LC-10 40-409
40 Troubleshooting
Failure code [DAF0MB] Monitor ROM Abnormality (PC220_10-DAF0MB-400-A-00-A)
Action Monitor internal memory (ROM) error

Failure code
level Failure
― (Machine monitor system)
DAF0MB
Details of • Program of machine monitor is rewritten (program error).
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Defective machine Machine monitor is defective. (Since this is an internal defect, troubleshooting
1 cannot be performed.)
monitor
40-410 PC210LC-10
40 Troubleshooting
Failure code [DAF0MC] Monitor Error (PC220_10-DAF0MC-400-A-00-A)
Action Monitor malfunctions

Failure code
level Failure
― (Machine monitor system)
DAF0MC
Details of
• Machine monitor malfunctions.
failure
Action of
controller
Problem on • Indication of machine monitor is unreliable.
machine • Machine monitor is incapable of normally exchanging data with controllers.
information
Replacement of Machine monitor is defective. (Since this is an internal defect, troubleshooting
machine monitor
PC210LC-10 40-411
40 Troubleshooting
Failure code [DAF8KB] Camera Power Supply Short Circuit (PC200-DAF8KB-400-A-00-

A)
Action Short circuit in camera power supply
Failure code
level Failure
L03 DAF8KB
Details of • Output power supply voltage (rating: 8 V) from machine monitor to camera is below 6.0 V
failure or above 10 V.
• Stops output power supply voltage (rating: 8 V) to camera.
Problem on • Camera image is not displayed on monitor screen.
machine
information
Defective camera 1. Turn starting switch to OFF position.
2. Disconnect camera connector(s), and turn starting switch to ON position.
1 (internal open
Disconnect camera connectors and perform failure reproduction operation. If
circuit)
failure code disappears at this time, camera has an internal defect.
2. Disconnect connector CM04.
Defective machine 3. Connect T-adapters to male side of connector CM04.
2
monitor 4. Turn starting switch to ON position.
Voltage Between CM04 (male) (1) and ground 6 to 10 V
wiring harness 2. Disconnect connector CM04 and camera connector(s).
3 (contact with GND 3. Connect T-adapters to female side of connector CM04.
circuit) Resistance Between CM04 (female) (1) and ground Min. 1 Mz
2. Disconnect camera connector(s).
Hot short circuit in
3. Insert T-adapters into connector CM04.
wiring harness
(contact with 24 V
(Disconnect camera connector(s) and check that camera is not defective in
circuit)
advance.)
Voltage Between CM04 (1) and (7) Max. 10 V
40-412 PC210LC-10
40 Troubleshooting
Circuit diagram related to camera power supply
PC210LC-10 40-413
40 Troubleshooting
Failure code [DAF9KQ] Model Selection Abnormality (PC200LC_10-DAF9KQ-400-A-Z0-A)
Action level Failure code Model selection abnormality

Failure
L03 DAF9KQ (Machine monitor system)
Detail of • Model registered in the machine monitor and pump controller differs.
failure (Machine monitor or pump controller has been replaced with a wrong part.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Condition of model selection signal can be checked by using monitoring function (Code:
02201 Switch Input 2)
a PC210LC–10
Model select 1 = OFF
Model select 2 = ON
Model select 3 = ON
Related Model select 4 = OFF
information Model select 5 = ON
• Assembly part No. of pump controller program can be checked by using monitoring
function (Code: 20229)
• Assembly part No. of machine monitor program can be checked by using monitoring
function (Code: 20227)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
1 Defective machine monitor Defective machine monitor
(a different model is registered)
1. Use monitoring function to display assembly part number and check
whether it is identical to that listed in Parts book.
Defective pump controller
40-414 PC210LC-10
40 Troubleshooting
Failure code [DAFGMC] GPS Module Error (PC200-DAFGMC-400-A-00-A)
Action GPS module malfunction

Failure code
level Failure
- (KOMTRAX system in machine monitor)
DAFGMC
Details of • Position data is not sent from GPS module (in machine monitor) to KOMTRAX
failure communication modem in 50 seconds after KOMTRAX started.
Problem on
machine
Related • Method of reproducing failure code: Turn starting switch to ON position (at least 50
information seconds after starting switch is turned to ON position).
Defective machine GPS module of machine monitor may be defective. (Since this is an internal
1 defect, troubleshooting cannot be performed.)
monitor
PC210LC-10 40-415
40 Troubleshooting
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) (PC300-DAFLKA-

400-A-Z0-A)

Failure
— DAFLKA (Machine monitor system)
• Machine monitor determines that system operating lamp circuit is open because voltage
Detail of of output circuit remains at about 5 V or below for about 3 seconds after starting switch is
failure turned to ON position, during which machine monitor outputs no current to system
operating lamp.
controller
machine in machine monitor memory.
• Although machine monitor is not able to light system operating lamp, no trouble will result
switch is turned to ON position. This allows machine monitor to detect open circuit in
system operating lamp circuit.
1
box F01 When fuse is blown, circuit may have ground fault.
Open circuit in wiring harness 2. Remove fuse No. 16 in fuse box F01.
2 (wire breakage or defective 3. Disconnect connector CM01 and connect T-adapters to female side.
contact of connector) Resis- Between CM01 (female) (8) and F01-16
Max. 1 z
tance
2. Remove fuse No. 16 in fuse box F01.
3 (contact with ground circuit) Connect T-adapters to female side of connector CM01.
Resis- Between CM01 (female) (8) and ground
Min. 1 Mz
tance
40-416 PC210LC-10
40 Troubleshooting
PC210LC-10 40-417
40 Troubleshooting
Failure code [DAFLKB] System Operating Lamp Short Circuit

(Monitor) (PC300-DAFLKB-400-A-Z0-A)
Failure
— DAFLKB (Machine monitor system)
• Machine monitor determines that system operating lamp circuit shorts because voltage of
Detail of output circuit does not become Low level while machine monitor outputs current to
failure system operating lamp.
controller
machine in machine monitor memory.
Related • Although machine monitor is not able to light system operating lamp, no trouble will result
2. Remove fuse No. 16 in fuse box F01.
Min. 1 Mz
tance
40-418 PC210LC-10
40 Troubleshooting
Failure code [DAFQKR] CAN2 Discon (Monitor) (PC220_10-DAFQKR-400-A-00-A)
Action CAN communication-2 line of machine monitor is disabled

Failure code
level Failure
— DAFQKR (KOMTRAX terminal detected it) (KOMTRAX system)
Details of • KOMTRAX terminal does not recognize machine monitor through CAN communication-2
failure line.
Action of
controller
Problem on • System sometimes does not work properly.
machine
switch is received.
• Since a failure code is displayed on machine monitor through CAN communication, this
Related failure code [DAFQKR] does not appear if CAN communication of machine monitor fails.
information Therefore, the code becomes recognizable over KOMTRAX system alone.
receive power even while starting switch is in OFF position.
using multimeter.
Defective power Perform troubleshooting for "E-3" of E-mode.
1 supply to machine
monitor
Defective CAN Perform check on cause 5 of troubleshooting for failure code [DB2QKR].
2
communication
PC210LC-10 40-419
40 Troubleshooting
Failure code [DAZ9KQ] A/C Model Selection Abnormality (PC200LC_10-DAZ9KQ-400-A-

Z0-A)
Action level Failure code Air Conditioner Model Selection Abnormality

Failure
– DAZ9KQ (Machine monitor system)
Detail of • Model registered in the machine monitor and air conditioner controller differs.
failure (Machine monitor or air conditioner controller has been replaced with a wrong part.)
Action of
controller
Problem on • Machine does not operate normally.
machine
• Condition of model selection signal can be checked by using monitoring function (Code:
02201 Switch Input 2)
a PC210LC–10
Model select 2 = ON
Model select 3 = ON
Related Model select 5 = ON
information • Model code registered in air conditioner controller can not be checked by using
• Model codes registered in machine monitor can be checked by using monitoring function.
(Code: 00500)
• Air conditioner control data (series and model) in the machine monitor can be checked by
using monitoring function. (Code: 55200)
• Air conditioner control data (series and model) in the air conditioner controller can be
checked by using monitoring function. (Code: 55201) (It is normal if control data is 01H
(which means PC).)
Defective machine monitor
Defective air conditioner Defective air conditioner controller
2
controller (a different model is registered)
40-420 PC210LC-10
40 Troubleshooting
Failure code [DAZQKR] CAN2 Discon (AC) (PC400-DAZQKR-400-A-Z0-A)
Action level Failure code Communication on CAN communication 2 line of air

Failureconditioner controller impossible
L01 DAZQKR
(Detected by machine monitor) (Machine monitor system)
Detail of • In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air
failure conditioner controller.
Action of
controller
• Function to collect information from engine controller does not work.
Problem on codes sent from engine controller)
machine • Air conditioner will be inoperable.
• Air conditioner control screen will not be displayed correctly on the machine monitor.
switch is received.
• When the machine monitor detects a CAN communication error in CAN2, failure code
[DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR] becomes active. If all four of these
failure code are displayed, there is a possibility of short circuit to ground, another circuit,
or positive side of battery in the harness (CAN communication line).
Related
information a If ID controller is not installed, failure code [F7FQKR] is not generated. Therefore, the
number of failure codes that may be generated is four; [DA2QKR], [DB2QKR], [D8AQKR],
and [DAZQKR].
• Since each controller and machine monitor are directly connected to continuous power
supply, they receive continuous power even while starting switch is at OFF position.
• Since active CAN communication line signal is pulse voltage, it cannot be measured by
using multimeter.
Defective power supply to air a Perform troubleshooting in Chapter 80 "Troubleshooting for power
1
conditioner controller supply system".
Defective CAN terminating 1. Turn starting switch to OFF position.

resis- 2. Disconnect connectors CM02 and K02, and connect T-adapters to
2 each male side.
tor (internal open or short
circuit) Resis- Between K02 (male) (A) and (B) 120 ± 12 z
tance Between CM02 (male) (7) and (9) 120 ± 12 z
PC210LC-10 40-421
40 Troubleshooting

• CAN communication line
a Machine monitor also has 120 z CAN terminating resistor in it. Since
120 z resistors are connected in parallel, if resistance measured at
connector of controller other than machine monitor is 60 z which is
combined resistance, there is no open circuit in wiring harness.
2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect CAN communication connectors of all controllers. Then,
check whether short circuit is in wiring harnesses or within controller.
3 Approx.
harness Between CM02 (female) (8) and (9)
120 z
Between CE03 (female) (17) and (18) Approx. 60
z
Between CP01 (female) (45) and (64) Approx. 60
z
Resis- Between AC01 (female) (1) and (2) Approx. 60
tance z
Between CK01 (female) (10) and (11) Approx. 60
z
*Between CC01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx.
120 z
40-422 PC210LC-10
40 Troubleshooting

• ACC signal from starting switch (CAN communication start is not
sensed)
2. Disconnect connector at which measurement is performed and
insert T-adapters into it.
3. Turn battery disconnect switch to ON position, and turn starting
switch to ON position.
Between CP01 (24), (43), (80) and (2) 20 to 30 V
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
*Between CC01 (2) and (7) 20 to 30 V
2. Disconnect related connectors and connect T-adapters to female
side of connector at which measurement is performed.
Between CM02 (female) (8) and CP01 (female)
Open circuit in wiring harness (45) Max. 1 z
4 (wire breakage or defective Between CM02 (female) (9) and CP01 (female)
contact of connector) (64) Max. 1 z
Between CM02 (female) (8) and CE03 (female)
(17) Max. 1 z
(18) Max. 1 z
Between CM02 (female) (8) and AC01 (female)
(1) Max. 1 z
Max. 1 z
Resis- (2)
tance Between CM02 (female) (8) and CK01 (female)
(10) Max. 1 z
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
Between CM02 (female) (8) and CC01 (female)
(3) Max. 1 z
(9) Max. 1 z
Between CE03 (female) (17) and K02 (female)
(A) Max. 1 z
(B) Max. 1 z
PC210LC-10 40-423
40 Troubleshooting

a If no failure is found by checks on cause 3 (no open circuit), measure
voltage at one connector.
Ground fault in wiring harness 2. Disconnect related connectors and connect T-adapters to female
5
(contact with ground circuit) side of connector at which measurement is performed.
Between CP01 (female) (45), CM02 (female)
Min. 1 Mz
Resis- (7), (8), or CE03 (female) (17) and ground
tance Between CP01 (female) (64), CM02 (female)
(9), or CE03 (female) (18) and ground Min. 1 Mz

insert T-adapters into connector.
3. Turn the battery disconnect switch to the ON position.
Short circuit or hot short 4. Turn starting switch to ON position.
circuit in wiring harness a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
6 (contact with 24 V during communication, harnesses are considered normal as long as
circuit) their voltages are between 1 and 4 V.
Between ground and any one of CM02 (female)
(8), CP01 (female) (45), CK01 (female) (10),
AC01 (female) (2), CC01 (female) (3), or CE03 1 to 4 V
(female) (17)
Voltage
(female) (18)
• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR] are displayed
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
Defective engine controller, switch to OFF position.
pump controller, air 2. Disconnect CAN communication connector of engine controller
7 conditioner unit, *ID (connector CE03), pump controller (connector CP01), air conditioner
controller, or KOMTRAX unit (connector AC01), *ID controller (connector CC01), and
terminal KOMTRAX terminal (connector CK01) one by one.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. and troubleshoot next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
If no abnormality is found by above diagnosis, air conditioner controller
Defective air conditioner is defective.
8
controller
*The ID controller is an optional device.
40-424 PC210LC-10
40 Troubleshooting
Circuit diagram related to CAN communication 2
PC210LC-10 40-425
40 Troubleshooting
Failure code [DB2QKR] CAN2 Discon (Engine Con) (PC400-DB2QKR-400-A-Z0-A)
Action level Failure code Communication on CAN communication 2 line of engine

controller impossible
Failure
L03 DB2QKR
Detail of • Machine monitor cannot recognize engine controller through CAN communication 2 line
failure (KOMNET/c).
Action of
controller
• Information to be obtained from engine controller is not displayed and special functions
Problem on that use them do not work. Or, received data is no longer updated. (such as failure codes
machine and monitoring
codes sent from engine controller)
switch is received.
• If failure code [DB2RKR] is also displayed, engine controller may be defective (cause 2).
• ID controller is optional device (connector CC01)
• Machine monitor indicates a CAN communication error in CAN2 with failure code
[DA2QKR], [DB2QKR], [D8AQKR], or [DAZQKR]. If all four of these failure code are
displayed, harness (CAN communication line) may have ground fault, short circuit, or hot
short circuit. Since air conditioner is also controlled via CAN communication, check
whether air conditioner is operated (ON/OFF and air flow adjustment) on air conditioner
Related screen.
information a If ID controller is not installed, failure code [F7FQKR] is not generated. Therefore, the
number of failure codes that may be generated is four; [DA2QKR], [DB2QKR], [D8AQKR],
and [DAZQKR].
a Air conditioner can be operated even when failure code is displayed on machine monitor
screen. If air conditioner is operated, there is no possibility of ground fault, short circuit, or
hot short circuit in harness (CAN communication line).
• Since each controller and machine monitor are directly connected to continuous power
supply, they receive continuous power even while starting switch is at OFF position.
• Since active CAN communication line signal is pulse voltage, it cannot be measured by
using multimeter.
Defective fuses Nos. 15 and 1. Turn starting switch to OFF position.

1 2. Remove fuses No. 15 and No. 18 from fuse box F01.
18 in fuse box F01
• When fuse is blown, engine controller may have short circuit in it.
a If fuse is not blown, this check is not required.
2 Defective engine controller 2. Disconnect connector CE03 and connect T-adapters to male side.
Resis- Between CE03 (male) (1) and (21) Min. 10 z
tance Between CE03 (male) (11) and (31) Min. 10 z
a Check ground terminal T12 for looseness and rust.
2. Disconnect connector CE03, and connect T-adapters to female side.
Improper power supply to 3. Turn starting switch to ON position.
3 engine controller
a If result is abnormal, perform troubleshooting for [CA441].
Between CE03 (female) (1) and (21) 20 to 30 V
Voltage
Between CE03 (female) (11) and (31) 20 to 30 V
Defective CAN terminating 1. Turn starting switch to OFF position.
resis- 2. Disconnect connectors CM02 and K02, and connect T-adapters to
4 each male side.
tor (internal open or short
circuit) Resis- Between K02 (male) (A) and (B) 120 ± 12 z
tance Between CM02 (male) (7) and (9) 120 ± 12 z
40-426 PC210LC-10
40 Troubleshooting

a Machine monitor also has 120 z CAN terminating resistor in it. Since
120 z resistors are connected in parallel, if resistance measured at
connector of controller other than machine monitor is 60 z which is
combined resistance, there is no open circuit in wiring harness.
2. Disconnect related connectors and connect T-adapters to connector
at which measurement is performed.
a If short circuit occurs (if resistance between terminals is 1 z or less),
disconnect CAN communication connectors of all controllers. Then,
check whether short circuit is in wiring harnesses or within controller.
5 Approx.
harness Between CM02 (female) (8) and (9)
120 z
Between CE03 (female) (17) and (18) Approx. 60
z
Between CP01 (female) (45) and (64) Approx. 60
z
Resis- Between AC01 (female) (1) and (2) Approx. 60
tance z
Between CK01 (female) (10) and (11) Approx. 60
z
*Between CC01 (female) (10) and (11) Approx. 60
z
Between K02 (female) (A) and (B) Approx.
120 z
• ACC signal from starting switch (CAN communication start is not
sensed)
insert T-adapters into it.
3. Turn battery disconnect switch to ON position, and turn starting
switch to ON position.
Open circuit in wiring harness Between CE03 (3) and (21) 20 to 30 V
6 (wire breakage or defective Between CP01 (24), (43), (80) and (2) 20 to 30 V
contact of connector) Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
*Between CC01 (2) and (7) 20 to 30 V
side of connector at which measurement is performed.
PC210LC-10 40-427
40 Troubleshooting

(45) Max. 1 z
(64) Max. 1 z
(17) Max. 1 z
(18) Max. 1 z
(1) Max. 1 z
Open circuit in wiring harness Max. 1 z
Resis- (2)
6 (wire breakage or defective tance Between CM02 (female) (8) and CK01 (female)
contact of connector) Max. 1 z
(10)
Between CM02 (female) (9) and CK01 (female)
(11) Max. 1 z
(3) Max. 1 z
(9) Max. 1 z
(A) Max. 1 z
(B) Max. 1 z

Ground fault in wiring harness side of connector at which measurement is performed.
7
(contact with ground circuit) Between ground and any point in CP01
(female) (45), CM02 (female) (7), (8) or CE03 Min. 1 Mz
Resis- (female) (17)
tance Between ground and any point in CP01
(female) (64), CM02 (female) (9) or CE03 Min. 1 Mz
(female) (18)
40-428 PC210LC-10
40 Troubleshooting

a If no failure is found by check on cause 5 (no open circuit), measure
in only one place each.
insert T-adapters into connector.
Short circuit or hot short 4. Turn starting switch to ON position.
circuit in wiring harness a Since voltages of CAN H and CAN L lines are 2.5 ± 1 V including
8 (contact with 24 V during communication, harnesses are considered normal as long as
circuit) their voltages are between 1 and 4 V.
(female) (17)
Voltage
(female) (18)
• If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and
[DAZQKR] are displayed
a Repeat following steps 1. to 3. to disconnect controllers one by one
from CAN communication and to identify defective controller.
Defective engine controller, switch to OFF position.
pump controller, air 2. Disconnect CAN communication connector of engine controller
9 conditioner unit, *ID (connector CE03), pump controller (connector CP01), air conditioner
controller, or KOMTRAX unit (connector AC01), *ID controller (connector CC01), and
terminal KOMTRAX terminal (connector CK01) one by one.
3. Turn battery disconnect switch to ON position, turn starting switch to
ON position, then perform troubleshooting.
4. Return to step 1. and troubleshoot next controller.
Has the number of displayed failure codes If YES, disconnected
decreased from four? controller is defective.
*The ID controller is an optional device.
PC210LC-10 40-429
40 Troubleshooting
Circuit diagram related to CAN communication 2
40-430 PC210LC-10
40 Troubleshooting
Failure code [DB2RKR] CAN1 Discon (Engine Con) (PC220_10-DB2RKR-400-A-00-A)
Action CAN communication-1 line of engine controller is disabled

Failure code
level Failure
L04 DB2RKR
Details of • Machine monitor does not recognize engine controller through CAN communication-1 line
failure (KOMNET/r).
• Holds current working mode.
Action of
• Holds current selection of auto-deceleration.
controller
• Holds information at failure occurrence.
• Information obtained from engine controller is not displayed or special function that uses
information from engine controller does not work. Or update of received data is stopped.
Problem on • Engine is uncontrollable.
machine • Engine speed and coolant temperature are undetectable.
• Gauge pointers for engine coolant temperature and hydraulic oil temperature disappear
from machine monitor.
switch is received.
• If failure code [DB2QKR] is also displayed, engine controller system may be defective
due to cause 1.
• Machine monitor uses failure code [DA2RKR] to indicate CAN communication failure
through CAN 1 line. When failure code [DA2RKR] is also displayed, ground fault, short
Related circuit or hot short circuit in wiring harness (CAN communication line) may occur.
information • Terminating resistor of CAN1 on cab side is inside machine monitor, and that on engine
side is connector terminal port. (Connector Terminal port is not on CAN communication 1
line but connected to it via connector "ECMJ2").
receive power even while starting switch is at OFF position.
using multimeter.
Defective engine Perform checks on causes 1 to 3 of troubleshooting for [DB2QKR].
1 controller system
Defective CAN 1. Turn starting switch to OFF position.
terminating resistor 2. Disconnect connector CM02 and terminal port, and connect T-adapters to each
2 (open circuit or male sides of them.
short circuit in Between terminal port (male) (A) and (B) 120 ± 12 z
internal wiring) Resistance
Between CM02 (male) (10) and (12) 120 ± 12 z
a CAN communication terminating resistor of 120 z is provided in machine
monitor, too. Since 120 z resistors are connected in parallel, if combined
resistance measured at connector of controller other than machine monitor is
60 z, there is no open circuit in wiring harness.
2. Disconnect connectors CM02, CP01, ECM J1, ECM J2 and Terminal port one
by one, and connect T-adapters to each female side.
Open circuit or
3 short circuit in a When short circuit occurs (1 z or less between terminals), disconnect every
wiring harness CAN communication connector of controllers. Then, check where short circuit
occurs, namely between wiring harnesses or within the controller.
Between CM02 (female) (11) and (12) Approx. 120 z
Between CP01 (female) (7) and (26) Approx. 120 z
Between Terminal port (female) (A) and
Approx. 120 z
Resistance (B)
Between ECM J1 (female) (8) and (18) Approx. 120 z
Between ECM J2 (female) (24) and (25) Approx. 120 z
PC210LC-10 40-431
40 Troubleshooting

• ACC signal from starting switch (start of CAN communication is not identifiable)
1. Turn starting switch to OFF position and disconnect battery ground cable.
Open circuit in 2. Disconnect connectors CM01, CP01, and CE03, and insert T-adapters.
wiring harness 3. Connect ground cable and turn starting switch to ON position.
4 (wire breakage or Between CM01 (10) and (3) 20 to 30 V
connector) Voltage
Between CP01 (2) and each of CP01
(24), (43), and (80) 20 to 30 V

2. Disconnect connectors CM02, CP01, ECM J1, ECM J2, and Terminal port, and
connect T-adapters to any female side.
Between CM02 (female) (11) and CP01
Open circuit in
wiring harness Between CM02 (female) (12) and CP01
5 (wire breakage or
defective contact of Between CM02 (female) (11) and ECM
J1 (female) (8) Max. 1 z
connector)
Resistance
Between CM02 (female) (12) and ECM
J1 (female) (18) Max. 1 z
Terminal port (female) (A) Max. 1 z
Terminal port (female) (B) Max. 1 z
2. Disconnect connectors CM02, CP01, ECM J1, ECM J2, and Terminal port, and
connect T-adapters to any female side.
Between ground and any of CP01
(female) (7), CM02 (female) (10), (11) or Min. 1 Mz
Ground fault in ECM J1 (female) (8)
wiring harness Between ground and ECM J2 (female)
6 (contact with GND Min. 1 Mz
(24) or Terminal port (female) (A)
circuit) Resistance Between ground and any of CP01
(female) (26), CM02 (female) (12) or Min. 1 Mz
ECM J1 (female) (18)
Between ground and any of ECM J2
(female) (25) or Terminal port (female) Min. 1 Mz
(B)
a If no failure is found by check on cause 3 (no open circuit), measure at only one
place each.
2. Disconnect either connector CM02, CP01 or Terminal port, and connect T-
adapters to female side.
3. Connect battery ground cable.
Short circuit or hot 4. Turn starting switch to ON position.
short circuit in
7 wiring harness a Measurement is not conducted on ECM J1 and ECM J2.
(contact with 24 V a Since voltages of CAN_H and CAN_L lines normally 2.5±1 V including during
circuit) communication, regard lines as normal if their voltages are between 1 and 4 V.
(female) (7), CM02 (female) (10), (11) or 1 to 4 V
Terminal port (female) (A)
Voltage
(female) (26), CM02 (female) (12) or 1 to 4 V
Terminal port (female) (B)
40-432 PC210LC-10
40 Troubleshooting

• When failure code [DA2RKR] is also displayed
a Identify which of pump controller and engine controller fails by disconnecting
them one by one from CAN communication.
Defective pump 1. Turn starting switch to OFF position and disconnect battery ground cable.
8 2. Disconnect pump controller (connector CP01).
controller
3. Connect the ground cable and turn starting switch to ON position.
If YES, pump Does any or both of failure codes [DA2RKR] and [DB2RKR]
controller is for CAN1 communication failure disappear?
defective.
• When failure code [DA2RKR] is also displayed
a Identify which of pump controller and engine controller has failed by
disconnecting them one by one from CAN communication.
Defective engine 1. Turn starting switch to OFF position and disconnect battery ground cable.
9 2. Disconnect engine controller (connector ECM J1).
controller
3. Connect the ground cable and turn the starting switch to ON position.
If YES, engine Does any or both of failure codes [DA2RKR] and [DB2RKR]
controller is for CAN1 communication failure disappear?
defective.
controller
monitor
PC210LC-10 40-433
40 Troubleshooting
Circuit diagram related to CAN communication line 1
40-434 PC210LC-10
40 Troubleshooting
Failure code [DGH2KB] Hyd Oil Sensor Short (PC400-DGH2KB-400-A-Z0-A)
Action level Failure code Short circuit in hydraulic oil temperature sensor system
Failure
L01 DGH2KB (Pump controller system)
Detail of • Signal voltage of hydraulic oil temperature sensor circuit is below 1 V, so pump controller
failure determines that circuit shorts.
controller
Problem on • While hydraulic oil temperature rises to normal range, indicator of hydraulic oil
machine temperature gauge does not move from top of white range (bottom of green range).
• Signal voltage from hydraulic oil temperature sensor can be checked with monitoring
Related function.
information (Code: 04402: Hydr. Temp. Sensor Volt)
Approx. 90
10 °C
Defective hydraulic oil kz
Between P22 (male) (1) and (2) Approx. 35
temperature sensor 30 °C
1 kz
tor (internal open or short Resis- a Temperature-Resistance Approx.
circuit) tance characteristics of oil 80 °C
temperature sensor 6.5 kz
Approx.
100 °C
3.5 kz
Between P22 (male) (2) and ground Min. 1 Mz
2. Disconnect connector P22 and connect T-adapters to female side.
Open circuit, short circuit, a If voltage is 0 V, wiring harness has open circuit or ground fault or
ground fault or hot short short circuit, and if voltage is 24 V, wiring harness has hot short
2
circuit in wiring harness circuit.
a Voltage of approximately 5 V is applied to temperature sensor signal
circuit through resistor in pump controller.
Voltage Between P22 (female) (1) and (2) Approx. 5
V
a Use Temperature-Resistance characteristics table for
troubleshooting on cause 1 as resistance criteria.
Short circuit or ground fault in
3 wiring harness a If resistance is above 1 Mz , wiring harness has open circuit. If
resistance is below 1 z , wiring harness has short circuit.
3.5 to 90
Resis- Between CP01 (female) (28) and (46) kz
tance Between CP01 (female) (28) and ground Min. 1 Mz
4 2. Disconnect connectors CP01 and P22, and connect T-adapters to
Resis- Between ground and CP01 (female) (28) or
tance
PC210LC-10 40-435
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
40-436 PC210LC-10
40 Troubleshooting
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit (PC220_10-DHA4KA-
400-A-00-A)
Action Open circuit in air cleaner clogging sensor
Failure code
level Failure
L01 DHA4KA
Details of • Air cleaner clogging switch signal voltage is not below 1 V while engine is stopped, so
failure machine monitor determines that air cleaner is clogged (switch contact is open).
Action of • Displays system abnormality monitor yellow on machine monitor.
controller
Problem on • If machine is operated as it is, engine may be broken.
machine
• Input state (ON/OFF) from air cleaner clogging switch can be checked with monitoring
Related function.
information (Code: 04501 Monitor input: 2)
Defective air 1. Turn starting switch to OFF position.
cleaner clogging 2. Disconnect connector P23 and connect T-adapters to male side.
switch 3. Turn starting switch to ON position.
1
(internal open
circuit in wiring Between P23 When air cleaner is
Resistance (male) (1) and (2) Max. 1 z
harness) normal *1
Open circuit in
2. Disconnect connectors CM02 and P23, and connect T-adapters to each female
wiring harness
side.
2 (wire breakage or
Between CM02 (female) (4) and P23
defective contact of Max. 1 z
Resistance (female) (1)
connectors)
Between P23 (female) (2) and ground Max. 1 z
Defective machine 3. Turn starting switch to ON position.
3
monitor
Between CM02 (4) When air cleaner is
Voltage Max. 1 V
and CM01 (3) normal
• Air cleaner suction resistance
*1: Max. -3,430 Pa {-350 mmH2O}
Circuit diagram related to air cleaner clogging
PC210LC-10 40-437
40 Troubleshooting
Failure code [DHPAMA] F Pump Press Sensor Abnormality (PC200-DHPAMA-400-A-00-

A)
Action Front pump pressure sensor malfunction
Failure code
level Failure
L01 DHPAMA
Details of • Signal voltage of front pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that front pump pressure is 0 MPa {0 kg/cm 2}.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected to reverse
polarities, pressure sensor is damaged. Accordingly, take extreme care when checking.
Related • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
information be measured at pump controller connector.
• Front pump pressure can be checked with monitoring function.
(Code: 01100 F pump pressure).
Defective 5 V If failure code [DA25KP] is also displayed, perform troubleshooting for it first.
1 sensor power
supply 1 line
Defective 5 V 3. Turn starting switch to ON position.
2 sensor power
supply 1 line a If power supply voltage is abnormal, proceed to check on cause 4.
Between P25
Voltage power supply 4.5 to 5.5 V
(female) (3) and (1)
2. Insert T-adapters into connector P25.
Between P25 (2)
and (1)
a If power supply voltage is normal and sensor output voltage is abnormal, it is
Defective front difficult to judge whether cause is defective sensor, ground fault or hot short
pump pressure circuit of wiring harness. Check as followings.
3 sensor
(internal defect) 2. Replace connector P25 with connector P26 of R pump PPC pressure sensor.
3. Turn starting switch to ON position and display "Abnormality Record" screen of
electrical system on machine monitor.
4. If E mark is not displayed for this failure code, front pump pressure sensor is
defective.
a After finishing test, restore connector.
40-438 PC210LC-10
40 Troubleshooting

2. Disconnect connectors CP01 and P25, and connect T-adapters to each female
side.
a If power supply voltage in check on
cause 2 is normal, this check is not
Open circuit in required. Max. 1 z
wiring harness Between CP01 (female) (18) and P25
4 (wire breakage or (female) (1)
defective contact of Between CP01 (female) (11) and P25
connector) Resistance (female) (2) Max. 1 z

required. Max. 1 z
Between CP01 (female) (6) and P25
(female) (3)

wiring harness 2. Disconnect connectors CP01 and P25, and connect T-adapters to either
circuit) Between ground and CP01 (female) (11)
Resistance or P25 (female) (2) Min. 1 Mz

Hot short circuit in
wiring harness
(contact with 24 V
circuit)
Voltage Between P25 (female) (2) and ground Max. 1 V
Defective pump If no failure is found by above checks, pump controller is defective. (Since this is
controller
PC210LC-10 40-439
40 Troubleshooting
Circuit diagram related to front pump pressure sensor
40-440 PC210LC-10
40 Troubleshooting
Failure code [DHPBMA] R Pump Press Sensor Abnormality (PC200-DHPBMA-400-A-

00-A)
Action Rear pump pressure sensor malfunction
Failure code
level Failure
L01 DHPBMA
Details of • Signal voltage of rear pump pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that rear pump pressure is 0 MPa {0 kg/cm2}.
Problem on • Automatic travel speed selector function does not work.
machine • Straight travel performance or steering performance lowers.
• Rear pump pressure can be checked with monitoring function.
(Code: 01101 R pump pressure).
1 sensor power
supply 1 line
2 sensor power
Between P26
2. Insert T-adapters to connector P26.
Between P26 (2)
and (1)
Defective rear difficult to judge whether cause is defective sensor, ground fault or hot short
pump pressure circuit of wiring harness. Check as followings.
3 sensor 1. Turn starting switch to OFF position.
(internal defect) 2. Replace connector P26 with connector P25 of front pump PPC pressure
sensor.
4. If E mark is not displayed for this failure code, rear pump pressure sensor is
defective.
PC210LC-10 40-441
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
Ground fault in 2. Disconnect connectors CP01 and P26, and connect T-adapters to either
wiring harness female side.
5
(contact with GND Between CP01 (female) (30) and
circuit) Resistance ground, or between P26 (female) (2) and Min. 1 Mz
ground
wiring harness 2. Disconnect connector P26.
(contact with 24 V 4. Turn starting switch to ON position.
circuit)
controller
40-442 PC210LC-10
40 Troubleshooting
Circuit diagram related to rear pump pressure sensor
PC210LC-10 40-443
40 Troubleshooting
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality (PC200LC_10-DHS3MA-400-A-Z0-A)
Action level Failure code Arm IN PPC Sensor Abnormality

Failure
L01 DHS3MA (Pump controller system)
Detail of • Signal voltage of arm IN PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that arm IN PPC pressure is 0 MPa {0 kg/cm 2 }.
Problem on • Automatic deceleration does not cancel.
machine • Controllability of arm IN deteriorates.
a If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely,
pressure sensor will be broken. Accordingly, take extreme care when checking.
• Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
If failure code [DA25KP] is also displayed, perform troubleshooting for it
first.
Defective 5V sensor power 2. Disconnect connector P04 and connect T-adapters to female side.
1 supply 1 system 3. Turn starting switch to ON position.
a If power supply voltage is abnormal, proceed to check on cause 3.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
Voltage Between P04 (2) and (1)
output V
a If power supply voltage is normal and sensor output voltage is
abnormal, it is difficult to judge whether cause of failure is defective
Defective arm IN PPC sensor, ground fault or hot short circuit in wiring harness. Check as
2 pressure sensor (internal below.
defect)
2. Replace connector P04 with connector of other PPC pressure
sensor.
3. Turn starting switch to ON position and display "Abnormality Record"
screen of electrical system on machine monitor.
4. If E mark is not displayed again for this failure code, arm IN PPC
a After finishing test, restore connectors.
40-444 PC210LC-10
40 Troubleshooting

2. Disconnect connectors CP01 and P04, and connect T-adapters to
each female side.
a If power supply voltage measured in check
on cause 1 is normal, this check is not
required. Max. 1 z
Open circuit in wiring harness Between CP01 (female) (18) and P04 (female)
3 (wire breakage or defective (1)
contact of connector) Resis- Between CP01 (female) (14) and P04 (female)
(2) Max. 1 z
tance
required. Max. 1 z
Between CP01 (female) (6) and P04 (female)
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P04, and connect T-adapter to
tance
5 harness 3. Connect T-adapters to female side of connector P04.
(contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
Circuit diagram related to arm IN PPC pressure sensor
PC210LC-10 40-445
40 Troubleshooting
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality (PC200-
DHS4MA-400-A-00-A)
Action Bucket CURL PPC pressure sensor malfunction
Failure code
level Failure
L01 DHS4MA
Details of • Signal voltage of bucket CURL PPC pressure sensor circuit is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that bucket CURL PPC pressure is 0 MPa {0 kg/cm 2}.
Problem on • Automatic deceleration cannot be canceled.
machine • Bucket CURL performance lowers.
• Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P01
Voltage Power supply 4.5 to 5.5 V
Between P01 (2)
and (1)
Defective bucket difficult to judge whether cause is defective sensor, ground fault or hot short
CURL PPC circuit of harness. Check as followings.
3 pressure sensor
(internal defect) 2. Replace connector P01 with connector of other PPC pressure sensor.
4. If E mark is not displayed for this failure code, bucket CURL PPC pressure
40-446 PC210LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
Between ground and CP01 (female) (69)
circuit) Resistance Min. 1 Mz
or P01 (female) (2)
circuit)
controller
PC210LC-10 40-447
40 Troubleshooting
Circuit diagram related to bucket CURL PPC pressure sensor
40-448 PC210LC-10
40 Troubleshooting
Failure code [DHS8MA] Boom Raise PPC Press Sensor

Abnormality (PC200-DHS8MA-400-A-00-A)
Action Boom RAISE PPC pressure sensor malfunction
Failure code
level Failure
L01 DHS8MA
Details of • Signal voltage of boom RAISE PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that boom RAISE PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Boom RAISE performance lowers.
• Boom RAISE PPC pressure can be checked with monitoring function.
(Code: 07400 Boom RAISE PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P06
2. Insert T-adapters in connector P06.
Between P06 (2)
and (1)
Defective boom difficult to judge whether cause is defective sensor, ground fault or hot short
RAISE PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed for this failure code, boom RAISE PPC pressure
PC210LC-10 40-449
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P06 (female) (2)
circuit)
controller
40-450 PC210LC-10
40 Troubleshooting
Circuit diagram related to boom RAISE PPC pressure sensor
PC210LC-10 40-451
40 Troubleshooting
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality (PC400-

DHS9MA-400-A-Z0-A)
Action level Failure code Boom LOWER pressure sensor malfunction

Failure
L01 DHS9MA (Pump controller system)
Detail of • Signal voltage of boom LOWER pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
machine • Controllability of boom LOWER deteriorates.
• Boom lower PPC pressure can be checked with monitoring function.
(Code: 07500 Boom LOWER PPC pressure)
first.
Defective 5 V sensor power 2. Disconnect connector P02 and connect T-adapters to female side.
1 supply 2 line 3. Turn starting switch to ON position.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective boom LOWER PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again for this failure code, boom LOWER
PPC pressure sensor is defective.
40-452 PC210LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
Ground fault in wiring harness 2. Disconnect connectors CP01 and P02, and connect T-adapters to
Resis- Between ground and CP01 (female) (13) and
ground, or between P02 (female) (2) Min. 1 Mz
tance
(contact with 5 V/24 V circuit) 4. Turn starting switch to ON position.
PC210LC-10 40-453
40 Troubleshooting
Circuit diagram related to boom LOWER PPC pressure sensor
40-454 PC210LC-10
40 Troubleshooting
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality (PC200-

DHSAMA-400-A-00-A)
Action Swing RIGHT PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSAMA
Details of • Signal voltage of swing RIGHT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing RIGHT PPC pressure is 0 MPa {0 kg/cm2}.
machine • Poor operability of right swing operation
• Swing RIGHT PPC pressure can be checked with monitoring function.
(Code 09002: Swing RIGHT PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P07
2. Connect T-adapters to connector P07.
Between P07 (2)
and (1)
Defective swing difficult to judge whether cause is defective sensor, ground fault or hot short
RIGHT PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed for this failure code, swing RIGHT PPC pressure
PC210LC-10 40-455
40 Troubleshooting

side.
connectors) Resistance (female) (2) Max. 1 z

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P07 (female) (2)
(contact with 5 V or 4. Turn starting switch to ON position.
24 V circuit)
controller
40-456 PC210LC-10
40 Troubleshooting
Circuit diagram related to swing RIGHT PPC pressure sensor
PC210LC-10 40-457
40 Troubleshooting
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality (PC200-

DHSBMA-400-A-00-A)
Action Swing LEFT PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSBMA
Details of • Signal voltage of swing LEFT PPC pressure sensor circuit is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that swing LEFT PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Swing LEFT performance lowers.
• Swing LEFT PPC pressure can be checked with monitoring function.
(Code 09001: Swing LEFT PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P03
Between P03 (2)
and (1)
Defective swing difficult to judge whether cause is defective sensor, ground fault or hot short
LEFT PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E-mark for this failure code is not displayed, swing LEFT PPC pressure
40-458 PC210LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P03 (female) (2)
24 V circuit)
controller
PC210LC-10 40-459
40 Troubleshooting
Circuit diagram related to swing LEFT PPC pressure sensor
40-460 PC210LC-10
40 Troubleshooting
Failure code [DHSCMA] Arm Dump PPC Press Sensor

Abnormality (PC220_10-DHSCMA-400-A-01-A)
Action Arm OUT PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSCMA
Details of • Signal voltage of arm OUT PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that arm OUT PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Arm OUT performance lowers.
• Arm OUT PPC pressure can be checked with monitoring function.
(Code 07600: Arm OUT PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P08
Between P08 (2)
and (1)
Defective arm OUT difficult to judge whether cause is defective sensor, ground fault or hot short
PPC pressure circuit of harness. Check as followings.
3 sensor
4. If E mark is not displayed in this failure code column, arm out PPC pressure
PC210LC-10 40-461
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P08 (female) (2)
circuit)
controller
40-462 PC210LC-10
40 Troubleshooting
Circuit diagram related to arm DUMP (arm OUT) PPC pressure sensor
PC210LC-10 40-463
40 Troubleshooting
Failure code [DHSDMA] Bucket Dump PPC Press Sensor

Abnormality (PC400-DHSDMA-400-A-Z0-A)
Action level Failure code Bucket DUMP PPC pressure sensor malfunction
Failure
L01 DHSDMA (Pump controller system)
Detail of • Signal voltage of bucket DUMP PPC pressure sensor is below 0.3 V or above 4.5 V.
failure
Action of • Controls machine taking it that bucket DUMP PPC pressure is 0 MPa {0 kg/cm 2 }.
machine • Controllability of bucket DUMP deteriorates.
• Bucket DUMP PPC pressure can be checked with monitoring function.
(Code: 07301 Bucket DUMP PPC pressure)

first.
Power 4.5 to 5.5
supply V
Sensor 0.5 to 4.5
output V
Defective bucket DUMP PPC sensor, ground fault or hot short circuit in wiring harness. Check as
defect)
sensor.
4. If E mark is not displayed again in this failure code column, bucket
DUMP PPC pressure sensor is defective.
40-464 PC210LC-10
40 Troubleshooting

each female side.
required. Max. 1 z
(2) Max. 1 z
tance
required. Max. 1 z
(3)
tance
PC210LC-10 40-465
40 Troubleshooting
Circuit diagram related to bucket DUMP PPC pressure sensor
40-466 PC210LC-10
40 Troubleshooting
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor

Abnormality (PC220_10-DHSFMA-400-A-01-A)
Action Left travel FORWARD PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSFMA
Details of • Signal voltage of left travel FORWARD PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance lowers.
• Left travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07102 Left travel FORWARD PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P09
Between P09 (2)
and (1)
Defective left travel difficult to judge whether cause is defective sensor, ground fault or hot short
FORWARD PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed in this failure code column, left travel FORWARD
PC210LC-10 40-467
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P09 (female) (2)
24 V circuit)
controller
40-468 PC210LC-10
40 Troubleshooting
Circuit diagram related to travel PPC pressure sensor
PC210LC-10 40-469
40 Troubleshooting
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor

Abnormality (PC220_10-DHSGMA-400-A-01-A)
Action Right travel FORWARD PPC pressure sensor abnormality
Failure code
level Failure
L01 DHSGMA
Details of • Signal voltage of right travel FORWARD PPC pressure sensor is below 0.3 V or above
failure 4.5 V.
Action of • Controls machine taking it that right travel FORWARD PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance is poor.
• Right travel FORWARD PPC pressure can be checked with monitoring function.
(Code: 07103 Right travel FORWARD PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P11
Between P11 (2)
and (1)
Defective right a If power supply voltage is normal and sensor output voltage is abnormal, it is
travel FORWARD difficult to judge whether cause is defective sensor, ground fault or hot short
3 PPC pressure circuit of harness. Check as followings.
4. If E mark is not displayed in this failure code column, right travel FORWARD
40-470 PC210LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P11 (female) (2)
24 V circuit)
controller
PC210LC-10 40-471
40 Troubleshooting
40-472 PC210LC-10
40 Troubleshooting
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor

Abnormality (PC220_10-DHSHMA-400-A-01-A)
Action Left travel REVERSE PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSHMA
Details of • Signal voltage of left travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that left travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance lowers.
• Left travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07104 Travel left reverse PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P10
Between P10 (2)
and (1)
Defective left travel difficult to judge whether cause is defective sensor, ground fault or hot short
REVERSE PPC circuit of harness. Check as followings.
3 pressure sensor
4. If E mark is not displayed in this failure code column, left travel REVERSE PPC
PC210LC-10 40-473
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P10 (female) (2)
24 V circuit)
controller
40-474 PC210LC-10
40 Troubleshooting
PC210LC-10 40-475
40 Troubleshooting
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor

Abnormality (PC220_10-DHSJMA-400-A-01-A)
Action Right travel REVERSE PPC pressure sensor malfunction
Failure code
level Failure
L01 DHSJMA
Details of • Signal voltage of right travel REVERSE PPC pressure sensor is below 0.3 V or above 4.5
failure V.
Action of • Controls machine taking it that right travel REVERSE PPC pressure is 0 MPa {0 kg/cm 2}.
machine • Travel performance is poor.
• Right travel REVERSE PPC pressure can be checked with monitoring function.
(Code: 07105 Travel right reverse PPC pressure)
1 sensor power
supply 1 line
2 sensor power
Between P12
Between P12 (2)
and (1)
Defective right a If power supply voltage is normal and sensor output voltage is abnormal, it is
travel REVERSE difficult to judge whether cause is defective sensor, ground fault or hot short
3 PPC pressure circuit of harness. Check as followings.
4. If E mark is not displayed in this failure code column, right travel REVERSE
a After finishing test, return connector to condition as it was.
40-476 PC210LC-10
40 Troubleshooting

side.

required. Max. 1 z
(female) (3)
5 female side.
(contact with GND
or P12 (female) (2)
24 V circuit)
controller
PC210LC-10 40-477
40 Troubleshooting
40-478 PC210LC-10
40 Troubleshooting
Failure code [DKR0MA] F pump S/P sensor Abnormality (PC400-DKR0MA-400-A-Z0-A)
Action level Failure code F pump swash plate sensor malfunction

Failure
L01 DKR0MA (Pump controller system)
Detail of • Signal voltage of F pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
failure

controller
• Automatic deceleration does not cancel.
Problem on • One-touch power maximizing function does not work.
machine • When engine is running with light load, engine control that runs engine at lowered engine-
pump matching speed does not function.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from front pump swash plate sensor can be checked with monitoring function.
(Code: 01138 F pump swash plate sensor voltage)
first.
Defective 5V sensor power 2. Disconnect connector P27, and connect T-adapters to female side.
Power 4.5 to 5.5
Voltage Between P27 (female) (A) and (B)
supply V
Between P27 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P27 (female) (B) and (C) kz
tance Approx.
Between P27 (female) (A) and (C)
170 z
Defective F pump swash 3. Turn starting switch to ON position.
2 plate sensor Sensor Approx. 3
Voltage Between P27 (C) and (B)
(internal defect) output V
sensor, ground fault or hot short circuit in wiring harness. Check as
below.
2. Replace connector P27 with connector P28.
4. If E mark is not displayed again in this failure code column, F pump
swash plate sensor is defective.
a After finishing test, restore connectors .
PC210LC-10 40-479
40 Troubleshooting

each female side.
required. Max. 1 z
3 (wire breakage or defective (A)
tance
required. Max. 1 z
(B)
(C) Max. 1 z

P27 (female) (C) Min. 1 Mz
tance
Voltage Between P27 (female) (C) and ground Max. 1 V
Circuit diagram related to F and R pump swash plate sensors
40-480 PC210LC-10
40 Troubleshooting
Failure code [DKR1MA] R pump S/P sensor Abnormality (PC400-DKR1MA-400-A-Z0-A)
Action level Failure code R pump swash plate sensor malfunction

Failure
L01 DKR1MA (Pump controller system)
Detail of • Signal voltage of R pump swash plate sensor circuit is below 0.4 V or above 4.6 V.
failure
controller
• Automatic deceleration does not cancel.
Problem on • One-touch power maximizing function does not work.
machine • When engine is running with light load, engine control that runs engine at lowered engine-
pump matching speed does not function.
a If 5 V circuit (A) and ground circuit (B) of swash plate sensor are connected inversely,
sensor will be broken. Accordingly, take extreme care when checking.
• Voltage from rear pump swash plate sensor can be checked with monitoring function.
(Code: 01140 R Pump Sw Plate Sensor Volt)
first.
Power 4.5 to 5.5
Voltage Between P28 (female) (A) and (B)
supply V
Between P28 (male) (A) and (B) Approx. 6
kz
Approx. 6
Resis- Between P28 (female) (B) and (C) kz
tance Approx.
Between P28 (female) (A) and (C)
170 z
2. Insert T-adapters into connector P28
Defective R pump swash 3. Turn starting switch to ON position.
2 plate sensor Sensor Approx. 3
Voltage Between P28 (C) and (B)
(internal defect) output V
sensor, ground fault or hot short circuit in wiring harness. Check as
below.
2. Replace connector P28 with connector P27.
4. If E mark is not displayed again in this failure code column, R pump
swash plate sensor is defective.
3 (wire breakage or defective 2. Disconnect connectors CP01 and P28, and connect T-adapters to
contact of connector) each female side.
PC210LC-10 40-481
40 Troubleshooting

required. Max. 1 z
(A)
Resis-
tance
required. Max. 1 z
(B)
(C) Max. 1 z

P28 (female) (C) Min. 1 Mz
tance
(contact with 24 v circuit) 4. Turn starting switch to ON position.
Voltage Between P28 (female) (C) and ground Max. 1 V
Circuit diagram related to F and R pump swash plate sensors
40-482 PC210LC-10
40 Troubleshooting
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality (PC220_10-

DR21KX-400-A-00-A)
Action Camera 2 image reverse drive malfunction
Failure code
level Failure
L01 DR21KX
Details of • Output voltage of camera 2 image reverse drive line (pin 6 of connector CM04) differs
failure from command voltage output from machine monitor.
Action of • Does not display image of camera 2.
controller
Problem on • Image of camera 2 is not displayed.
machine
• When output voltage of camera 2 image reverse drive line (pin 6 of connect or CM04) is 0
V, original image is sent. When it is 8 V, mirror image is sent (since power supply voltage
Related of camera is 8 V, 8 V is used as command voltage to send mirror image).
information • Since two or more connector A46 may be provided, you must check connector A41 to
identify which camera is assigned to camera 2.
Open circuit in 2. Disconnect connectors CM04 and A46, and connect T-adapters to each female
1 (wire breakage or Between CM04 (female) (6) and A46
connector) Resistance
Between CM04 (female) (8) and A46

wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapters to either
circuit) Between ground and CM04 (female) (6)
Resistance or A46 (female) (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector A46 and connect T-adapters to female side.
wiring harness 3. Turn starting switch to ON position.
3
(contact with 24 V a Check that camera 2 is set for original images.
circuit) Between A46 (female) (3) and (4), or
Voltage Max. 1 V
between A46 (female) (3) and ground
Short circuit in 2. Disconnect connector CM04 and connect T-adapters to female side.
4 wiring harness Between CM04 (female) (6) and each
Resistance pin other than (6) Min. 1 Mz
If no failure is found by above checks, camera 2 is defective. (Since this is an
5 Defective camera 2 internal defect, troubleshooting cannot be performed.)
monitor
PC210LC-10 40-483
40 Troubleshooting
Circuit diagram related to camera
40-484 PC210LC-10
40 Troubleshooting
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality (PC220_10-

DR31KX-400-A-00-A)
Action Camera 3 image reverse drive malfunction
Failure code
level Failure
L01 DR31KX
Details of • Output voltage of camera 3 image reverse drive line (pin 7 of connector CM04) differs
failure from command voltage output from machine monitor.
Action of • Does not display image of camera 3.
controller
Problem on • Image of camera 3 is not displayed.
machine
• When output voltage of camera 3 image reverse drive line (pin 7 of connect or CM04) is 0
V, original image is sent. When it is 8 V, mirror image is sent (since power supply voltage
Related of camera is 8 V, 8 V is used as command voltage to send mirror image).
information • Since two or more connector A46 may be provided, you must check connector A42 to
identify which camera is assigned to camera 3.
Open circuit in 2. Disconnect connectors CM04 and A46, and connect T-adapters to each female
1 (wire breakage or Between CM04 (female) (7) and A46
Between CM04 (female) (8) and A46

wiring harness 2. Disconnect connectors CM04 and A46, and connect T-adapters to either
circuit) Between ground and CM04 (female) (7)
Resistance or A46 (female) (3) Min. 1 Mz

Hot short circuit in 2. Disconnect connector A46 and connect T-adapters to female side.
wiring harness 3. Turn starting switch to ON position.
3
(contact with 24 V a Check that camera 3 is set for original images.
circuit) Between A46 (female) (3) and (4) or
Voltage Max. 1 V
ground
Short circuit in 2. Disconnect connector CM04 and connect T-adapter to female side.
4 wiring harness Between CM04 (female) (7) and each
Resistance pin other than (7) Min. 1 Mz
If no failure is found by above checks, camera 3 is defective. (Since this is an
5 Defective camera 3 internal defect, troubleshooting cannot be performed.)
monitor
PC210LC-10 40-485
40 Troubleshooting
Circuit diagram related to camera
40-486 PC210LC-10
40 Troubleshooting
Failure code [DV20KB] Travel Alarm Short Circuit (PC220_10-DV20KB-400-A-01-A)
Action Short circuit in travel alarm circuit

Failure code
level Failure
L01 DV20KB
Details of • Abnormal current flows when drive current is output to travel alarm circuit.
failure
• Stops output to travel alarm circuit.
Problem on
• Travel alarm does not sound.
machine
2. Disconnect connector M14 and connect T-adapters to female side.
4. Operate travel lever to perform troubleshooting.
Defective travel Travel lever:
alarm Max. 1 V
1 Between M14 NEUTRAL
(internal defect) Voltage Travel lever:
FORWARD or 20 to 30 V
REVERSE
a If above voltage is normal but travel alarm does not sound, travel alarm is
defective.
wiring harness 2. Disconnect connectors CP02 and M14, and connect T-adapters to either
2 female side.
(contact with GND
(107) or M14 (female) (1)
2. Insert T-adapters into connector M14.
4. Operate travel lever to perform troubleshooting.
Defective pump
3 Travel lever:
controller Max. 1 V
Between M14 (1) NEUTRAL
Voltage Travel lever:
and (2)
FORWARD or 20 to 30 V
REVERSE
PC210LC-10 40-487
40 Troubleshooting
Circuit diagram related to travel alarm
40-488 PC210LC-10
40 Troubleshooting
Failure code [DW43KA] Travel Speed Sol Open Circuit (PC400-DW43KA-400-A-Z0-A)
Action level Failure code Open circuit in travel speed selector solenoid circuit
Failure
L01 DW43KA (Pump controller system)
Detail of • No current flows when pump controller drives travel speed selector solenoid, so pump
failure controller determines that open circuit exists in travel speed selector solenoid circuit.
Action of • None in particular (Since no current flows, solenoid is not energized.)
Problem on • "Hi" travel speed is slow. (Although "Hi" is displayed on machine monitor, actual travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to short
Related
circuit.)
information
(Code: 02300 Solenoid 1)
• Method of reproducing failure code: Start engine, set travel speed to High and operate
travel lever.
Defective travel speed 2. Disconnect connector V04, and connect T-adapters to male side.
1
selector solenoid
Resistance Between V04 (male) (1) and (2) 20 to 60 z
Between CP02 (female) (93) and each of
Resistance (115), (117), and (120) 20 to 60 z
Open circuit in wiring
a If no failure is found by above checks , this check is not required.
harness
2 1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V04, and connect T-adapters to
each female side.
Between CP02 (female) (93) and V04
Resistance
Between each of CP02 (female) (115),
(117), and (120), and V04 (female) (2) Max. 1 z
PC210LC-10 40-489
40 Troubleshooting
Circuit diagram related to travel speed selector solenoid
40-490 PC210LC-10
40 Troubleshooting
Failure code [DW43KB] Travel Speed Sol Short Circuit (PC200-DW43KB-400-A-00-A)
Action Travel speed selector solenoid short circuit

Failure code
level Failure
L01 DW43KB
Details of • When output current to travel speed selector solenoid is turned off, voltage at controller
failure output terminal was detected to be above the standard value.
• Stops output to travel speed selector solenoid.
Problem on • "Hi" travel speed is slow. (Although "Hi" speed is displayed on machine monitor, travel
machine speed is still "Lo".)
• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (If controller sends solenoid ON command, monitoring display is ON
Related even if solenoid is not switched ON due to short circuit.)
information (Code: 02300 Solenoid 1)
Defective travel 1. Turn starting switch to OFF position.
speed selector 2. Disconnect connector V04, and connect T-adapter to male side.
solenoid
1 Between V04 (female) (1) and (2) 20 to 60 z
(internal short
circuit or ground Resistance
fault)
Short circuit or 2. Disconnect connector CP02 and connect T-adapter to female side.
2 ground fault in Between CP02 (female) (93) and each
harness of CP02 (female) (115), (117) and (120) 20 to 60 z
Resistance
Between CP02 (female) (93) and ground Min. 1 Mz
a If no abnormality is found in check on cause 2, this check is not required.
harness 2. Disconnect connectors CP02 and V04, and connect T-adapters to either
3 female side.
(Contact with GND
circuit) Between CP02 (female) (93) and
Resistance ground, or between V04 (female) (1) and Min. 1 Mz
ground
Hot short-circuiting 1. Turn starting switch to OFF position.
of harness 2. Disconnect connector V04.
4 3. Connect T-adapter to female side of connector V04.
(Contact with 24 V 4. Turn starting switch to ON position.
circuit)
Voltage Between V04 (female) (1) and ground Max. 1 V
controller
PC210LC-10 40-491
40 Troubleshooting
Circuit diagram related to travel speed solenoid
40-492 PC210LC-10
40 Troubleshooting
Failure code [DW45KA] Swing holding brake Sol Open Circuit (PC200LC_10-
DW45KA-400-A-Z0-A)
Action
Failure code Swing Holding Brake Solenoid Open Circuit
level Failure
L03 DW45KA
• Controller output voltage to solenoid is above standard value when pump controller does
Detail of not drive swing holding brake solenoid, so pump controller determines that open circuit
failure exists in swing holding brake solenoid circuit.
• None in particular. (Since no current flows, solenoid is not energized, so swing holding
Action of brake is kept applied.)
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• If solenoid and wiring harness are normal, swing operation is possible by setting swing
brake cancel switch to RELEASE position. (However, swing brake is not released when
starting switch is in OFF position. Swing holding brake remains applied.)
• Keep swing brake cancel switch in RELEASE position during troubleshooting. When
starting switch is turned to ON position in this condition, normally current flows through
swing holding brake solenoid circuit to release swing holding brake.
Related • Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is "ON", sensor status
displayed on monitoring screen is "ON" even if solenoid is not energized due to open
circuit.)
• Power for swing holding brake solenoid is supplied from pin (101) of pump controller
connector CP02 or fuse No.1 in fuse box F01.
Blown fuse No. 1 (right top
1 If fuse is blown, see failure code [DW45KB].
fuse) in fuse box F01
Defective swing holding 2. Disconnect connector V03, and connect T-adapters to male side.
2
brake solenoid
Resistance Between V03 (male) (1) and (2) 20 to 60 z
2. Remove diode arrays D01 and D03, and connect T-adapters to each
male side.
Defective diode array D01 or a Check by using multimeter in diode range.
3
D03 Between D01 (male) (3) (+) and (7) (-) No continuity
Between D01 (male) (7) (+) and (3) (-) Continuity
Continuity
Between D03 (male) (5) (+) and (1) (-) No continuity
2. Remove diode D01.
3. Disconnect connector CP02, and connect T-adapter to each female
Open circuit in wiring side.
harness
4 a Swing lock switch OFF position.
contact of connector) Between CP02 (female) (101) and D01
Resistance
Between D01 (female) (3) and CP02
(female) (115) 20 to 60 z
PC210LC-10 40-493
40 Troubleshooting

a If no failure is found by above checks, this check is not required.
Open circuit in wiring 2. Disconnect connectors D01, CP02, and V03, and connect T-adapters
harness to each female side.
4
(wire breakage or defective Between D01 (female) (3) and V03 (female)
contact of connector) (1) Max. 1 z
Resistance
Between each of CP02 (female) (115),
(117), (120), and V03 (female) (2) Max. 1 z
40-494 PC210LC-10
40 Troubleshooting
Circuit diagram related to swing holding brake solenoid
PC210LC-10 40-495
40 Troubleshooting
Failure code [DW45KB] Swing holding brake Sol Short Circuit (PC200LC_10-
DW45KB-400-A-Z0-A)
Action
Failure code Swing Holding Brake Solenoid Short Circuit
level Failure
L03 DW45KB
Detail of • Abnormal current flows when pump controller drives swing holding brake solenoid, so
failure pump controller determines that short circuit exists in swing holding brake solenoid circuit.
• Stops driving swing holding brake solenoid.
Problem on • Upper structure does not swing (swing holding brake is not released).
machine
• If solenoid and wiring harness are normal, swing operation is possible by setting swing
brake cancel switch to RELEASE position. (However, swing brake is not released when
starting switch is in OFF position. Swing holding brake remains applied.)
• Keep swing lock switch in OFF position and swing brake cancel switch in RELEASE
position during troubleshooting. When starting switch is turned to ON position in this
condition, normally current flows through swing holding brake solenoid circuit to release
swing holding brake.
Related
• Controller's command (ON/OFF) to swing holding brake solenoid can be checked with
information
circuit.)
• Power for swing holding brake solenoid circuit is supplied from pin (101) of pump
controller connector CP02 or fuse No.1 in fuse box F01.
Blown fuse No. 1 (right top Even if fuse is blown, perform troubleshooting according to following
1 fuse) in fuse box F01 steps to identify cause.
Defective swing holding 2. Disconnect connector V03, and connect T-adapters to male side.
2
brake solenoid Resis- Between V03 (male) (1) and (2) 20 to 60 z
tance Between V03 (male) (1) and ground Min. 1 Mz
2. Remove diode arrays D01 and D03, and connect T-adapters to each
male side.
a Check by using multimeter in diode range.
Defective diode array D01 or No
3 Between D01 (male) (3) (+) and (7) (-)
D03 continuity
Continuity
No
Between D03 (male) (1) (+) and (5) (-)
continuity
2. Remove fuse No.1 (right top, 5A) in fuse box F01 and diode D01.
Ground fault in wiring harness 3. Disconnect connectors CP02, D01, and V03.
4 4. Connect T-adapters to female side of connectors CP02 and D01.
Resis- Between CP02 (female) (101) and ground Min. 1 Mz
tance Between D01 (female) (3) and ground Min. 1 Mz
40-496 PC210LC-10
40 Troubleshooting

2. Remove fuse No.1 (right top, 10 A) in fuse box F01 and diode D01.
3. Disconnect connector CP02.
4. Connect T-adapters to female side of connectors D01 and CP02.
Resis- Between D01 (female) (3) and CP02 (female)
(115), (117), or (120) 20 to 60 z
tance
PC210LC-10 40-497
40 Troubleshooting
40-498 PC210LC-10
40 Troubleshooting
Failure code [DW91KA] Travel Junction Sol Open Circuit (PC200-DW91KA-400-A-00-A)
Action Open circuit in travel junction solenoid circuit

Failure code
level Failure
L01 DW91KA
Details of • Controller output voltage to travel junction solenoid exceeds standard value when it stops
failure outputting drive current to travel junction solenoid.
Action of • None in particular (Since no current flows, solenoid does not operate.)
Problem on • Machine cannot turn easily during traveling.
machine
• Controller's command (ON/OFF) to travel junction valve solenoid can be checked with
Related even if solenoid is not switched to ON due to open circuit.)
junction solenoid 2. Disconnect connector V05 and connect T-adapters to male side.
1
(internal open
circuit) Resistance Between V05 (male) (1) and (2) 20 to 60 z
Open circuit or
2 short circuit in
wiring harness Between CP02 (female) (85) and each
Resistance of CP02 (female) (115), (117) and (120) 20 to 60 z

Open circuit in 1. Turn starting switch to OFF position.
wiring harness 2. Disconnect connectors CP02 and V05, and connect T-adapters to each female
3 (wire breakage or side.
defective contact of Between CP02 (female) (85) and V05
Between V05 (female) (2) and each of
CP02 (female) (115), (117) and (120) Max. 1 z
controller
PC210LC-10 40-499
40 Troubleshooting
Circuit diagram related to travel junction valve solenoid
40-500 PC210LC-10
40 Troubleshooting
Failure code [DW91KB] Travel Junction Sol Short Circuit (PC200-DW91KB-400-A-00-A)
Action Travel junction solenoid short circuit

Failure code
level Failure
L01 DW91KB
Details of • When outputting current to travel junction valve solenoid, abnormal current flows in circuit
failure and short circuit is detected.
• Stop outputting current to travel junction solenoid.
Problem on • Machine is not steered easily during travel.
machine
• Controller's command (ON/OFF) to travel junction valve solenoid can be checked with
Related even if solenoid is not switched ON due to short circuit.)
junction solenoid 2. Disconnect connector V05, and connect T-adapter to male side.
1 (internal short Between V05 (male) (1) and (2) 20 to 60 z
fault) Between V05 (male) (1) and ground Min. 1 Mz
Resistance
3 female side.
(Contact with GND
ground
circuit)
controller
PC210LC-10 40-501
40 Troubleshooting
Circuit diagram related to travel junction valve solenoid
40-502 PC210LC-10
40 Troubleshooting
Failure code [DWA2KA] Attachment Sol Open Circuit (PC200-DWA2KA-400-A-00-A)
Action Open circuit in ATT 1-way/2-way selector solenoid circuit

Failure code
level Failure
L03 DWA2KA
Details of • Controller output voltage to ATT return selector solenoid exceeds standard value when it
failure stops outputting drive current to ATT return selector solenoid.
Problem on • Hydraulic circuit for attachment does not change to single-acting circuit.
machine
• Command of controller (ON/OFF) to ATT return selector solenoid can be checked with
monitoring function. (even if solenoid is not switched to ON due to open circuit, display on
Related monitor is ON when ON command is sent from controller).
• Method of reproducing failure code: Turn starting switch to ON and set machine in mode
other than breaker mode (B).
Defective 1. Turn starting switch to OFF position.
attachment return 2. Disconnect connector V07, and connect T-adapters to male side.
1 selector solenoid
(internal open Resistance Between V07 (male) (1) and (2) 20 to 60 z
circuit)
Open circuit or 2. Disconnect connector CP02 and connect T-adapters to female side.
wiring harness of CP02 (female )(115), (117) and (120) 20 to 60 z
Resistance
a If no failure is found in check on cause 2, this check is not required.
controller
PC210LC-10 40-503
40 Troubleshooting
Circuit diagram related to ATT 1–way/2–way selector solenoid
40-504 PC210LC-10
40 Troubleshooting
Failure code [DWA2KB] Attachment Sol Short Circuit (PC200-DWA2KB-400-A-00-A)
Action Attachment 1–way/2–way selector solenoid short circuit

Failure code
level Failure
L03 DWA2KB
Details of • When outputting current to attachment return selector solenoid, abnormal current flows in
failure circuit and short circuit is detected.
• Stops outputting current to attachment return selector solenoid.
Problem on • Hydraulic circuit for attachment does not change to single-acting circuit.
machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (If controller sends solenoid ON command, monitoring display is
Related ON even if solenoid is not switched ON due to short circuit.)
• Method of reproducing failure code: Turn starting switch to ON position and set machine
in breaker mode (B).
attachment return 2. Disconnect connector V07, and connect T-adapter to male side.
1 selector solenoid
(Internal short Resistance
circuit, ground fault) Between V07 (male) (1) and ground Min. 1 Mz
2 ground fault in
harness Between CP02 (female) (86) and each

Ground fault in
harness
3 2. Disconnect connectors CP02 and V07, and connect T-adapters to either
(Contact with GND female side.
circuit) Between CP02 (female) (86) or V07
Resistance (female) (1) and ground Min. 1 Mz

circuit)
controller
PC210LC-10 40-505
40 Troubleshooting
Circuit diagram related to ATT 1–way/2–way selector solenoid
40-506 PC210LC-10
40 Troubleshooting
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit (PC200-DWK0KA-400-A-00-A)
Action 2-stage relief solenoid system open circuit

Failure code
level Failure
L01 DWK0KA
Details of • When stop outputting current to 2-stage relief solenoid circuit, controller solenoid output
failure voltage is above standard value and open circuit is detected.
Problem on • Travel power is low (The main relief valve is not set in the HIGH-PRESSURE position)
machine • Power maximizing function does not work.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
even if solenoid is not switched ON due to open circuit.)
Related (Code: 02300 Solenoid 1)
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
• Controller detects open circuit if output to solenoid is OFF.
Defective 2-stage 1. Turn starting switch to OFF position.
relief solenoid 2. Disconnect connector V02, and connect T-adapter to male side.
1
(internal open
circuit in harness) Resistance Between V02 (male) (1) and (2) 20 to 60 z
2. Disconnect connector CP02 and connect T-adapter to female side.
Open circuit or
2 short circuit in a If resistance is above 1 Mz, harness has open circuit. If resistance is below 1
wiring harness z, harness has short circuit.
Between CP02 (female) (109) and each
a If cause 2 is not the cause for the trouble, this check is not required.
Breaking of 1. Turn starting switch to OFF position.
harness 2. Disconnect connectors CP02 and V02, and connect T-adapters to each female
3 (Wire breakage or side.
connectors) Resistance
controller
PC210LC-10 40-507
40 Troubleshooting
Circuit diagram related to 2-stage relief solenoid
40-508 PC210LC-10
40 Troubleshooting
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit (PC400-DWK0KB-400-A-Z0-A)
Action
Failure code Short circuit in 2-stage relief solenoid
level Failure
L01 DWK0KB
Detail of • Abnormal current flows when pump controller drives 2-stage relief solenoid, so pump
failure controller determines that short circuit exists in 2-stage relief solenoid circuit.
• Stops driving 2-stage relief solenoid.
controller is set to OFF position.
Problem on • Travel power is low (main relief valve is not set to high-pressure setting).
machine • One-touch power maximizing function does not work.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with
circuit.)
Related (Code: 02300 Solenoid 1)
information • As T-adapter for pump controller connector is "socket-type box", operating voltage cannot
• Controller detects open circuit only when Open circuit in 2-stage relief solenoid.
Defective 2-stage relief 1. Turn starting switch to OFF position.
solenoid 2. Disconnect connector V08, and connect T-adapters to male side.
1
(internal short circuit or Resis- Between V08 (male) (1) and (2) 20 to 60 z
ground fault) tance Between V08 (female) (1) and ground Min. 1 Mz
Ground fault in wiring harness 2. Disconnect connectors CP02 and V08, and connect T-adapters to
2 female side of V08.
V08 (female) (1) Min. 1 Mz
tance
2. Disconnect connectors CP02 and V08, and connect T-adapters to
3 Short circuit in wiring harness female side of V08.
Resis- Between V08 (female) (1) and (2)
Min. 1 Mz
tance
PC210LC-10 40-509
40 Troubleshooting
40-510 PC210LC-10
40 Troubleshooting
Failure code [DWK2KA] Variable Back Press Sol Open Circuit (PC220_10-DWK2KA-
400-A-00-A)
Action Open circuit in variable back-pressure solenoid circuit
Failure code
level Failure
L01 DWK2KA
Details of • Controller output voltage to variable back-pressure solenoid exceeds standard value
failure when it stops outputting drive current to variable back-pressure solenoid.
Problem on • Set pressure of back-pressure valve cannot be changed
machine
• Controller's command (ON/OFF) to variable back-pressure solenoid can be checked with
Related even if solenoid is not switched to ON due to open circuit.)
Defective variable 1. Turn starting switch to OFF position.
back pressure 2. Disconnect connector V25 and connect T-adapters to male side.
1 solenoid
circuit)
Open circuit or
2 ground fault in
a If no failure is found in check on cause 2, this check is not required.

controller
PC210LC-10 40-511
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
40-512 PC210LC-10
40 Troubleshooting
Failure code [DWK2KB] Variable Back Press Sol Short Circuit (PC220_10-DWK2KB-
400-A-00-A)
Action Short circuit in variable back pressure solenoid valve
Failure code
level Failure
L01 DWK2KB
Details of • When outputting current to variable back pressure solenoid, abnormal current flows in
failure circuit and short circuit is detected.
• Stops output to variable back pressure solenoid.
Problem on • Set pressure of back pressure valve cannot be changed.
machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked by
using monitoring function. (If controller sends solenoid ON command, monitoring display
Related is ON even if solenoid is not switched ON due to short circuit.)
Defective variable 1. Turn starting switch to OFF position.
back pressure 2. Disconnect connector V25, and connect T-adapter to male side.
solenoid
1 Between V25 (male) (1) and (2) 20 to 60 z
(internal short
fault)
Short circuit or
2 ground fault in 20 to 60 z
of CP02 (female) (115), (117) and (120)
harness Resistance
Between CP02 (female) (113) and
ground Min. 1 Mz

3 female side.
(Contact with GND
ground
circuit)
controller
PC210LC-10 40-513
40 Troubleshooting
Circuit diagram related to variable back pressure solenoid
40-514 PC210LC-10
40 Troubleshooting
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit (PC220_10-DWK8KA-400-A-
00-A)
Action Open circuit of swing cut-off solenoid system
Failure code
level Failure
L01 DWK8KA
Details of • When the output to swing cut-off solenoid is OFF, open circuit is detected due to
failure excessive output voltage of controller solenoid above standard value.
Problem on • Swing motor relief pressure remains Lo.
machine
• Command (ON/OFF) to swing cut-off solenoid by controller can be checked with
monitoring function. (Even if solenoid is not ON due to open circuit, if controller command
Related is ON, monitoring display is ON.)
information (Code: 02301 solenoid 2)
Defective swing 1. Turn starting switch to OFF position.
cut-off solenoid 2. Disconnect connector V06, and connect T-adapter to male side.
1
(internal open
circuit) Resistance Between V06 (male) (1) and (2) 20 to 60 z
Open circuit or
2 ground fault of

wiring harness 2. Disconnect connectors CP02 and V06, then connect T-adapters to each
3 (Wire breakage or female side.
controller
PC210LC-10 40-515
40 Troubleshooting
Circuit diagram related to swing cut-off solenoid
40-516 PC210LC-10
40 Troubleshooting
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit (PC220_10-DWK8KB-400-A-
00-A)
Action Short circuit of swing cut-off solenoid system
Failure code
level Failure
L01 DWK8KB
Details of • When output to swing cut-off solenoid is ON, short circuit is detected due to abnormal
failure current in circuit.
• Output to swing cut-off solenoid is turned to OFF position.
Problem on • Swing motor relief pressure remains Lo.
machine
• Command (ON/OFF) to swing cut-off solenoid by controller can be checked with
Related (Code: 02301 solenoid 2)
information • Method of reproducing failure code: Engine start + Hoist swing only operation (Do not
operate arm.)
Defective swing 1. Turn starting switch to OFF position.
cut-off solenoid 2. Disconnect connector V06, and connect T-adapter to male side.
1 (internal short Between V06 (male) (1) and (2) 20 to 60z
fault) Between V06 (male) (1) and ground Min. 1 Mz
Short circuit or
2 ground fault in 20 to 60 z
of CP02 (female) (115), (117) and (120)
harness Resistance
Between CP02 (female) (113) and
ground Min. 1 Mz

Ground fault in
wiring harness
3 2. Disconnect connectors CP02 and V06, then connect T-adapters to either
(Contact with female side.
ground circuit) Between ground and CP02 (female) (94)
Resistance or V06 (female) (1) Min. 1 Mz

wiring harness 2. Disconnect connector V06.
circuit)
controller
PC210LC-10 40-517
40 Troubleshooting
Circuit diagram related to swing cut-off solenoid
40-518 PC210LC-10
40 Troubleshooting
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit (PC200LC_10-DXA8KA-400-A-Z0-A)
Action level Failure code PC-EPC (Front) Solenoid Open Circuit

Failure
L03 DXA8KA (Pump controller system)
Detail of • No current flows when pump controller drives F-PC-EPC solenoid, so pump controller
failure determines that open circuit exists in F-PC-EPC solenoid circuit.
Problem on • If pump load increases, engine speed decreases largely and engine may stall.
machine
• When solenoid and wiring harness are normal, engine can be prevented from stalling by
setting emergency pump drive switch to ON position.
Related • Drive current to F-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective F-PC-EPC solenoid 2. Disconnect connector V11, and connect T-adapters to male side.
2
Resis- Between V11 (male) (1) and (2)
3 to 14 z
tance
2. Disconnect connector S25 and connect T-adapters to male side.
Switch position:
Max. 1 z
Between S25 (male) Normal
Defective emergency pump
(3) and (2) Switch position:
3 drive switch Min. 1 Mz
Resis- Emergency
tance Switch position:
Max. 1 z
Emergency Min. 1 Mz

Open or short circuit in wiring a Check that emergency pump drive switch is at normal position (lower
4
harness side).
Resis- Between CP02 (female) (96) and each of (115),
(117), (120) 3 to 14 z
tance
2. Disconnect connectors CP02, S25 and V11, and connect T-adapters
Open circuit in wiring harness to each female side.
Between CP02 (female) (96) and S25 (female)
5 (wire breakage or defective Max. 1 z
(3)
Resis- Between S25 (female) (2) and V11 (female) (1) Max. 1 z
tance Between each of CP02 (female) (115), (117),
(120) and S25 (female) (6) Max. 1 z
Between S25 (female) (5) and V11 (female) (2) Max. 1 z
PC210LC-10 40-519
40 Troubleshooting
Circuit diagram related to PC-EPC solenoid
40-520 PC210LC-10
40 Troubleshooting
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit (PC200LC_10-DXA8KB-400-A-Z0-A)
Action
Failure code PC-EPC (Front) Solenoid Short Circuit
level Failure
L03 DXA8KB
Detail of • Abnormal current flows when pump controller drives F-PC-EPC solenoid, so pump
failure controller determines that short circuit exists in F-PC-EPC solenoid circuit.
• Stops driving F-PC-EPC solenoid.
machine
Related • Drive current to F-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC solenoid current (F))
Defective F-PC-EPC solenoid 1. Turn starting switch to OFF position.

2. Disconnect connector V11, and connect T-adapters to male side.
1 (internal short circuit or
ground fault) Resis- Between V11 (male) (1) and (2) 3 to 14 z
drive switch (internal short Between S25 (male) and each of
2 Switch Min. 1 Mz
circuit or ground fault) Resis- S25 (male) (2) and (3)
position:
tance Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground fault in a Check that emergency pump drive switch is at normal position (lower
3 wiring harness side).
Between CP02 (female) (96) and each of (115),
Resis- (117), (120) 3 to 14 z
tance
Ground fault in wiring harness to any female side.
4
(contact with ground circuit) Between ground and CP02 (female) (96) or
Min. 1 Mz
Resis- S25 (female) (3)
tance Between ground and S25 (female) (5) or V11
(female) (2) Min. 1 Mz
PC210LC-10 40-521
40 Troubleshooting
40-522 PC210LC-10
40 Troubleshooting
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit (PC200LC_10-DXA9KA-400-A-Z0-A)
Action
Failure code PC-EPC (Rear) Solenoid Open circuit
level Failure
L03 DXA9KA
Detail of • No current flows when pump controller drives R-PC-EPC solenoid, so pump controller
failure determines that open circuit exists in R-PC-EPC solenoid circuit.
machine
Related • Drive current to R-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Incorrect operation of
1 Set emergency pump drive switch at its normal position (lower side).
emergency pump drive switch
Defective R-PC-EPC 1. Turn starting switch to OFF position.
2
(internal open circuit) Resis- Between V12 (male) (1) and (2)
3 to 14 z
tance
Switch position:
Max. 1 z
Defective emergency pump Between S25 (male) Normal
drive (3) and (2) Switch position:
3 Min. 1 Mz
Resis- Emergency
switch (internal open circuit)
tance Switch position:
Max. 1 z
Emergency Min. 1 Mz

Open or short circuit in wiring a Check that emergency pump drive switch is at normal position (lower
4
harness side).
Resis- Between CP02 (female) (104) and each of
(115), (117), (120) 3 to 14 z
tance
to each female side.
Open circuit in wiring harness Between CP02 (female) (104) and S25
5 (wire breakage or defective (female) (9) Max. 1 z
contact of connector) Between S25 (female) (8) and V12 (female) (1) Max. 1 z
Resis-
Between S25 (female) (12) and each of CP02
tance Max. 1 z
(female) (115), (117), (120)
Between S25 (female) (11) and V12 (female)
(2) Max. 1 z
PC210LC-10 40-523
40 Troubleshooting
40-524 PC210LC-10
40 Troubleshooting
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit (PC200LC_10-DXA9KB-400-A-Z0-A)
Action
Failure code PC-EPC (Rear) Solenoid Short Circuit
level Failure
L03 DXA9KB
Detail of • Abnormal current flows when pump controller drives R-PC-EPC solenoid, so pump
failure controller determines that short circuit exists in R-PC-EPC solenoid circuit.
• Stops driving R-PC-EPC solenoid.
machine
Related • Drive current to R-PC-EPC solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC solenoid current (R))
Cause Procedure, measuring location, criteria and remarks
Defective R-PC-EPC 1. Turn starting switch to OFF position.
1
(internal short circuit or Resis- Between V12 (male) (1) and (2) 3 to 14 z
ground fault) tance Between V12 (male) (1) and ground Min. 1 Mz
drive switch (internal short Between S25 (male) (5) and each
2 Switch Min. 1 Mz
circuit or ground fault) Resis- of (2) and (3)
position:
tance Between ground and each of S25
Normal Min. 1 Mz
(male) (2) and (3)
Short circuit or ground fault in a Check that emergency pump drive switch is at normal position (lower
3 wiring harness side).
Between CP02 (female) (104) and each of
Resis- (115), (117), (120) 3 to 14 z
tance
Ground fault in wiring harness to either female side.
4
(contact with ground circuit) Between ground and CP02 (female) (104) or
Min. 1 Mz
Resis- S25 (female) (3)
tance Between ground and S25 (female) (5) or V12
PC210LC-10 40-525
40 Troubleshooting
40-526 PC210LC-10
40 Troubleshooting
Failure code [DXE0KA] LS-EPC Sol Open Circuit (PC200LC_10-DXE0KA-400-A-Z0-A)
Action
Failure code LS-EPC Solenoid Open Circuit
level Failure
L01 DXE0KA
Detail of • No current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that open circuit exists in LS-EPC solenoid circuit.
Problem on • Travel speed is high with speed setting at Lo and Mi.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current to LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC solenoid 2. Disconnect connector V19, and connect T-adapters to male side.
1
Resis- Between V19 (male) (1) and (2)
3 to 14 z
tance
Open or short circuit in wiring 2. Disconnect connector CP02 and connect T-adapters to female side.
2
harness Resis- Between CP02 (female) (88) and each of (115),
(117), (120) 3 to 14 z
tance
Open circuit in wiring harness 2. Disconnect connectors CP02 and V19, and connect T-adapters to
contact of connector) Resis- Between CP02 (female) (88) and V19 (female)
(1) Max. 1 z
tance
Resis- Between V19 (female) (2) and each of CP02
(female) (115), (117), (120) Max. 1 z
tance
PC210LC-10 40-527
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
40-528 PC210LC-10
40 Troubleshooting
Failure code [DXE0KB] LS-EPC Sol Short Circuit (PC200LC_10-DXE0KB-400-A-Z0-A)
Action
Failure code LS-EPC Solenoid Short Circuit
level Failure
L01 DXE0KB
Detail of • Abnormal current flows when pump controller drives LS-EPC solenoid, so pump controller
failure determines that short circuit exists in LS-EPC solenoid circuit.
• Stops driving LS-EPC solenoid.
Problem on • Travel speed is high with speed setting at Lo and Mi.
machine • Work equipment speed and swing speed are high in fine control mode (L).
• Drive current to LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500 LS-EPC solenoid current)
Defective LS-EPC solenoid 1. Turn starting switch to OFF position.

2. Disconnect connector V19 and connect T-adapters to male side.
1 (internal short circuit or
ground fault) Resis- Between V19 (male) (1) and (2) 3 to 14 z
2 wiring harness Between CP02 (female) (88) and each of (115),
Resis- (117), (120) 3 to 14 z
tance
3 harness 2. Disconnect connectors CP02 and V19, and connect T-adapters to
Resis- Between ground and CP02 (female) (88) or V19
tance
PC210LC-10 40-529
40 Troubleshooting
Circuit diagram related to LS-EPC solenoid
40-530 PC210LC-10
40 Troubleshooting
Failure code [DXE4KA] Attachment Flow EPC Open Circuit (PC200-DXE4KA-400-A-00-

A)
Action Open circuit in Attachment flow throttle EPC circuit
Failure code
level Failure
DXE4KA
Details of • When attachment flow throttle EPC solenoid is driven, no current flows.
failure
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow throttle EPC solenoid can be checked with monitoring
function.
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch to ON position and set machine
in breaker mode (B).
attachment flow 2. Disconnect connector V30, and connect T-adapters to male side.
throttle EPC
1 solenoid
circuit)
Open circuit or
2 short circuit in

connector)
Resistance
controller
PC210LC-10 40-531
40 Troubleshooting
Circuit diagram related to service flow throttle EPC
40-532 PC210LC-10
40 Troubleshooting
Failure code [DXE4KB] Attachment Flow EPC Short Circuit (PC200-DXE4KB-400-A-00-

A)
Action Short circuit in attachment flow throttle EPC solenoid circuit
Failure code
level Failure
DXE4KB
Details of • When attachment flow throttle EPC solenoid is driven, abnormal current flows.
failure
• Stops outputting current to attachment flow throttle EPC solenoid.
Problem on
• Attachment does not move.
machine
• Drive current of attachment flow throttle EPC solenoid can be checked with monitoring
function.
Related (Code: 01700 Service solenoid current)
information • Method of reproducing failure code: Turn starting switch ON and set machine in breaker
mode (B).
attachment flow 2. Disconnect connector V30, and connect T-adapters to male side.
throttle EPC
1 solenoid
(internal short Resistance
circuit or ground Between V30 (male) (1) and ground Min. 1 Mz
fault)
Short circuit or 2. Disconnect connector CP02 and connect T-adapters to female side.
Resistance
wiring harness 2. Disconnect connectors CP02 and V30, and connect T-adapters to either
circuit) Between ground and CP02 (female)
Resistance (97), or V30 (female) (1) Min. 1 Mz
controller
PC210LC-10 40-533
40 Troubleshooting
Circuit diagram related to service flow throttle EPC
40-534 PC210LC-10
40 Troubleshooting
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit (PC200LC_10-DXE5KA-

400-A-Z0-A)
Action
Failure code Merge-divide Main Solenoid Open Circuit
level Failure
L01 DXE5KA
• No current flows when pump controller drives merge-divider (main) EPC solenoid, so
Detail of
pump controller determines that open circuit exists in merge-divider (main) EPC solenoid
failure
circuit.
• Stops output command to merge-divider main solenoid and merge-divider LS solenoid,
Action of and keeps pump always in merged state.
Problem on • Single operation speed of work equipment and swing is high in fine control mode (L).
machine • Machine does not turn easily during travel.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
information (Code: 08000 Merge-divider (main) solenoid current)
Defective merge-divider main 1. Turn starting switch to OFF position.

1 EPC solenoid (internal open 2. Disconnect connector V23, and connect T-adapters to male side.
circuit) Resis- Between V23 (male) (1) and (2)
3 to 14 z
tance
2
harness Resis- Between CP02 (female) (112) and each of
(115), (117), (120) 3 to 14 z
tance
contact of connector) Between CP02 (female) (112) and V23 (female)
Max. 1 z
Resis- (1)
tance Between V23 (female) (2) and each of CP02
(female) (115), (117), (120) Max. 1 z
PC210LC-10 40-535
40 Troubleshooting
Circuit diagram related to pump merge-divider main EPC solenoid
40-536 PC210LC-10
40 Troubleshooting
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit (PC200LC_10-DXE5KB-

400-A-Z0-A)
Action
Failure code Merge-divider Main Solenoid Short Circuit
level Failure
L01 DXE5KB
• Abnormal current flows when pump controller drives merge-divider (main) EPC solenoid,
Detail of
so pump controller determines that short circuit exists in merge-divider (main) EPC
failure
solenoid circuit.
• Drive current to merge-divider main EPC solenoid can be checked with monitoring
Related function.
information (Code: 08000 Merge-divider (main) solenoid current)
Defective merge-divider main 2. Disconnect connector V23, and connect T-adapters to male side.
1 EPC solenoid (internal short
circuit or ground fault) Resis- Between V23 (male) (1) and (2) 3 to 14 z
2 wiring harness Between CP02 (female) (112) and each of
Resis- (115), (117), (120) 3 to 14 z
tance
3 2. Disconnect connectors CP02 and V23, and connect T-adapters to
tance
PC210LC-10 40-537
40 Troubleshooting
Circuit diagram related to pump merge-divider main EPC solenoid
40-538 PC210LC-10
40 Troubleshooting
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit (PC200LC_10-DXE6KA-400-A-

Z0-A)
Action
Failure code Merge-divider LS Solenoid Open Circuit
level Failure
L01 DXE6KA
Detail of • No current flows when pump controller drives merge-divider (LS) EPC solenoid, so pump
failure controller determines that open circuit exists in merge-divider (LS) EPC solenoid circuit.
• Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related (Code: 08001 Merge-divider (LS) solenoid current)
Defective merge-divider LS 1. Turn starting switch to OFF position.

EPC solenoid (internal open 2. Disconnect connector V24, and connect T-adapters to male side.
1
circuit) Resis- Between V24 (male) (1) and (2)
3 to 14 z
tance
2
harness Resis- Between CP02 (female) (89) and each of (115),
(117), (120) 3 to 14 z
tance
contact of connector) Between CP02 (female) (89) and V24 (female)
Max. 1 z
Resis- (1)
tance Between V24 (female) (2) and each of CP02
(female) (115), (117), (120) Max. 1 z
PC210LC-10 40-539
40 Troubleshooting
Circuit diagram related to merge-divider LS EPC solenoid
40-540 PC210LC-10
40 Troubleshooting
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit (PC200LC_10-DXE6KB-400-A-

Z0-A)
Action
Failure code Merge-divider LS Solenoid Short Circuit
level Failure
L01 DXE6KB
• Abnormal current flows when pump controller drives merge-divider (LS) EPC solenoid, so
Detail of
pump controller determines that short circuit exists in merge-divider (LS) EPC solenoid
failure
circuit.
• Drive current to merge-divider LS EPC solenoid can be checked with monitoring function.
Related (Code: 08000 Merge-divider (LS) solenoid current)
Defective merge-divider LS 2. Disconnect connector V24, and connect T-adapters to male side.
1 EPC solenoid (internal short
circuit or ground fault) Resis- Between V24 (male) (1) and (2) 3 to 14 z
2 wiring harness Between CP02 (female) (89) and each of (115),
Resis- (117), (120) 3 to 14 z
tance
3 2. Disconnect connectors CP02 and V24, and connect T-adapters to
tance
PC210LC-10 40-541
40 Troubleshooting
Circuit diagram related to merge-divider LS EPC solenoid
40-542 PC210LC-10
40 Troubleshooting
Failure code [DY20KA] Wiper Working Abnormality (PC200-DY20KA-400-A-00-A)
Action Wiper operation malfunction

Failure code
level Failure
DY20KA
Details of • When windshield wiper is turned on, W signal to indicate that wiper blade reaches end of
failure cleaning area is not input.
Action of • Stops output of actuating signal to wiper motor.
Problem on • Wiper motor does not operate.
machine
• Signal input (ON/OFF) of W contact signal to indicate that wiper blade reaches end of
cleaning area can be checked with monitoring function.
(Code: 02204 Switch input 5)
• Method of reproducing failure code: Turn starting switch to ON position and set wiper
switch to INT or ON position.
Wiper position:
Defective wiper Both ends of Max. 1 z
motor cleaning area
Between M05
1 Wiper position:
(internal open (female) (6) and (5)
circuit) Resistance Other than both
Min. 1 Mz
ends of cleaning
area
Between M05 Wiper position:
(female) (1) and (3) Max. 20 z
Whole area
2. Disconnect connectors CP01 and CP02, and connect T-adapters to each
female side.
Wiper position:
Both ends of Max. 1 z
Open circuit or Between CP01 cleaning area
2 short circuit in (female) (56) and Wiper position:
wiring harness ground Other than both
Resistance Min. 1 Mz
ends of cleaning
area
Between CP02
(female) (114) and Wiper position:
Max. 20 z
(119) Whole area

2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connectors CP01 and CP02 and male
Open circuit in side of M05.
wiring harness Between CP01 (female) (56) and M05
3 (wire breakage or (male) (6) Max. 1 z
defective contact of Between M05 (male) (5) and ground
connector) (T01) Max. 1 z
Resistance
Between CP02 (female) (114) and M05
(male) (1) Max. 1 z
(male) (3) Max. 1 z
controller
PC210LC-10 40-543
40 Troubleshooting
Circuit diagram related to wiper
40-544 PC210LC-10
40 Troubleshooting
Failure code [DY20MA] Wiper Parking Abnormality (PC200-DY20MA-400-A-00-A)
Action Wiper resting malfunction

Failure code
level Failure
DY20MA
Details of • When windshield wiper rests, P signal to indicate that wiper blade is in rest area is not
failure input.
Action of • Stops output of signal for resting wiper to wiper motor.
Problem on • Wiper motor does not rest wiper blade.
machine
• Condition of P contact signal to indicate that wiper blade is in area can be checked with
• Method of reproducing failure code: Turn starting switch to ON position, set wiper switch
to INT or ON position, and then set it to OFF position.
Defective wiper Wiper position:
motor Max. 1 z
Between M05 Rest area
1
(internal open (female) (4) and (5) Wiper position:
circuit) Resistance Cleaning area Min. 1 Mz
Between M05 Wiper position:
(female) (1) and (3) Max. 20 z
Whole area
2. Disconnect connectors CP01 and CP02, and connect T-adapters to each
female side.
Wiper position:
Open circuit or Between CP01 Max. 1 z
Rest area
2 short circuit in (female) (75) and
wiring harness Wiper position:
ground Min. 1 Mz
Resistance Cleaning area
Between CP02
(female) (114) and Wiper position:
Max. 20 z
(119) Whole area

2. Disconnect connectors CP01, CP02, and M05.
3. Connect T-adapters to female sides of connectors CP01 and CP02 and male
Open circuit in side of M05.
wiring harness Between CP01 (female) (75) and M05
3 (wire breakage or (male) (4) Max. 1 z
defective contact of Between M05 (male) (5) and ground
connector) (T01) Max. 1 z
Resistance
(male) (1) Max. 1 z
(male) (3) Max. 1 z
controller
PC210LC-10 40-545
40 Troubleshooting
40-546 PC210LC-10
40 Troubleshooting
Failure code [DY2CKB] Washer Drive Short Circuit (PC200-DY2CKB-400-A-00-A)
Action Short circuit in washer drive circuit

Failure code
level Failure
DY2CKB
Details of • Abnormal current flows when activating window washer motor drive.
failure
• Stops output of activating signal to washer motor.
Problem on • Window washer does not operate.
machine
Related • Method of reproducing failure code: Turn starting switch to ON position and turn washer
information switch to ON position.
1 Defective fuse No.4 If the fuse is broken, the circuit probably has a ground fault, etc. (See Cause 5.)
Defective washer 1. Turn starting switch to OFF position.
motor 2. Disconnect connector M06 and connect T-adapters to male side.
2 (internal open Between M06 (male) (1) and (2) 5 to 20 z
circuit or ground Resistance Between ground and each of M06
fault) (male) (1) and (2) Min. 1 Mz

Defective diode 2. Disconnect diode array D02 and connect T-adapters to mail side.
array D02
3 a Check by using multimeter in diode range.
(internal open
circuit) Between D02 (male) (6) (+) and (2) (-) Continuity
Continuity
4 short circuit in 2. Disconnect connectors CP01 and connect T-adopters to each female side.
wiring harness Voltage Between CP01 (female) (3) and ground 20 to 30 V
Ground fault in 2. Remove fuse F01 (4).
wiring harness 3. Disconnect connectors M06, CP01, and D02, and connect T-adapters to any
circuit) Between ground and F01 (4), M06
(female) (2), or D02 (female) (2) Min. 1 Mz
Resistance
Between ground and CP01 (female) (3),
M06 (female) (1), or D02 (female) (6) Min. 1 Mz

wiring harness 2. Disconnect connectors CP01 and M06, and connect T-adapters to female side
6 of CP01.
(contact with 24 V
3. Remove fuse No. 4.
circuit)
Voltage Between CP01 (female) (3) and ground Max. 1 V
controller
PC210LC-10 40-547
40 Troubleshooting
Circuit diagram related to window washer motor
40-548 PC210LC-10
40 Troubleshooting
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit (PC200-DY2DKB-400-A-00-A)
Action Short circuit in wiper motor drive (normal rotation) circuit

Failure code
level Failure
DY2DKB
Details of • Abnormal current flows when activating wiper motor drive (normal rotation side).
failure
• Stops output of activating signal to wiper motor drive (normal rotation side).
Problem on • Windshild wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
Defective wiper 1. Turn starting switch to OFF position.
motor 2. Disconnect connector M05 and connect T-adapters to female side.
1 (internal short Continuity Between M05 (female) (1) and (3) Continuity
circuit or ground
fault) Resistance Between M05 (female) (3) and ground Min. 1 Mz
Short circuit in 2. Disconnect connectors CP02 and M05 and connect T-adapters to either
2 wiring harness harness side.
Between CP02 (female) (119) and (114),
Resistance or between M05 (male) (1) and (3) Min. 1 Mz

wiring harness 2. Disconnect connectors CP02 and M05, and connect T-adapter to either
3 harness side.
(contact with GND
(119) or M05 (male) (3)
If no failure is found by above checks, pump controller is defective. (Since this is
• Reference
Defective pump 3. Turn starting switch to ON position.
4
controller 4. Set wiper switch to ON and OFF to perform troubleshooting.
Wiper switch: OFF Max. 3 V
Between M05 (3) Pulse of voltages
Voltage
and (5) Wiper switch: ON below 3 V and
above 20 V
PC210LC-10 40-549
40 Troubleshooting
40-550 PC210LC-10
40 Troubleshooting
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit (PC200-DY2EKB-400-A-00-A)
Action Short circuit in wiper motor drive (reverse rotation) circuit

Failure code
level Failure
DY2EKB
Details of • Abnormal current flows when activating wiper motor drive (reverse rotation side).
failure
• Stops activating signal to wiper motor drive (reverse rotation side).
Problem on • Windshild wiper does not operate.
machine
information • Method of reproducing failure code: Turn starting switch to ON position and set wiper
Defective wiper 1. Turn starting switch to OFF position.
motor 2. Disconnect connector M05 and connect T-adapters to female side.
1 (internal short Continuity Between M05 (female) (1) and (3) Continuity
circuit or ground
fault) Resistance Between M05 (female) (1) and ground Min. 1 Mz
Short circuit in 2. Disconnect connectors CP02 and M05 and connect T-adapters to either
2 wiring harness harness side.
Between CP02 (female) (119) and (114),
Resistance or between M05 (male) (1) and (3) Min. 1 Mz

wiring harness 2. Disconnect connectors CP02 and M05, and connect T-adapters to either
3 harness side.
(contact with GND
(114) or M05 (male) (1)
If no failure is found by above checks, pump controller is defective. (Since this is
• Reference
Defective pump 3. Turn starting switch to ON position.
4
controller 4. Turn wiper switch ON and OFF to perform troubleshooting.
Wiper switch: OFF Max. 3 V
Between M05 (3) Pulse of voltages
Voltage
and (5) Wiper switch: ON below 3 V and
above 20 V
PC210LC-10 40-551
40 Troubleshooting
40-552 PC210LC-10
40 Troubleshooting
Troubleshooting of electrical system (E-mode)
Troubleshooting of electrical system (E-mode) (ALL-3840-001-A-01-A)
E-1 Engine does not start (Engine does not crank) (PC200LC_10-A21-400-A-Z0-A)
Failure • Engine does not start (engine does not crank)

• Engine starting circuit has following two start lock mechanisms.
1. Start lock by password protection of machine monitor
2. Start lock by lock lever position
Related information • If failure symptom "Battery relay operation sound is not heard" appears when
starting switch is turned to ON position, perform troubleshooting for E-1 also.
• If machine monitor does not light up when turning starting switch ON, main electric
power supply system is supposed to be defective. Perform the troubleshooting for E-
5 (lines of fusible link F05 and fuse No. 17).
Loose terminal connection or 1. Turn starting switch to OFF position.

1 open circuit at terminal Check terminals of starting motor, alternator, battery relay, grounds T04
and T08, etc.
Between battery relay terminal R01 and
Defective contact (grounding) ground
2 between battery relay and Resis-
frame a Use machine frame as GND for Max. 1 z
tance
measurement.
a Loosened or rusted terminal T08
a Be ready with starting switch at OFF, then perform troubleshooting
Insufficient battery capacity without turning starting switch to ON position.
3
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
Defects of engine controller power supply and ACC signal are indicated
Defective engine controller
4 with failure codes [DB2QKR] and [DB2RKR]. If these codes appear,
system
perform troubleshooting for causes 1 to 3 of [DB2QKR] first.
Defective fuse No. 3 in fuse If fuse is blown, circuit probably has ground fault. (See cause 22.)
5
box F01
1. Turn starting switch to ON position (to connect ACC).
6 Defective battery relay system
a If battery relay operation sound is not heard, go to troubleshooting
on cause 19.
1. Turn starting switch to OFF position, and remove fuse No. 3 in fuse
box F01.
Defective fusible link F04 or 2. Turn starting switch to ON position (to connect ACC).
7 wiring harness Between input terminal (1A) of fuse box F01-3
Voltage 20 to 30 V
and ground
a If voltage is unusual, go to troubleshooting on cause 10.
2. Remove fuse No. 18 (30 A) of fuse box F01. (to prevent engine start
Defective starting switch, lock during troubleshooting).
lever switch, starting motor 3. Insert T-adapters into connector E10.
8 cut-off relay R06, personal 4. Turn starting switch to START position and hold (two persons
code relay R07, battery relay, required for this check).
or wiring harness Voltage Between E10 (1) and ground 20 to 30 V
a If voltage is unusual, go to cause 13.
PC210LC-10 40-553
40 Troubleshooting

If fusible link is blown, circuit may have ground fault. In this case,
perform troubleshooting for cause 6 first.
9 Defective fusible link F04 • Fuses No. 1 to 13 are connected to fusible link F04.
a This fusible link protects wide area of circuit. If no failure is found by
check on cause 6, reproduce failure and locate ground fault point by
sound and burnt smell.
1. Turn starting switch to OFF position, and turn battery disconnect
Open circuit in wiring harness switch to OFF position.
1 (To prevent short circuit during troubleshooting)
10 2. Disconnect fusible link F04 and No. 3 of fuse box F01.
contact of connector) 3. Connect T-adapters to male side of connector F04.
Between battery relay (R03) and F04 (male)
Resis- (1) Max. 1 z
tance
Between F04 (male) (2) and F01-1A Max. 1 z
Ground fault in wiring harness 2. Disconnect fusible link F04, fuse No. 3 of fuse box F01, and battery
11 1 relay R03 (M terminal).
(contact with ground circuit) 3. Connect T-adapters to male side of connector F04.
Between ground and battery relay R03
Resis- (harness side) or F04 (male) (1) Min. 1 Mz
tance
Between ground and F04 (male) (2) or F01-1A Min. 1 Mz
2. Disconnect connector H15 and connect T-adapters to male side.
3. After troubleshooting, perform troubleshooting again with starting
switch at ON and START positions.
Defective starting switch Between H15 (male) Starting switch: OFF Min. 1 Mz
12
(internal open circuit) (1) and (2) Starting switch: ON Max. 1 z
Between H15 (male) Starting switch: OFF Min. 1 Mz
Resis-
(1) and (5) Starting switch: ON Max. 1 z
tance
Starting switch: OFF Min. 1 Mz
Between H15 (male)
(1) and (4) Starting switch:
Max. 1 z
START
Defective lock lever switch 1. Turn starting switch to OFF position.
13 2. Disconnect connector S14 and connect T-adapters to female side.
Resis- Between S14 (female) Lock lever: FREE Min. 1 Mz
tance (1) and (3) Lock lever: LOCK Max. 1 z
40-554 PC210LC-10
40 Troubleshooting

2. Remove starting motor cut-off relay R06 and personal code relay
R07.
Defective starting motor cut-off 200 to 600
relay R06 or personal code Between R06 (male) (1) and (2)
z
14 relay R07
Between R06 (male) (3) and (4) Max. 1 z
(internal open or short circuit) Resis- Between R06 (male) (3) and (5) Min. 1 Mz
tance Between R07 (male) (1) and (2) 200 to 600
z
Between R07 (male) (3) and (4) Max. 1 z
Between R07 (male) (3) and (5) Min. 1 Mz
Defective alternator 2. Turn starting switch to ON position.
15 Input from
(internal short circuit) Between alternator IG terminal and
Voltage alternator Max. 1 V
ground
generation
2. Turn starting switch to START position and perform troubleshooting.
Between starting motor terminal B Power
(SB) and ground supply 20 to 30 V
Defective starting motor
16 Voltage Starting
(internal defect) Between starting motor terminal C input to
(SC) and ground 20 to 30 V
starting
motor
If power supply and starting input to starting motor are normal but
starting motor does not rotate, starting motor is defective.
2. Disconnect connector D01 and connect T-adapters to diode.
Defective diode D01 a Check by using multimeter in diode range.

17 Between D01 (male) (1) (+) and (5) (-) No continuity
(internal open or short circuit)
• Battery relay
Resis- Between terminal R02 and H15 (female) (2)
Max. 1 z
tance
• Battery relay
18 (wire breakage or defective 2. Turn starting switch to ON position.
contact of connector) a To check to where 24 V is supplied to locate open section
Between terminals R04 and R01 20 to 30 V
Voltage
Between terminal R01 and ground Max. 1 V
PC210LC-10 40-555
40 Troubleshooting

• Alternator and starting motor
2. Turn the battery disconnect switch to the OFF position.
3. Insert T-adapters into connectors H15, S14, R07, and E10.
5. Turn starting switch to START position and perform troubleshooting.
a To check to where 24 V is supplied to locate open section
Between H15 (4) and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Between S14 (3) and ground 20 to 30 V
Voltage Between R07 (4) and ground 20 to 30 V
Between E10 (1) and ground 20 to 30 V
Between alternator B terminal and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
• If fuse or fusible link is blown, replace it with a new one.
2. Disconnect connectors H15, S14, R06, R07, and CM01.
Open circuit in wiring harness 3. Connect T-adapters to female sides of H15, R06, R07, CM01 and to
18 (wire breakage or defective male side of S14.
contact of connector) 4. Remove fuse F01-3.
Between H15 (female) (4) and R06 (female) (3) Max. 1 z
Between R06 (female) (5) and R07 (female) (3) Max. 1 z
Between R07 (female) (1) and S14 (male) (1) Max. 1 z
Between R07 (female) (2) and CM01 (female)
(6) Max. 1 z
Between R07 (female) (4) and starting motor
Max. 1 z
terminal S
Between alternator terminal B and starting
Max. 1 z
Resis- motor terminal B
tance Between starting motor B and battery relay
Max. 1 z
R03
Between alternator terminal R (terminal M18)
and starting motor terminal R Max. 1 z
Between alternator terminal R and D01
Between F01-3 and S14 (male) (1) Max. 1 z
Between S14 (male) (3) and R06 (male) (1) Max. 1 z
Between R06 (female) (2) and ground (T05) Max. 1 z
Defective battery relay If only terminal R03 voltage is unusual among results of battery relay
19 checks on cause 18, battery relay is defective.
(Does not work)
2. Disconnect connectors H15, S14, R06, R07, and E10.
3. Connect T-adapters to female sides of H15, R06 and R07, and to
male side of S14.
Between ground and H15 (female) (4) or R06
20 Between ground and R06 (female) (5) or R07
(contact with ground circuit) Min. 1 Mz
(female) (3)
Resis- Between ground and R07 (female) (4) or E10
tance (female) (1) Min. 1 Mz
Between ground and F01-3 or S14 (male) (1) Min. 1 Mz
Between ground and S14 (male) (3) or R06
40-556 PC210LC-10
40 Troubleshooting

2. Insert T-adapters into connector E10.
Voltage Between ground and E10 (2) or E08 (1) Max. 1 V
PC210LC-10 40-557
40 Troubleshooting
Circuit diagram related to engine starting circuit
40-558 PC210LC-10
40 Troubleshooting
E-2 Manual preheating system does not work (PC220_10-FEM-400-A-00-A)
Failure • Manual preheating function does not work.

a This troubleshooting describes procedures to be followed when manual preheating does
not function to heat clectrical intake air heater mounting section.
• "Automatic preheating function" and "manual preheating function" are available for
preheating. Whichever function is turned on, preheating monitor lights up. (When only
Related preheating monitor does not light up, perform troubleshooting for "E-4 Preheating monitor
information does not light up when preheater is operated(PAGE 40-564) ")
• If "machine monitor does not light up" or "battery relay does not make operating sound"
when turning starting switch to ON position, main electric power supply system may be
defective. So, perform troubleshooting for E-5 and E-1.
• Before performing troubleshooting, check that no related failure code is displayed.
(If failure codes [D110KB] is displayed, perform troubleshooting for it first.)
Defective fuse No. If fuse No. 17 in fuse box F01 is broken, circuit probably has ground fault. In this
1 case, perform troubleshooting for cause 8 first.
17 in fuse box F01
Loose terminal or 1. Turn starting switch to OFF position.
2 open circuit at Check terminals of heater relay, battery relay, clectrical intake air heater, etc.
terminal
Defective diode 1. Turn starting switch to OFF position.
D02 2. Disconnect connector D02 and connect T-adapters to diode.
3 (internal open a Check by using multimeter in diode range.
circuit or short Between D02 (male) (1) (+) and (5) (-) No continuity
circuit ) Continuity
Defective clectrical 1. Turn starting switch to OFF position.
intake air heater 2. Disconnect terminal E01.
4
(internal open
Continuity Between E01 terminal and ground Continuity
circuit)
2. Disconnect battery ground cable.
Defective starting 3. Disconnect connector H15 and connect T-adapters to male side.
5 4. Turn starting switch to OFF/HEAT position and perform troubleshooting.
switch
Between H15 OFF Min. 1 Mz
Resistance (male) (1) and (3) HEAT Max. 1 z
short circuit in 2. Disconnect connectors CM01 and H15, and connect T-adapters to female side
6
wiring harness of H15.
Continuity Between H15 (female) (3) and ground Continuity
Open circuit or
7 short circuit in
wiring harness Between input terminal on contact side
Voltage 20 to 30 V
of heater relay and ground
2. Disconnect heater relay terminal R16.
Open circuit or a To prevent current from flowing in heater when starting switch is turned to
8 short circuit in HEAT position.
wiring harness 3. Turn starting switch to HEAT position (connect R1).
Between heater relay terminal R15 and
Voltage 20 to 30 V
ground
Defective heater If no failure is found by check on causes 6 and 7, and heater relay operation sound
9 relay is not heard, heater relay is defective.
PC210LC-10 40-559
40 Troubleshooting

a If no failure is found by checks on causes 6 and 7, this check is not required.
2. Disconnect connectors H15 and CM01, terminals R15 and E01, and starting
Ground fault in motor terminal B.
wiring harness Between heater relay terminal R15
10 (contact with GND Min. 1 Mz
(wiring harness side) and ground
circuit) Between input terminal on contact side
Resistance of heater relay and ground Min. 1 Mz
Between heater relay terminal E01
(wiring harness side) and ground Min. 1 Mz
40-560 PC210LC-10
40 Troubleshooting
Circuit diagram related to preheating of engine
PC210LC-10 40-561
40 Troubleshooting
E-3 Automatic preheating system does not work (PC220_10-FE1-400-A-00-A)
Failure • Automatic preheating function does not work.

• Automatic preheating function works when boost temperature is - 4°C or below.
(Monitoring code: 18500 Boost temperature)
• If automatic preheating does not work, check if manual preheating works.
Related • Engine controller generates failure code [CA2555] or [CA2556] if it detects failure in
information primary (coil) side of preheat relay (connector R18).
• Engine controller generates failure code [CA153] or [CA154] if it detects failure in boost
temperature sensor.
Defective fuse No. If fuse No. 6 in fuse box F01 is blown, circuit probably has ground fault. In this
1 case, perform troubleshooting for cause 5 first.
6 in fuse box F01
Defective preheat 1. Turn starting switch to OFF position.
relay R18 2. Replace preheat relay (connector R18) with other relay like horn relay
(connector).
2 (internal open
circuit or short
If automatic preheating function works when boost temperature is - 4°C or below,
circuit)
original preheat relay is defective.
2. Disconnect connectors CM01 and R18, and connect T-adapters to female side
of R18.
Open circuit or
3 ground fault in a If resistance is above 1 Mz, wiring harness has open circuit. If resistance is
wiring harness below 1 z, wiring harness has short circuit.
a Heater relay coil resistance
Resistance Between R18 (female) (5) and ground Approx. 20 z
Open circuit in 2. Disconnect connectors R18 and CM01, and connect T-adapters to female side
wiring harness of R18.
4 (wire breakage or 3. Remove fuse No. 6 in fuse box F01.
defective contact of Between R18 (female) (3) and F01-6 Max. 1 z
connector) Resistance Between R18 (female) (5) and heater
relay terminal R15 Max. 1 z
If the fuse is not blown, this check is not required.
Ground fault in
wiring harness
5 2. Disconnect connectors CM01, R18, and starting motor terminal B, and connect
(contact with GND
T-adapters to female side of R18.
circuit)
Resistance Between R18 (female) (3) and ground Min. 1 Mz
40-562 PC210LC-10
40 Troubleshooting
PC210LC-10 40-563
40 Troubleshooting
E-4 Preheating monitor does not light up when preheater is

operated (PC220_10-FE2-400-A-00-A)
Failure • While performing preheating, preheating monitor does not light up.
• "Automatic preheating function" and "manual preheating function" are available for
Related preheating. When either function is activated, preheating monitor lights up.
information • Check that manual preheater operates first.
Open circuit in 2. Disconnect connectors H15, CM01, and R18, and connect T-adapters to each
1 (wire breakage or Between H15 (female) (3) and CM01
defective contact of (female) (12) Max. 1 z
Between R18 (female) (5) and CM01
• Reference
Defective machine 3. Disconnect heater relay terminal R16.
2
monitor
a To prevent current from flowing in heater when starting switch is turned to
HEAT position.
4. Turn starting switch to HEAT position.
Resistance Between CM01 (12) and (3) 20 to 30 V
40-564 PC210LC-10
40 Troubleshooting
PC210LC-10 40-565
40 Troubleshooting
E-5 When starting switch is turned to ON position, machine monitor

displays nothing (PC200LC_10-FEG-400-A-Z0-A)
Failure • When starting switch is turned to ON position, machine monitor displays nothing
• When starting switch is turned to ON position, machine monitor displays KOMATSU
logo screen, password input screen (if set), breaker mode confirmation screen (if
selected), check before starting screen, working mode and travel speed
Related information confirmation screen, and standard screen in order.
• When engine is started, battery voltage may lower suddenly, depending on ambient
temperature and condition of battery.
Battery disconnect switch Turn starting switch to OFF and then make sure battery disconnect
1 inadvertently left off switch is ON.
a Be ready with starting switch at OFF, then perform troubleshooting
Insufficient battery capacity without turning starting switch to ON position.
2
Battery voltage (two pieces) Min. 24 V
Electrolyte specific gravity (each) Min. 1.26
If the fusible link is burnt out, the circuit probably has a grounding fault.
3 Defective fusible link F05 (See Cause 9.)
If the fuse is broken, the circuit probably has a grounding fault. (See
4 Defective fuse F01-15 Cause 9.)
If the fuse is broken, the circuit probably has a grounding fault. (See
5 Defective fuse F01-17 Cause 9.)
Loose terminal or open circuit 1. Turn starting switch to OFF position.
6
at terminal Check terminals of battery relay, etc.
Defective wiring harness, 3. Turn the battery disconnect switch to ON position, and turn the
7 starting switch, or machine starting switch to ON position (connect ACC).
monitor Between CM01 (1) and (3) 20 to 30 V
2. Disconnect connector H15 and connect T-adapters to male side.
3. Turn starting switch to ON position and perform troubleshooting
Defective starting switch again.
8
Between H15 (male) Turn starting switch to
Min. 1 Mz
Resis- (1) and (5) OFF position.
tance Between H15 (male) Turn starting switch to
(1) and (5) ON position. Max. 1 z
40-566 PC210LC-10
40 Troubleshooting

If no failure is found by check on cause 7, this check is not required.
2. Disconnect fusible link F05, No. 15 and 17 fuses of F01, and
connectors H15 and CM01.
3. Connect T-adapters to male side of connector F05 and female side
of H15 and CM01.
Between battery (-) and ground Max. 1 z
Open circuit in wiring harness Between battery (+) and F05 (male) (1) Max. 1 z
9
Between F05 (male) (2) and F01-16F Max. 1 z
Between F01-17 and each of CM01 (female)
Max. 1 z
Resis- (1) and (2)
tance Between ground (T04) and CM01 (female) (3),
(4) Max. 1 z
Between F01-17 and H15 (female) (1) Max. 1 z
Between H15 (female) (5) and F01-15E Max. 1 z
Between F0-15 and CM01 (female) (10) Max. 1 z
If no failure is found by checks on causes 3 to 5 and 7, this check is not
required.
2. Disconnect fusible link F05, No. 17 of fuse F01, terminal 14D, and
connectors H15, CM01, and CP01.
3. Connect T-adapters to male side of connector F05 and female side
Ground fault in wiring harness of H15 and CM01.
10 Between battery (+) or F05 (male) (1) and
(contact with ground circuit) Min. 1 Mz
ground
Between ground and F05 (male) (2) or F01-16F Min. 1 Mz
Resis- Between F01-17 and ground, or between
tance CM01 (female) (1), (2) and ground, or between Min. 1 Mz
H15 (female) (1) and ground
Between ground and H15 (female) (5) or CM01
If no failure is found by above diagnoses, machine monitor is defective.
PC210LC-10 40-567
40 Troubleshooting
Circuit diagram related to machine monitor power supply
40-568 PC210LC-10
40 Troubleshooting
E-6 When starting switch is turned to ON position (before starting

engine), engine oil level monitor lights up in yellow (PC220_10-FEJ-400-A-00-A)
• When starting switch is turned to ON position (with engine stopped), engine oil level
Failure monitor lights up in yellow.
Related
information
Defective engine oil Carry out troubleshooting for failure code [B@BAZK].
level switch system
1
(Machine monitor
system)
monitor
PC210LC-10 40-569
40 Troubleshooting
E-7 When starting switch is turned to ON position (before starting

engine), radiator coolant level monitor lights up in yellow (PC220_10-FEH-400-A-00-A)
• When starting switch is turned to ON position (with engine stopped), radiator coolant level
Failure monitor lights up in yellow.
Related
information
Low radiator Coolant level may be low. Check coolant level and add coolant if necessary.
coolant level
1
(When system
works properly)
Defective radiator Carry out troubleshooting for failure code [B@BCZK].
2 sub tank coolant
level switch system
40-570 PC210LC-10
40 Troubleshooting
E-8 Coolant temperature monitor lights up in white while engine is

running (PC220_10-FES-400-A-00-A)
Failure • Engine coolant temperature monitor lights up white while engine is running.
Related transmitted to machine monitor through CAN communication system.
information • Engine coolant temperature can be checked with monitoring function.
(Code: 04107 Engine coolant temperature)
Insufficient warm-If coolant temperature monitor lights up in white, engine coolant temperature may
up of machine be low (below approx. 30°C). Perform warm-up operation.
1
(when system • Lighting up in white: Engine coolant temperature is low.
works properly) • Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by above check, engine coolant temperature gauge system
Defective engine may be defective. Perform the following troubleshooting.
coolant • E-19 Coolant temperature gauge indicates either Min. or Max. and does not
2 temperature gauge move(PAGE 40-582)
system • E-20 Coolant temperature gauge indicates incorrect temperature (indicates
PC210LC-10 40-571
40 Troubleshooting
E-9 Hydraulic oil temperature monitor lights up in white while engine is

running (PC220_10-FEU-400-A-00-A)
Failure • Hydraulic oil temperature monitor lights up white while engine is running.
information • Hydraulic oil temperature can be checked with monitoring function.
Insufficient warm- If coolant temperature monitor lights up in white, engine coolant temperature may
up of machine be low (below approx. 30°C). Perform warm-up operation.
1
(when system • Lighting up in white: Engine coolant temperature is low.
works properly) • Lighting up in blue: Engine coolant temperature is proper.
If no failure is found by above check, hydraulic oil temperature gauge system may
be defective. Perform the following troubleshooting.
Defective hydraulic
oil temperature • E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does
2
gauge system not move(PAGE 40-584)
• E-22 Hydraulic oil temperature gauge indicates incorrect temperature
(indicates neither Min. nor Max.)(PAGE 40-586)
40-572 PC210LC-10
40 Troubleshooting
E-10 Charge level monitor lights up while engine is running (PC220_10-FEP-400-A-00-

A)
Failure • Charge level monitor lights up while engine is running.

Related • Power generation signal from alternator can be checked with monitoring function.
information (Code: 04300 Charge voltage)
Defective alternator Perform troubleshooting for failure code [AB00KE].
1 system
PC210LC-10 40-573
40 Troubleshooting
E-11 Fuel level monitor lights up in red while engine is running (PC220_10-FEQ-
400-A-00-A)
Failure • Fuel level monitor lights up in red while engine is running.

Related • Signal voltage of fuel level sensor can be checked with monitoring function.
information (Code: 04200 Fuel sensor voltage)
Low fuel level Fuel level may be low. Check it and add fuel if necessary.
1 (When system
works properly)
If no failure is found by above checks, fuel level gauge system may be defective.
Perform troubleshooting.
Defective fuel level • E-17 Fuel gauge indicates either full or empty and does not move(PAGE 40-
2 gauge system 580)
• E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)
(PAGE 40-581)
40-574 PC210LC-10
40 Troubleshooting
E-12 Air cleaner clogging monitor lights up in yellow while engine is

running (PC220_10-FER-400-A-00-A)
Failure • Air cleaner clogging monitor lights up in yellow while engine is running.
Related • Air cleaner clogging switch signal can be checked with monitoring function.
information (Code: 04501 Monitor Input 2)
Clogging of air Air cleaner may be clogged. Check it, then clean or replace if necessary.
cleaner
1
(When system
works properly)
Defective air Carry out troubleshooting for failure code [AA10NX].
2 cleaner clogging
switch system
PC210LC-10 40-575
40 Troubleshooting
E-13 Water separator monitor lights up while engine is running (PC220_10-FET-

400-A-00-A)
Failure • Water separator monitor lights up while engine is running.

Related • Water level sensed by WIF sensor can be checked with monitoring function.
information (Code: 18800 Condition of WIF sensor)
High water level in Water is detected in water separator. Check and drain water separator.
water separator
1
(When system
works properly)
Defective fuel filter If no failure is found by above checks, fuel filter system may be defective. Perform
sensor system troubleshooting for failure codes [CA428] and [CA429].
2
(engine controller
circuit)
monitor
40-576 PC210LC-10
40 Troubleshooting
E-14 Coolant temperature monitor lights up in red while engine is

running (PC220_10-FEV-400-A-00-A)
Failure • Engine coolant temperature monitor lights up in red while engine is running.
(Code: 04107 Engine coolant temperature)
If monitor lights up in red, engine coolant temperature may be high (about 102°C
Overheating of or above). Decrease engine coolant temperature (Run engine at low idle).
engine coolant • Lighting up in red: Engine coolant temperature is high (overheating).
1 • Lighting up in blue: Engine coolant temperature is proper.
(When system
works properly) Perform troubleshooting for failure code "S-17 Coolant temperature rises too high
(Overheating)".
If no failure is found by above check, engine coolant temperature gauge system
Defective engine may be defective. Perform the following troubleshooting.
coolant • E-19 Coolant temperature gauge indicates either Min. or Max. and does not
2 temperature gauge move(PAGE 40-582)
system • E-20 Coolant temperature gauge indicates incorrect temperature (indicates
PC210LC-10 40-577
40 Troubleshooting
E-15 Hydraulic oil temperature monitor lights up in red while engine is

running (PC220_10-FEW-400-A-00-A)
Failure • Hydraulic oil temperature monitor lights up in red while engine is running.
• Signal of hydraulic oil temperature sensor is input to pump controller and then the data is
information • Hydraulic oil temperature can be checked with monitoring function.
Overheating of If monitor lights up in red, hydraulic oil temperature may be high (about 102°C or
hydraulic oil above). Decrease hydraulic oil temperature (Run engine at low idle or stop it).
1
(When system • Lighting up in red: Hydraulic oil temperature is high (overheating).
works properly) • Lighting up in blue: Hydraulic oil temperature is proper.
If no failure is found by above check, hydraulic oil temperature gauge system may
be defective. Perform the following troubleshooting.
Defective hydraulic
oil temperature • E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does
2
gauge system not move(PAGE 40-584)
• E-22 Hydraulic oil temperature gauge indicates incorrect temperature
(indicates neither Min. nor Max.)(PAGE 40-586)
40-578 PC210LC-10
40 Troubleshooting
E-16 Engine oil pressure monitor lights up in red while engine is

running (PC220_10-FEX-400-A-00-A)
Failure • Engine oil pressure monitor lights up in red while engine is running.
• Signals from the engine oil pressure switch is input to the engine controller. If engine oil
Related pressure switch is turned ON while engine is running, failure code [B@BAZG] is
information transmitted from engine controller to machine monitor through CAN.
Low engine oil Engine oil level may be low. If oil level is low, carry out troubleshooting in "S-14
pressure Engine oil pressure drops(PAGE 40-719)".
1
(When system
works properly)
Defective engine oil If no abnormality is found by above diagnoses, engine oil pressure switch system
2 pressure switch may be defective. Carry out troubleshooting for failure code [CA435].
system
PC210LC-10 40-579
40 Troubleshooting
E-17 Fuel gauge indicates either full or empty and does not move (PC220_10-
FGE-400-A-00-A)
• While fuel is added, fuel level gauge does not rise from red range (E).
Failure • While fuel level is low, fuel level gauge does not lower from top green range (F).
Defective fuel level 1. Starting switch: OFF
sensor 2. Disconnect connector P21 and connect T-adapters to male side.
1 Between P21 Fuel level: FULL Approximately 12 z
(internal open or
short circuit) Resistance (male) (1) and
ground Fuel level: EMPTY 85 to 110 z
Open circuit or 2. Disconnect connector CM01 and connect T-adapter to female side.
2 short circuit in Between CM01 Fuel level: FULL Approximately 12 z
wiring harness Resistance (female) (15) and
Open circuit in a if no failure is found by check on cause 2, this check is not required.
wiring harness 1. Starting switch: OFF
3 (wire breakage or 2. Disconnect connectors CM01 and P21, and connect T-adapters to each female
connector) Between CM01 (female) (15) and P21

Ground fault in 2. Disconnect connectors CM01 and P21, and connect T-adapter to either female
4
(contact with Between CM01 (female) (15) and
ground circuit) Resistance ground, or between P21 (female) (1) and Min. 1 Mz
ground
Hot short circuit in 2. Disconnect connector P21.
wiring harness 3. Insert T-adapter into connector CM01 or connect T-adapter to female side of
5 connector P21.
(contact with 24 V 4. Starting switch: ON
circuit)
Between CM01 (15) and ground, or
Voltage Approx. 3.3 V
between P21 (female) (1) and ground
monitor
Circuit diagram related to fuel level sensor
40-580 PC210LC-10
40 Troubleshooting
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor
empty) (PC220_10-FGF-400-A-00-A)
• Indication of fuel level gauge is different from actual fuel level.
Failure • Indication of fuel level gauge is different from display of fuel level monitor.
Defective fuel level 1. Starting switch: OFF
sensor 2. Disconnect connector P21 and connect T-adapters to male side.
1 Between P21 Fuel level: FULL Approximately 12 z
(internal open or
short circuit) Resistance (male) (1) and
a Turn starting switch to ON position or start engine and perform troubleshooting.

Reading of fuel
Fuel level
level gauge Blue
304 l
6
Reading of fuel
Fuel level
level gauge Blue
245 l
5
Reading of fuel
Fuel level
Defective machine level gauge Blue
2 Color of monitor 200 l
monitor 4
light (a) Reading of fuel
Fuel level
level gauge Blue
100 l
3
Reading of fuel
Fuel level
level gauge Blue
60 l
2
Reading of fuel
Fuel level
level gauge Red
41 l
1
Fuel level gauge and fuel level monitor
PC210LC-10 40-581
40 Troubleshooting
E-19 Coolant temperature gauge indicates either Min. or Max. and does
not move (PC220_10-FGG-400-A-00-A)
• While engine coolant temperature is rising properly, temperature gauge indicator does not
rise above white range (C).
Failure • Although engine coolant temperature is stabilized at the proper level, temperature gauge
rises to red range (H).
information • Engine coolant temperature can be checked with monitoring function
(Code: 04107 Coolant temperature)
Defective engine The engine coolant temperature sensor system may be defective. Carry out
coolant troubleshooting for failure codes [CA144] and [CA145].
system
monitor
Engine coolant temperature gauge and engine coolant temperature

monitor
40-582 PC210LC-10
40 Troubleshooting
E-20 Coolant temperature gauge indicates incorrect temperature

(indicates neither Min. nor Max.) (PC220_10-FGH-400-A-00-A)
• Indication of engine coolant temperature gauge is different from actual engine coolant
temperature.
Failure • Indication of engine coolant temperature gauge is different from display of engine coolant
temperature monitor.
• Signal voltage of engine coolant temperature sensor is input to engine controller and then
Related data is transmitted to machine monitor through CAN communication system.
(Code: 04107 Coolant temperature)
Defective engine The engine coolant temperature sensor system may be defective. Carry out
coolant troubleshooting for failure codes [CA144] and [CA145].
system
coolant
Engine coolant
temperature gauge
temperature Red
level
105°C
6
coolant
Engine coolant
temperature gauge
temperature Red
level
102°C
5
coolant
Engine coolant
temperature gauge
temperature Blue
Defective machine level
2 Color of monitor 100°C
monitor 4
light (a) coolant
Engine coolant
temperature gauge
temperature Blue
level
85°C
3
coolant
Engine coolant
temperature gauge
temperature Blue
level
60°C
2
coolant
Engine coolant
temperature gauge
temperature White
level
30°C
1

monitor
PC210LC-10 40-583
40 Troubleshooting
E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and
does not move (PC220_10-FGJ-400-A-00-A)
• While hydraulic oil temperature is rising normally, indication of temperature gauge does
not rise from white range (C).
Failure • While hydraulic oil temperature is stabilized normally, indication of temperature gauge
rises to red range (H).
information • Hydraulic oil temperature can be checked by using monitoring function.
Defective hydraulic 10°C Approx. 90 kz
oil temperature Between P22 30°C Approx. 35 kz
1 sensor (male) (1) and (2) Approx. 6.5 kz
80°C
(internal open or Resistance 100°C Approx. 3.5 kz
short circuit)
Between P22
(male) (2) and Whole range Min. 1 Mz
ground
Open circuit or Between CP01 (female) (28) and (46)
2 short circuit in
a Resistance accords with value on 3.5 to 90 kz
wiring harness Resistance temperature characteristics table in
cause 1.
Open circuit in 1. Starting switch: OFF
wiring harness 2. Disconnect connectors CP01 and P22, and connect T-adapter to either female
3 (Open circuit or side.
defective contact in Between CP01 (female) (28) and P22

Ground fault in 1. Starting switch: OFF
wiring harness 2. Disconnect connectors CP01 and P22, and connect T-adapter to either female
4 side.
(contact with
ground circuit) Between CP01 (female) (28) and
Resistance ground, or between P22 (female) (2) and Min. 1 Mz
ground
Hot short circuit in 2. Disconnect connector P22.
wiring harness 3. Insert T-adapter to connector CP01 or connect T-adapter to female side of
5 connector P22.
(contact with 24 V 4. Starting switch: ON
circuit)
Between CP01 (28) or P22 (female) (2)
Voltage Approx. 5 V
and ground
controller
40-584 PC210LC-10
40 Troubleshooting
Circuit diagram related to hydraulic oil temperature sensor
PC210LC-10 40-585
40 Troubleshooting
E-22 Hydraulic oil temperature gauge indicates incorrect temperature

(indicates neither Min. nor Max.) (PC220_10-FGK-400-A-00-A)
• Indication of hydraulic oil temperature gauge is different from actual hydraulic oil
temperature.
Failure • Indication of hydraulic oil temperature gauge is different from display of hydraulic oil
temperature monitor.
information • Hydraulic oil temperature can be checked by using monitoring function
Reading of
Hydraulic oil
hydraulic oil
temperature Red
temperature gauge
105°C
6
Reading of
Hydraulic oil
hydraulic oil
temperature Red
temperature gauge
102°C
5
Reading of
Hydraulic oil
hydraulic oil
temperature Blue
Defective machine temperature gauge
1 Color of monitor 100°C
monitor 4
light (a) Reading of
Hydraulic oil
hydraulic oil
temperature Blue
temperature gauge
85°C
3
Reading of
Hydraulic oil
hydraulic oil
temperature Blue
temperature gauge
40°C
2
Reading of
Hydraulic oil
hydraulic oil
temperature White
temperature gauge
20°C
1
Hydraulic oil temperature gauge and hydraulic oil temperature monitor
40-586 PC210LC-10
40 Troubleshooting
E-23 Content of display on machine monitor is different from that of

actual machine (PC200_10-FFB-400-A-00-A)
Failure • Displays on machine monitor are different from those for actual machine
Related information
a Turn starting switch to ON position and perform troubleshooting (with
monitoring function).
Model selection1
= OFF
Model selection2
= ON
Defective model code Monitoring code
1 Monitoring display 00201 Switch Model selection3
signal PC210LC-10
Input 2 = ON
Model selection4
= OFF
Model selection5
= ON
If display on monitor is incorrect, perform troubleshooting for failure code
[DA29KQ].
Defective machine If no problem is found by above checks, machine monitor is defective. (Since
2 this is an internal defect, troubleshooting cannot be performed.)
monitor
PC210LC-10 40-587
40 Troubleshooting
E-24 Machine monitor does not display some items (PC220_10-FFC-400-A-00-A)
Failure • Some areas of machine monitor are not displayed.

• The LCD panel sometimes has black points (points which are not lighted) and bright
Related points (points which do not go off) for the reason of its characteristics. If the number of the
information bright points and black points does not exceed 10, the LCD panel is not faulty or
defective.
Defective machine a Turn starting switch to ON position to perform troubleshooting.

monitor When following switches are operated, if whole LCD panel is lighted up (whole
1
(LCD panel) surface becomes white), LCD panel has no failure.
• Switch operation: [4] + [F2] (Press simultaneously)
monitor
40-588 PC210LC-10
40 Troubleshooting
E-25 Function switch does not work (PC220_10-HBC-400-A-00-A)
Failure • Function switch does not operate.

Related • Condition of signal of function switch can be checked with the monitoring function.
information (Code: 04503 Monitor function switch)
Defective machine Machine monitor may be defective. (Since this is an internal defect,
1 troubleshooting cannot be performed.)
monitor
PC210LC-10 40-589
40 Troubleshooting
E-26 Automatic preheating system does not work (In cold season) (PC220_10-
FEN-400-A-00-A)
Failure • Automatic warm-up system does not operate (in cold weather).
• Automatic warm-up function increases engine speed to 1,200 rpm when engine coolant
temperature is below 30°C.
• With starting switch at ON position or after engine is started, if fuel control dial is kept at
70% throttle position or higher for 3 seconds, automatic warm-up operation is canceled.
Related • If machine is equipped with air conditioner, when blower is turned on, ambient
information temperature is below 5°C and engine coolant temperature is below 55°C, automatic
warm-up function increases engine speed to 1,300 rpm. If engine coolant temperature
reaches 60°C, automatic warm-up function is canceled.
• If engine oil pressure is below 50 kPa {0.51 kg/cm2}, turbocharger protection function
works to keep engine speed below 1,050 rpm for up to 20 seconds after engine is started.
Engine coolant
temperature 6 (a: Red)
105°C
Engine coolant
temperature 5 (a: Red)
102°C
Engine coolant
temperature 4 (a: Blue)
Coolant Monitoring code
100°C
temperature gange 04107 Coolant
Defective engine Engine coolant
level temperature
coolant temperature 3 (a: Blue)
1 temperature signal 85°C
system Engine coolant
temperature 2 (a: Blue)
60°C
Engine coolant
temperature 1 (a: White)
30°C
If engine coolant temperature does not match with coolant temperature gauge
level, perform the following troubleshooting procedures.
• E-19 Coolant temperature gauge indicates either Min. or Max. and does not
move(PAGE 40-582)
• E-20 Coolant temperature gauge indicates incorrect temperature (indicates
Defective engine If no problem is found by above checks, engine controller is defective. (Since this
2 is an internal defect, troubleshooting cannot be performed.)
controller

monitor
40-590 PC210LC-10
40 Troubleshooting
E-27 Auto-deceleration monitor does not light up or does not go out

when auto-deceleration switch is operated (PC220_10-FFD-400-A-00-A)
• When auto-deceleration switch is operated, auto-deceleration monitor does not light up or
Failure does not go off.
• Condition of signal of auto-deceleration switch can be checked by using monitoring
Related function.
information (Code: 04504 Monitor 1st & 2nd row switches)
monitor
PC210LC-10 40-591
40 Troubleshooting
E-28 Auto-deceleration is not actuated or canceled when lever is

operated (PC220_10-FPM-400-A-00-A)
Failure • Auto-decelerator is not operated or canceled interlocking with control lever.
Related • Since auto-deceleration set speed is 1,050 rpm, auto-deceleration is not operated or
information canceled if engine speed higher than this speed is set by fuel control dial.
a Start engine and perform troubleshooting (with monitoring function).
When lever
operated: ON
Swing
With lever in
NEUTRAL: OFF
When lever
operated: ON
Travel
With lever in
NEUTRAL: OFF
When lever
operated: ON
Boom LOWER
Monitoring code With lever in
NEUTRAL: OFF
01900 Pressure When lever
switch 1 operated: ON
Boom RAISE
With lever in
NEUTRAL: OFF
When lever
Defective PPC operated: ON
1 Correct display Arm IN
pressure signal With lever in
NEUTRAL: OFF
When lever
operated: ON
Arm OUT
With lever in
NEUTRAL: OFF
When lever
operated: ON
Bucket CURL
With lever in
NEUTRAL: OFF
When lever
Monitoring code
operated: ON
01901 Pressure Bucket DUMP
With lever in
switch 2
NEUTRAL: OFF
When lever
operated: ON
Service
With lever in
NEUTRAL: OFF
If monitoring data shows any abnormality, perform troubleshooting for "E-49 to 57
Monitoring function does not display *** normally".
monitor
controller
Defective engine If no problem is found by above checks, engine controller is defective. (Since this
4 is an internal defect, troubleshooting cannot be performed.)
controller
40-592 PC210LC-10
40 Troubleshooting
E-29 Working mode selection screen is not diplayed when working mode
switch is operated (PC220_10-FFE-400-A-00-A)
Failure • When working mode switch is operated, working mode selection screen is not displayed.
Related • Condition of signal of working mode switch can be checked by using monitoring function.
monitor
PC210LC-10 40-593
40 Troubleshooting
E-30 Engine or hydraulic pump setting does not change when working
mode is changed (PC220_10-FP9-400-A-00-A)
Failure • When working mode is changed, setting of engine and hydraulic pump is not changed.
Related
information
monitor
Defective pump Pump controller may be defective. (Since this is an internal defect, troubleshooting
controller
40-594 PC210LC-10
40 Troubleshooting
E-31 Travel speed monitor does not change when travel speed switch is
operated (PC220_10-FFF-400-A-00-A)
Failure • When travel speed switch is operated, travel speed monitor does not change.
Related • Condition of signal of travel speed switch can be checked by using monitoring function.
monitor
PC210LC-10 40-595
40 Troubleshooting
E-32 Travel speed does not change while travel speed selection is
changed (PC200LC_10-BQ3-400-A-Z0-A)
Failure When selection of travel speed is changed, actual travel speed does not change.
• When failure due to cause 1 occurs, actual travel speed does not decrease when
travel speed setting is changed to "Lo".
Related information • As T-adapter for pump controller connector is "socket-type box", operating voltage
cannot be measured at pump controller connector.
harness 2. Disconnect connector V04 and connect T-adapters to female side.
circuit)
Voltage Between V04 (female) (1) and ground Max. 4.5 V
If no failure is found by check on cause 1, machine monitor may be
2 Defective machine monitor defective.
If no failure is found by checks for causes 1 and 2, pump controller may
3 Defective pump controller be defective.
40-596 PC210LC-10
40 Troubleshooting
E-33 Alarm buzzer does not stop sounding (PC220_10-KB3-400-A-00-A)
Failure • Alarm buzzer cannot be canceled.

• Condition of signal of alarm buzzer cancel switch can be checked by using monitoring
Related function.
monitor
PC210LC-10 40-597
40 Troubleshooting
E-34 When starting switch is turned to OFF position, service meter is not
displayed (PC220_10-FFL-400-A-00-A)
Failure • When starting switch is in OFF position, service meter is not displayed.
• While starting switch is in OFF position, if following switches are operated, service meter
Related is displayed at top center of screen.
information Switch operation: [4] + [1] (Press simultaneously)
If machine monitor displays nothing when the starting switch is turned ON, the
Defective backup backup power supply system is supposed to be defective. Carry out the following
1 power supply troubleshooting procedures.
system • E-5 When starting switch is turned to ON position, machine monitor displays
nothing
monitor
40-598 PC210LC-10
40 Troubleshooting
E-35 Service mode cannot be selected (PC220_10-HB1-400-A-00-A)
Failure • Service mode can not be selected.

Related • Following switch operation sets machine monitor in service mode.
information Switch operation: [4] + [1] o [2] o [3] (While pressing [4], press [1], [2], and [3] in order)
monitor
PC210LC-10 40-599
40 Troubleshooting
E-36 Any of work equipment, swing and travel does not work (PC220_10-FT5-400-A-
00-A)
Failure • All work equipment, swing, and travel system do not operate.
Related
information
Defective fuse F01- If fuse is broken, circuit probably has grounding fault. (See troubleshooting for
1 cause 7.)
3
Defective lock lever 1. Starting switch: OFF
switch 2. Disconnect connector S14 and connect T-adapter to female side.
2
(internal open Between S14 Lock lever: Lock Min. 1 Mz
circuit) Resistance (female) (1) and (2) Lock lever: Free Max. 1 z
Defective PPC lock 1. Starting switch: OFF
solenoid 2. Disconnect connector V01 and connect T-adapter to male side.
3
(internal open or Between V01 (male) (1) and (2) 20 to 60 z
short circuit) Resistance
Defective diode 2. Remove diode array D01 and connect T-adapter to male side.
array D01
4 a Check using multimeter in diode range.
(internal short
circuit) Between D01 (male) (8) (+) and (4) (-) Continuity
Continuity
wiring harness 2. Set lock lever to FREE position.
5 (wire breakage or 3. Remove fuse F01-3.
defective contact of Between F01-3 and ground (coil
connector) Resistance resistance of PPC lock solenoid) 20 to 60 z
a If no failure is found by above check, this check is not required.

Open circuit in 2. Remove fuse F01-3.
wiring harness 3. Disconnect connectors S14 and V01 and then connect T-adapters to male side
6 (wire breakage or of S14 and female side of V01.
defective contact of Between F01-3 and S14 (male) (1) Max. 1 z
connector) Between S14 (male) (2) and V01
Resistance
Between V01 (female) (2) and ground
(T09) Max. 1 z

2. Remove fuse F01-3.
Ground fault in 3. Disconnect connectors S14, V01, and D01, and then connect T-adapter to
wiring harness male side of S14 or female side of V01 or D01.
7
(contact with Between F01-3 and ground, or between
S14 (male) (1) and ground Min. 1 Mz
ground circuit)
Resistance
Between S14 (male) (2), V01 (female)
(1) or D01 (female) (4) and ground Min. 1 Mz
40-600 PC210LC-10
40 Troubleshooting
PC210LC-10 40-601
40 Troubleshooting
E-37 Any of work equipment, swing and travel cannot be locked (PC200LC_10-
FT7-400-A-Z0-A)
Failure All of work equipment, swing, and travel mechanism do not lock
Related information
Defective lock lever switch 2. Disconnect connector S14 and connect T-adapters to female side.
1
(internal short circuit) Resis- Between S14 (male) Lock lever: LOCK Min. 1 Mz
tance (1) and (2) Lock lever: FREE Max. 1 z
Hot short circuit in wiring 2. Disconnect connector V01 and connect T-adapter to female side.
circuit) 4. Turn lock lever to LOCK position.
Voltage Between V01 (female) (2) and (1) Max. 1 V
Circuit diagram related to PPC lock solenoid
40-602 PC210LC-10
40 Troubleshooting
E-38 Machine cannot swing while swing brake cancel switch is

canceled (PC200LC_10-FGM-400-A-Z0-A)
Failure When swing brake cancel switch is set to CANCEL position, machine cannot swing.
• Signal of swing lock switch can be checked with monitoring function.
Related information (Pump controller system code: 02200 Switch input 1)
Defective No. 1 in fuse box If fuse is blown out, circuit probably has ground fault. In this case,
1 perform troubleshooting for cause 5 first.
F01

Defective swing brake cancel swing brake cancel
2 switch (internal short circuit) Min. 1 Mz
Resis- Between S25 (male) switch: Normal
tance (13) and (14) swing brake cancel
Max. 1 z
switch: FREE
2. Remove diode array and connect T-adapter to male side.
Defective diode array D01 a Check by using multimeter in diode range.
3
(internal short circuit) Continuity Between D01 (male) (7) (+) and (3) (-) Continuity
No
Continuity Between D01 (male) (3) (+) and (7) (-)
continuity
2. Remove diode array and connect T-adapter to male side.
Defective diode array D03 a Check by using multimeter in diode range.
4
(internal short circuit) Continuity Between D03 (male) (5) (+) and (1) (-) Continuity
No
Continuity Between D03 (male) (1) (+) and (5) (-)
continuity
2. Disconnect connector V03 and connect T-adapter to female side.
5 Defective harness a Swing lock switch OFF position.
swing brake cancel
Between V03 (female) switch: FREE 20 to 30 V
Voltage
(1) and (2) swing brake cancel
Max. 1 V
switch: Normal
Open circuit in wiring harness 2. Disconnect connectors V03 and S25, and connect T-adapters to
each female side.
contact of connector) a Swing lock switch OFF position.
Between V03 (female) (1) and S25 (female)
Resis- (14) Max. 1 z
tance
Between V03 (female) (2) and ground Max. 1 z
7 2. Disconnect connectors S25 and V03, and connect T-adapter to
(contact with ground circuit) female side of V03.
Resis- Between V03 (female) (1) and ground
Min. 1 Mz
tance
PC210LC-10 40-603
40 Troubleshooting
Circuit diagram related to swing holding brake
40-604 PC210LC-10
40 Troubleshooting
E-39 Swing brake does not operate while swing brake cancel switch is
locked (PC200LC_10-FGN-400-A-Z0-A)
Failure Swing brake does not operate while swing brake cancel switch is locked.
Related information
Defective swing brake cancel swing brake cancel
1 switch (internal short circuit) Min. 1 Mz
Resis- Between S25 (male) switch: Normal
tance (13) and (14) swing brake cancel
Max. 1 z
switch: FREE
2. Disconnect connector V03 and connect T-adapter to female side.
Hot short circuit in wiring 3. Turn starting switch to ON position.
2 harness 4. Set swing lock switch to ON position.
circuit)
a Measure voltage again under swing lock switch OFF position.
PC210LC-10 40-605
40 Troubleshooting
40-606 PC210LC-10
40 Troubleshooting
E-40 One-touch power maximizing function does not work or monitor is

not displayed (PC220_10-FGL-400-A-00-A)
• When L.H. knob switch is pressed, work equipment power is not increased.
Failure • When L.H. knob switch is pressed, one-touch power maximizing monitor is not displayed.
• One-touch power maximizing function does not operate when working mode is not power
Related mode (P) or economy mode (E).
information • Condition of L.H. knob switch signal can be checked with monitoring function.
When L.H. knob switch is pressed, if work equipment power is increased but fact
Defective machine is not displayed on monitor, machine monitor may be defective (Since this is an
1
monitor internal defect, troubleshooting cannot be performed.)
Defective fuse No. If fuse is broken, circuit probably has grounding fault. (See troubleshooting for
2 cause 6.)
9
Defective left knob 2. Disconnect connector S11, and connect T-adapter to male side.
switch L.H. knob switch:
3 Min. 1 Mz
(internal open Between S11 Released
circuit in harness) Resistance (female) (1) and (2) L.H. knob switch:
1 z Max.
Pressed
Defective 2-stage 1. Starting switch: OFF
relief solenoid 2. Disconnect connector V05, and connect T-adapter to male side.
4
(internal open or Between V05 (male) (1) and (2) 20 to 60 z
short circuit) Resistance
3. Starting switch: ON
Open circuit or
5 ground fault in a Ignore displayed failure code.
wiring harness L.H. knob switch:
Between CP01 Max. 1 V
Voltage (female) (42) and Released
ground L.H. knob switch:
20 to 30 z
Pressed
wiring harness 2. Remove fuse F01-8.
6 (wire breakage or 3. Disconnect connectors CP01 and S11, and connect T-adapters to each female
connector) Between F01-8 and S11 (female) (1) Max. 1 z
Resistance Between S11 (female) (2) and CP01

Ground fault in 2. Remove fuse F01-8.
wiring harness 3. Disconnect connectors CP01 and S11, and connect T-adapter to female side of
7 S11.
(contact with
ground circuit) Between F01-8 or S11 (female) (1) and
ground Min. 1 Mz
Resistance
Between S11 (female) (2) or CP01
(female) (42) and ground Min. 1 Mz
controller
PC210LC-10 40-607
40 Troubleshooting
Circuit diagram related to one-touch power maximizing switch
40-608 PC210LC-10
40 Troubleshooting
E-41 One-touch power maximizing function cannot be canceled (PC200LC_10-

FPB-400-A-Z0-A)
Failure When L.H. knob switch is released, work equipment power is not returned to normal.
• Signal of L.H. knob switch can be checked with monitoring function.
Related information (Code: 02200 Switch input 1)
harness 2. Disconnect connector V08 and connect T-adapter to female side.
circuit)
Voltage Between V08 (female) (1) and (2) Max. 4.5 V
If no failure is found by checks on cause 1, pump controller is defective.
PC210LC-10 40-609
40 Troubleshooting
E-42 Travel alarm does not sound when machine travels (PC220_10-KA4-400-A-00-A)
Failure • When the machine is traveling, the travel alarm does not sound.
Related • Output to travel alarm can be checked with monitoring function.
information (Code: 03701 Controller output 2)
Defective travel 1. Starting switch: OFF
1 alarm 2. Disconnect connector M14 and connect T-adapter to male side.
(internal defect) Continuity Between M14 (male) (1) and (2) Continuity
Open circuit in 2. Disconnect connectors M14 and CP02 and connect T-adapters to each female
2 (wire breakage or Between CP02 (female) (107) and M14

wiring harness 2. Disconnect connectors CP02 and M14, and connect T-adapter to either female
3 side.
(contact with
Between CP02 (female) (107) or M14
ground circuit) Resistance Min. 1 Mz
(female) (1) and ground
40-610 PC210LC-10
40 Troubleshooting
E-43 Alarm does not stop sounding while machine is stopped (PC200LC_10-KB5-
400-A-Z0-A)
Failure Alarm does not stop sounding while machine is stopped.

Related information
harness 2. Disconnect connector M14 and connect T-adapters to female side.
circuit)
Voltage Between M14 (female) (1) and ground Max. 4.5 V
PC210LC-10 40-611
40 Troubleshooting
E-44 Horn does not sound (PC220_10-KA2-400-A-00-A)
Failure • The horn does not sound.

Related
information
Defective fuse F01- If fuse F01(5) is broken, circuit probably has ground fault. In this case, carry out
1 troubleshooting for cause 7 first.
5
Defective horn 1. Starting switch: OFF
relay 2. Replace horn relay (connector: R08) with another relay.
2 3. Starting switch: ON
(internal open or
4. Press L.H. knob switch.
short circuit)
If horn sounds, original horn relay is defective.
switch 2. Disconnect connector S10 and connect T-adapters to male side.
3
(internal open or Between S10 Switch: OFF Min. 1 Mz
short circuit) Resistance (male) (1) and (2) Switch: ON Max. 1 z
Defective high-tone 1. Starting switch: OFF
horn (M07) or low- 2. Disconnect connectors M07 and M08, and connect T-adapters to each male
4 tone horn (M08) side.
(internal open or Between M07 (male) (1) and (2) Continuity
Continuity
short circuit) Between M08 (male) (1) and (2) Continuity
2. Disconnect connector R08 and connect T-adapter to female side.
Defective wiring 3. Starting switch: ON
5 4. Press L.H. knob switch.
harness
Between R08 (female) (1) and (2) 20 to 30 V
Voltage
Between R08 (female) (3) and (2) 20 to 30 V
wiring harness 2. Disconnect connector R08 and connect T-adapter to female side.
6 (wire breakage or Between R08 (female) (5) and ground Continuity
defective contact of Continuity
connector) Between R08 (female) (1) and ground Continuity
a If no failure is found by above checks, this check is not required.

Open circuit in 2. Remove fuse F01-5.
wiring harness 3. Disconnect connectors R08 and S10, and connect T-adapters to each female
side.
7 (wire breakage or
Between F01-5 and S10 (female) (1) Max. 1 z
connector) Between S10 (female) (2) and R08
Resistance
Between R08 (female) (2) and ground Max. 1 z
Between R08 (female) (3) and F01-5 Max. 1 z
a If fuse is not broken, this check is not required.
Ground fault in 2. Remove fuse F01-5.
wiring harness 3. Disconnect connectors R08, M07, and M08, and connect T-adapter to female
8
(contact with side of R08.
ground circuit) Between R08 (female) (1) and ground Min. 1 Mz
Resistance Between R08 (female) (3) and ground Min. 1 Mz
Between R08 (female) (5) and ground Min. 1 Mz
Defective horn If no failure is found by above checks, horn may be defective.
9
(internal defect)
40-612 PC210LC-10
40 Troubleshooting
Circuit diagram related to horn
PC210LC-10 40-613
40 Troubleshooting
E-45 Horn does not stop sounding (PC220_10-KB2-400-A-00-A)
Failure • Horn does not stop sounding.

Related
information
relay 2. Remove horn relay (connector R08).
1
(internal open or 3. Starting switch: ON
short circuit) If horn stops sounding, original horn relay is defective.
Hot short circuit in 2. Disconnect connectors M07 and M08, and connect T-adapters to their female
wiring harness sides.
2 3. Starting switch: ON
(contact with 24 V
circuit) Between M07 (female) (2) and (1) Max. 1 V
Voltage
Between M08 (female) (2) and (1) Max. 1 V
Circuit diagram related to horn
40-614 PC210LC-10
40 Troubleshooting
E-46 Wiper monitor does not light up or go out when wiper switch is
operated (PC220_10-FG4-400-A-00-A)
Failure • When wiper switch is operated, wiper monitor does not light up or go off.
Related • Condition of wiper switch signal can be checked by using monitoring function.
monitor
PC210LC-10 40-615
40 Troubleshooting
E-47 Wiper does not operate when wiper switch is operated (PC220_10-FG0-400-A-00-
A)
Failure • When wiper switch is operated, windshield wiper does not operate.
• Condition of window rear limit switch signal can be checked by using monitoring function.
Related (Code: 02204 Switch input 5)
information • Wiper motor is troubleshooted for failure codes [DY20KA], [DY20MA], [DY2DKB], and
[DY2EKB].
2. Disconnect connector W03.
Defective rear limit Front window:
switch for window When installed to Min. 1 Mz
1
(internal short Between W03 front
circuit) Resistance (male) (1) and (2) Front window:
When retracted to Max. 1 z
rear
Defective wiper 1. Starting switch: OFF
motor 2. Disconnect connector M05 and connect T-adapter to female side.
2
(internal open
circuit in harness) Continuity Between M05 (female) (1) and (3) Continuity
Open circuit in
a Wiper motor system
wiring harness
See troubleshooting for [DY20KA], [DY20MA], [DY2DKB], and [DY2EKB].
3 (wire breakage or
connector)
Open circuit in a Rear limit switch system
wiring harness 1. Starting switch: OFF
4 (wire breakage or 2. Disconnect connectors CP01 and connect T-adapters to each female side.
defective contact of 3. Pull up front window.
connector) Resistance Between CP01 (female) (76) and ground Max. 1 Mz
wiring harness 2. Disconnect connector CP01 and connect T-adapter to female side.
5
(contact with 3. Front window installed to front
ground circuit) Resistance Between CP01 (female) (76) and ground Min. 1 Mz
controller
40-616 PC210LC-10
40 Troubleshooting
PC210LC-10 40-617
40 Troubleshooting
E-48 Window washer does not operate when window washer switch is
operated (PC220_10-FH0-400-A-00-A)
Failure • When window washer switch is operated, window washer does not operate.
• Condition of window washer switch signal can be checked with monitoring function.
Related (Code: 04504 Monitor 1st, 2nd line switches)
information • As for window washer, perform troubleshooting for failure code [DY2CKB].
monitor
40-618 PC210LC-10
40 Troubleshooting
E-49 BOOM LOWER indication is not displayed properly with monitoring

function (PC220_10-FFR-400-A-00-A)
Failure • "Boom LOWER" is not displayed properly by monitoring function.
Related • Monitoring code: 01900 Pressure switch 1
information
Defective boom Carry out troubleshooting for failure code [DHS9MA].
LOWER PPC oil
1 pressure sensor
(internal open or
short circuit)
PC210LC-10 40-619
40 Troubleshooting
E-50 ARM DUMP indication is not displayed properly with monitoring

function (PC220_10-FFS-400-A-00-A)
Failure • "Arm OUT (Arm Dump)" is not displayed properly with monitoring function.
information
Defective arm OUT Carry out troubleshooting for failure code [DHSCMA].
PPC oil pressure
1 sensor system
(internal open or
short circuit)
40-620 PC210LC-10
40 Troubleshooting
E-51 ARM IN indication is not displayed properly with monitoring

function (PC220_10-FFN-400-A-00-A)
Failure • "Arm IN" is not displayed properly with monitoring function
information
Defective arm IN Carry out troubleshooting for failure code [DHS3MA].
PPC oil pressure
1 sensor system
(internal open or
short circuit)
PC210LC-10 40-621
40 Troubleshooting
E-52 BOOM RAISE indication is not displayed properly with monitoring

function (PC220_10-FFM-400-A-00-A)
Failure • "Boom RAISE" is not displayed properly by monitoring function.
information
Defective boom Carry out troubleshooting for failure code [DHS8MA].
RAISE PPC oil
pressure sensor
1 system
(internal open or
short circuit)
40-622 PC210LC-10
40 Troubleshooting
E-53 BUCKET CURL indication is not displayed properly with monitoring

function (PC220_10-FFP-400-A-00-A)
Failure • "Bucket CURL" is not displayed properly with monitoring function.
information
Defective bucket Carry out troubleshooting for failure code [DHS4MA].
CURL PPC oil
1 pressure sensor
system
PC210LC-10 40-623
40 Troubleshooting
E-54 BUCKET DUMP indication is not displayed properly with monitoring

function (PC220_10-FFQ-400-A-00-A)
Failure • "Bucket DUMP" is not displayed properly with monitoring function.
information
Defective bucket Carry out troubleshooting for failure code [DHSDMA].
DUMP PPC oil
1 pressure sensor
system
40-624 PC210LC-10
40 Troubleshooting
E-55 SWING indication is not displayed properly with monitoring

function (PC220_10-FFT-400-A-00-A)
Failure • "Swing" is not displayed properly with monitoring function.
information
Defective swing Carry out troubleshooting for failure codes [DHSAMA] and [DHSBMA].
PPC pressure
1 sensor system
(internal open or
short circuit)
PC210LC-10 40-625
40 Troubleshooting
E-56 TRAVEL indication is not displayed properly with monitoring

function (PC220_10-FFU-400-A-00-A)
Failure • Travel indicator is not displayed properly with monitoring function.
information
Defective travel Carry out troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA]
PPC oil pressure and [DHSJMA].
1 sensor system
(internal open or
short circuit)
40-626 PC210LC-10
40 Troubleshooting
E-57 Service is not displayed properly with monitoring function (PC220_10-FFW-

400-A-00-A)
Failure • Attachment is not displayed properly with monitoring function.

• Monitoring code: 01901 Pressure switch 2
Related • For safety, use "short connector" 799-601-7230 for 2-pin X connector in tests for Causes
information 1 to 4.
k Do not check oil pressure switch connector while engine is running.
A. If "Service" operation signal displayed on monitoring screen is not "ON" when
engine is started and attachment control pedal is depressed at front end
Defective pre- 1. Starting switch: OFF
service PPC oil 2. Disconnect connector P14 and connect "short connector" to male side.
1 pressure switch 3. Starting switch: ON
(P14) a After finishing troubleshooting, return connectors as they were.
If "Service" operation signal displayed on monitoring screen changes to "ON", front
service PPC pressure switch (P14) is defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
Defective pre-
service PPC oil 1. Starting switch: OFF
2 pressure switch 2. Disconnect connector P14.
(P14) 3. Starting switch: ON
If "Service" operation signal displayed on monitoring screen changes to "OFF",
front service PPC pressure switch (P14) is defective (Note 2).
A. If "Service" operation signal displayed on monitoring screen is not "ON" when
engine is started and attachment control pedal is depressed at rear end
Defective post- 1. Starting switch: OFF
service PPC oil 2. Disconnect connector P15 and connect "short connector" to male side.
3 pressure switch 3. Starting switch: ON
(P15) a After finishing troubleshooting, return connectors as they were.
If "Service" operation signal displayed on monitoring screen changes to "ON", rear
service PPC pressure switch (P15) is defective (Note 1).
B. If "Service" operation signal displayed on monitoring screen is ON" when
starting switch is turned to ON position
Defective post-
service PPC oil 1. Starting switch: OFF
4 pressure switch 2. Disconnect connector P15.
(P15) 3. Starting switch: ON
If "Service" operation signal displayed on monitoring screen changes to "OFF",
rear service PPC pressure switch (P15) is defective (Note 2).
2. Insert T-adapters into P13.
3. Start engine.
Defective wiring 4. Operate attachment control pedal, and perform troubleshooting.
5 harness or pump Attachment control
controller Approx. 7 V
pedal: NEUTRAL
Between P13 (1)
Voltage Attachment control
and (2) Max. 1 V
pedal: front end or
rear end depressed
PC210LC-10 40-627
40 Troubleshooting

2. Disconnect connectors CP01, P14, and P15, and connect T-adapters to each
female side.
Open circuit in Between CP01 (female) (35) and P14
wiring harness (female) (1) Max. 1 z
6 (wire breakage or Between CP01 (female) (35) and P15
Between P14 (female) (2) and ground
(T06) Max. 1 z
Between P15 (female) (2) and ground
(T06) Max. 1 z

Ground fault in 2. Disconnect connectors CP01, P14, and P15, and connect T-adapter to either
7
(contact with Between CP01 (female) (35), P14
ground circuit) Resistance (female) (1), or P15 (female ) (1) and Min. 1 Mz
ground
2. Disconnect connectors P14 and P15, and connect T-adapter to either female
Short circuit in side.
8 wiring harness 3. Starting switch: ON
Between P14 (female) (1) or P15
Voltage Approx. 7 V
(female) (1) and ground
controller
Note 1: If voltage between CP01 (35) and ground is below 1 V but “Service“ operation signal displayed on
monitoring screen remains “OFF“, pump controller is defective.
Note 2: If voltage between CP01 (35) and ground is approximately 7 V but “Service“ operation signal
displayed on monitoring screen remains “ON“, pump controller is defective.
40-628 PC210LC-10
40 Troubleshooting
Circuit diagram related to attachment control pedal PPC oil pressure

switch (service pressure switch)
PC210LC-10 40-629
40 Troubleshooting
E-58 Attachment hydraulic circuit cannot be changed (PC200LC_10-HBD-400-A-Z1-A)
• Attachment circuit can not be changed

1) When working mode P or E is selected, crusher circuit (two-way circuit) is not
Failure selected.
2) When working mode B is selected, breaker circuit (one-way circuit) is not selected.
• Failures (open circuit/short circuit) in attachment oil return selector solenoid are
Related information indicated by failure codes [DWA2KA] and [DWA2KB].
Defective attachment oil return 2. Disconnect connector SSTC and connect T-adapters to male side.
1 selector solenoid (internal
short circuit) Resis- Between V07 (male) (1) and (2) 20 to 60 z
harness 2. Disconnect connector V06 and connect T-adapters to female side.
circuit)
Voltage Between V07 (female) (1) and ground Max. 4.5 V
Circuit diagram related to attachment oil return selector solenoid
40-630 PC210LC-10
40 Troubleshooting
E-59 KOMTRAX system does not operate normally (PC200LC_10-F50-400-A-Z1-A)
Failure • KOMTRAX system does not operate properly.

• Perform following troubleshooting if administrator of KOMTRAX system requests to
Related check whether failure is occurring in system on machine.
information • Even when KOMTRAX system is defective, no problem appears on machine.
• Check all of results of troubleshooting on service menu display of machine monitor.
2. Display “Terminal status” screen.
1 Defective communication 1
Monitoring Check item:
To be completed
display Station set-up check
2. Display “GPS & Communication Status” screen.
N ###.##.## (Latitude)
Monitoring Check item:
2 Defective positioning by GPS E ###.##.## (Longitude)
display Positioning
In positioning
If latitude and longitude are not displayed within 5 minutes with
machine stayed outdoor where opens clearly for sky, contact
KOMTRAX service hot line.
Monitoring Check item: Satellite in View or No Satellite in
Defective communication display Communication View
3
environment If Communication Status does never display “Satellite in View” within
15 minutes with machine stayed outdoor where opens clearly for sky,
check if connector of TC330 or antenna on top of cab are properly
connected.
4 Defective communication 2 Check item:
Monitoring
Number of message 0 to 60 (normally 0)
display
not yet sent
a Select “Terminal Status” from “KOMTRAX settings” in service menu of machine monitor.
PC210LC-10 40-631
40 Troubleshooting
a Select “GPS & Communication Status” from “KOMTRAX settings” in service menu of machine monitor.
40-632 PC210LC-10
40 Troubleshooting
Troubleshooting of hydraulic and mechanical system (H-
mode)
Troubleshooting of hydraulic and mechanical system (H-mode) (ALL-

3840-001-A-02-A)
Information described in troubleshooting table (H-mode) (ALL-5170-010-A-00-A)
(Rev. 2011/03)
Failure Failure symptom that appears on machine
Related Information on occurred failure or troubleshooting
information
1
2 Probable cause of failure <Contents of description>
(Each number is serial
3 number, not priority • Criteria to determine probable causes
4 sequence.) • Remarks for determination of probable cause
5
PC210LC-10 40-633
40 Troubleshooting
mode)
System chart for hydraulic system (PC220-C000-054-K-00-A)
a This is a system chart that is drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
40-634 PC210LC-10
40 Troubleshooting
mode)
PC210LC-10 40-635
40 Troubleshooting
mode)
Failure mode and cause table (PC220-5340-40D-A-00-A)

Failed parts
Tank Hydraulic pump
Diagnosis codes
Engine system
PC-EPC valve
LS-EPC valve
Damper
Servo piston
Piston pump
Hydraulic oil
PC valve
LS valve
stainer
Cap
Failure mode
Speed or power of all work equipment, swing and travel is low. q q q q q q q q q q H-1
Engine speed lowers extremely or engine stalls. q q q q q q q q H-2

Any of work equipment,
All work equipment, travel, and swing systems do not work. q q q H-3
swing and travel
Abnormal sound comes out from around hydraulic pump q q q q H-4
Fine control performance or response is low q q q H-5
Speed or power of boom is low. H-6
Speed or power of arm is low. H-7
Speed or power of bucket is low H-8
Work equipment single operation does not function. H-9

Work equipment
Boom H-10
Hydraulic drift of work equipment is large. Arm H-11
Bucket H-12
Time lag in work equipment operation is large. q H-13

When performing hydraulic relief of a work equipment, other work
H-14
equipment move.
Power maximizing function does not work. H-15
Work equipment on large load side moves slower during combined
H-16
operation
Swing and
When performing combined operation of swing and boom RAISE , boom

boom
H-17
RAISE speed is slow.
Swing and
When performing combined operation of swing and travel , travel speed

travel
H-18
lowers significantly.
Machine deviates during travel q H-19
Travel speed is low q H-20

Travel
Machine is not steered well or steered-travel power is low. H-21
Travel speed does not switch or travel speed is too low or high. q H-22
One of tracks does not run H-23
40-636 PC210LC-10
40 Troubleshooting
mode)
Failed parts
Tank Hydraulic pump
Diagnosis codes
Engine system
PC-EPC valve
LS-EPC valve
Damper
Piston pump
Servo piston
Hydraulic oil
PC valve
LS valve
stainer
Cap
Failure mode
Upper structure swings
H-24
neither to the right nor left
Machine does not swing
Upper structure does not
H-25
swing in only one direction
Poor or low for both of the
Swing acceleration is poor or swing speed is right and left H-26
low Poor or low for only in one

H-27
direction
Largely for both of the right
Swing
Upper structure overruns considerably when H-28

and left
it stops swinging Largely for only in one
H-29
direction
Large shock is made when upper structure stops swinging H-30
Large unusual noise is heard when upper structure stops swinging. H-31
When swing holding brake
H-32
Swing drift on a slope is excessive applied
H-33
released
Attachment circuit is not switched to desired one. H-34
Attachment
Flow rate of attachment circuit cannot be adjusted H-35
PC210LC-10 40-637
40 Troubleshooting
mode)
Failed parts
Control valve
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Pump merge-divider main valve
Pressure compensation valve
Pump merge-divider LS valve

Self-pressure reducing valve
Boom throttle EPC solenoid
Service valve (safety valve)

Boom regeneration valve
Arm lock valve ( O P T )

Arm regeneration valve
Arm quick return valve
Diagnosis codes
Swing LS select valve
Travel junction valve
Back pressure valve
Boom lock valve
Main relief valve
LS shuttle valve
LS line throttle
Suction valve
Unload valve
Safety valve
Spool
Failure mode
Speed or power of all work equipment, swing and travel is low. q q q H-1
Engine speed lowers extremely or engine stalls. H-2

All work equipment, travel, and swing systems do not work. q H-3
swing and travel
Abnormal sound comes out from around hydraulic pump H-4
Fine control performance or response is low q H-5
Speed or power of boom is low. q q q q q q q q q q q q H-6
Speed or power of arm is low. q q q q q q q q q q q q H-7
Speed or power of bucket is low q q q q q H-8
Work equipment single operation does not function. q q H-9

Work equipment
Boom q q q q H-10
Hydraulic drift of work equipment is large. Arm q q q H-11
Bucket q q q q H-12
Time lag in work equipment operation is large. q q H-13

q H-14
equipment move.
Power maximizing function does not work. q H-15
q H-16
operation
Swing and
When performing combined operation of swing and boom RAISE ,

boom
q H-17
boom RAISE speed is slow.
Swing and
When performing combined operation of swing and travel , travel

travel
q q H-18
speed lowers significantly.
40-638 PC210LC-10
40 Troubleshooting
mode)
Failed parts
Control valve
Pump merge-divider main EPC valve

Pump merge-divider LS-EPC valve
Pump merge-divider main valve
Pressure compensation valve
Pump merge-divider LS valve

Self-pressure reducing valve
Boom throttle EPC solenoid
Service valve (safety valve)

Boom regeneration valve
Arm lock valve ( O P T )

Arm regeneration valve
Arm quick return valve
Diagnosis codes
Swing LS select valve
Travel junction valve
Back pressure valve
Boom lock valve
Main relief valve
LS shuttle valve
LS line throttle
Suction valve
Unload valve
Safety valve
Failure mode Spool
Machine deviates during travel q q q q q H-19
Travel speed is low q q q q q H-20

Travel
Machine is not steered well or steered-travel power is low. q q q q q q q q q H-21
Travel speed does not switch or travel speed is too low or high. H-22
One of tracks does not run q H-23

neither to the right nor q H-24
Machine does not swing left

Upper structure does
not swing in only one q H-25
direction
Poor or low for both of
Swing acceleration is poor or swing speed is the right and left q q H-26
low Poor or low for only in

q q H-27
one direction
Swing
Largely for both of the

Upper structure overruns considerably when right and left H-28

q H-29
direction
Large unusual noise is heard when upper structure stops swinging. q H-31
When swing holding
H-32
Swing drift on a slope is excessive brake applied
When swing holding
q q H-33
brake released
Attachment circuit is not switched to desired one. q H-34
Attachment
PC210LC-10 40-639
40 Troubleshooting
mode)
Failed parts
Solenoid valve Swing motor
Oil flow adjuster EPC valve for attachment

Swing PPC slow return valve
Travel interconnection solenoid
Travel speed selector solenoid

Work equipment lock solenoid
PPC valve (travel lever)
Swing holding brake solenoid

PPC valve (right lever)
ATT return selector solenoid

PPC valve (left lever)
PPC valve (service)
Diagnosis codes
Shockless valve
Parking brake
Suction valve
Check valve
Piston motor
Safety valve
Failure mode
Speed or power of all work equipment, swing and travel is low. H-1
Engine speed lowers extremely or engine stalls. q H-2

All work equipment, travel, and swing systems do not work. H-3
swing and travel
Fine control performance or response is low H-5
Speed or power of boom is low. q H-6
Speed or power of arm is low. q H-7
Speed or power of bucket is low q H-8
Work equipment single operation does not function. q q H-9

Work equipment
Boom H-10
Hydraulic drift of work equipment is large. Arm H-11
Bucket H-12
Time lag in work equipment operation is large. H-13

H-14
equipment move.
Power maximizing function does not work. q H-15
H-16
operation
Swing and

boom
H-17
Swing and

travel
H-18
40-640 PC210LC-10
40 Troubleshooting
mode)
Failed parts
Solenoid valve Swing motor
Oil flow adjuster EPC valve for attachment

Swing PPC slow return valve
Travel interconnection solenoid
Travel speed selector solenoid

Work equipment lock solenoid
PPC valve (travel lever)
Swing holding brake solenoid

PPC valve (right lever)
ATT return selector solenoid

PPC valve (left lever)
PPC valve (service)
Diagnosis codes
Shockless valve
Parking brake
Suction valve
Check valve
Piston motor
Safety valve
Failure mode
Machine deviates during travel q q H-19
Travel speed is low q H-20

Travel
Machine is not steered well or steered-travel power is low. q q H-21
One of tracks does not run H-23

q q Q q H-24
q q q H-25
Swing acceleration is poor or swing speed is right and left q q q H-26

q q q H-27
direction
Swing
Upper structure overruns considerably when q q H-28

and left
q q q q H-29
direction
Large shock is made when upper structure stops swinging q q q H-30
Large unusual noise is heard when upper structure stops swinging. q q H-31
q q H-32
q q q q H-33
released
Attachment circuit is not switched to desired one. q H-34
Attachment
Flow rate of attachment circuit cannot be adjusted q q H-35
PC210LC-10 40-641
40 Troubleshooting
mode)
Failed parts
Travel motor
Center swivel joint
Hydraulic cylinder
Swing machinery
Diagnosis codes
Counterbalance valve
Parking brake
Check valve
Piston motor
Safety valve
Final drive
Failure mode
Speed or power of all work equipment, swing and travel is low. H-1
Engine speed lowers extremely or engine stalls. H-2

All work equipment, travel, and swing systems do not work. H-3
swing and travel
Fine control performance or response is low H-5
Speed or power of boom is low. q H-6
Speed or power of arm is low. q H-7
Speed or power of bucket is low q H-8
Work equipment single operation does not function. H-9

Work equipment
Boom q H-10
Hydraulic drift of work equipment is large. Arm q H-11
Bucket q H-12
Time lag in work equipment operation is large. H-13

H-14
equipment move.
Power maximizing function does not work. H-15
H-16
operation
Swing and

boom
H-17
Swing and

travel
H-18
40-642 PC210LC-10
40 Troubleshooting
mode)
Failed parts
Travel motor
Center swivel joint
Hydraulic cylinder
Swing machinery
Diagnosis codes
Counterbalance valve
Parking brake
Check valve
Piston motor
Safety valve
Final drive
Failure mode
Machine deviates during travel q q q q q H-19
Travel speed is low q q H-20

Travel
Machine is not steered well or steered-travel power is low. q q q q H-21
One of tracks does not run q q q q q H-23

q H-24
H-25
Swing acceleration is poor or swing speed is right and left q H-26

H-27
direction
Swing
Upper structure overruns considerably when H-28

and left
H-29
direction
Large unusual noise is heard when upper structure stops swinging. q H-31
H-32
H-33
released
Attachment circuit is not switched to desired one. H-34
Attachment
PC210LC-10 40-643
40 Troubleshooting
mode)
H-1 All of work equipment, swing and travel operation lacks speed or
power (PC200LC_10-A8A-400-A-Z0-A)
Failure • All of work equipment, swing and travel operation lacks speed or power.
• Perform all troubleshooting with working mode set in P mode.
• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA, DKR1MA,
DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA, DXE0KB)
• As for speed other than swing speed, check whether normal speed is obtained with swing
Related lock switch turned ON.
information If normal speed is obtained, perform troubleshooting on causes (1) and (2) to check pump
swash plate sensor for malfunction.
If normal speed is not obtained, perform troubleshooting on cause (3) and after.
• F pump pressure and R pump can be checked with monitoring function. (Code: F pump
pressure 01100, R pump pressure 01101)
a Be ready with engine stopped, then perform troubleshooting with engine
running at full speed.
Malfunction of pump swash All levers in NEUTRAL 1.35 ± 0.63 V
1 plate sensor (front)
Sensor output L.H. track only: Running idle off
voltage ground 3.35 ± 0.63 V
Swing lock switch: ON
2 plate sensor (rear)
Sensor output R.H. track only: Running idle off
Malfunction of unload valve running at full speed.
3 (front)
3.5 ± 1.0 MPa
Unload pressure All levers in NEUTRAL
{36 ± 10 kg/cm2}
Malfunction of unload valve running at full speed.
4 (rear)
3.5 ± 1.0 MPa
Unload pressure All levers in NEUTRAL
{36 ± 10 kg/cm2}
Malfunction of main relief
5 valve (front) 33.1 to 37.2 MPa
Main relief
Boom RAISE hydraulic relief {338 to 380 kg/
pressure
cm2}
6 valve (rear) 33.1 to 37.2 MPa
Main relief
Arm IN hydraulic relief {338 to 380 kg/
pressure
cm2}
If normal oil pressure is not obtained after adjustment, check main relief
7 valve (front) valve for malfunction (setting of spring) and internal failure (defective valve
seat).
Malfunction of main relief valve for malfunction (setting of spring) and internal failure (defective valve
8 valve (rear)
seat).
40-644 PC210LC-10
40 Troubleshooting
mode)

Control circuit 2.84 to 3.43 MPa
Malfunction of self- All levers in NEUTRAL
9 pressure reducing valve source pressure {29 to 35 kg/cm2}
a Since relief valve of self-pressure reducing valve is not adjustable,
replace self-pressure reducing valve assembly if normal pressure is not
obtained.
running at low idle and at high idle.
Engine at low idle and all levers in 2.9 MPa
Malfunction of PC-EPC NEUTRAL {30 kg/cm2}
10 valve (front) PC-EPC valve
output pressure Engine at high idle and all levers in 0.70 to 1.09 MPa
NEUTRAL {7.1 to 11.1kg/
cm2}
Replace PC-EPC valve if any failure is found.
running at low idle and at high idle.
Engine at low idle and all levers in 2.9 MPa
Malfunction of PC-EPC NEUTRAL {30 kg/cm2}
11 valve (rear) PC-EPC valve
output pressure Engine at high idle and all levers in 0.70 to 1.09 MPa
NEUTRAL {7.1 to 11.1kg/
cm2}
Replace PC-EPC valve if any failure is found.
Measurement condition
measured
Defective adjustment of PC Pump delivery 1
12 valve (front) pressure Boom RAISE hydraulic relief
PC valve output Swing lock switch: ON Approx. 0.6
pressure Boom RAISE hydraulic relief (Approx. 3/5)
If normal pressure is not obtained after adjustment, PC valve may
malfunction (setting of spring) or have internal failure (locked or trapped PC
spool). Check PC valve.
measured
Pump delivery Swing lock switch: ON
Defective adjustment of PC 1
13 valve (rear) pressure Arm IN hydraulic relief
pressure Arm IN hydraulic relief (Approx. 3/5)
If normal pressure is not obtained after adjustment, PC valve may
malfunction (setting of spring) or have internal failure (locked or trapped PC
spool). Check PC valve.
If normal oil pressure is not obtained after adjustment, check PC valve for
Malfunction of PC valve
14 (front) malfunction (setting of spring) and internal failure (locked or trapped PC
spool).
If normal oil pressure is not obtained after adjustment, check PC valve for
Malfunction of PC valve
15 (rear) malfunction (setting of spring) and internal failure (locked or trapped PC
spool).
PC210LC-10 40-645
40 Troubleshooting
mode)

Malfunction of LS-EPC Travel control 2.9MPa
16 Travel speed: Lo
valve LS-EPC valve lever: NEUTRAL {30 kg/cm2}
output pressure Travel control
lever: Finely Travel speed: Hi 0 MPa {0 kg/cm2}
moved
Lever position and oil pressure ratio
L.H. track:
Running idle off
Oil pressure to be ground in Hi
Defective adjustment of LS measured All levers in NEUTRAL
17 valve (front) speed setting
Lever moved
halfway
Pump delivery Almost same as LS valve output
pressure pressure 1
LS valve output Almost same as pump delivery Approx. 0.6
pressure pressure (Approx. 3/5)
R.H. track:
Running idle off
18 valve (rear) speed setting
Lever moved
halfway
pressure pressure 1
LS valve out put Almost same as pump delivery Approx. 0.6
If normal oil pressure is not obtained after adjustment, check LS valve for
Malfunction of LS valve
19 malfunction (setting of spring) and internal failure (locked or trapped LS
(front)
spool).
20 malfunction (setting of spring) and internal failure (locked or trapped LS
(rear)
spool).
If sensor output voltage is normal in checks on causes (1) and (2),
Malfunction of servo piston determine that servo piston is normal.
21 or PC valve (*)
Check orifices and filters in pump servo devices for clogging.
If no failure is found by above checks, piston pump may have degraded
22 Malfunction of piston pump performance, malfunction, or have internal failure.
Check hydraulic tank strainer and return filter element for metal particles.
(*) Since PC valve is built in servo piston, servo piston assembly must be replaced if PC valve is defective.
40-646 PC210LC-10
40 Troubleshooting
mode)
H-2 Engine speed drops significantly or engine stalls (PC200LC_10-FPN-400-A-Z0-A)
Failure • Engine speed lowers significantly or engine stalls.

• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA,
DKR1MA, DXA8KA, DXA8KB, DXA9KA, DXA9KB, DXE0KA, DXE0KB)
• As for speed other than swing speed, check whether normal speed is obtained with swing
Related lock switch turned ON.
information If normal speed is obtained, perform troubleshooting on causes (1) and (2) to check pump
swash plate sensor for malfunction.
If normal speed is not obtained, perform troubleshooting on cause (3) and after.
a Be ready with engine stopped, then perform troubleshooting with
1 plate sensor (front) Sensor output L.H. track only: Running idle
voltage off ground 3.35 ± 0.63 V
2 plate sensor (rear) Sensor output R.H. track only: Running idle
voltage off ground 3.35 ± 0.63 V
Malfunction of main relief engine running at full speed.
3 valve (front) 33.1 to 37.2 MPa
Main relief pressure Boom RAISE hydraulic relief
{338 to 380 kg/cm2}
Malfunction of main relief engine running at full speed.
4 valve (rear) 33.1 to 37.2 MPa
Main relief pressure Arm IN hydraulic relief
{338 to 380 kg/cm2}
5 valve for malfunction (setting of spring) and internal failure (defective
valve (front)
valve seat).
6 valve for malfunction (setting of spring) and internal failure (defective
valve (rear)
valve seat).
engine running at low idle and at high idle.
Malfunction of PC-EPC valve Engine at low idle and all 2.9 MPa
7 (front) PC-EPC valve levers in NEUTRAL {30 kg/cm2}
output pressure Engine at high idle and all 0.70 to 1.09 MPa
levers in NEUTRAL {7.1 to 11.1 kg/cm2}
engine running at low idle and at high idle.
Malfunction of PC-EPC valve Engine at low idle and all 2.9 MPa {30 kg/
8 (rear) levers in NEUTRAL cm2}
PC-EPC valve
output pressure 0.70 to 1.09 MPa
Engine at high idle and all
levers in NEUTRAL {7.1 to 11.1 kg/cm2}
PC210LC-10 40-647
40 Troubleshooting
mode)

Defective adjustment of PC measured
9 valve (front) Swing lock switch: ON
Pump delivery
pressure 1
Boom RAISE hydraulic relief
pressure Boom RAISE hydraulic relief (Approx. 3/5)

Defective adjustment of PC measured
10 valve (rear) Swing lock switch: ON
Pump delivery
pressure 1
Arm IN hydraulic relief
pressure Arm IN hydraulic relief (Approx. 3/5)
If normal oil pressure is not obtained after adjustment, check PC valve
11 Malfunction of PC valve (front) for malfunction (setting of spring) and internal failure (locked or trapped
PC spool).
If normal oil pressure is not obtained after adjustment, check PC valve
12 Malfunction of PC valve (rear) for malfunction (setting of spring) and internal failure (locked or trapped
PC spool).
Travel Approx. 2.9 MPa
Travel control lever: {Approx. 30 kg/
13 Malfunction of LS-EPC valve speed:
LS-EPC valve NEUTRAL cm2}
Lo
output pressure
Travel control lever: Travel
speed: 0 MPa {0 kg/cm2}
Finely moved
Hi
Track running idle
Oil pressure to be off ground
14 valve (front) (Lever moved
halfway)
Pump delivery Almost same as LS valve
pressure pressure 1
Pump delivery pressure is
LS valve output Approx. 0.6
almost same as LS valve
pressure (Approx. 3/5)
pressure.
Track running idle
Oil pressure to be off ground
measured All levers in NEUTRAL
Defective adjustment of LS (Lever moved
15 valve (rear) halfway)
Pump delivery
almost same as LS valve 1
pressure
pressure.
LS valve output Approx. 0.6
almost same as LS valve
pressure (Approx. 3/5)
pressure.
40-648 PC210LC-10
40 Troubleshooting
mode)

If normal oil pressure is not obtained after adjustment, check LS valve
16 Malfunction of LS valve (front) for malfunction (setting of spring) and internal failure (locked or trapped
LS spool).
If normal oil pressure is not obtained after adjustment, check LS valve
17 Malfunction of LS valve (rear) for malfunction (setting of spring) and internal failure (locked or trapped
LS spool).
If sensor output voltage is normal in checks on causes (1) and (2),
Malfunction of servo piston or determine that servo piston is normal.
18 PC valve (*)
If no failure is found by above checks, piston pump may malfunction, or
have internal failure.
19 Malfunction of piston pump
Check hydraulic tank strainer and return filter element for metal
particles.
(*) Since PC valve is built in servo piston, servo piston assembly must be replaced if PC valve is defective.
PC210LC-10 40-649
40 Troubleshooting
mode)
H-3 All work equipment, swing and travel does not work (PC200LC_10-FT5-400-A-Z0-A)
Failure • All work equipment, travel, and swing systems do not work.
Related information • Perform all troubleshooting with working mode in power mode (P).
a Be ready with engine stopped, then troubleshoot with engine at full
speed.
Measurement Solenoid output
Malfunction of PPC lock Lock lever pressure
1 conditions
solenoid valve
• Hydraulic oil at LOCK position 0 MPa {0 kg/cm2 }
temperature: Within 2.9 MPa
operation range at FREE position
{30 kg/cm2 }
a Be ready with engine stopped, then troubleshoot with engine at full
speed.
Measurement Control circuit source
Control lever pressure
conditions
Malfunction of self-pressure
2 reducing valve • Hydraulic oil When all control levers 2.84 to 3.43 MPa
temperature: Within are in NEUTRAL
operation range position {29 to 35 kg/cm2 }
a Relief valve of self-pressure reducing valve cannot be adjusted. If it

is defective, replace self-pressure reducing valve assembly.
Piston pump may malfunction or have internal defect. Check it by
following method.
3 Defective piston pump
• Crank the engine with main oil pressure pickup port plug. If oil flows
out, it is in normal.
Pump shaft may not rotate due to some internal defect of damper.
4 Defective damper
Check the damper.
40-650 PC210LC-10
40 Troubleshooting
mode)
H-4 Unusual sound is heard from around hydraulic pump (PC400-BAA-400-A-Z0-A)
Failure • Unusual sound is heard from around hydraulic pump

Related information —
Check hydraulic oil level directly.
1 Lowering of hydraulic oil level (Reference) If the hydraulic oil level is low while no hydraulic oil leaks to
the outside, it is assumed that hydraulic oil may flow in the flywheel
chamber due to a pump shaft seal damage.
2 Defective hydraulic oil Air may mix in hydraulic oil. Check it for bubbles or milky state.
Cap of the hydraulic tank cap may be clogged, causing negative
3 Clogging of hydraulic tank cap
pressure inside the tank. Check the cap.
Clogging of hydraulic tank Strainer in the hydraulic tank may be clogged, causing negative
4 pressure in the suction circuit. Check the strainer.
strainer
Clogging of hydraulic tank Check the return filter in the hydraulic tank may be clogged, especially
5 by metallic materials. Check the return filter.
return filter
If any metallic materials are detected in Cause 4 and 5 above, piston
6 Defective piston pump
pump may have internal defect.
PC210LC-10 40-651
40 Troubleshooting
mode)
H-5 Fine control performance or response is poor (PC200LC_10-FTB-400-A-Z0-A)
Failure • Fine control performance or response is poor.

• If failure codes are displayed, perform troubleshooting for them first. (DKR0MA, DKR1MA,
Related DXE0KA, DAXE0KB)
information • Signal voltage from swash plate sensor can be checked with monitoring function. (Code: F
pump side 01138, R pump side 01140)
1 plate sensor (front)
Sensor output L.H. track only: Running idle off
2 plate sensor (rear)
Sensor output R.H. track only: Running idle off
Malfunction of LS-EPC Travel control 2.9 MPa
3 Travel speed: Lo
valve LS-EPC valve lever: NEUTRAL {30 kg/cm2}
moved
4 Clogged orifice in LS circuit Orifice may be clogged. Check it.
L.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
R.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
40-652 PC210LC-10
40 Troubleshooting
mode)

7 (front) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
8 (rear) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
If sensor output voltage is normal in checks on causes (1) and (2) is
9 Malfunction of servo piston normal, determine that servo piston is normal.
PC210LC-10 40-653
40 Troubleshooting
mode)
H-6 Boom speed or power is low (PC200LC_10-A8B-400-A-Z0-A)
Failure Speed or power of boom is low.

• If failure codes are displayed, perform troubleshooting for them first. (DXE5KB, DXE6KA,
DXE6KB)
• Boom RAISE PPC pressure can be checked with monitoring function. (Code: 07400)
Related • Current to merge-divider (main) solenoid can be checked with monitoring function. (Code:
information 08000)
• Current to merge-divider (LS) solenoid can be checked with monitoring function. (Code:
08001)
• F pump pressure and R pump pressure can be checked with monitoring function. (Code: F
pump pressure 01100, R pump pressure 01101)
R.H. work
Malfunction of right PPC equipment control NEUTRAL 0 MPa {0 kg/cm2}
1 valve (boom circuit)
PPC valve output lever
pressure R.H. work
Boom RAISE or 2.84 to 3.43 MPa
equipment control
LOWER {29 to 35 kg/cm2}
lever
a If boom lacks speed, check all work equipment speeds. If any failure is
found, perform troubleshooting on causes (3) to (5) related to merge-
divider valve failure.
a Perform troubleshooting with engine running at full speed.
Malfunction of merge-
2 divider valve assembly Max. 4.8/3.7
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.5
work equipment Arm IN/OUT
seconds
to move
Max. 3.3/2.7
Bucket CURL/DUMP
seconds
All work equipment control levers in 0 to 0.49 MPa
Main EPC output NEUTRAL {0 to 5 kg/cm2}
Malfunction of merge- pressure
3
divider main EPC valve Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
relief {29 to 35 kg/cm2}
All work equipment control levers in
0 mA
NEUTRAL
EPC current
Bucket CURL and Arm IN hydraulic
800 to 1000 mA
relief
LS-EPC output NEUTRAL {0 to 5 kg/cm2}
4
divider LS-EPC valve Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
0 mA
NEUTRAL
EPC current
Bucket CURL and Arm IN hydraulic 800 to 1000 mA
relief
40-654 PC210LC-10
40 Troubleshooting
mode)

a Release remaining pressure from hydraulic tank and piping and then
perform troubleshooting with engine stopped.
Malfunction of merge- • Check for stuck or seized main spool in merge-divider valve body.
5 divider main spool
(Spool must move smoothly.)
• Remove main spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing spool.
Malfunction of merge- • Check for stuck or seized LS spool in merge-divider valve body.
6 divider LS spool
• Remove LS spool from valve body and check it for defects and dirt.
Malfunction of boom • Check for stuck or seized boom spool in control valve body.
7 control valve (spool)
• Remove boom spool from valve body and check it for defects and dirt.
Boom relief 33.1 to 37.2
Boom RAISE hydraulic relief
pressure {338 to 380g/cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Hydraulic oil temperature within If visible hydraulic
operating range, bucket wit rated drift is observed,
Malfunction of boom Hydraulic drift
load, boom horizontal, arm cylinder control valve is
control valve (pressure fully retracted defective.
8 compensation valve)
(boom RAISE side) a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, control valve is
defective.)
a If any failure is found in either of above check items, interchange
pressure compensation valves on RAISE and LOWER sides, and
check whether failure symptom changes.
(Pressure compensation valves have different area ratio, so return them
to their original positions after test.)
PC210LC-10 40-655
40 Troubleshooting
mode)

33.1 to 37.2 MPa
Boom relief Boom LOWER At low-pressure
pressure hydraulic relief setting {338 to 380 kg/
cm2}
a Check hydraulic drift of boom cylinder with engine stopped.
Malfunction of boom
control valve (pressure Hydraulic drift operating range, arm cylinder fully drift is observed,
9 compensation valve) extended, machine raised off ground control valve is
defective.
(boom LOWER side)
a Check whether boom cylinder moves slowly when performing hydraulic
relief of other work equipment. (If boom cylinder moves, control valve is
defective.)
pressure compensation valves on RAISE and LOWER sides, and
(Pressure compensation valves have different area ratio, so return them
to their original positions after test.)
• Check for locked or trapped boom regeneration valve in control valve
body.
Malfunction of boom
(Valve must move smoothly.)
10 control valve (regeneration • Check that regeneration valve (check valve ) is seated on control valve
valve)
in position (it is not stopped halfway), and then remove it from control
valve body and check it for dents and dirt.
• Check spring of check valve for setting and deformation.
• Take care not to let foreign matter enter control valve when re-installing
check valve.
Boom relief Boom RAISE hydraulic relief, arm IN 33.1 to 37.2 MPa
pressure and arm hydraulic relief, and arm OUT {338 to 380 kg/
Malfunction of boom relief pressure hydraulic relief cm2}
11 control valve (safety valve
for lock valve) a Among above relief pressures, if arm IN lief pressure and boom RAISE
relief pressure is below standard relief pressure, safety valve may be
defective. Check safety valve for damaged sealing material.
a Since relief pressure cannot be adjusted with safety valve installed on
machine, replace safety valve assembly if safety valve is found to be
defective.
• Check that pilot piston and poppet are seated on lock valve body in
position (they are not trapped halfway).
• Check for locked or trapped pilot piston and poppet in lock valve body
(pilot piston and poppet must move smoothly).
Malfunction of boom • Remove pilot piston and poppet from valve body and check them for
12 control valve (lock valve)
defects and dirt.
• Check poppet spring for setting and deformation.
• Take care not to let foreign matter enter lock valve when re-installing
pilot piston and poppet.
40-656 PC210LC-10
40 Troubleshooting
mode)

33.1 to 37.2 MPa
Boom relief
Boom RAISE hydraulic relief {338 to 380 kg/
pressure
cm2}
Malfunction of boom
13 control valve (suction a If boom RAISE relief pressure is below standard value, suction valve
valve) (boom RAISE side) may be defective. Check it.
• Check that check valve is seated on valve body in position (it is not
trapped halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
check valve.
33.1 to 37.2 MPa
Boom relief Boom LOWER At low-pressure
pressure hydraulic relief setting {338 to 380 kg/
Malfunction of boom cm2}
control valve (suction-
14 safety valve) (boom a If boom LOWER relief pressure is below standard value, suction-safety
valve may be defective. Check it.
LOWER side)
trapped halfway).
defective.
All work equipment control lever in 3.5± 1.0 MPa
NEUTRAL {36 10 kg/cm2}
Malfunction of boom LS differential 1.8(+0.05/-0.1)
15 control valve (LS shuttle pressure MPa
valve) Fine control of boom RAISE
{18(+0.5/-1.0) kg/
cm2}
If LS differential pressure is above standard value, LS shuttle valve may be
defective. Clean check valve seat on shuttle valve block of boom control
valve.Also check for defects on check valve.
Malfunction of LS shuttle
16 valve (L.H. travel control Clean check valve seat on shuttle valve block of L.H. travel control valve.
valve)
17 valve (bucket control valve) Clean check valve seat on shuttle valve block of bucket control valve.
18 valve (service valve) Clean check valve seat on shuttle valve block of service valve.

19 Defective boom cylinder running at full speed.
Leakage from
Boom RAISE hydraulic relief Max. 20 cc/min
boom cylinder
PC210LC-10 40-657
40 Troubleshooting
mode)
H-7 Arm speed or power is low (PC200LC_10-A8C-400-A-Z0-A)
Failure • Speed or power of arm is low.

• If failure codes are displayed, perform troubleshooting for them first. (DHS3MA, DXE5KA,
DXE5KB, DXE6KA, DXE6KB)
• Arm IN PPC pressure can be checked with monitoring function. (Code: 07200)
information 08000)
08001)
L.H. work
Malfunction of left PPC 0 MPa {0 kg/cm2}
1 valve (arm circuit) equipment control NEUTRAL
pressure L.H. work 2.84 to 3.43 MPa
equipment control Arm IN or OUT {29 to 35 kg/cm2}
lever
a If arm lacks speed, check all work equipment speeds. If any failure is
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.5
seconds
to move
Max. 3.3/2.7
Bucket CURL/DUMP
seconds
3
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
4
0 mA
NEUTRAL
EPC current
relief
40-658 PC210LC-10
40 Troubleshooting
mode)

Malfunction of merge- • Check for locked or trapped main spool in merge-divider valve body.
5 divider main spool (Spool must move smoothly.)
• Take care not to let foreign matter enter valve when re-installing main
spool.
Malfunction of merge- • Check for locked or trapped LS spool in merge-divider valve body.
6 divider LS spool (Spool must move smoothly.)
• Take care not to let foreign matter enter valve when re-installing LS
spool.
Malfunction of arm control • Check for locked or trapped arm spool in control valve body.
7 valve (spool) (Spool must move smoothly.)
• Remove arm spool from valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing arm
spool.
33.1 to 37.2 MPa
Arm relief
pressure
cm2}
a Check hydraulic drift of arm cylinder with engine stopped.
Malfunction of arm control Hydraulic drift operating range, bucket with rated drift is observed,
valve (pressure load, arm cylinder fully extended control valve is
8 compensation valve) (arm defective.
IN side) a Check whether arm cylinder moves slowly when performing hydraulic
relief of other work equipment. (If arm cylinder moves, control valve is
defective.)
pressure compensation valves on arm IN and OUT sides, and check
whether failure symptom changes.
(Pressure compensation valves have different area ratio, so be sure to
return them to their original positions after test.)
PC210LC-10 40-659
40 Troubleshooting
mode)

33.1 to 37.2 MPa
Arm relief
Arm OUT hydraulic relief {338 to 380 kg/
pressure
cm2}
Malfunction of arm control
valve (pressure Hydraulic drift operating range, bucket with rated drift is observed,
9 compensation valve) (arm load, arm cylinder fully retracted: control valve is
defective.
OUT side)
a Check whether arm cylinder moves slowly when performing hydraulic
defective.)
pressure compensation valves on arm IN and OUT sides, and check
• Check for locked or trapped arm regeneration valve in control valve
body.
Malfunction of arm control (Regeneration valve must move smoothly.)
10 valve (regeneration valve) • Check that regeneration valve (check valve ) is seated on control valve
in position (it is not trapped halfway), and then remove it from control
valve body and check it for defects and dirt.
• Take care not to let foreign matter enter valve when re-installing check
valve.
Measurement condition Hydraulic drift
If visible hydraulic
• Hydraulic oil temperature within operating range,
drift is observed,
bucket with rated load, arm cylinder fully extended
control valve is
•
defective.
11 valve (quick return valve) • Check that pilot spool and check valve are seated on valve body in
• Check for locked or trapped pilot spool and check valve in quick return
valve body.
(Pilot spool and check valve must move smoothly.)
• Remove pilot spool and check valve from valve body and check them
for defects and dirt.
pilot spool and check valve.
40-660 PC210LC-10
40 Troubleshooting
mode)

relief pressure hydraulic relief cm2}
a Among above relief pressures, if arm OUT relief pressure and boom
12 valve (safety valve for lock RAISE relief pressure is below standard value, safety valve may be
valve)
machine, replace safety valve if safety valve is found to be defective.
(Reference) Safety valve circuit connects to both boom RAISE and arm
OUT circuits via check valve. Determine that boom lock valve is defective if
arm IN or OUT relief pressure is normal.
Malfunction of arm control (pilot piston and poppet should move smoothly).
13 valve (lock valve)(if • Remove pilot piston and poppet from valve body and check them for
equipped) defects and dirt.
• Take care not to let foreign matter enter valve when re-installing piston
and poppet.
33.1 to 37.2 MPa
Arm relief
Arm OUT hydraulic relief {338 to 380 kg/
pressure
cm2}
14 valve (suction valve) (arm a If arm OUT relief pressure is below standard value, suction valve (check
OUT side) valve) may be defective. Check it.
trapped halfway).
• Remove check valve from valve body and check it for defects and dirt.
• Check spring for setting and deformation.
• Take care not to let foreign matter enter valve when re-installing check
valve.
33.1 to 37.2 MPa
Arm relief
pressure
cm2}
a If arm IN relief pressure is below standard value, suction-safety valve
15 valve (suction-safety valve)
(arm IN side) may be defective. Check it.
• Check that check valve of suction-safety valve is seated on valve body
in position (it is not trapped halfway).
defective.
PC210LC-10 40-661
40 Troubleshooting
mode)

All work equipment control lever in 3.5 ± 1.0 MPa
NEUTRAL {36 ± 10 kg/cm2}
Malfunction of arm control LS differential 1.8(+0.05/-0.1)
16 valve (LS shuttle valve) pressure MPa
Finely moved to arm IN and OUT
{18(+0.5/-1.0) kg/
cm2}
a If LS differential pressure is above standard value, LS shuttle valve may
be defective. Clean check valve seat on shuttle valve block of arm
control valve.Also check for defects on check valve.
Clean check valve seat on shuttle valve block of R.H. travel control valve,
17 valve (R.H. travel control
valve) and then check it.

18 Defective arm cylinder running at full speed.
Leakage from
Arm IN hydraulic relief Max. 20 cc/min
arm cylinder
40-662 PC210LC-10
40 Troubleshooting
mode)
H-8 Bucket speed or power is low (PC200LC_10-A8D-400-A-Z0-A)
Failure • Speed or power of bucket is low.

• If failure codes are displayed, perform troubleshooting for them first. (DHS4MA, DXE5KA,
DXE5KB, DXE6KA, DXE6KB)
• Bucket CURL PPC pressure can be checked with monitoring function. (Code: 07300)
information 08000)
08001)
R.H. work
Malfunction of right PPC equipment control NEUTRAL 0 MPa {0 kg/cm2}
1 valve (bucket circuit)
pressure R.H. work 2.84 to 3.43 MPa
equipment control Arm IN or OUT {29 to 35 kg/cm2}
lever
a If bucket lacks speed, check all work equipment speeds. If any failure is
Boom RAISE/LOWER
seconds
Time required for
Max. 4.5/3.5
seconds
to move
Max. 3.3/2.7
Bucket CURL/DUMP
seconds
All work equipment control levers in 0 to 0.49 MPa {0
Main EPC output NEUTRAL to 5 kg/cm2}
3 Bucket CURL and Arm IN hydraulic 2.84 to 3.43 MPa
divider main EPC valve {29 to 35 kg/cm2}
relief
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
All work equipment control levers in 0 to 0.49 MPa {0
LS-EPC output NEUTRAL to 5 kg/cm2}
Malfunction of merge- pressure 2.84 to 3.43 MPa
4 Bucket CURL and Arm IN hydraulic
divider LS-EPC valve {29 to 35 kg/cm2}
relief
0 mA
NEUTRAL
EPC current
relief
PC210LC-10 40-663
40 Troubleshooting
mode)

5 divider main spool (Spool must move smoothly.)
main spool.
6 divider LS spool (Spool must move smoothly.)
LS spool.
Malfunction of bucket • Check for locked or trapped bucket spool in control valve body.
7 control valve (spool) (Spool must move smoothly.)
• Remove bucket spool from valve body and check it for defects and dirt.
bucket spool.
33.1 to 37.2 MPa
Bucket relief
Bucket CURL hydraulic relief {338 to 380 kg/
pressure
cm2}
a Check hydraulic drift of bucket cylinder with engine stopped.
Hydraulic oil temperature within
operating range, bucket with rated If visible hydraulic
Malfunction of bucket load, arm cylinder fully retracted, drift is observed,
Hydraulic drift
control valve (pressure bucket cylinder fully extended, boom control valve is
top face horizontal defective.
(bucket CURL side)
a Check whether bucket cylinder moves slowly when performing
hydraulic relief of other work equipment. (If bucket cylinder moves,
control valve is defective.)
pressure compensation valves on bucket CURL and DUMP sides, and
33.1 to 37.2 MPa
Bucket relief
Bucket DUMP hydraulic relief {338 to 380 kg/
pressure
Malfunction of bucket cm2}
control valve (pressure
9 compensation valve) a Check hydraulic drift of bucket cylinder with engine stopped.
(bucket DUMP side) Hydraulic oil temperature within
operating range, bucket with no load, If visible hydraulic
Hydraulic drift arm cylinder fully retracted, bucket drift is observed,
cylinder fully retracted, boom top control valve is
face horizontal defective.
40-664 PC210LC-10
40 Troubleshooting
mode)

hydraulic relief of other work equipment. (If bucket cylinder moves,
control valve is defective.)
pressure compensation valves on bucket CURL and DUMP sides, and
33.1 to 37.2 MPa
Bucket relief
Bucket CURL hydraulic relief {338 to 380 kg/
Malfunction of bucket pressure
cm2}
control valve (suction-
10 safety valve) (bucket CURL • If bucket CURL relief pressure is below standard value, suction valve
may be defective. Check it.
side) • Check that check valve of suction-safety valve is seated on valve body
defective.
33.1 to 37.2 MPa
Bucket relief
Bucket DUMP hydraulic relief {338 to 380 kg/
Malfunction of bucket pressure
cm2}
control valve (suction- • If bucket DUMP relief pressure is below standard value, suction valve
11 safety valve) (bucket
may be defective. Check it.
DUMP side) • Check that check valve of suction-safety valve is seated on valve body
defective.
All work equipment control lever in 3.5 ± 1.0 MPa
NEUTRAL {36 ± 10 kg/cm2}
Malfunction of bucket LS differential 1.8(+0.05/-0.1)
12 control valve (LS shuttle pressure Finely moved to bucket CURL or MPa
valve) DUMP {18(+0.5/-1.0) kg/
cm2}
a If LS differential pressure is above standard value, LS shuttle valve may
be defective. Clean check valve seat on shuttle valve block of bucket
control valve.Also check for defects on check valve.
Clean check valve seat on shuttle valve block of L.H. travel control valve,
13 valve (L.H. travel control
valve) and then check it.

14 Defective bucket cylinder running at full speed.
Leakage from
Bucket CURL hydraulic relief Max. 20 cc/min
bucket cylinder
PC210LC-10 40-665
40 Troubleshooting
mode)
H-9 Work equipment does not move in single operation (PC300-FTC-400-A-Z0-A)
(1) Boom does not move in single operation.

Failure (2) Arm does not move in single operation.
(3) Bucket does not move in single operation.
• If failure codes are displayed, perform troubleshooting for them first. (DHS3MA, DHS4MA,
DHS8MA, DHSDMA)
• PPC pressure of each work equipment can be checked with monitoring function.
Related Monitoring codes for them are shown below.
information Boom RAISE PPC pressure: 07400
Arm IN PPC pressure: 07200
Bucket CURL PPC pressure: 07300
Bucket DUMP PPC pressure: 07301
1 Malfunction of PPC valve Work equipment 0 MPa {0 kg/cm2}
NEUTRAL
PPC valve output control levers
pressure Work equipment 2.84 to 3.43 MPa
Operated
control levers {29 to 35 kg/cm2}
Malfunction of boom • Check for locked or trapped boom spool in control valve body.
• Remove boom spool from valve body and check it for defects and dirt.
boom spool.
Malfunction of arm control • Check for locked or trapped arm spool in control valve body.
3 valve (spool) (Spool must move smoothly.)
arm spool.
bucket spool.
(Reference) While work equipment is moved in single operation, if pump pressure remains at approx. 4 MPa
{approx. 40 kg/cm2}, control valve spool probably stays at NEUTRAL position.(All oil from pump is drained to
tank through unload valve.)
40-666 PC210LC-10
40 Troubleshooting
mode)
H-10 Hydraulic drift of boom is large (PC200LC_10-MS3-400-A-Z0-A)
Failure • Hydraulic drift of boom is large.

Related • Perform all troubleshooting with working mode set in P mode.
information
1 Defective boom cylinder running at full speed.
Leak from boom
Boom RAISE hydraulic relief Max. 20 cc/min
cylinder
Malfunction of boom relief pressure hydraulic relief cm2}
2 control valve (safety valve
for lock valve) a Among above relief pressures, if arm OUT relief pressure and boom
RAISE relief pressure is below standard value, safety valve may be
defective.
Malfunction of boom
3 control valve (lock valve) (pilot piston and poppet must move smoothly).
• Remove pilot piston and poppet from valve body and check them for
defects and dirt.
PC210LC-10 40-667
40 Troubleshooting
mode)
H-11 Hydraulic drift of arm is large (PC200LC_10-MS4-400-A-Z0-A)
Failure • Hydraulic drift of arm is large.

information
1 Defective arm cylinder running at full speed.
Leak from arm
Arm IN hydraulic relief Max. 20 cc/min
cylinder
Malfunction of arm control relief pressure hydraulic relief cm2}
2 valve (safety valve for lock
valve) a Among above relief pressures, if arm OUT relief pressure and boom
RAISE relief pressure is below standard value, safety valve may be
defective.
Malfunction of arm control • Check for locked or trapped pilot piston and poppet in lock valve body
3 valve (lock valve)(if (pilot piston and poppet must move smoothly).
equipped) • Remove pilot piston and poppet from valve body and check them for
defects and dirt.
33.1 to 37.2 MPa
Arm relief
pressure
cm2}
4 valve (suction-safety valve) a If arm IN relief pressure is below standard value, suction-safety valve
(arm IN side) may be defective. Check it.
• Check that check valve of suction-safety valve is seated on valve body
defective.
Malfunction of arm control perform troubleshooting with engine stopped.
5 valve (spool) • Check for locked or trapped arm spool in control valve body.
a Check whether arm cylinder moves slowly when performing hydraulic
defective.)
6 valve (pressure a If any failure is found in either of above check items, interchange
compensation valve) pressure compensation valves on arm IN and OUT sides, and check
40-668 PC210LC-10
40 Troubleshooting
mode)
H-12 Hydraulic drift of bucket is large (PC200LC_10-MS2-400-A-Z0-A)
Failure • Hydraulic drift of bucket is large.

information
1 Defective bucket cylinder running at full speed.
Leak from bucket
Bucket CURL hydraulic relief Max. 20 cc/min
cylinder
33.1 to 37.2 MPa
Bucket relief Bucket CURL or DUMP hydraulic
Malfunction of bucket {338 to 380 kg/
pressure relief
2 control valve (suction- cm2}
safety valve)
a If relief pressure is below standard value, suction-safety valve may be
defective..
a You can replace suction-safety valve with other one and check whether
failure symptom changes for judgment.
bucket spool.
hydraulic relief of other work equipment.
(If bucket cylinder moves, control valve is defective.)
Malfunction of bucket
4 control valve (pressure a If any failure is found in above check item, interchange pressure
compensation valve) compensation valves on bucket CURL and DUMP sides, and check
PC210LC-10 40-669
40 Troubleshooting
mode)
H-13 Time lag of work equipment is large (PC200LC_10-FTD-400-A-Z0-A)
Failure • Time lag of work equipment is large.

Related • If failure codes are displayed, perform troubleshooting for them first. (DXE0KA, DXE0KB)
information • F pump pressure and R pump pressure can be checked with monitoring function. (Code: F
Approx. 2.9 MPa
Malfunction of LS-EPC Travel control Travel speed: Lo {Approx. 30 kg/
1 lever: NEUTRAL
valve LS-EPC valve cm2}
moved
• Check for locked or trapped boom regeneration valve in control valve
Malfunction of boom body.
2 control valve (regeneration (Regeneration valve must move smoothly.)
valve) • Check that regeneration valve (check valve ) is seated on control valve
• Check for locked or trapped arm regeneration valve in control valve
Malfunction of arm control body.
3 valve (regeneration valve) (Regeneration valve must move smoothly.)
• Check that regeneration valve (check valve ) is seated on control valve
a Check relief pressure of each work equipment. If relief pressure only of
Malfunction of boom boom cylinder head end is unusual, suction-safety valve of boom
4 control valve (suction- control valve may malfunction.
safety valve)
arm cylinder bottom end is unusual, suction-safety valve of arm control
5 valve (suction-safety valve) valve may malfunction.
Malfunction of bucket bucket cylinder head end is unusual, suction-safety valve of bucket
control valve may malfunction.
6 control valve (suction-
safety valve) a You can replace suction-safety valve with other one and check whether
40-670 PC210LC-10
40 Troubleshooting
mode)

a Check whether boom cylinder moves slowly to RAISE side when
performing hydraulic relief of other work equipment. (If boom cylinder
Malfunction of boom moves, control valve is defective.)
control valve (pressure a If any failure is found in above check item, interchange pressure
compensation valves between both ports, and check whether failure
(boom RAISE side) symptom changes.
Malfunction of boom
control valve (pressure a Check whether boom cylinder moves slowly to LOWER side when
8 compensation valve) performing hydraulic relief of other work equipment. (If boom cylinder
(boom LOWER side) moves, control valve is defective.)
valve (pressure a Check whether arm cylinder moves slowly to arm IN side when
9 compensation valve) (arm performing hydraulic relief of other work equipment. (If arm cylinder
IN side) moves, control valve is defective.)
valve (pressure a Check whether arm cylinder moves slowly to arm OUT side when
10 compensation valve) (arm performing hydraulic relief of other work equipment. (If arm cylinder
OUT side) moves, control valve is defective.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket CURL side
11 compensation valve) when performing hydraulic relief of other work equipment. (If bucket
(bucket CURL side) cylinder moves, control valve is defective.)
control valve (pressure a Check whether bucket cylinder moves slowly to bucket DUMP side
12 compensation valve) when performing hydraulic relief of other work equipment. (If bucket
(bucket DUMP side) cylinder moves, control valve is defective.)
PC210LC-10 40-671
40 Troubleshooting
mode)
H-14 When part of work equipment is relieved singly, other parts of work
equipment move (PC300-FT4-400-A-Z0-A)
Failure • Other wok equipment moves when one of work equipment is relieved.
information
When work equipment other than boom is hydraulically relieved singly, if
boom moves to RAISE side arbitrarily, pressure compensation valve on
Malfunction of boom boom RAISE side may malfunction.
1 compensation valve) a Pressure compensation valve is equipped with outer seal, inner seal,
(boom RAISE side) and LS check valve (ball).
Since slipper seal is installed to inner seal, damage on O-ring inside
inner seal cannot be checked visually.
When work equipment other than arm is hydraulically relieved singly, if arm
valve (pressure
2 compensation valve) (arm moves to IN side arbitrarily, pressure compensation valve on arm IN side
may malfunction.
IN side)
When work equipment other than bucket is hydraulically relieved singly, if
3 compensation valve) bucket moves to CURL side arbitrarily, pressure compensation valve on
bucket CURL side may malfunction.
(bucket CURL side)
When work equipment other than bucket is hydraulically relieved singly, if
4 compensation valve) bucket moves to DUMP side arbitrarily, pressure compensation valve on
bucket DUMP side may malfunction.
(bucket DUMP side)
40-672 PC210LC-10
40 Troubleshooting
mode)
H-15 One-touch power maximizing function does not operate (PC200LC_10-FGL-

400-A-Z0-A)
Failure • One-touch power maximizing function does not work..

information • If failure codes are displayed, perform troubleshooting for them first. (DWK0KA, DWK0KB)
Malfunction of 2-stage
1 2-stage relief Swing lock switch OFF 0 MPa {0 kg/cm2}
relief solenoid valve
solenoid output 2.9 MPa
pressure Swing lock switch ON
{30 kg/cm2}
33.1 to 37.2 MPa
Normal hydraulic Hydraulic relief of
relief bucket only {338 to 380 kg/
Defective adjustment or cm2}
Front pump main
2 malfunction of main relief relief pressure Hydraulic relief
36.1 to 39.7 MPa
valve (front) during one-touch Hydraulic relief of
{368 to 405 kg/
power bucket only
cm2}
maximizing
If normal relief pressure is not obtained after adjustment, check main relief
valve for malfunction (setting of spring) and internal failure (defective valve
seat).
33.1 to 37.2 MPa
Normal hydraulic Hydraulic relief of
relief arm only {338 to 380 kg/
Defective adjustment or cm2}
Rear pump main
3 malfunction of main relief relief pressure Hydraulic relief
36.1 to 39.7 MPa
valve (rear) during one-touch Hydraulic relief of
{368 to 405 kg/
power arm only
cm2}
maximizing
If normal relief pressure is not obtained after adjustment, check main relief
valve for malfunction (setting of spring) and internal failure (defective valve
seat).
PC210LC-10 40-673
40 Troubleshooting
mode)
H-16 In combined operation of work equipment, equipment having

heavier load moves slower (PC200LC_10-D34-400-A-Z0-A)
Failure • In combined operation of work equipment, equipment having heavier load moves slower.
Related
information
Operations
Malfunction of control valve Heavier load side Smaller load side
combined
on smaller load side Boom RAISE and
1 (pressure compensation Boom RAISE Arm IN
arm IN
valve) (arm IN) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
on smaller load side Boom RAISE and
2 (pressure compensation Arm OUT Boom RAISE
arm OUT
valve) (boom RAISE) Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
Heavier load side Smaller load side
combined
Boom RAISE and
Boom RAISE Bucket CURL
bucket CURL
Malfunction of control valve Pressure compensation valve of control valve on smaller load side may
on smaller load side malfunction.
3 (pressure compensation
Operations
valve) (bucket CURL) Heavier load side Smaller load side
combined
Arm OUT and
Arm OUT Bucket CURL
bucket CURL
Pressure compensation valve of control valve on smaller load side may
malfunction.
Operations
combined
on smaller load side Boom LOWER
4 (pressure compensation Arm OUT Boom LOWER
and arm OUT
valve) (boom LOWER) Pressure compensation valve of control valve on smaller load side may
malfunction.
a Pressure compensation valve is equipped with outer seal, inner seal, and LS check valve (ball).
Since slipper seal is installed to inner seal, damage on O-ring inside inner seal cannot be checked visually.
40-674 PC210LC-10
40 Troubleshooting
mode)
H-17 In combined operations of swing and boom RAISE, boom rising

speed is low (PC220_10-D35-400-A-00-A)
Failure • In combined operations of swing and boom RAISE, boom speed is low.
• If boom RAISE speed is slow even in single operation of boom RAISE, perform following
Related troubleshooting.
information
• “H-6 Boom operation lacks speed or power“
Malfunction of or LS select valve of swing control valve may malfunction or sealing may be
defective sealing defective. Check it.
1 for swing control
valve (LS select
valve)
PC210LC-10 40-675
40 Troubleshooting
mode)
H-18 In combined operations of swing and travel, travel speed drops

largely (PC220_10-D26-400-A-00-A)
Failure • Travel speed drops significantly in combined operation of swing and travel.
• If travel speed is slow even in single operation of travel, perform following
Related troubleshooting.
information
• “H-20 Travel speed is too low“
Malfunction of L.H. LS shuttle valve of L.H. travel control valve may malfunction. Check it.
1 travel control valve
(LS shuttle valve)
Malfunction of LS shuttle valve of swing control valve may malfunction. Check it.
2 swing control valve
(LS shuttle valve)
40-676 PC210LC-10
40 Troubleshooting
mode)
H-19 Machine does not travel straight (PC200LC_10-FTF-400-A-Z0-A)
Failure • Machine deviates during travel.

Related • If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB,
information DHS3MA, DXE5KA, DXE5KB, DXE6KA, DXE6KB)
• Travel PPC pressure can be checked with monitoring function. (Code: 01882)
Malfunction of R.H. travel
1 R.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve R.H travel control
valve output FORWARD and 2.84 to 3.43 MPa
pressure lever
REVERSE {29 to 35 kg/cm2}
Malfunction of L.H. travel NEUTRAL 0 MPa {0 kg/cm2}
2 L.H. travel control
PPC valve L.H. travel PPC
lever FORWARD and 2.84 to 3.43 MPa
valve output REVERSE {29 to 35 kg/cm2}
pressure Difference in output pressure Max. 0.4 MPa
between L.H. and R.H. PPC valves {Max. 4 kg/cm2 }
Malfunction of self- Control circuit 2.84 to 3.43 MPa
3 pressure reducing valve source pressure All levers in NEUTRAL {29 to 35 kg/cm2}
a Since relief valve of self-pressure reducing valve is not adjustable,
replace self-pressure reducing valve assembly if normal pressure is not
obtained.
L.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
R.H. track:
Running idle off
Lever moved
halfway
pressure pressure 1
6 (front) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
PC210LC-10 40-677
40 Troubleshooting
mode)

7 (rear) malfunction (setting of spring) and internal failure (locked or trapped LS
spool).
Malfunction of travel Both levers in
8 junction solenoid valve 0 MPa {0 kg/cm2}
Solenoid valve Travel control NEUTRAL
outlet pressure lever When either lever 2.9 MPa
is operated {30 kg/cm2}
• Check for locked or trapped travel junction valve spool in merge-divider
Malfunction of travel valve body.
9 junction valve (spool)
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
Malfunction of R.H.travel • Check for locked or trapped travel spool in control valve body.
• Remove travel spool from valve body and check it for defects and dirt.
Malfunction of L.H.travel perform troubleshooting with engine stopped.
11 control valve (spool) • Check for locked or trapped travel spool in control valve body.
36.8 to 40.2 MPa
Malfunction of travel control Travel relief R.H. travel FORWARD hydraulic
pressure relief {375 to 410 kg/
valve (pressure
12 compensation valve) (R.H. cm2}
travel FORWARD side) a If normal relief pressure is not obtained, pressure compensation valve
may malfunction.
Interchange pressure compensation valves on FORWARD and
REVERSE sides, and check whether failure symptom changes.
Malfunction of travel control
valve (pressure
13 compensation valve) (R.H. 36.8 to 40.2 MPa
Travel relief
travel REVERSE side) R.H travel REVERSE hydraulic relief {375 to 410 kg/
pressure
cm2}
valve (pressure
14 compensation valve) (L.H. 36.8 to 40.2 MPa
Travel relief L.H. travel FORWARD hydraulic
travel FORWARD side) pressure {375 to 410 kg/
relief
cm2}
valve (pressure
Travel relief
travel REVERSE side) L.H. travel REVERSE hydraulic relief {375 to 410 kg/
pressure
cm2}
40-678 PC210LC-10
40 Troubleshooting
mode)

Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
16 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
17 Defective travel motor running at full speed.
Leakage from Travel hydraulic relief Max. 27.2 l /min
travel motor
18 Defective final drive a Check for unusual noise, unusual heat, and metallic powders in drained
oil to make judgment.
PC210LC-10 40-679
40 Troubleshooting
mode)
H-20 Travel speed is slow (PC200LC_10-D20-400-A-Z0-A)
Failure • Travel speed is low.

• If failure codes are displayed, perform troubleshooting for them first. (DXE0KA, DXE0KB)
Related • Pump pressure can be checked with monitoring function. (Code: F pump pressure 01100,
information R pump pressure 01101)
• Travel PPC pressure can be checked with monitoring function. (Code: 01882)
• Current to LS-EPC solenoid can be checked with monitoring function. (Code: 01500)
pressure lever
Malfunction of L.H. travel
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve L.H. travel control
pressure lever
Malfunction of self- running at full speed.
3 pressure reducing valve
Control circuit 2.84 to 3.43 MPa
source pressure All control levers in NEUTRAL {29 to 35 kg/cm2}
Malfunction of LS-EPC Approx. 2.9 MPa
4 Travel control Travel speed: Lo {Approx. 30 kg/
valve LS-EPC valve lever: NEUTRAL cm2}
output pressure
走行レバー:
Travel speed: Hi 0 MPa {0 kg/cm2}
Finely moved
36.8 to 40.2 MPa
Travel relief R.H. travel FORWARD hydraulic
Malfunction of travel control {375 to 410 kg/
pressure relief
valve (pressure cm2}
7 compensation valve) (R.H.
travel FORWARD side) a If normal relief pressure is not obtained, pressure compensation valve
may malfunction.
40-680 PC210LC-10
40 Troubleshooting
mode)

valve (pressure
8 compensation valve) (R.H. 36.8 to 40.2 MPa
Travel relief
travel REVERSE side) R.H travel REVERSE hydraulic relief {375 to 410 kg/
pressure
cm2}
valve (pressure
Travel relief L.H. travel FORWARD hydraulic
travel FORWARD side) pressure {375 to 410 kg/
relief
cm2}
valve (pressure
Travel relief
travel REVERSE side) L.H. travel REVERSE hydraulic relief {375 to 410 kg/
pressure
cm2}
If relief pressure of only one port is below standard value after adjusting
Malfunction of travel control relief valve, suction valve may malfunction.
11 valve (suction valve)
Check suction valve (check valve) for defects and setting of spring.
12 Defective travel motor running at full speed.
Leakage from Travel hydraulic relief Max. 27.2 l /min
travel motor
PC210LC-10 40-681
40 Troubleshooting
mode)
H-21 Machine is hard to steer or travel power is low (PC200LC_10-L18-400-A-Z0-A)
Failure • Machine is not steered well or steering power is low.

• If failure codes are displayed, perform troubleshooting for them first. (DW91KA, DW91KB,
DHS3MA, DXE5KA, DXE5KB, DXE6KA, DXE6KB)
Related • Travel PPC pressure can be checked with monitoring function. (Code: 01882)
information • Current to merge-divider (main) solenoid can be checked with monitoring function. (Code:
08000)
08001)
pressure lever
2 L.H. travel PPC NEUTRAL 0 MPa {0 kg/cm2}
PPC valve L.H. travel control
pressure lever
Malfunction of travel Both levers in
3 junction solenoid valve Travel junction 0 MPa {0 kg/cm2}
Travel control NEUTRAL
solenoid valve 2.9 MPa
lever When either lever
output pressure
is operated {30 kg/cm2}
• Check for locked or trapped travel junction valve spool in merge-divider
Malfunction of travel valve body.
4 junction valve (spool)
• Remove travel junction valve spool from valve body and check it for
defects and dirt.
5
0 mA
NEUTRAL
EPC current
relief
40-682 PC210LC-10
40 Troubleshooting
mode)

6
0 mA
NEUTRAL
EPC current
800 to 1000 mA
relief
7 divider main spool
8 divider LS spool
36.8 to 40.2 MPa
Travel relief R.H. travel FORWARD hydraulic
pressure {375 to 410 kg/
relief
Malfunction of travel control cm2}
valve (pressure
11 compensation valve) (R.H. a If normal relief pressure is not obtained, pressure compensation valve
may malfunction.
travel FORWARD side)
a If relief pressures of R.H. travel FORWARD and L.H. travel REVERSE
are same and below standard value, main relief valve of rear pump may
malfunction. Check arm relief pressure additionally.
Malfunction of travel control 36.8 to 40.2 MPa
valve (pressure Travel relief
12 compensation valve) (R.H. R.H travel REVERSE hydraulic relief {375 to 410 kg/
pressure
cm2}
travel REVERSE side)
If measured values in checks on causes (11) and (12) are same and below
standard value, main relief valve of rear pump may malfunction. Check arm
relief pressure additionally.
PC210LC-10 40-683
40 Troubleshooting
mode)

valve (pressure Travel relief L.H. travel FORWARD hydraulic
13 compensation valve) (L.H. pressure relief {375 to 410 kg/
cm2}
travel FORWARD side)
If relief pressures of L.H. travel FORWARD and L.H. travel REVERSE are
same and below standard value, main relief valve of front pump may
malfunction. Check bucket relief pressure additionally.
valve (pressure Travel relief
14 compensation valve) (L.H. L.H. travel REVESE hydraulic relief {375 to 410 kg/
pressure
cm2}
travel REVERSE side)
If measured values in checks on causes (13) and (14) are same and below
standard value, main relief valve of front pump may malfunction. Check
bucket relief pressure additionally.
If relief pressure of only one port is below standard value after adjusting
Malfunction of travel control relief valve, suction valve may malfunction.
15 valve (suction valve)
Check suction valve (check valve) for defects and setting of spring.
Connect hoses from L.H. and R.H. travel motors to swivel joint changing
Defective center swivel
16 joint connecting ports with each other, and check whether direction in which
machine deviates changes.
If relief pressures of both R.H. travel FORWARD and REVERSE are
unusual in checks on causes (11) and (12) respectively, respective safety
Defective R.H. travel motor valves may be defective.
17 (safety valve)
Interchange safety valves of L.H. and R.H. travel motors, and check
If relief pressures of both L.H. travel FORWARD and REVERSE are
unusual in checks on causes (13) and (14) respectively, respective safety
Defective L.H. travel motor valves may be defective.
18 (safety valve)
If pressure compensation valves are found to be normal in checks on
Defective R.H. travel motor causes (11) and (12), check valves may malfunction.
19 (safety valve)
Interchange check valves on FORWARD and REVERSE sides of same
travel motor, and check whether failure symptom changes.
If pressure compensation valves are found to be normal in checks on
Defective L.H. travel motor causes (13) and (14), check valves may malfunction.
20 (check valve)
21 Defective R.H. travel motor running at full speed.
Leakage from
R.H. travel relief Max. 27.2 l /min
travel motor
22 Defective L.H. travel motor running at full speed.
Leakage from L.H. travel hydraulic relief Max. 27.2 l /min
travel motor
40-684 PC210LC-10
40 Troubleshooting
mode)
H-22 Travel speed does not change, or travel speed is too slow or
fast (PC200LC_10-BQ4-400-A-Z0-A)
Failure • Travel speed does not change or travel speed is too low or high.
• If failure codes are displayed, perform troubleshooting for them first.(DW43KA, DW43KB)
Related • Current to LS-EPC solenoid can be checked with monitoring function. (Code: 01500)
information • Signal (ON/OFF) of travel speed selector solenoid can be checked with monitoring
function. (Code: 02300)
Travel control 600 mA
lever: Finely Travel speed: Lo
moved (* Reference)
Travel control
LS-EPC current Travel speed: Mi
lever: Finely 644 mA
value
moved
Travel control
Malfunction of LS-EPC lever: Finely Travel speed: Hi 0 mA
1
valve moved
Approx. 2.9 MPa
Travel control Travel speed: Lo {Approx. 30 kg/
LS-EPC output lever: NEUTRAL cm2}
pressure Travel control
moved
Malfunction of travel speed Travel control Travel speed: Lo 0 MPa {0 kg/cm2}
2 lever: NEUTRAL
selector solenoid valve Solenoid valve
Travel control Approx. 2.9 MPa
outlet pressure
lever: Finely Travel speed: Hi {Approx. 30 kg/
moved cm2}
Malfunction of travel motor If no failure is found by checks on causes (1) and (2), speed switching
3 (speed switching portion) portion of travel motor may malfunction.
* : Travel speed of Lo setting can be adjusted by using adjustment function of machine monitor. If it is
changed from default value, LS-EPC current value changes slightly.
PC210LC-10 40-685
40 Troubleshooting
mode)
H-23 One of tracks does not run (PC200LC_10-BG1-400-A-Z0-A)
Failure • One of tracks does not run..

Related • Travel PPC pressure can be checked with monitoring function. (Code: 01882)
information • Pump pressure can be checked with monitoring function. (Code: F pump pressure 01100,
R pump pressure 01101)
Malfunction of R.H. travel R.H travel control
1 NEUTRAL 0 MPa {0 kg/cm2}
PPC valve PPC valve output lever
pressure R.H travel control FORWARD and 2.84 to 3.43 MPa
lever REVERSE {29 to 35 kg/cm2}
Malfunction of L.H. travel L.H. travel control
PPC valve PPC valve output lever
pressure L.H. travel control FORWARD and 2.84 to 3.43 MPa
lever REVERSE {29 to 35 kg/cm2}
If no failure is found by check on cause (1) and one track does not run
Malfunction of R.H.travel
3 control valve (spool) when travel control lever is operated with pump pressure at approx. 4 MPa,
check whether spool is locked near NEUTRAL position.
If no failure is found by check on cause (2) and one track does not run
Malfunction of L.H.travel
4 control valve (spool) when travel control lever is operated with pump pressure at approx. 4 MPa,
check whether spool is locked near NEUTRAL position.
When R.H. travel control lever is operated, if R.H. track does not run
5 control valve (suction because of low pump pressure, check suction valve.
valve)
When L.H. travel control lever is operated, if L.H. track does not run
6 control valve (suction because of low pump pressure, check suction valve.
valve)
36.8 to 40.2 MPa
Travel relief R.H. travel FORWARD and
Defective R.H. travel motor pressure hydraulic relief REVERSE {375 to 410 kg/
7 (safety valve) cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
36.8 to 40.2 MPa
Travel relief L.H. travel FORWARD and
Defective L.H. travel motor pressure hydraulic relief {375 to 410 kg/
8 (safety valve) REVERSE
cm2}
If relief pressures of travel FORWARD and REVERSE are unusual to the
same degree, sealing of safety valve may be defective.
If safety valve is found to be normal in checks on cause (7), sealing of
check valve may be defective.
Defective R.H. travel motor
9 (check valve) Interchange check valves on FORWARD and REVERSE sides of same
40-686 PC210LC-10
40 Troubleshooting
mode)

If safety valve is found to be normal in checks on cause (8), sealing of
Defective L.H. travel motor check valve may be defective.
10 (check valve)
Defective travel motor When running R.H. track idle off ground, if R.H. track does not run with R.
11 (parking brake) H. travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
Defective L.H. travel motor When running L.H. track idle off ground, if L.H. track does not run with L.H.
12 (parking brake) travel circuit pressure reaching relief pressure, travel parking brake may
malfunction.
13 Defective R.H. travel motor running at full speed.
Leakage from R. R.H travel control R.H travel
hydraulic relief Max. 27.2 l /min
H. travel motor lever
14 Defective L.H. travel motor running at full speed.
Leakage from L. L.H. travel control L.H. travel
hydraulic relief Max. 27.2 l /min
H. travel motor lever
PC210LC-10 40-687
40 Troubleshooting
mode)
H-24 Upper structure does not swing to the right or left (PC200LC_10-L41-400-A-Z0-A)
Failure • Upper structure does not swing in both right and left directions.
Related • If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
Malfunction of swing PPC Swing control
valve Swing PPC valve lever
output pressure Swing control Left swing and 2.84 to 3.43 MPa
lever Right swing {29 to 35 kg/cm2}
Malfunction of swing
2 holding brake solenoid Swing control 0 MPa {0 kg/cm2}
Swing holding NEUTRAL
valve lever
brake solenoid 2.9 MPa
Swing control Left swing and
output pressure
lever Right swing {30 kg/cm2}
When no failure is found by check on cause (1), if upper structure does not
Malfunction of swing motor swing with swing circuit pressure reaching relief pressure, swing holding
3 (swing holding brake) brake may malfunction.
(Check pump pressure by using monitoring function to make judgment.)
If no failure is found by checks on causes (1) and (2) and upper structure
4 control valve (spool) does not swing when swing control lever is operated with pump pressure at
approx. 4 MPa, check whether spool is locked near NEUTRAL position.
27.4 to 31.3 MPa
Swing relief Swing lock Swing hydraulic
Defective swing motor {280 to 320 kg/
5 (safety valve) pressure switch: ON. relief cm2}
If relief pressures of left swing and right swing are same and below
standard value, sealing of safety valve may be defective.
Safety valve has 2-stage relief function, however, set pressures for Hi and
Lo settings are same (relief flow rate differs).
6 Defective swing motor running at full speed.
Leakage from Swing lock Swing hydraulic
swing motor Max. 10l /min
switch: ON. relief
Swing machinery may have internal failure.
7 Defective swing machinery a Check for unusual noise, unusual heat, and metallic powders in drained
40-688 PC210LC-10
40 Troubleshooting
mode)
H-25 Upper structure swing only to the right or left (PC200LC_10-L42-400-A-Z0-A)
Failure • Upper structure does not swing in only one direction.

Related • Swing PPC pressure can be checked with monitoring function. (Code: Left swing 09001,
information Right swing 09002)
valve Swing PPC valve lever
output pressure Swing control Left swing and 2.84 to 3.43 MPa
If no failure is found by check on cause (1) and upper structure does not
2 control valve (spool) swing when swing control lever is operated with pump pressure at approx.
4 MPa, check whether spool is locked near NEUTRAL position.
Interchange shuttle valves on left and right swing sides of swing motor, and
Defective seating of swing check whether failure symptom changes to make judgment.
3 motor (shuttle valve)
When removing valve, check it for lock and defects.
Interchange check valves on left and right swing sides of swing motor, and
4 motor (check valve)
PC210LC-10 40-689
40 Troubleshooting
mode)
H-26 Swing acceleration or swing speed is low in both directions (right

and left) (PC200LC_10-L44-400-A-Z0-A)
Failure • Swing acceleration or swing speed is low in both directions (right and left).
Related • If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
Malfunction of swing Swing spool may malfunction.
1 control valve (spool) Check spool for getting trapped and defects.
Remove LS shuttle valve block of R.H. travel control valve and clean check
2 control valve (LS shuttle
valve portion. Check shuttle valve for defects.
valve)
Remove LS shuttle valve block of L.H. travel control valve and clean check
valve portion.
valve)
Malfunction of boom
Remove LS shuttle valve boom control valve and clean check valve
portion.
valve)
Malfunction of arm control Remove LS shuttle valve block of arm control valve and clean check valve
5 valve (LS shuttle valve) portion.
Remove LS shuttle valve block of bucket control valve and clean check
valve portion.
valve)
Malfunction of service Remove LS shuttle valve block of service valve and clean check valve
7 valve (LS shuttle valve) portion.
valve lever
output pressure
Malfunction of swing motor If no failure is found by check on cause (8), swing holding brake may
9 (swing holding brake) malfunction (dragging).
27.4 to 31.3 MPa
10 (safety valve) pressure switch: ON. relief cm2}
If normal pressure is not obtained after adjustment, sealing of safety valve
may be defective.
switch: ON. relief
40-690 PC210LC-10
40 Troubleshooting
mode)
H-27 Swing acceleration performance is poor or swing speed is slow in

only one direction (PC200LC_10-L45-400-A-Z0-A)
Failure • Swing acceleration performance is poor or swing speed is slow in only one direction.
valve PPC valve output lever
pressure Swing control Left swing and 2.84 to 3.43 MPa
If no failure is found by check on cause (1) and upper structure does not
2 swing when swing control lever is operated with pump pressure at approx.
control valve (spool)
4 MPa, check whether spool is locked near NEUTRAL position.
Malfunction of swing Pressure compensation valve on right swing side of swing control valve
control valve (pressure may malfunction.
3 compensation valve on Interchange pressure compensation valves on left and right swing sides
right swing side) and check whether failure symptom changes to make judgment.
Malfunction of swing Pressure compensation valve on left swing side of swing control valve may
control valve (pressure malfunction.
4 compensation valve on left Interchange pressure compensation valves on left and right swing sides
swing side) and check whether failure symptom changes to make judgment.
Interchange suction valves on left and right swing sides of swing motor,
Defective seating of swing and check whether failure symptom changes to make judgment.
5 motor (suction valve)
PC210LC-10 40-691
40 Troubleshooting
mode)
H-28 Upper structure overruns excessively when it stops swinging (both

right and left) (PC200LC_10-L47-400-A-Z0-A)
• Upper structure overruns remarkably when it stops swinging in both directions (right and
Failure left).
Related • If failure codes are displayed, perform troubleshooting for them first. (DWK0KA, DWK0KB)
27.4 to 31.3 MPa
1 (safety valve) pressure switch: ON relief cm2}
may be defective.
switch: ON relief
40-692 PC210LC-10
40 Troubleshooting
mode)
H-29 Upper structure overruns excessively when it stops swinging

(either right or left) (PC200LC_10-L48-400-A-Z0-A)
Failure • Upper structure overruns excessively when it stops swinging in only one direction.
Slow return valve for right swing PPC may malfunction. Interchange slow
return valves for left and right swings, and check whether failure symptom
Clogged slow return valve changes to make judgment.
2 for right swing
When removing slow return valve, check slow return valve strainer for
clogging.
Slow return valve for left swing PPC may malfunction. Interchange slow
return valves for left and right swings, and check whether failure symptom
Clogged slow return valve changes to make judgment.
3 for left swing PPC
When removing slow return valve, check slow return valve strainer for
clogging.
Malfunction of swing Swing spool may malfunction.
Check spool for getting trapped and defects.
Defective sealing of swing and check whether failure symptom changes to make judgment.
PC210LC-10 40-693
40 Troubleshooting
mode)
H-30 Shock is large when upper structure stops swinging (PC200LC_10-L49-400-A-Z0-A)
Failure • Shock is large when upper structure stops swinging.

Slow return valve for right swing PPC may malfunction. Interchange slow
Malfunction of slow return
2 return valves for left and right swings, and check whether failure symptom
valve for right swing PPC
changes to make judgment.
Slow return valve for left swing PPC may malfunction. Interchange slow
Malfunction of slow return
3 return valves for left and right swings, and check whether failure symptom
valve for left swing PPC
changes to make judgment.
Malfunction of swing motor Reverse prevention valve of swing motor may malfunction.
4 (reverse prevention valve) Check for locked or almost trapped spool and setting of spring.
40-694 PC210LC-10
40 Troubleshooting
mode)
H-31 Large unusual noise is heard when upper structure stops

swinging (PC200LC_10-BAB-400-A-Z0-A)
Failure • Large unusual noise is heard when upper structure stops swinging.
information • If failure codes are displayed, perform troubleshooting for them first. (DWK2KA, DWK2KB)
Malfunction of solenoid running at full speed.
1 valve of variable back Output pressure Swing control 0 MPa {0 kg/cm2}
NEUTRAL
pressure valve of solenoid valve lever
of variable back Swing control Left swing and 2.84 to 3.43 MPa
pressure valve lever Right swing {29 to 35 kg/cm2}
If no failure is found by check on cause (1), back pressure valve of control
Malfunction of back valve may malfunction.
2 pressure valve Check for locked or almost trapped valve, defects of valve, and setting of
spring.
Safety valve of swing motor may malfunction.
Malfunction of swing motor
3 (safety valve) If normal pressure is not obtained after adjustment, safety valve may have
internal failure.
PC210LC-10 40-695
40 Troubleshooting
mode)
H-32 Swing drift on a slope is large while swing holding brake is

applied (PC200LC_10-MS6-400-A-Z0-A)
Failure • Hydraulic drift of swing is large (when swing holding brake is applied).
• When swing lock switch is set to ON position or swing brake cancel switch is set to
Related NORMAL position, swing brake is applied and swing system is locked by disc brake.
information • Perform all troubleshooting with working mode set in P mode.
• If failure codes are displayed, perform troubleshooting for them first. (DW45KA, DW45KB)
valve lever
output pressure
Malfunction of swing motor If no failure is found by check on cause (1), swing holding brake may
2 (swing holding brake)
malfunction.
swing motor Max. 10 l /min
switch: ON. relief
40-696 PC210LC-10
40 Troubleshooting
mode)
H-33 Swing drift on a slope is large while swing holding brake is

released (PC200LC_10-MS7-400-A-Z0-A)
Failure • Hydraulic drift of swing is large (when swing holding brake is released).
Related • Pump pressure can be checked with monitoring function. (Code: F pump pressure 01100,
information R pump pressure 01101)
1 control valve (spool) Spool of swing control valve may malfunction. Check for locked spool.
Malfunction of swing Pressure compensation valve on right swing side of swing control valve
control valve (pressure may malfunction.
2 compensation valve on
Interchange pressure compensation valves on left and right swing sides
right swing side) and check whether failure symptom changes to make judgment.
Malfunction of swing Pressure compensation valve on left swing side of swing control valve may
control valve (pressure malfunction.
3 compensation valve on left
Interchange pressure compensation valves on left and right swing sides
swing side) and check whether failure symptom changes to make judgment.
27.4 to 31.3 MPa
Defective swing motor pressure {280 to 320 kg/
4 switch: ON. relief
(safety valve) cm2}
may be defective.
When removing valve, check it for lock valve and defects.
Malfunction of swing motor Reverse prevention valve of swing motor may malfunction.
7 (reverse prevention valve) Check for locked or almost trapped spool and setting of spring.
PC210LC-10 40-697
40 Troubleshooting
mode)
H-34 Attachment hydraulic circuit cannot be changed while attachment

is installed (PC200LC_10-HBD-400-A-Z0-A)
Failure • When additional attachment is installed, attachment circuit is not switched.
• For machines with provision for attachment, attachment circuit switches as follows
depending on selected working mode.
1. When ATT mode is selected: Attachment circuit switches to 2-way circuit and safety
valve is set to low-pressure setting.
2. Wnen B mode is selected: Attachment circuit switches to 1-way circuit and safety valve
Related is set to high-pressure setting.
information
a Note that set pressure of safety valve switches only on port B side, and that on port A
side remains at low-pressure setting without switching.
• If failure codes are displayed, perform troubleshooting for them first. (DWA2KA, DWA2KB)
Malfunction of ATT return ATT return Working mode ATT mode 0 MPa {0 kg/cm2}
1
selector solenoid valve selector solenoid
2.9 MPa
valve output Working mode B mode
pressure {30 kg/cm2}
If no failure is found by check on cause (1), ATT return selector solenoid
Malfunction of ATT return valve may malfunction.
2
selector solenoid valve Check for locked or almost trapped valve, defects of valve, and setting of
spring.
Defective adjustment or Safety valve of service valve may malfunction.
3 malfunction of service If normal pressure is not obtained after adjustment, safety valve may have
valve (safety valve) internal failure.
40-698 PC210LC-10
40 Troubleshooting
mode)
H-35 Oil flow in attachment circuit cannot be controlled (PC200LC_10-HBE-400-A-Z0-A)
Failure • Oil flow in attachment circuit cannot be controlled.

• For machines with provision for attachment, oil flow rate of attachment circuit varies
depending on selected working mode.
Related • Procedure for oil flow rate adjustment differs between working modes, ATT mode and B
information mode. For details, see Operation and Maintenance Manual.
• If failure codes are displayed, perform troubleshooting for them first. (DXE4KA, DXE4KB)
Attachment
NEUTRAL 0 MPa {0 kg/cm2}
ATT oil flow control pedal
adjustment EPC Pressure
valve output Attachment corresponding to
Malfunction of ATT oil flow pressure Depressed
1 adjustment EPC valve control pedal selected oil flow
setting
a If output pressure of EPC valve is 0 MPa, check "Service solenoid
current" with monitoring function. (Code: 01700)
If current value is 0.3 to 0.91 A, EPC valve may be defective.
Check that output pressure changes according to selected oil flow
setting.
Attachment
NEUTRAL 0 MPa {0 kg/cm2}
Malfunction of service PPC control pedal
2 Service PPC
valve valve output Pressure
pressure Attachment corresponding to
Depressed
control pedal selected oil flow
setting
• Check that output pressure changes according to pedal stroke.
PC210LC-10 40-699
40 Troubleshooting
Troubleshooting of engine (S-mode)
Troubleshooting of engine (S-mode) (ALL-3840-001-A-03-A)
Information mentioned in troubleshooting table (S mode) (ALL-5170-010-A-01-A)
(Rev. 2011/01)
a Troubleshooting Table collectively carries the following information. Carry out troubleshooting work after
fully grasping its contents.
Failure Problem on engine
Related Information related to the detected failure or troubleshooting
information
Probable cause Contents of check and remarks Remedy
1 <Contents of description>
2 Probable causes for
trouble (Each number is • Contents of check to judge • Actions to eliminate probable
3 serial number, not priority probable causes causes of trouble
4 sequence.) • Remarks required for
5 judgment
40-700 PC210LC-10
40 Troubleshooting
S-1 When starting switch is turned to START position, engine does not
crank (PC220_10-A26-400-A-00-A)
Failure When starting switch is turned to "START" position, engine does not crank.
Related • For troubleshooting of electrical system, see E-1 in E mode troubleshooting.
information • If a failure code is displayed, perform troubleshooting for it first.
No. Cause Check item and remarks Remedy
Defective starting • When starting switch is turned to START, starter Perform troubleshooting
1 circuit wiring pinion does not plunge. for E-1 and repair failure.
• Rasping sound is heard around starting motor Perform troubleshooting
pinion. for E-1 and repair failure.
(When starting switch is turned to START, starting
motor pinion plunges.)
• Starting motor pinion returns halfway.
Defective starting
2 motor (safety relay
section)
• Brattle is heard and starting motor does not rotate.
(Reference: Brattle is made by starting motor pinion
when it repeats plunging and returning.)
• If rasping sound is heard from starting motor pinion Replace if broken.
Broken flywheel
3 and starting motor does not rotate, visually check
ring gear
flywheel ring gear.
Cracked EGR • Remove gas piping from EGR inlet and outlet, and Replace EGR cooler, and
cooler check if water containing coolant flows out of them. then remove water in
4 (Reference: engine cylinders.
a Moisture in exhaust gas may condense into water.
Coolant in exhaust So, check whether water contains coolant.
pipe)
PC210LC-10 40-701
40 Troubleshooting
S-2 Engine cranks but no exhaust smoke comes out (WA380_7-A27-400-A-Z0-A)
Failure Engine cranks but no exhaust smoke comes out.

Related • If any failure code is displayed, perform troubleshooting for that code first.
information
No. Cause Point to check, remarks Remedy
1 Insufficient fuel in tank • Fuel tank is empty. Add fuel.
Flush air breather hole
Clogged air breather hole in
2 • Air breather hole in fuel tank cap is clogged. in fuel tank cap and
fuel tank cap clean surrounding
area.
• Check used hours of fuel filter. If used
Clogged fuel filter element beyond specified hours, fuel filter element Replace fuel filter
3
may be clogged. element.
Foreign material in fuel • Rust and water are found in fuel drained Replace fuel.
4
from fuel tank.
• Air is bled during air bleeding of fuel system. Perform air bleeding.
5 Air in fuel piping system (Reference: See Testing and adjusting, Repair or replace fuel
"Bleeding air from fuel system".) piping.
• Fuel leaks from fuel piping.
Leakage from fuel piping Repair or replace fuel
6 (Reference: See Testing and adjusting,
system piping related parts.
"Checking fuel circuit for leakage".)
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Tighten or replace inlet
7 "Measuring fuel delivery, return and
and inlet connector connector.
leakage".)
• See Testing and adjusting, "Measuring fuel Replace supply pump
8 Defective supply pump
delivery, return and leakage". or pressure limiter.
• No resistance is felt or large effort is
9 Defective priming pump Replace priming pump.
required when operating priming pump.
• Monitored common rail pressure does not Loosen injection piping
Improper air bleeding of lower even after engine is stopped. (Code: and high-pressure pipe
10 common rail or injection 36400 Common rail pressure) mounting nuts on
piping (Pressure may not decrease if air still common rail and bleed
remains.) air.
40-702 PC210LC-10
40 Troubleshooting
S-3 Fuel is being injected but engine does not start (misfiring: engine
cranks but does not start) (WA380_7-A28-400-A-Z0-A)
Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
Failure does not start).
information
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
area.
4
5
from fuel tank.
• Injector return rate is excessive.
Fuel leakage from injector (Reference: See Testing and adjusting, Tighten or replace inlet
8 "Measuring fuel delivery, return and connector.
and inlet connector
leakage".)
• No resistance is felt or large effort is
9 Defective priming pump Replace priming pump.
required when operating priming pump.
10 Clogged air cleaner element • Air cleaner dust indicator indicates that dust Check and clean air
is at caution level. cleaner element.
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Check valve clearance.
(Reference: See Testing and adjusting,
Worn valve or rocker arm, "Testing and adjusting valve clearance".) Replace valve or
12
etc. • When engine is cranked, unusual noise is rocker arm.
heard from around cylinder head.
• Measuring compression pressure
Replace piston ring or
13 Defective piston ring (Reference: See Testing and adjusting,
piston.
"Testing compression pressure".)
• When engine is run in cylinder cutout mode
Defective injector with some cylinder cut out, engine speed
14 (clogged injector or defective does not change. Replace injector.
fuel spray) (Reference: See Testing and adjusting,
"Handling cylinder cutout mode operation".)
Since this is an internal defect, troubleshooting Replace engine
cannot be performed. controller.
PC210LC-10 40-703
40 Troubleshooting
S-4 Engine startability is poor (WA380_7-A10-400-A-Z0-A)
Failure Engine startability is poor.

• If any failure code is displayed, perform troubleshooting for that code first.
• Common rail fuel injection system (CRI) controls fuel injection timing electrically.
Related
Therefore, in some cases, engine does not start before crankshaft makes two turns
information
maximum even if starting operation is performed. This does not indicate any abnormality,
however.
• Specific gravity of electrolyte and voltage of Add battery electrolyte
1 Defective battery
battery are low. and charge battery.
• Fuel other than specified one is used.
• Fuel used does not accord with ambient
temperature. Use proper fuel
(Reference: If engine can start in warm specified in Operation
3 Improper fuel used
weather but does not easily start in cold and Maintenance
weather) Manual.
• Deposited wax (milky) is found in clear bowl
of fuel pre-filter.
area.
5
6
from fuel tank.
• Air cleaner dust indicator indicates that dust Check and clean air
10 Clogged air cleaner element
• When preheating works, intake air heater
mounting area does not become hot.
• When preheating works or when Replace intake air
11 Defective intake air heater
temperature is low, preheating monitor does heater.
not indicate properly.
• Remove exhaust gas piping from EGR
cooler outlet and inlet, and check whether
Cracked EGR cooler Replace EGR cooler
coolant containing COOLANT flows out.
12 (Reference: Coolant enters and drain water from
exhaust gas piping.) a Water in exhaust gas can be normally engine cylinders
condensed, so check that condensate is
coolant or not.
• Some cylinder is found to be cool when
exhaust manifolds are touched by hand
immediately after engine is started.
13 Defective injector Replace injector.
with some cylinder cut out, engine speed
does not change.
14 Defective engine controller cannot be performed. controller.
40-704 PC210LC-10
40 Troubleshooting

• Measure compression pressure (see
Standard value table).
(Reference: See Testing and adjusting, Correct contact
Defective contact between "Testing compression pressure".) between valve and
15
valve and valve seat • Check valve clearance. valve seat or replace
(Reference: See Testing and adjusting, them.
"Testing and adjusting valve clearance".)
• Open exhaust color inspection hole that is
just upstream of KDPF, and check exhaust
gas.
"Testing exhaust color".) Replace piston ring or
16 Defective piston ring • Measure compression pressure (see piston.
• Check piston ring and piston ring groove.
PC210LC-10 40-705
40 Troubleshooting
S-5 Engine does not pick up smoothly (WA380_7-A30-400-A-Z0-A)
Failure Engine does not pick up smoothly.

information
area.
3
4
from fuel tank.
• When crankcase pressure high error (failure
code: CA555) is still displayed even after
Abnormally high crankcase KCCV filter is replaced, blowby pressure is Perform following
8 pressure probably high (see Testing and adjusting, checks on causes 10
"Measuring blowby pressure"). In this case, and after.
KVGT may be seized or damaged.
does not change.
• Unusual noise is heard from KVGT.
• Check whether KVGT shaft rotates.
10 Seized or broken KVGT Replace KVGT.
(Move KVGT vanes with hand in axial and
radial directions to make judgement.)
• When engine is cranked, unusual noise is
11 Incorrect valve clearance • Check valve clearance. Adjust valve clearance.
40-706 PC210LC-10
40 Troubleshooting

13
gas.
PC210LC-10 40-707
40 Troubleshooting
S-6 Engine stops during operation (PC220_10-AF0-400-A-00-A)
Failure Engine stops during running.

Related • If a failure code is displayed, perform troubleshooting for it first.
information
Insufficient fuel in • When fuel tank is inspected, it is found to be empty. Add fuel.
1
tank
Clogged breather • Breather hole in fuel tank cap is clogged. Flush air breather hole in
2 hole in fuel tank fuel tank cap and clean
cap surrounding area.
Clogged fuel filter • Check used hours of fuel filter. If used beyond Replace fuel filter
3 specified hours, fuel filter element may be clogged. element.
element
Foreign material in • Rust and water are found when fuel tank is drained. Replace fuel.
4
fuel
• When air bleeding operation for fuel system is Perform air bleeding
performed, air comes out. operation.
5 Air in fuel piping (Reference: See Testing and adjusting, "Bleeding Correct or replace fuel
air from fuel system".) piping.
• Fuel is leaking from fuel piping. Correct or replace fuel
Leakage from fuel
6 (Reference: See Testing and adjusting, "Testing piping related parts.
piping system
fuel circuit for leakage".)
Defective priming • When priming pump is operated, no resistance is Replace priming pump.
7 pump felt or it is heavy.
Defective supply • See Testing and adjusting, "Testing fuel delivery, Replace supply pump and
8 pump return and leakage".) pressure limiter.
Defective air intake • Visually check the air intake hose for damage. Replace air intake hose
hose
9
(from air cleaner to
KVGT inlet)
Defective air intake • Check the intake manifold for internal damage. Replace air intake
10
manifold manifold.
Defective boost • Air comes out of boost piping. Repair or replace boost
piping and joint piping.
11 (Between KVGT
and air intake
manifold)
Defective exhaust • Check exhaust pipes for damage and exhaust gas Replace exhaust gas
pipes leakage. piping.
12 (from exhaust (Check heat insulation cover and soot on heat
manifold to KDPF shield plate.)
inlet)
• Check valve and rocker arm. Replace valve and rocker
Damage of valve (Engine is stopped suddenly after unusual sound is arm.
13
and rocker arm heard.)
• Metal particles are found in oil drained from oil pan. Replace piston and
Broken or seized • Remove oil pan and check piston and connecting connecting rod.
14 piston connecting rod.
rod (Reference: Engine is stopped after abnormal usual
sound is heard or overheated.)
Broken or seized • Metal particles are found in oil drained from oil pan. Replace crankshaft main
15 crankshaft main • Remove oil pan and check crankshaft main bearing.
bearing bearing.
Defective engine • Check engine controller power supply wiring. Repair engine controller
16 controller power (Reference: See Troubleshooting by failure code power supply wiring.
supply wiring [CA343].)
40-708 PC210LC-10
40 Troubleshooting

Defective starting • Check starting switch wiring. Perform troubleshooting
17 switch wiring for E-1 and repair.
Malfunction of • See H mode, "H-2 Engine speed lowers Perform troubleshooting
18 hydraulic system significantly or engine stalls". for H-2 and repair.
PC210LC-10 40-709
40 Troubleshooting
S-7 Engine runs rough or is unstable (PC220_10-A40-400-A-00-A)
Failure Engine runs rough or is unstable.

Related • If a failure code is displayed, troubleshoot it first.
information
Insufficient fuel in • When fuel tank is inspected, it is found to be empty. Add fuel.
1
tank
Clogged breather • Breather hole in fuel tank cap is clogged. Flush air breather hole in
2 hole in fuel tank fuel tank cap and clean
cap surrounding area.
Clogged fuel filter • Check used hours of fuel filter. If used beyond Replace fuel filter
3 specified hours, fuel filter element may be clogged. element.
element
4
fuel
Perform air bleeding
• When air bleeding operation for fuel system is
performed, air comes out. operation.
5 Air in fuel piping (Reference: See Testing and adjusting, "Bleeding
Correct or replace fuel
air from fuel system".) piping.
• Fuel is leaking from fuel piping. Correct or replace fuel
Leakage from fuel
6 (Reference: See Testing and adjusting, "Testing piping related parts.
piping system
fuel circuit for leakage".)
• Check whether leakage is present in boost system Repair the section around
Leakage in boost
7 (between KVGT outlet and aftercooler, and boost piping or replace it.
system
between aftercooler and intake manifold).
Defective mass air • Replace sensor and see if engine becomes normal. Replace mass air flow
8 flow and (Failure code may not appear due to dusts on and temperature sensor.
temperature sensor sensor.)
40-710 PC210LC-10
40 Troubleshooting
S-8 Engine lacks power (WA380_7-A60-400-A-Z0-A)
Failure Engine lacks power.

information
area.
3
4
from fuel tank.
Clogged air cleaner element • Air cleaner dust indicator indicates that dust Check and clean air
8
• Check air cleaner and rectifying wire net for Correct or replace air
9 Defective air cleaner
deformation. cleaner.
Defective air intake hose
10 (Between air cleaner and • Visually check air intake hose for breakage. Replace air intake
hose.
KVGT inlet)
• Check air intake manifold for internal Replace air intake
11 Defective air intake manifold breakage. manifold.
Defective boost piping and
connections Repair or replace
12 • Air leaks from boost piping.
(Between KVGT outlet and air boost piping.
intake manifold)
Defective installation of boost • Air leaks from mounting part of boost Correct installation of
13 pressure sensor pressure sensor. boost pressure sensor.
Defective exhaust gas piping • Check exhaust gas piping for damage and
exhaust gas leakage. Replace exhaust gas
14 (Between exhaust manifold (Check soot on heat insulation cover and piping.
and KDPF inlet) heat insulation plate.)
Exhaust gas leakage from
15 EGR piping • Exhaust gas leaks from EGR piping. Replace EGR piping.
Defective intake and exhaust
system • Measure boost pressure.
Repair or replace
16 (Between KVGT outlet and air (Reference: See Testing and adjusting,
defective part.
intake manifold, air intake "Measuring boost pressure".)
manifold and KDPF inlet)
• Unusual noise is heard from KVGT.
17 Seized or broken KVGT Replace KVGT.
• Open exhaust color inspection hole being
gas (see Standard value table). Clean or replace
18 Excessive soot load in KDPF
(Reference: See Testing and adjusting, KDPF.
"Testing exhaust color".)
PC210LC-10 40-711
40 Troubleshooting

• KDPF is clogged. Check back pressure at Clean or replace
19 Defective KDPF location just upstream of KDPF. KDPF.
• When engine is cranked, unusual noise is
20 Incorrect valve clearance • Check valve clearance. Adjust valve clearance.
does not change.
23
gas.
40-712 PC210LC-10
40 Troubleshooting
S-9 Exhaust smoke is black (KDPF clogs up early) (PC220_10-AH5-400-A-00-A)
Failure Exhaust gas color is black (KDPF is prematurely plugged).

information
• Fuel other than specified one is used. Use fuel specified in
Use of unspecified
1 Operation and
fuel
Maintenance Manual.
2
fuel
Defective air • Check air cleaner and airflow screen for Correct or replace air
3
cleaner deformation. cleaner.
Defective exhaust • Check exhaust pipes for damage and exhaust gas Replace exhaust gas
pipes leakage. piping.
4 (from exhaust (Check heat insulation cover and soot on heat
manifold to KDPF shield plate.)
inlet)
Improperly installed • Air leaks from boost pressure sensor mounting. Correct mounting of boost
5 boost pressure pressure sensor.
sensor
Defective boost • Air flows out from boost piping Correct or replace boost
piping and piping
connections
6
(From KVGT outlet
to air intake
manifold)
• KDPF clogging - check exhaust pressure before Clean or change KDPF.
7 Defective KDPF
KDPF
Gas leakage from • Gas leaks from EGR piping Replace EGR piping
8 EGR piping
• Unusual sound is heard from KVGT. Replace KVGT.
KVGT seized or • Check if KVGT shaft rotates.
9 (Move KVGT vanes with hand in axial and radial
broken
directions to judge.)
• When exhaust manifold is touched immediately Replace injector.
after starting engine, temperature of some cylinder
is low.
10 Defective injector • When a certain cylinder is cut out, engine speed
does not change.
(Reference: See Testing and adjusting, "Handling
cylinder cutout mode operation".)
• Measured fuel return rate is large. Repair or replace fuel
Defective fuel (Reference: See Testing and adjusting, "Testing return pipe.
11 return piping fuel delivery, return and leakage".)
• Check fuel return piping for clogging.
Defective mass air • Replace sensor and see if engine becomes normal. Replace mass air flow
12 flow and (Failure code may not appear due to dusts on and temperature sensor.
temperature sensor sensor.)
• When engine is cranked, unusual noise is Adjust valve clearance.
generated around cylinder head.
Incorrect valve • Check valve clearance.
13
clearance (Reference: See Testing and adjusting, "Testing
and adjusting valve clearance".)
PC210LC-10 40-713
40 Troubleshooting

• Measure compression pressure (see standard Correct or replace valve
values table). or valve seat.
Defective contact of (Reference: See Testing and adjusting, "Testing
14 valve with valve compression pressure".)
seat • Test the valve clearances.
(Reference: See Testing and adjusting, "Testing
and adjusting valve clearance".)
• Open the exhaust gas color measuring hole before Replace piston ring or
the KDPF and check the color of the exhaust gas. piston.
exhaust gas color".)
Defective piston
15 ring • Measure the compression pressure (see standard
values table).
compression pressure".)
• Check piston rings and piston ring grooves.
40-714 PC210LC-10
40 Troubleshooting
S-10 Engine oil consumption is excessive (PC400-B10-400-A-Z0-A)
Failure Engine oil consumption is excessive

Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Dust sucked in from intake • When intake piping between air cleaner Clean or replace
1 system and engine is removed, dust is found intake piping
inside.
• Measured blowby pressure exceeds
standard value.
• Blow-by pressure is still high after KCCV
filter element is replaced Replace or correct
2 Broken or worn piston ring
• Measure the compression pressure (see piston ring
standard values table).
Oil leakage from KCCV oil • Check for oil leaks from KCCV oil return Correct or replace oil
3 return piping piping piping
External leakage of oil from
4 engine • Check for oil leaks Correct oil leaks
Oil leakage from oil filter Reinstall or replace oil

5 • Check for oil leaks from oil filter
filter
Correct or replace oil
6 Oil leakage from oil piping • Check for oil leaks from oil piping
piping
7 Oil leakage from oil drain plug • Check for oil leaks from oil drain plug Retighten oil drain plug
Correct or replace oil
8 Oil leakage from oil pan • Check for oil leaks from oil pan
pan
Correct or replace
9 Oil leakage from cylinder head • Check for oil leaks from cylinder head
cylinder head
• Oil level in clutch chamber or damper Correct or replace rear
10 Worn or damaged rear oil seal
chamber on machine is low. oil seal
• KVGT blower inlet and outlet, and turbine
outlet are dirty with oil.
11 Oil leakage from KVGT • Check if KVGT shaft rotates Replace KVGT
radial directions to judge)
• Oil in coolant
• Remove oil cooler and check for external oil
12 Oil leakage from oil cooler leaks Replace oil cooler
• Check for leaks by applying air pressure to
oil cooler
Oil leakage from EGR valve • When EGR valve is removed, outlet port is
13 Replace EGR valve
stem found to be dirty with oil.
• Check valve guide and stem seal
• Remove cylinder head. Check inside
Worn or damaged valve guide, diameter of guide, and check stem seal for Replace valve guide
14
stem seal damages. and stem seal
(Reference: See "Maintenance standard".)
PC210LC-10 40-715
40 Troubleshooting
S-11 Engine oil becomes contaminated early (PC400-B20-400-A-Z0-A)
Failure Engine oil becomes contaminated quickly.

information
Use proper fuel
Improper fuel used • Fuel other than specified one is used. specified in Operation
1
and Maintenance
Manual.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
2
and Maintenance
Manual.
• Check exhaust gas color at location just Perform
Black exhaust gas color
upstream of KDPF. troubleshooting for "S-
3 checked at location just
(Reference: See Testing and adjusting, 9 Exhaust gas is
upstream of KDPF
"Testing exhaust color".) black".
standard value. Perform following
4 Excessive blowby gas
• Blowby pressure is still high after KCCV checks.
filter element is replaced.
• Rotate KVGT shaft and check for play.
Defective KVGT seal on (Move KVGT vanes with hand in axial and Replace KVGT.
5
turbine side radial directions to make judgement.)
• Remove EGR valve and check stem seal,
guide, and stem.
6 Worn EGR valve guide Replace EGR valve.
• When EGR valve is remove, outlet port is
dirty with oil.
• Check oil level for excessive refilling.
7 Excessive refilling of oil (If oil level is excessive, oil will reach high Refill with oil to correct
temperatures and early deteriorates.) oil level.
• Visually check oil cooler element for
contamination. Clean or replace oil
8 Dirty oil cooler element
(Contaminated oil cooler element can cooler element.
increased oil temperature.)
standard value.
• Blowby pressure is still high after KCCV
filter element is replaced. Replace piston ring or
9 Broken or worn piston ring
• Measure compression pressure (see correct its installation.
• Check valve guide and stem seal.
• Remove cylinder head, and check inside
Worn or damaged valve Replace valve guide
10 guide or stem seal diameter of guide and stem seal for
damage. and stem seal.
(Reference: See "Maintenance standards".)
40-716 PC210LC-10
40 Troubleshooting
S-12 Fuel consumption is excessive (PC220_10-B70-400-A-00-A)
Failure Fuel consumption is excessive.

information
• Check spill rate from injector. Replace injector.
Excessive spillage (Reference: see "Testing fuel delivery, return and Since much dust may be
1 from injector leakage" in Testing and adjusting.) contained in fuel, check
fuel control condition.
• Check fuel return pipe for clogging. Repair or replace fuel
Clogged fuel return
2 (Clogging of fuel return pipe increases injection return pipe.
pipe
volume).
• When exhaust manifold is touched immediately Replace injector.
after starting engine, temperature of some cylinders
is low.
3 Defective injector • Even if a cylinder is cut out, engine speed does not
change.
(Reference: see "Handling cylinder cutout mode
operation" in Testing and adjusting.)
Fuel leakage inside • Check if oil level increases. Repair defective parts.
4 cylinder head • Check for smell of diesel fuel.
Fuel leakage • Engine oil level rises and oil smells of diesel fuel. Replace feed pump oil
5 through feed pump • Check feed pump oil seal seal.
oil seal
External fuel • Check engine for external leakage of fuel. Repair defective parts.
6 leakage
PC210LC-10 40-717
40 Troubleshooting
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) (PC400-
B40-400-A-Z0-A)
Failure Oil is in coolant (or coolant spurts or coolant level goes down)
Related information • If any failure code is displayed, carry out troubleshooting for it first.
No. Cause Detail of work, remarks Remedy
Perform
troubleshooting for "S-
1 Milky engine oil • Engine oil level rises and oil is milky
16 Water mixes into
engine oil (milky)".
Damaged oil cooler element Replace oil cooler
2 • Check oil cooler element
element
• Coolant in radiator has excessive air
bubbles and blows back.
3 Damaged cylinder head • Overhaul engine and perform a pressure Replace cylinder head
tightness test on cylinder head to check for
abnormalities
• Coolant in radiator has excessive air
Damaged cylinder head bubbles and blows back. Replace cylinder head
4 gasket • Overhaul engine and check cylinder head gasket
gasket for abnormalities
• Engine oil level rises and oil is milky
Cracks or pitting in cylinder • Disassemble engine and check for cracks Replace cylinder block
5
block or pitting in cylinder block
40-718 PC210LC-10
40 Troubleshooting
S-14 Engine oil pressure drops (PC220_10-10D-400-A-00-A)
Failure Engine oil pressure decreases.

• If a failure code is displayed, perform troubleshooting for it first.
Related
• Check whether machine is operated on a slope steeper than that specified in Operation
information
and Maintenance Manual.
• Oil level in oil pan is low. Supply oil.
1 Lack of oil in oil pan • If machine is operated on a slope, oil pressure
monitor may light up.
Defective oil • Check oil pressure sensor, wiring harness, and Replace oil pressure
2 pressure sensor or connector. sensor, wiring harness,
wiring harness and connector.
• Perform oil analysis to determine whether fuel is If oil is mixed with fuel,
mixed in oil. perform troubleshooting
3 Fuel in oil • If mixed, oil has smell of diesel fuel. for "S-15 Fuel is
contaminated in engine
oil".
• Perform oil analysis to determine whether fuel is If oil is mixed with water,
mixed in oil. perform troubleshooting
• If mixed, oil is milky. for "S-16 Coolant is
4 Water in oil contaminated in engine oil
(Oil becomes cloudy
white)".
• Check oil filter. Replace oil filter.
(Reference: when oil filter has been used for more
5 Clogged oil filter than specified period, oil may be deteriorated
extremely).
• Oil filter may be blocked when water is in oil
6 Clogged oil strainer • Check oil strainer. Clean oil strainer.
Crushed or clogged • Hydraulic piping may be crushed or clogged. Replace hydraulic piping.
7 hydraulic piping
• Check oil pump. Replace oil pump.
8 Defective oil pump (Worn or broken gear)
• Oil pump rotation is heavy or play is in oil pump.
Defective regulator • Check valve spring for fatigue and damage Replace regulator valve
9
valve
Defective oil pump • Valve spring of oil pump relief valve is fatigued or Replace oil pump relief
10 damaged. valve.
relief valve
Cracked oil pump • Check oil pump suction piping (cracking of piping). Replace oil pump suction
11 suction piping piping.
Defective seal • Check seal. Replace seal.
between oil pump
12 and oil pump
suction piping
Defective boost oil • Check boost oil pump. Replace boost oil pump.
13 pump
Leakage from EGR • Check EGR hydraulic piping. Replace EGR hydraulic
14 hydraulic piping piping.
• Check main journal bearing. Replace main journal
Worn main journal
15 • Metal particles may be found in oil drained from oil bearing
bearing
pan
Worn pin journal • Check pin journal bearing Replace pin journal
16 bearing • Metal particles are found in oil drained from oil pan. bearing.
Worn idler bushing • Check idler bushing and idler gear. Replace idler bushing and
17 or broken idler gear idler gear.
Broken or removed • Check piston cooling nozzle. Replace piston cooling
18 piston cooling nozzle.
nozzle
PC210LC-10 40-719
40 Troubleshooting
S-15 Fuel is contaminated in engine oil (PC220_10-B31-400-A-00-A)
Failure Fuel mixes with engine oil (engine oil smells of diluted diesel fuel).
information
• If exhaust manifold is touched immediately after Replace injector.
starting engine, temperature of some cylinders is
low.
1 Defective injector • Even if a cylinder is cut out, engine speed does not
change.
(Reference: See "Handling cylinder cutout mode
operation" in Testing and adjusting.)
Fuel leakage from • Check injector and O-ring. Replace injector and O-
2 injector and O-ring ring.
(spill circuit)
Defective sealing • Check sealing between injector and injection pipe, Repair or replace.
between injector and injection pipe.
3 and injection pipe,
and cracked
injection pipe
Defective supply • Replace supply pump and see if fuel stops Replace supply pump.
4 pump entering.
40-720 PC210LC-10
40 Troubleshooting
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy

white) (PC220_10-B32-400-A-00-A)
Failure Engine oil is mixed with water (milkiness)
• If oil is mixed with coolant, perform troubleshooting for "S-13 Oil is in coolant".
• If a failure code is displayed, perform troubleshooting for it first.
If you repeat stopping and restarting of engine under low ambient temperatures, moisture
Related in blowby gas may condense into water in installed KCCV, making oil cloudy or causing
information emulsion on inner surface of engine. These symptoms do not matter unless coolant
leakage is not recognized.
If coolant level decreases in short period, perform following troubleshooting.
• When EGR cooler outlet gas piping is removed, Replace EGR cooler.
water containing coolant flows out.
(Check whether it is coolant containing antifreeze
Cracked EGR or condensed water.)
1
cooler (Reference: lowered coolant level may cause
cracks on EGR cooler. Before replacing EGR
cooler, check cooling system piping for leakage.)
• Check of oil cooler element and O-ring. Replace oil cooler
Damaged oil cooler
2 • Pressure tightness test of oil cooler allows for element and O-ring.
element and O-ring
detection of oil leakage.
Leakage through • Check water pump mechanical seal for leakage. Replace water pump
3 water pump mechanical seal.
mechanical seal
Clogged water • Check water pump drain hole. Clean water pump drain
4
drain hole hole.
Damaged cylinder • Disassemble engine and check cylinder head and Replace cylinder head or
5 head gasket. cylinder head gasket.
head
Cracking or pitting • Engine oil level rises and oil is milky. Replace cylinder block.
6 of inside of cylinder • Disassemble engine and check inside of cylinder
block block for cracking or pitting.
PC210LC-10 40-721
40 Troubleshooting
S-17 Coolant temperature rises too high (overheating) (WA380_7-AL0-400-A-Z0-A)
Failure Coolant temperature rises too high (overheating).

information
Clogged radiator core • Check radiator core for clogging, and check
1 Clean radiator core.
fin for crush.
• Thermostat does not open at cracking
temperature.
2 Malfunction of thermostat a Thermostat cracking temperature: 79.4 to Replace thermostat.
83.3 °C
(Full open temperature: 95 °C)
• Error related to coolant temperature is Replace coolant
Defective coolant temperature temperature sensor,
3 displayed, but measured value of radiator
gauge monitor or wiring
coolant temperature is normal.
harness.
Perform
Increased fuel injection rate • Fuel injection rate is high. troubleshooting for "S-
4
12 Fuel consumption is
excessive".
5 Low coolant level • Check coolant level. for lowering. Refill with coolant.
Replace coolant
6 Leakage of coolant • Check water leakage from coolant piping.
piping.
• Visually check water pump.
(Check shaft seal for water leakage,
7 Breakage of water pump Replace water pump.
impeller for damage, and shaft for
breakage.)
Overheating due to increased
EGR ratio (EGR amount Replace mass air flow
against fresh air amount) • Check mass air flow and temperature
8 and temperature
caused by defective mass air sensor.
sensor.
flow and temperature sensor
Overheating due to increased
EGR ratio (EGR amount
• Check air cleaner and rectifying wire net for Repair or replace air
9 against fresh air amount)
deformation. cleaner.
caused by air cleaner
deformation
Defective cylinder head or • Check radiator coolant for excessive Perform
10 cylinder head gasket bubbles and spurt back. troubleshooting for "S-
13 Oil is in coolant".
gas.
40-722 PC210LC-10
40 Troubleshooting
S-18 Unusual noise is heard (PC400-BA1-400-A-Z0-A)
Failure Unusual noise is heard.

• Check whether noise source is in or outside engine before starting troubleshooting.
• Engine runs in low-temperature mode while it is not warmed up sufficiently. Accordingly,
engine sound becomes slightly larger. This does not indicate abnormality, however.
Related • When engine accelerates, it switches into acceleration mode and its sound becomes
information slightly large further for up to approximately 3 to 5 seconds. This does not indicate
abnormality, however.
• Exhaust gas leaks from piping between
cylinder head and exhaust manifold,
Exhaust gas leakage from between exhaust manifold and KVGT, or Repair or replace
1 piping between KVGT outlet and KDPF. defective parts.
• Exhaust gas leaks from EGR piping or air
intake piping.
Vibration of exhaust piping or • Visually check for vibration. Check and retighten
2 piping brackets.
exhaust bellows
3 Seized or broken KVGT (Move KVGT vanes with hand in axial and Replace KVGT.
Clean or replace
4 Internal damage of KDPF • Check inside of KDPF.
KDPF.
does not change.
• Check valve clearance.
6 Incorrect valve clearance (Reference: See Testing and adjusting, Adjust valve clearance.
Seized pin bushing, front Repair or replace
7 bearing, or main bearing • Check for metal particles in oil pan.
damaged parts.
• If metal particles is found in oil pan or oil
filter, overhaul engine and check piston ring
and cylinder liner.
Worn piston ring or cylinder Replace piston ring or
8 • Measure compression pressure (see
liner cylinder liner.
• Overhaul engine and check valves and Replace valve or
9 Damaged valve or rocker arm rocker arm parts. rocker arm.
10 Damaged idler gear • Overhaul engine and check idler gear parts. Replace idler gear.
PC210LC-10 40-723
40 Troubleshooting
S-19 Vibration is excessive (PC400-BC0-400-A-Z0-A)
Failure Vibration is excessive.

• If unusual noise is heard and vibration is excessive, perform troubleshooting for "S-18
Related Unusual noise is heard", too.
information • If any failure code is displayed, perform troubleshooting for that code first.
• Visually check engine mounting bolts for
Loose engine mounting bolts Retighten bolts or
1 looseness and cushions for cracks and
or defective cushions replace cushions.
hardening.
• Visually check viscous damper for Replace engine
2 Damaged engine damper
discoloration. damper.
Defective output shaft or • Check output shaft for damage and damper Replace defective
3 internal defect of damper parts.
for internal defect.
Misalignment and facial
• Measure misalignment and facial runout at
runout at connection between Replace defective
4 connection between engine and hydraulic
engine and hydraulic pump parts.
pump.
are out of standard range.
does not change.
Worn main bearing or • If metal particles are found in oil pan or oil Repair or replace
6 connecting rod bearing filter, overhaul engine. damaged parts.
• If metal particles are found in oil pan or oil Repair or replace
7 Stuck valve or rocker arm filter, open cylinder head cover and check damaged parts.
valves and rocker arms.
• If metal particles are found in oil pan or oil
Replace camshaft
8 Worn camshaft bushing filter, overhaul engine and check camshaft
bushings.
bushings.
40-724 PC210LC-10
40 Troubleshooting
S-20 Air cannot be bled from fuel circuit (WA380_7-A29-400-A-Z0-A)
Failure Air cannot be bled from fuel circuit.

information
• Check drain valve of fuel pre-filter for
Loosened drain valve of fuel looseness.
2 pre-filter (Air enters fuel circuit from loosened drain Close drain valve.
valve.)
3
• Air is bled during air bleeding of fuel system.
Repair or replace fuel
4 Air in fuel piping system (Reference: See Testing and adjusting,
piping.
"Bleeding air from fuel system".)
PC210LC-10 40-725
40 Troubleshooting
S-21 Active regeneration is executed frequently (PC400-AQ0-400-A-Z0-A)
Failure Active regeneration is executed frequently.

information
Long-term machine operation
Perform Regeneration
with engine at low to medium • Soot can accumulate if machine does not
1 for Service to burn
speeds (exhaust temperature perform heavy-duty work.
away soot completely.
does not rise)
• Open exhaust color inspection hole being Perform
just upstream of KDPF, and check exhaust troubleshooting for "S-
2 Defective exhaust gas color gas (see Standard value table). 9 Exhaust gas is black
(Reference: See Testing and adjusting, (KDPF gets clogged in
"Testing exhaust color".) a short time)".
• If regeneration frequency does not return to
Plugged KDOC resulting from normal after remedies for cause 2 are taken,
3 Clean KDOC.
bad exhaust color KDOC is plugged.
Use proper oil
Improper oil used • Oil other than specified one is used. specified in Operation
4
and Maintenance
Manual.
• If regeneration frequency does not return to
Plugged KCSF due to use of
5 normal after remedies for cause 4 are taken, Clean or replace
improper oil KCSF.
KCSF is plugged.
Perform
Coolant leaking into exhaust troubleshooting for "S-
6 system • Check for low coolant level. 16 Water mixes into
Plugged KCSF due to coolant Clean or replace
7 leaking into exhaust system • Check KCSF inlet for plugging.
KCSF.
Use proper fuel
specified in Operation
8 Improper fuel used • Fuel other than specified one is used.
and Maintenance
Manual.
• KDOC is deteriorated by high sulfur content.
Deteriorated KDOC due to (If regeneration frequency does not return to
9 use of improper fuel Replace KDOC.
normal after remedies for causes 1 to 8 are
taken, KDOC is deteriorated.)
• If regeneration frequency is not improved
10 Plugged KDOC after remedies on causes 1 to 9, KDOC is Clean KDOC.
blocked.
11 Damaged KDOC • Check KDOC for damage. Replace KDOC.
40-726 PC210LC-10
40 Troubleshooting
S-22 Active regeneration takes time (D65-AQ1-400-A-Z0-A)
Failure Active regeneration takes time.
Related • Since the time required for manual stationary regeneration depends on the accumulated
information soot level, see failure code CA2639.

• If values of KDOC inlet temperature:
approximately 250°C or below and KVGT
solenoid current: approximately 1000 mA Replace the whole
remain unchanged after performing KVGT (including
1 Malfunction of KVGT regeneration for service, KVGT is defective. hydraulic actuator and
• Since the time required for manual KVGT position sensor).
stationary regeneration depends on the
accumulated soot level, see failure code
CA2639.
• Open exhaust color inspection hole being
just upstream of KDPF, and check exhaust Perform
Defective exhaust gas color gas (see Standard value table). troubleshooting for "S-
2
(Reference: See Testing and adjusting, 9 Exhaust smoke is
"Testing exhaust color".) black".
Plugged KDOC resulting from • If regeneration time is not improved after
3 remedies on cause 2, KDOC is plugged. Clean KDOC.
bad exhaust color
Perform
Plugged KCSF due to coolant
5 • Check KCSF for plugging. Clean KCSF.
leaking into exhaust system
Use proper fuel
6
and Maintenance
Manual.
Deteriorated KDOC due to (If regeneration time is not improved after
7 Replace KDOC.
use of improper fuel remedies on causes 1 to 6 are taken, KDOC
is deteriorated.)
• If regeneration time is not improved after
8 Plugged KDOC remedies on causes 1 to 7 are taken, KDOC Clean KDOC.
is blocked.
PC210LC-10 40-727
40 Troubleshooting
S-23 White smoke is exhausted during active regeneration (PC400-AQ2-400-A-Z0-A)
Failure White smoke is exhausted during active regeneration.

• White smoke may be observed for a short time immediately after engine is started in cold
Related weather or during regeneration, but this is normal.
information • If any failure code is displayed, perform troubleshooting for that code first.
Perform
Plugged KDOC due to • If white smoke problem is not resolved after
coolant leaking into exhaust remedies for cause 1 are taken, KDOC is Clean or replace
2
system plugged. KDOC.
Use proper fuel
3
and Maintenance
Manual.
Deteriorated KDOC due to (If white smoke problem is not resolved after
4 Replace KDOC.
use of improper fuel remedies for causes 1 to 3 are taken, KDOC
is deteriorated.)
• If white smoke problem is not resolved after
5 Plugged KDOC remedies for causes 1 to 4 are taken, KDOC Clean KDOC.
is plugged.
7 Damaged KCSF • Check KCSF for damage. Replace KCSF.
40-728 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
50 Disassembly and assembly

7 50 Disassembly and assembly
PC210LC-10 50-1
Table of contents

50 Disassembly and assembly ........................................................................................................... 50-1
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-19
Removal and installation of supply pump assembly............................................................... 50-19
Removal and installation of injector assembly....................................................................... 50-24
Removal and installation of cylinder head assembly.............................................................. 50-33
Removal and installation of radiator assembly ...................................................................... 50-53
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-55
Removal and installation of aftercooler assembly .................................................................. 50-58
Removal and installation of engine and main pump assembly ................................................ 50-60
Removal and installation of engine front oil seal .................................................................... 50-72
Removal and installation of engine rear oil seal..................................................................... 50-76
Removal and installation of fuel cooler assembly .................................................................. 50-79
Removal and installation of fuel tank assembly ..................................................................... 50-80
Removal and installation of engine hood assembly ............................................................... 50-83
Removal and installation of KDPF assembly......................................................................... 50-86
Disassembly and assembly of KDPF ................................................................................... 50-94
Removal and installation of KCCV assembly ...................................................................... 50-102
Removal and installation of air cleaner assembly ................................................................ 50-106
Power train............................................................................................................................. 50-109
Removal and installation of travel motor and final drive assembly ......................................... 50-109
Disassembly and assembly of final drive ............................................................................ 50-110
Removal and installation of swing motor and swing machinery assembly .............................. 50-118
Disassembly and assembly of swing machinery.................................................................. 50-121
Removal and installation of swing circle assembly .............................................................. 50-128
Undercarriage and frame......................................................................................................... 50-129
Separation and connection of track shoe assembly ............................................................. 50-129
Removal and installation of sprocket.................................................................................. 50-132
Removal and installation of idler and idler cushion assembly ............................................... 50-133
Disassembly and assembly of idler assembly ..................................................................... 50-134
Disassembly and assembly of idler cushion........................................................................ 50-137
Disassembly and assembly of track roller assembly ............................................................ 50-139
Disassembly and assembly of carrier roller......................................................................... 50-141
Removal and installation of revolving frame assembly ......................................................... 50-144
Removal and installation of counterweight assembly ........................................................... 50-146
Hydraulic system .................................................................................................................... 50-149
Removal and installation of center swivel joint assembly ..................................................... 50-149
Disassembly and assembly of center swivel joint ................................................................ 50-152
Removal and installation of hydraulic tank assembly ........................................................... 50-153
Removal and installation of main pump assembly ............................................................... 50-157
Removal and installation of control valve assembly ............................................................. 50-161
Disassembly and assembly of control valve........................................................................ 50-168
Disassembly and assembly of work equipment PPC valve................................................... 50-173
Disassembly and assembly of travel PPC valve.................................................................. 50-175
Work equipment ..................................................................................................................... 50-178
Removal and installation of work equipment assembly ........................................................ 50-178
Disassembly and assembly of work equipment cylinder....................................................... 50-181
Removal and installation of operator's cab assembly........................................................... 50-187
Removal and installation of operator cab glass (adhered glass) ........................................... 50-192
Removal and installation of front window assembly ............................................................. 50-202
Removal and installation of floor frame assembly................................................................ 50-208
50-2 PC210LC-10
Table of contents
Removal and installation of air conditioner unit assembly..................................................... 50-214

Removal and installation of operator's seat......................................................................... 50-218
Removal and installation of seat belt .................................................................................. 50-220
Removal and installation of front wiper assembly ................................................................ 50-222
Removal and installation of air conditioner compressor assembly......................................... 50-229
Removal and installation of air conditioner condenser assembly .......................................... 50-232
Removal and installation of engine controller assembly ....................................................... 50-234
Removal and installation of pump controller assembly......................................................... 50-236
Removal and installation of machine monitor assembly ....................................................... 50-239
Removal and installation of pump swash plate sensor ......................................................... 50-241
Removal and installation of mass air flow and temperature sensor ....................................... 50-242
Removal and installation of KOMTRAX terminal assembly .................................................. 50-243
PC210LC-10 50-3
General information on disassembly and assembly
General information on disassembly and assembly (ALL-3851-001-A-00-A)
How to read this manual (ALL-0320-011-A-00-A)

(Rev.2010.10)
Removal and installation of TTTT assembly • Common tools that are necessary for installation
Special tools are described as [1], [2] ... etc. and their part
• Special tools which are necessary for removal or numbers, part names and quantities are not
installation of assemblies are described as described.
A1•••X1 etc. and their part numbers, part names, • Marks shown in the installation section are
necessities, and quantities are described in the explained below.
special tool list. k: This mark indicates safety-related
• Marks used in the column of necessity are precautions which must be followed when
explained below. performing the work.
t: Tools are not substituted, must always be
equipped (used). a : This marks gives guidance or precautions
q: Tools extremely useful if available or tools when performing the work.
that can be substituted with commercially
available tool. 4 : This mark shows the weight of a part or
• For details and the sketches of the special tools, the assembled parts for a device.
see "special tool list" and "sketches of special
tools". 2 : This mark indicates a specific coating
Removal agent to be used.
• In the removal section, the work procedures, 3 : This mark indicates the specified
precautions and know-how to do the work and tightening torque.
the amount of oil and coolant to be drained are
described. 5 : This mark indicates the amount of oil or
• Common tools that are necessary for the coolant to be added.
removal work are indicated as [1], [2] ... etc. and
their part numbers, part names and quantities Disassembly and assembly of TTTT assembly
are not described. Special tools
• Marks used in the removal section are explained • Special tools which are necessary for
below. disassembly and assembly of assemblies are
described as A1•••X1 etc. and their part
k: This mark indicates safety-related numbers, part names, necessities, and
precautions which must be followed when quantities are described in the special tool list.
performing the work. • Marks used in the column of necessity are
explained below.
a : This mark gives guidance or precautions when t: Tools are not substituted, must always be
performing the work. equipped (used).
[*1]: This mark indicates that instructions or q: Tools extremely useful if available or tools
precautions for the assembly installation work are that can be substituted with commercially
given in the installation section. available tool.
• For details and the sketches of the special tools,
6 : This mark shows the amount of oil or see "special tool list" and "sketches of special
coolant to be drained. tools".
Disassembly
4 : This mark shows the weight of a part or • In the disassembly section, the work
the assembled parts for a device. procedures, precautions and know-how to do
Installation the work, and the amount of oil and coolant to be
• Unless otherwise instructed the installation of drained are described.
assemblies is to be made in the reverse order to • Common tools that are necessary for the
removal. disassembly work are indicated as [1], [2] ... etc.
• Instructions and precautions for assembly and their part numbers, part names, and
installation are shown with [*1] mark in the quantities are not described.
removal section, identifying which step the • Marks used in the disassembly section are
instructions are intended for. explained below.
50-4 PC210LC-10
k: This mark indicates safety-related

precautions which must be followed when
performing the work.
a : This marks gives guidance or precautions

when performing the work.
6 : This mark shows the amount of oil or

coolant to be drained.
4 : This mark shows the weight of a part or

the assembled parts for a device.
Assembly
• In the assembly section, the work procedures,
precautions and the know-how to do the work,
and the amount of oil or coolant to be added are
described.
• Common tools that are necessary for the
disassembly work are indicated as [1],[2] ... etc.
and their part numbers, part names, and
quantities are not described.
• Marks used in the assembly section are
explained below.
k: This mark indicates safety-related
precautions which must be followed when
a : This mark gives guidance or precautions when

4 : This mark shows the weight of a part or

the assembled parts for a device.
2 : This mark indicates a specific coating
agent to be used.
3 : This mark indicates the specified
tightening torque.
5 : This mark indicates the amount of oil or

coolant to be added.
PC210LC-10 50-5
Coating materials list (ALL-3540-071-A-00-A)

(Rev.2012.03)
a The recommended coating materials such as adhesives, gasket sealants, and greases used for
disassembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Adhesive
Komatsu code Part No. Capacity Container Main features and applications
• Use to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube cushions, and cork plugs from coming
out.
• Use for plastic (except polyethylene,
20g polypropylene, tetrafluoroethylene, and
Polyethylene vinyl chloride), rubber, metal, and non-
LT-1B 790-129-9050 (2 pcs. container metal parts which require immediate
contained)
and strong adhesion.
• Features: Resistance to heat and
50 g Polyethylene chemicals
LT-2 790-129-9180
container • Use to fix and seal bolts and plugs.
Adhesive:
790-129-9060 1 kg • Use to bond and seal metal, glass and
LT-3 (Set of adhesive Can
Hardener: plastics.
and hardener)
500 g
250 g Polyethylene • Use to seal plugs for blank holes.
LT-4 790-129-9040
container
• Heat-resistant seal used to repair
Holtz MH705 790-129-9120 75 g Tube engines
• Instantaneous adhesive
50 g Polyethylene • Curing time: From 5 sec. to 3 min.
ThreeBond 1735 790-129-9140 • Use mainly to bond metals, rubbers,
container
plastics, and woods.
• Instantaneous adhesive
• Quick-curing type (max. strength is
Aron Alpha 201 2g Polyethylene
790-129-9130 obtained after 30 minutes)
container
• Use mainly to bond rubbers, plastics,
and metals.
• General-purpose instantaneous
adhesive with excellent resistance to
Loctite 499 428-99-80070 20 g Tube heat and impact
• Use on the bushing mounting faces of
axle supports.
• Features: Resistance to heat and
Polyethylene chemicals
Loctite 648-50 79A-129-9110 50 cc • Use for fitted portions used at high
container
temperatures.
50-6 PC210LC-10
Liquid gasket
• Use to seal various thread portions,
Polyethylene pipe joints, and flanges.
LG-5 790-129-9080 1 kg
container • Use to seal taper plugs, elbows, and
nipples for hydraulic piping.
• Features: Silicon-based heat and
cold-resistant sealant
200 g • Use to seal thread portions and flange
LG-6 790-129-9160 Tube
surface.
• Use to seal oil pan, final drive case,
etc.
• Features: Silicon-based quick-curing
sealant
LG-7 790-129-9170 1 kg Tube • Use to seal flywheel housing, intake
manifold, oil pan, thermostat housing,
etc.
LG-8 • Features: Silicon-based, heat and
cold-resistant, vibration-resistant,
ThreeBond 419-15-18131 100 g Tube impact-resistant sealant
1207B • Use to seal transfer case, etc.
• Use for rough surfaces such as the
LG-9 circle gear top seal which is not
ThreeBond 790-129-9310 200 g Tube clamped by bolts, gaps in the weld
1206D which must be caulked, etc.
• Can be coated with paint.
LG-10 • Use as lubricant or sealant when the
ThreeBond 790-129-9320 200 g Tube radiator hoses are put on.
1206E • Can be coated with paint.
• Feature: Can be used together with
LG-11 solid gaskets.
790-129-9330 200 g Tube
ThreeBond 1121 • Use for covers of the transmission
case and steering case etc.
ThreeBond 1211 790-129-9090 100 g Tube • Liquid gasket used to repair engine
Molybdenum disulfide lubricant

• Use to prevent galling and seizure of
press-fitted portions, shrinkage-fitted
LM-P 09940-00040 200 g Tube portions, and thread portions.
• Use to lubricate linkages, bearings,
etc.
• Spray type
• Thin molybdenum disulfide films are
made on metal surfaces to prevent the
LM-S 09995-00250 190 g Can metals from galling.
• Use for the drive shaft splines, needle
bearings, pins and bolts of various
links, etc.
PC210LC-10 50-7
Seizure prevention compound

• Feature: Seizure and galling
prevention compound with metallic
LC-G super-fine-grain, etc.
— — Can
NEVER-SEEZ • Use for the mounting bolt in the high
temperature area of the exhaust
manifold and the turbocharger, etc.
Grease
SYG2-400LI-A
G2-LI SYG2-16LI • Lithium grease with extreme pressure
G0-LI (*) SYGA-16CNLI Various Various lubrication performance, general
*: For cold regions SYG0-400LI-A(*) purpose type
SYG0-16CNLI(*)
• Use for parts under heavy load.
Caution:
• Do not use this grease for rolling
Molybdenum SYG2-400M 400 g x 10 Bellows-type bearings like swing circle bearings,
disulfide grease SYG2-400M-A 400 g x 20 container etc. and splines.
LM-G (G2-M) SYGA-16CNM 16 kg Can • Use this grease for work
equipment pins only when
installing them, but do not use it
afterward.
Hyper White
SYG2-400T • Higher seizure resistant, heat
Grease Bellows-type
SYG2-16CNT 400 g resistant and water resistant than
G2-T container molybdenum disulfide grease.
SYG0-400T(*) 16 kg • Not conspicuous on machine since
G0-T (*) Can
SYG0-16CNT(*) color is white.
*: For cold regions
Bio grease
G2-B SYG2-400B
SYGA-16CNB 400 g Bellows-type • Since this grease is biodegradable in
G2-BT (*) container short period, it has less impact on
*: For use at high SYG2-400BT(*) 16 kg microorganisms, animals, and plants.
Can
temperature and SYGA-16CNBT(*)
under high load
• Silicone grease with wide usable
temperature range, high resistance to
G2-S thermal-oxidative degradation and
— 200 g Tube performance to prevent deterioration
ThreeBond 1855 of rubber and plastic parts
• Use for oil seals of the transmission,
etc.
• Urea (organic system) grease with
heat resistance and long life.
Enclosed type.
G2-U-SENS
427-12-11871 2 kg Can • Use for rubber, bearing and oil seal in
grease
damper.
Caution: Do not mix it with lithium
grease.
50-8 PC210LC-10
Primer
Glass • Use to accelerate hardening of
Loctite 712 428-99-80080 100 ml
container instantaneous adhesive.
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
Primer 580 Super 20 ml (Effective period: 4 months after
container
manufacture)
417-926-3910
• Use as primer for cab glass
Sunstar Glass Glass surface.
20 ml
For adhering cab glass

Primer 580 Super container (Effective period: 4 months after
manufacture)
• Use as primer for painted cab
Sunstar Paint Glass sheet metal surface.
22M-54-27230 20 ml (Effective period: 4 months after
Primer 435-95 container
manufacture)
• Use as primer for black ceramic-
coated glass surface and for hard
Sunstar Glass polycarbonate-coated surface.
22M-54-27240 150 ml Steel can
Primer 435-41 (Effective period: 4 months after
manufacture)
• Use as primer for sash (Almite)
Sunstar Sash Glass (Effective period: 4 months after
22M-54-27250 20 ml
Primer GP-402 container manufacture)
Adhesive
• Use "S" in high temperature
season and "W" in low
Sunstar Penguin
Polyethylene temperature season as adhesive

Seal 580 Super 417-926-3910 320 ml for glass.
container
"S" or "W" (Effective period: 4 months after
manufacture)
• Use as adhesive for glass.
Sika Japan, Polyethylene (Effective period: 6 months after
20Y-54-39850 310 ml
Sikaflex 256HV container manufacture)
Ecocart • Use as adhesive for glass.
Sunstar Penguin
22M-54-27210 320 ml (Special (Effective period: 6 months after
Super 560
container) manufacture)
Caulking material
• Use to seal joints of glass parts.
Sunstar Penguin Polyethylene
417-926-3920 320 ml (Effective period: 4 months after

Seal No.2505 container manufacture)
• Use to seal front window.
Sekisui Silicone Polyethylene (Effective period: 6 months after
20Y-54-55130 333 ml
Sealant container manufacture)
• Use to seal glass-to-glass joint.
GE Toshiba Translucent white seal.
Silicones 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after
TOSSEAL 381 manufacture)
PC210LC-10 50-9
Special tools list (PC200_10-3530-061-A-00-A)
a Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
a Necessity
t:Tools are not substituted, must always be equipped (used).
q: Tools extremely useful if available or tools that can be substituted with commercially available tool.
a New/Redesign
N: Tools with new part numbers, newly developed for this model.
R: Tools, with advanced part numbers, developed by improving existing tools for other models.
Blank: Tools already available for other models that can be used without any modification
a Tools marked with Q in the sketch column have the sketches. ((See “Sketches of special tools“.)
New/Redesign
Necessity
Sketch
Sym- Detail of work,
Q'ty
Work item Part No. Part Name
bol remarks

Holding of supply
of supply pump 1 795-799-6130 Support t 1
pump gear
assembly
Removal of injector
2 795-799-6700 Puller t 1
assembly
of injector assembly and Adjustment of valve
3 795-799-1131 Gear t 1
cylinder head assembly clearance
Removal of inlet
4 795-799-8150 Remover q 1
connector
of cylinder head Angle tightening of
5 790-331-1120 Wrench (angle) q 1
assembly and engine bolt
front seal
Check of cylinder
of cylinder head 6 795-790-4510 Gauge q 1 head bolt length
assembly
Removal and installation Installation of
of engine front seal 7 795-799-6400 Seal puller t 1
engine front seal
A
Removal and installation Installation of
of engine rear seal 8 795-799-6500 Seal puller t 1
engine rear seal
Removal,
installation of
9 796T-401-1110 Plate q 1 Q
engine mounting
bolts
of engine and main
Removal and
pump assembly
installation of
10 795-799-9300 Lifting tool q 1 engine and main
pump assembly
Removal installation, Removal and
and assembly of KDPF Commercially Long socket (1/2 in) installation of V-
11 q 1
assembly available clamp
Removal, installation,
disassembly and Removal and
assembly of cylinder Commercially Long socket (7/16 in) installation of V-
12 q 1
head assembly and available clamp and band
KDPF assembly
50-10 PC210LC-10
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
Removal and
1 796-427-1400 Wrench assembly t 1 installation of ring
nut
Installation of
2 796-427-1520 Installer t 1
floating seal
796T-427-1510 Push tool t 1 Q
790-101-2510 Block t 1
790-101-3310 Plate t 1
Disassembly and 790-101-2610 Leg t 2
assembly of final drive F 790-101-2730 Adapter t 2
Installation of hub
3 01580-11613 Nut t 2 assembly
790-101-2570 Plate t 2
01643-31645 Washer t 2
Puller (294 kN {30
790-101-2102 ton}) t 1
790-101-1102 Pump t 1
Tightening of cover
4 790-331-1110 Wrench t 1
mounting bolt
Press fit of main
1 796T-426-1410 Push tool t 1 Q bearing
Disassembly and Press fit of sub
2 796-426-1120 Push tool t 1
assembly of swing G bearing
machinery 796T-426-1130 Plate t 1 Q
3 790-101-5421 Grip t 1 Press fit of oil seal
01010-81240 Bolt t 1
Disassembly and Installation of
assembly of idler J 791-530-1510 Installer t 1
floating seal
K 796-670-1020 Installer t 1
assembly of track roller floating seal
L 790-434-1660 Installer t 1
assembly of carrier roller floating seal
791-600-2001 Compressor (A) t 1
or
Compressor (B) t 1
791-685-8006
790-201-2780 Spacer t 1 Disassembly and
1 791-635-3160 Extension t 1 assembly of idler
Cylinder (686 kN {70 cushion
790-101-1600 t 1
ton})
790-101-1102 Pump t 1
Disassembly and
assembly of idler M 790-640-2180 Guide bolt t 1
cushion 790-101-5201 Push tool kit (B) q 1
790-101-5241 • Plate 1
2 Press fit of bushing
790-101-5221 • Grip 1
01010-51225 • Bolt 2
790-201-1500 Push tool KIT q 1
790-201-1620 • Plate 1 Press fit of dust
3
790-101-5021 • Grip 1 seal
01010-50816 • Bolt 2
PC210LC-10 50-11
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
1 791-630-3000 Remover and installer t 1

Separation and Removal and
Cylinder (980 kN {100
connection of track shoe N 2 790-101-1300 t 1 installation of
ton})
assembly master pin
3 790-101-1102 Hydraulic pump t 1
Disassembly and 1 796T-416-1010 Push tool t 1 Q Press fit of bushing
assembly of travel PPC Q 2 796T-416-1030 Push tool t 1 Q Press fit of bushing
valve 3 796T-416-1020 Push tool t 1 Q Press fit of pin
Removal and installation 1 796-460-1210 Oil stopper q 1
of hydraulic oil cooler
assembly, engine and To stop flow of oil
main pump assembly, R from hydraulic tank
2 796-770-1320 Adapter q 1
and main pump
assembly
790-101-2501 Push-puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
Disassembly and 791-112-1180 • Nut 1
Removal of rotor
assembly of center S 790-101-2540 • Washer 1 and ring
swivel joint 790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2
790-101-2680 • Adapter 2
796-946-1310 Guide f 21.8 mm
t 1
(for 723-46-40100)
796-946-1610 Guide f 21.4 mm
t 1
(for 723-46-41100)
796-946-1810 Guide f 21.2 mm
1 t 1
(for 723-46-43100 and 723-46-43400)
796-946-1910 Guide f 21.0 mm
t 1
(for 723-46-46101 and 723-46-46300)
796-946-2210 Guide f 20.6 mm
t 1
(for 723-46-45100 and 723-46-45700) Replacement of
Disassembly and 796-946-1320 Guide f 21.8 mm
t 1 pressure
assembly of control T
(for 723-46-40100) compensation
valve
796-946-1620 Guide f 21.4 mm valve seal
t 1
(for 723-46-41100)
796-946-1820 Guide f 21.2 mm
t 1
(for 723-46-43100 and 723-46-43400)
2
796-946-1920 Guide f 21.0 mm
t 1
(for 723-46-46101 and 723-46-46300)
796-946-2220 Guide f 20.6 mm
t 1
(for 723-46-45100)
796-946-1420 Guide f 21.6 mm
t 1
(for 723-46-42700)
50-12 PC210LC-10
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
796-946-1330 Sleeve
t 1
(for 723-46-40100)
796-946-1630 Sleeve
t 1
(for 723-46-41100)
796-946-1830 Sleeve Replacement of
Disassembly and t 1
(for 723-46-43100 and 723-46-43400) pressure
assembly of control T 3
796-946-1930 Sleeve compensation
valve t 1
(for 723-46-46101 and 723-46-46300) valve seal
796-946-2230 Sleeve
t 1
(for 723-46-45100)
796-946-1430 Sleeve
t 1
(for 723-46-42700)
790–502–1003 Cylinder repair stand q 1 Disassembly and
1 assembly of work
790–101–1102 Pump q 1 equipment cylinder
790–102–4300 Wrench assembly t 1 Removal and
2 installation of
790–102–4310 Pin t 1 piston ring
3 790–720–1000 Expander q 1
Rubber band (for
796–720–1670 boom and bucket) q 1
Installation of
4 07281–01279 Clamp q 1 piston ring
796–720–1680 Rubber band (for arm) q 1
Disassembly and 07281–01589 Clamp q 1
assembly of work U 790–201–1702 Push tool KIT t 1
equipment cylinder
• Push tool (for boom
790-201–1841 and bucket) 1
5 Press fit of bushing
790–201–1851 • Push tool (for arm) 1
790–101–5021 Grip 1
01010–50816 Bolt 2
790–201–1500 Push tool KIT t 1
• Plate (for boom
790–201–1650 and bucket) 1
Press fit of dust
6
790–201–1660 • Plate (for arm) 1 seal
790–101–5021 • Grip 1
01010–50816 • Bolt 2
796-900-1200 Remover t 1
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1
799-900-1230 • Screw 1
Removal and installation 796-900-1240 • Adapter 1 Removal of boom
of work equipment V 01643-33080 • Washer 1 foot pin
assembly 01803-13034 • Nut 1
Puller (490 kN {50 ton}
790-101-4000 long) t 1
Pump (294 kN {30
790-101-1102 ton}) t 1
PC210LC-10 50-13
New/Redesign
Necessity
Sketch
Q'ty
bol remarks
Removal and installation 1 793-498-1210 Lifter (suction cup) t 2 Holding of glass

of operator's cab glass X
(adhered window glass) 2 20Y-54-13180 Stopper rubber t 2 Fixing of glass
Commercially Eyebolt
1 q 2 Ｍ48 × 3
Removal and installation available
of counterweight Commercially Impact wrench
Z 2 q 1
assembly available
Commercially Width across flats:
3 Socket wrench q 1
available 46 mm
50-14 PC210LC-10
Sketches of special tools (PC200_10-3531-066-A-00-A)
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
A9: Plate
F3: Push tool
PC210LC-10 50-15
Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
G1: Push tool
G3: Plate
50-16 PC210LC-10
Q1: Push tool
Q2: Push tool
PC210LC-10 50-17
Q3: Push tool
50-18 PC210LC-10
Removal and installation of supply pump assembly (PC220-AD70-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
A 1 795-799-6130 Support t 1

Removal (PC200_10-AD70-520-K-00-A)
5. Disconnect fuel filter hoses (7) and (8) from
1. Close the cock of fuel stop valve (1). supply pump assembly (20). [*1]
a While pressing locks (L) on both sides, pull
the hose in the direction of (a).
2. Remove undercover (2).
6. Disconnect fuel return hose (9). [*2]

7. Disconnect wiring harness connector (10).
8. Disconnect fuel supply hose (11). [*3]
9. Disconnect high-pressure pipe (13) according to
the following procedure. [*4]
1) Remove fuel spray prevention caps (12) and
(17).
2) Disconnect two tube clamps (14).
3) Disconnect high-pressure pipe (13).
10.Disconnect spill tube (16) according to the
following procedure. [*5]
3. Open engine hood (3). 1) Disconnect tube clamp (15).
4. Remove the following parts, referring to 2) Remove spill tube (16).
"Removal and installation of KCCV assembly".
• Step (4)
• KCCV ventilator assembly (5)
• Bracket (6)
PC210LC-10 50-19
a Supply pump assembly (20) comes off with

the gear. The gear is not worked on its teeth
(no missing tooth) to show the mark for 1, 6
TDC adjustment.
12.When removing the gear from the supply pump

assembly, follow the procedure described below.
[*7]
1) While locking the gear by using tool A1 and
1/2-inch spinner handle [1], loosen nut (21).
a Do not remove nut (21) from the shaft.
2) Install puller [2] between the flange and gear

11.Remove three nuts (at locations A), then remove (22).
supply pump assembly (20). [*6]
a Pull supply pump assembly (20) sideways in
a straight line when removing it. Otherwise
the pump assembly may interfere with the
end of boost pump (26).
3) Install puller [3] on puller [2] and the shaft.

4) Turn center bolt [4] until the gear comes off
the shaft.
5) Remove pullers [2] and [3].
50-20 PC210LC-10
6) Remove nut (21), lock washer (23) and gear [*2]

(22) from shaft (24). 3 Fuel return hose (9) mounting bolt:
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
[*3]
3 Fuel supply hose (11) mounting bolt:
25.4 to 34.3 Nm {2.6 to 3.5 kgm}
[*4]
Install high-pressure pipe (13) according to the
1. Tighten the sleeve nut of high-pressure pipe (13)
by hand. (both sides)
2. Tighten the sleeve nuts on the supply pump side
and then on the common rail side.
Installation (PC220-AD70-720-K-00-A) 3 Sleeve nut:
Perform installation in the reverse order to removal. 35 ± 3.5 Nm {3.57 ± 0.36 kgm}
[*1] 3. Install tube clamps (14) (2 places).
When installing a connector of quick coupler type, 3 Clamp bolt:
observe the following points. 24 ± 4 Nm {2.45 ± 0.41 kgm}
a The internal parts of the fitting may be damaged 4. Install fuel spray prevention caps (12) and (17).
when the hose or tube is removed. Accordingly, a Install the fuel spray prevention cap with the
do not reuse the hose or tube. slit out and down.
When installing, replace it with a new one. a The caps are installed so that fuel will not
a Ensure that mud or dirt is not sticking to the hose spout over the hot parts of the engine and
joint portions in advance. catch fire if it leaks for some reason.
a Push the connector straight (in the direction of
(b)). Do not pry it in or shake it.
If it is difficult to insert the connector, do not push
it in forcibly but pull it out. Then, check the male
and female couplings for damage and sticking
mud.
PC210LC-10 50-21
a Use a new socket when installing supply pump

assembly mounting nuts (19) because the
cylinder block side nuts are hard to install.
a If an old socket is used, the nut may fall or be
damaged due to excessive clearance between
the socket and mounting nut (19).
3 Supply pump assembly mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*7]
Install gear (22) according to the following
[*5] procedure.
3 Spill tube (16) mounting bolt: a Clean and dry the mating surfaces on shaft (24)
24 ± 4 Nm {2.45 ± 0.41 kgm} and gear (22) so that the surfaces are free of dirt
and foreign material.
3 Tube clamp (15) mounting bolt: 1. Install gear (22) to shaft (24).
24 ± 4 Nm {2.45 ± 0.41 kgm} 2. Install lock washer (23) and nut (21) and finger-
[*6] tighten the nut.
Install supply pump assembly (20).
a If too much grease is applied to O-ring (18), it will
ooze out. Accordingly, do not apply grease so
much. (Apply grease to the O-ring groove area
of part B.)
a When installing new supply pump mounting stud
bolts (25) to replace the existing ones, apply
LOCTITE to them.
3 Stud bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
3. While locking the gear by using tool A1 and 1/2-

inch spinner handle [1], tighten nut (21) to the
specified torque.
3 Supply pump gear mounting nut:
105 ± 5 Nm {10.7 ± 0.51 kgm}
50-22 PC210LC-10
• Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting,“Bleeding air from fuel
system“ .
PC210LC-10 50-23
Removal and installation of injector assembly (PC220-AE60-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
2 795-799-6700 Puller t 1
A 3 795-799-1131 Gear t 1
4 795-799-8150 Remover q 1

5. Disconnect EGR gas temperature sensor

Removal (PC200_10-AE60-520-K-00-A)
connector (EXHAUST GAS TEMPERATURE)
(7).
1. Remove undercover (1). 6. Loosen hose clamp (8), then disconnect hose
(9). [*1]
7. Remove four mounting bolts (10), then remove
EGR piping flange (11). [*2]
2. Drain the coolant through drain valve (2). (Drain

hose: inside diameter f7 mm)
6 Coolant: 8. Disconnect connectors (12), (13), and (14).

30.7 l • Connector (12): KVGT position sensor
(SVGT)
(VGT_REV)
CONNECT)

4. Remove the following parts, referring to
"Removal and installation of KCCV assembly".
• Step (4)
• KCCV ventilator assembly (5)
• Bracket (6) 9. Disconnect hoses (15) and (16). [*3]
50-24 PC210LC-10
k When disconnecting the hoses, always

disconnect at the intake manifold side to
avoid splashing oil to high temperature
area which causes fire.
• Hose (16): KVGT actuator drive pressure
circuit
13.Disconnect dipstick pipe (21).

14.Disconnect tubes (22) and (23).
15.Remove lower bracket (24) of the EGR valve.
16.Remove EGR valve (25).
10.Remove fan guards (17) and (18).
17.Remove air hose (26).

a Put marks on the hose end and tube to
indicate their fitting positions.
18.Disconnect four wiring harness clamps (27).

11.Disconnect hose clamp (19).[*4] 19.Disconnect intake air heater E01 (28) and the
12.Disconnect radiator hose (20).[*5] wiring harness clamp.
20.Remove intake assembly (29).
PC210LC-10 50-25
27.Remove six nuts (43), then remove head cover

(44).
21.Disconnect wiring harness connectors (30), (31),

and (32).
a After the disconnection, move wiring harness 28.Remove nuts (45) for the wiring harnesses from
(33) toward the counterweight. the injector assembly.
Wiring harness Cylinder No.
color
White 1, 3, 5
Black 2, 4, 6
a Do not remove injector wiring harness

connector (60) from the rocker housing
unless needed.
29.Remove 12 bolts (46), then remove rocker arm
assembly (47), crosshead (48), and the rocker
arm support.
a Loosen lock nuts (49) and then loosen
22.Remove 14 fuel spray prevention caps (41) of adjustment screws (50) a few turns each to
high-pressure pipes (34) to (40). prevent excessive forces from working on
23.Remove high-pressure pipes (34) to (39). the push rods when the rocker arms are
24.Remove the clamp, then remove high-pressure installed.
pipe (40). a Record the installed position and direction
25.Loosen the mounting bolts of common rail (125). (shapes of holes (a) and (b)) of each
crosshead. (This is necessary to reinstall
them in the original directions.)
26.Remove blowby duct (42).

a When removing blowby duct (42), take care
that the O-ring will not fall from it.
a Since the O-ring is fitted to the flywheel
housing side of blowby duct (42), it may be
removed together with cylinder head cover
(44).
50-26 PC210LC-10
a When replacing the injector assembly with a

new one, be sure to replace the inlet
connector with a new one, as well.
a Check that injector sleeve (56) is free from
flaws or dirt.
30.Remove retaining nuts (51), then remove six

inlet connectors (52).
a Clean the surrounding area to remove mud
and other contamination in advance to
prevent them from entering the connector
hole. 1) Install O-ring (58) and gasket (59) to injector
a Use tool A4 to remove inlet connector (52). (57).
31.Remove mounting bolts (53) of injector a Replace the O-ring and gasket with new
assembly (55), then remove holder (54). ones.
32.By using tool A2, remove fuel injector assembly 2) Apply engine oil to O-ring (58) of injector (57)
(55). and the cylinder head side surface.
2 O-ring (58) of injector (57) and
cylinder head side surface:
Engine oil (EO15W-40)
3) Engage the male and female parts at (A) to
install holder (54) to injector (57).
a Take care that dirt and foreign material do not

enter the injector assembly mounting area.
4) Install injector assembly (55) into the cylinder

head with the fuel inlet hole facing toward the
air intake manifold.
5) Screw in holder mounting bolts (53) three to
four threads.
6) Check the inlet connector visually. If it has
any of the following faults, replace it.
1] Burrs or wear is recognizable in the inlet
connector top-end (a) and rear-end (b)
portions.
Installation (PC200_10-AE60-720-K-00-A) 2] There is foreign matter in the edge filter at
1. Injector assembly rear end (c) of the inlet connector.
PC210LC-10 50-27
3] Cracks or deterioration is recognizable in 3 Retaining nut (51) (tightening

O-ring of the inlet connector upper portion lightly):
(d). 15 ± 5 Nm {1.53 ± 0.51 kgm}
4] There is a worn part or an uneven seat 9) Tighten mounting bolts (53) of holder (54)
contact mark on seating face (e) at the alternately.
top end of the inlet connector. 3 Holder mounting bolt:
a If high-pressure fuel leaks through the 8 ± 0.8 Nm {0.82 ± 0.08 kgm}
inlet connector, the seal face has fine 10)Tighten retaining nut (51) of inlet connector
streaks or cracks. (52).
3 Retaining nut (51) (tightening to
the specified torque):
50 ± 5 Nm {5.1 ± 0.5 kgm}
7) Apply engine oil to O-ring (part C) of inlet

connector (52) and the cylinder head (part
B).
2 Inlet connector O-ring and cylinder
head:
8) Insert inlet connector (52) in the mounting
hole for injector assembly (55) and lightly
tighten retaining nut (51).
a After tightening lightly, tighten to the
specified torque. Tighten to the specified
torque for each cases. Insufficient or
excessive torque may cause the fuel
leakage into the engine.
a The positioning balls (part D) on the inlet
connector must be at the guide groove in 2. Rocker arm and crosshead assembly
the cylinder head when installed. 1) Install rocker arm assembly (47), crosshead
(48), and the rocker arm support.
50-28 PC210LC-10
a When reusing the crosshead, install the a If injector wiring harness connector (60) is
same intake and exhaust valves in the removed, apply liquid gasket LG-7 to O-
same direction because the shapes of its ring (61) and flange (62) of the connector.
holes (a) and (b) are different, Apply a bead of liquid gasket, f3 mm in
diameter to the O-ring so that the ring
groove is completely covered.
If the O-ring is damaged, replace it and
the wiring harness assembly as a unit.
2 O-ring and flange face of
connector:
3 Connector flange mounting bolt
(63):
10 ± 2 Nm {1 ± 0.2 kgm}
a Check that the spherical portion of

adjustment screw (50) is set in the push
rod socket securely and then tighten
mounting bolts (46).
36 ± 5 Nm {3.7 ± 0.5 kgm}
2) Adjust the valve clearance.
a See Testing and adjusting, “Measuring
and adjusting valve clearance“.
a Adjust the valve clearance at each
cylinder by using tool A3 to turn the
crankshaft.
3) After valve clearance adjustment, ensure
that lock nut (49) is tightened to the specified
torque.
3 Lock nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install wiring harness mounting nuts (45) to
injector assembly (55).
a Check that the wiring harness does not
interfere with the rocker arm.
a Installed positions of wiring harnesses 3. Head cover
Wiring harness color Cylinder No. 1) Install the gasket and then install head cover
1, 3, 5 (44) with mounting nuts (43).
White
Black 2, 4, 6 3 Mounting nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Mounting nut:
2) Install blowby duct (42).
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
PC210LC-10 50-29
3 Mounting bolt: 1] High-pressure pipe (34) connector end,

7 ± 2 Nm {0.7 ± 0.2 kgm} Pipe (35) connector end, Pipe (36)
connector end, Pipe (34) common rail
end, Pipe (35) common rail end, then
Pipe (36) common rail end
2] High-pressure pipe (37) connector end,
Pipe (38) connector end, Pipe (39)
3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
3) Lightly tighten the sleeve nuts of high-
pressure pipes (40) and tube clamp.
4) Tighten high-pressure pipe (40) in the order
4. High-pressure pipe
of its supply pump end and its common rail
end.
k Do not use high-pressure pipes with
bending modification. 3 Sleeve nut:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
k Be sure to use the genuine high-pressure 5) Tighten common rail (125) with 4 bolts.
pipe fixing clamp and observe the
a Apply liquid gasket to the thread portion
tightening torque.
of two bolts (P) inside engine.
k Install each high-pressure pipe and wiring 2 Thread portion of bolt (P):
harness at least 10 mm apart from each Liquid gasket (LG-7)
other.
3 Mounting bolt:
a A high-pressure pipe may cause fuel leakage 24 ± 4 Nm {2.45 ± 0.41 kgm}
if visible lengthwise streaks (b) or spots (c) 6) Tighten the tube clamp to the specified
are found at the joint's taper seal at part (a) torque.
(within 2 mm from the end), or the stepped
wear at part (d) (2 mm from the end of taper 3 Mounting bolt:
seal) is as severe as it can be felt with a 24 ± 4 Nm {2.45 ± 0.41 kgm}
fingernail. If there is any of those defects, 7) Install fuel spray prevention cap (41).
replace the high-pressure pipe.
k When installing the fuel spray prevention
caps, direct their slits outward and
downward.
1) Tighten common rail (125) and high pressure

pipes (34) to (39) lightly.
3 Mounting bolt and sleeve nut
(tightening lightly):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2) Tighten high-pressure pipes (34) to (39) to
the specified torque according to the
50-30 PC210LC-10
5. EGR valve • MIKALOR clamps

1) Install gasket (64).
a Use a new clamp.
a Note the orientation of the part number 1] Set the hose to the original (marked)
tag when installing the gasket. position.
a Reference
Air hose fitting length: 80 mm (both
upper and lower sides)
2] Set the bridge (BR) under the clamp bolt
and lap it over band (BD) by at least 5
mm (b).
Dimension (b) : Min. 5 mm
2 Clamp bolt thread portion (BC):
Lubricant (THREEBOND
PANDO 18B)
a Impact wrench is not allowed to use.
2) Install intake assembly (29). • If hoses are to be reused
3 Mounting bolt of intake assembly: Install the clamp to the clamp mark put on
the hose.
24 ± 4 Nm {2.45 ± 0.41 kgm}
3) Install intake air heater connector E01 (28) 3 Clamp bolt:
and the wiring harness clamp. Min. 6 Nm {0.6 kgm}
3 Mounting nut for intake air heater • When using a new hose
connector: Tighten the clamp so that BDG dimension
is as follows.
3.4 to 4.6 Nm {0.34 to 0.47 kgm}
BDG: 7 to 10 mm
4) Install wiring harness connector and harness
clamp (27).
3 Mounting bolt (at intake assembly
side face):
24 ± 4 Nm {2.45 ± 0.41 kgm}
top):
43 ± 6 Nm {4.4 ± 0.6 kgm}
5) Install air hose (26).
6) Fit gasket and install EGR valve (25).

3 Mounting bolt for EGR valve:
43 ± 6 Nm {4.4 ± 0.6 kgm}
7) Install tubes (22) and (23).
PC210LC-10 50-31
3 Sleeve nut: 3 Sleeve nut:

25 ± 1.5 Nm {2.55 ± 0.15 kgm} 25 ± 1.5 Nm {2.6 ± 0.15 kgm}
8) Install bracket (24) to EGR valve (25) using • Hose (16): KVGT actuator drive pressure circuit
four mounting bolts.
3 Sleeve nut:
• Upper (EGR valve side)
15 ± 1 Nm {1.5 ± 0.1 kgm}
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
• Middle and lower (engine side)
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
9) Install dipstick pipe (21).
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*4]
3 Mounting bolt:
34 ± 5 Nm {3.5 ± 0.5 kgm}
[*5]
Radiator hose fitting length: 50 mm
3 Hose clamp:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
Perform the following installation in the reverse • Refilling of coolant
order to removal. Supply coolant through the coolant filler to the
specified level. Run the engine to circulate the
[*1]
coolant through the system. Then, check the
3 Hose clamp: coolant level again.
10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
5 Coolant: (Engine coolant)
[*2]
30.7 l
a Use an open-head type torque wrench when
installing EGR piping flange (11). It is difficult to
tighten by using a common type torque wrench.
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*3]
50-32 PC210LC-10
Removal and installation of cylinder head assembly (PC220-A100-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
2
795-799-6700 Puller t 1
3
795-799-1131 Gear t 1
4
795-799-8150 Remover q 1
A 5
790-331-1120 Wrench (Angle) q 1
6
795-790-4510 Gauge q 1
Commercially Long socket (7/16 4. Remove mounting bolts (118) (10 pieces) and
12 in) q 1 (119) (5 pieces) from frame (6) and cover (117).
available

Removal (PC200_10-A100-520-K-00-A)

6 Coolant:
30.7 l
3. Open the engine hood, then remove step (3) and

covers (4) and (5). 5. Remove frame (6).
PC210LC-10 50-33
11.Disconnect connectors (12), (13), and (14).

4 Frame
11 kg
(SVGT)
(VGT_REV)
CONNECT)
6. Lift up and remove cover (117). [*1]

a Take care not to let the cover damage any
wiring harness and hose.
a Cover (117) can be removed as it is, without
12.Disconnect hoses (15) and (16). [*4]
separating it into the upper and lower halves.
k When disconnecting the hoses, always

disconnect at the intake manifold side to
avoid splashing oil to high temperature
area which causes fire.
• Hose (16): KVGT drive hydraulic circuit
7. Remove KCCV ventilator assembly and bracket.

For details, see "Removal and installation of
KCCV assembly".
8. Disconnect EGR gas temperature sensor
connector (EXHAUST GAS TEMPERATURE)
(7).
9. Loosen hose clamp (8) and disconnect hose (9).
[*2] 13.Remove fan guards (17) and (18).
10.Remove four mounting bolts (10) to remove
EGR piping flange (11). [*3]
14.Disconnect hose clamp (19). [*5]

15.Remove radiator hose (20). [*6]
50-34 PC210LC-10
16.Disconnect dipstick pipe (21). 24.Disconnect wiring harness connectors (30), (31),
17.Disconnect tubes (22) and (23). and (32).
18.Remove bottom bracket (24) of the EGR valve.
a After the disconnection, move wiring harness
19.Remove EGR valve (25).
(33) toward the counterweight.
20.Remove air hose (26).

25.Remove 14 fuel spray prevention caps (41) of
a Make matchmarks on the hose end and tube high-pressure pipes (34) to (40).
so that they can be reconnected correctly. 26.Remove high-pressure pipes (34) to (39).
27.Disconnect the clamp and remove high-
pressure pipe (40).
28.Loosen the mounting bolts of common rail (125).
[*7]
21.Disconnect four wiring harness clamps (27).

22.Disconnect intake air heater E01 (28) and the
wiring harness clamp.
23.Remove intake assembly (29).
29.Remove the KDPF assembly (116). For details,
see "Removal and installation of KDPF
assembly".
PC210LC-10 50-35
30.Removal of base brackets 38.Disconnect tube (55) from KVGT.

1) Remove tube support bracket (43) . a KVGT side is tightened together.
2) Disconnect hose clamp (44), harness clamp 39.Disconnect tube (56).
(45), and tube clamp (46) from base bracket
(42) . a KVGT side is tightened together.
3) Remove eight mounting bolts (47), then sling 40.Disconnect tube (57).
and remove base bracket (42) . a The KVGT side is jointly fastened. Be careful
that there is only a narrow work space
4 Base bracket: available.
25 kg
41.Loosen the hose clamp, then remove KVGT

31.Remove tube (48). return tube (58).
42.Remove the four mounting bolts, then sling and
remove KVGT (59).
4 KVGT:
25 kg
32.Disconnect hose (49).

34.Remove clamp (51).
35.Disconnect tube (52).
37.Disconnect hose (54). 43.Remove bracket (60).
44.Remove heat insulation plate (61).
45.Remove tube (62) of the EGR cooler.
50-36 PC210LC-10
46.Remove air conditioner compressor belt (111)

1) Loosen three bolts (112).
2) Loosen lock nut (113).
3) Turn jack bolt (114) and move air conditioner
compressor (115) in the direction (B) of
loosening belt tension.
4) Loosen the tension of air conditioner
compressor belt (111) and remove the belt.
48.Disconnect terminal B (67) and connector E12

(68) from alternator (66).
49.Disconnect wiring harness clamp (69).
50.Remove alternator (66).
51.Disconnect connector (EXHAUST PRESSURE)
(70) of the exhaust manifold pressure sensor.
47.Remove fan belt (64).

a Install a wrench to portion A (width across
flats: 12.7 mm) of the tensioner assembly
(65), and rotate it in the direction opposite to
the winding-up direction (R) to decrease the
fan belt (64) tension, then remove it.
k Make sure before turning the wrench that

it is positively inserted into portion A of
tensioner assembly (65). (Since the spring
force of tensioner assembly (65) is strong,
the wrench might come off and induce
personal injury if it is turned when not
securely attached.)
k After removing fan belt (64), return

tensioner assembly (65) to its original
position slowly and carefully.
k Be careful not to get your fingers caught

between the pulley and fan belt (64)
during work. 52.Disconnect tube clamp (71).
PC210LC-10 50-37
53.Loosen hose clamp (72).

54.Disconnect and remove tube (55) from the EGR
cooler.
61.Remove spill tube (82).

62.Remove blowby duct (83).
63.Remove six mounting nuts (84), then remove
55.Remove tube (73). head cover (85).
56.Remove mounting bolt (74), then disconnect
EGR cooler (75) and exhaust manifold (76).
a When disconnecting , take care that the
gasket does not fall.
64.Remove harness nut (86) from the injector

assembly.
Color of wiring Cylinder No.
harness
White 1, 3, 5
57.Remove tube (77).
Black 2, 4, 6
58.Remove mounting bolts (78) to remove exhaust
manifold (76). a Remove injector harness connector (97) from
a When disconnecting , take care that the the rocker housing only when required.
gasket does not fall. 65.Remove 12 mounting bolts (87), then remove
rocker arm assembly (88), crosshead (89), and
the rocker arm support.
a Loosen lock nuts (90) and then loosen
adjustment screws (91) a few turns each to
prevent excessive forces from working on
the push rods when the rocker arms are
installed.
a Record the installed position and direction
(shapes of holes (a) and (b)) of each
crosshead. (This is necessary to reinstall
them in the original directions.)
59.Remove bottom side tube of EGR cooler (79).

60.Remove EGR cooler (75) and bracket (81).
50-38 PC210LC-10
69.Remove push rod (98).

70.Remove mounting bolt (99) and remove rocker
housing assembly (100).
66.Remove retainers (92) and then remove six inlet

connectors (93).
a Clean the surrounding area to remove mud 71.Remove 26 mounting bolts (101), then remove
and other contamination in advance to cylinder head assembly (102).
prevent them from entering the connector
hole. 4 Cylinder head assembly:
a Use tool A4 to remove inlet connector (93). 75 kg
67.Remove mounting bolts (94) of injector 72.Remove cylinder head gasket (103).
assembly (96), then remove holder (95).
68.By using tool A2, remove fuel injector assembly Installation (PC200_10-A100-720-K-00-A)
(96). 1. Cylinder head assembly
a Take care that dirt and foreign matter do not 1) Measure nominal length (a) of all the cylinder
enter the mounting portion of the injector head mounting bolts to check that each falls
assembly. within the using limit.
• Using limit length of bolt: less than 132.1
mm
PC210LC-10 50-39
a If a bolt is longer than the using limit, do

not reuse it but replace it.
a Measure the length by using tool A6.
2) Install cylinder head gasket (103) in position

on the cylinder block.
a Check that the cylinder head mounting
face and inside of the cylinders are free
from dirt and foreign matter.
a Check that the holes in cylinder head
gasket (103) are aligned with the holes in
the cylinder head.
3) Install cylinder head assembly (102) in
• When not using angle tightening tool
position on the cylinder block, and finger-
Put a mark across the cylinder head and
tighten mounting bolts (101) more than two
bolt with a marker pen, then retighten the
to three turns.
bolt by 90 ± 5 deg.
4 Cylinder head assembly:
75 kg
4) Tighten mounting bolts (101) in the order
shown in the figure as follows.
a Coat mounting bolt threads and bolt head
seat surface with engine oil.
2 Threads of mounting bolt and
seating surface of bolt head:
3 Mounting bolt:
1] 90 ± 3 Nm {9.2 ± 0.3 kgm}
2] 90 ± 3 Nm {9.2 ± 0.3 kgm} 2. Install rocker housing assembly (100) with
3] 90 ± 5 deg. (Use tool A5 to mounting bolt (99).
angle tighten)) 3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3. Install push rod (98).
a Check that the push rod is in the tappet.
a Fill the push rod socket with engine oil.
2 Push rod socket:
50-40 PC210LC-10
4) Install injector assembly (96) into the cylinder

head with the fuel inlet hole facing toward the
air intake manifold.
5) Screw in holder mounting bolts (94) three to
four threads.
6) Check the inlet connector visually. If it has
any of the following faults, replace it.
1] Burrs or wear is recognizable in the inlet
connector top-end (a) and rear-end (b)
portions.
2] There is foreign matter in the edge filter at
rear end (c) of the inlet connector.
4. Injector assembly 3] Cracks or deterioration is recognizable in
O-ring of the inlet connector upper portion
a When replacing the injector assembly with a (d).
new one, be sure to replace the inlet
connector with a new one, as well.
a Check that injector sleeve (104) is free from
flaws or dirt.
4] There is a worn part or an uneven seat

contact mark on seating face (e) at the
top end of the inlet connector.
1) Install O-ring (106) and gasket (107) to a If high-pressure fuel leaks through the
injector (105). inlet connector, the seal face has fine
streaks or cracks.
a Replace the O-ring and gasket with new
ones.
2) Apply engine oil to O-ring (106) of injector
(105) and the cylinder head side surface.
2 O-ring (106) of injector (105) and
the head side:
3) Engage the male and female parts at (A) to
install holder (95) to injector (105).
7) Apply engine oil to O-ring (part C) of inlet

connector (93) and the cylinder head (part
B).
2 Inlet connector O-ring and cylinder
head:
8) Insert inlet connector (93) in the mounting
hole for injector (96) and lightly tighten
retainer (92).
PC210LC-10 50-41
a After tightening lightly, tighten to the

specified torque. Tighten to the specified
torque for each cases. Insufficient or
excessive torque may cause the fuel
leakage into the engine.
a The positioning balls (part D) on the inlet
connector must be at the guide groove in
the cylinder head when installed.
3 Retaining nut (92) (tightening
lightly):
15 ± 5 Nm {1.53 ± 0.51 kgm}
5. Rocker arm and crosshead assembly
1) Install rocker arm assembly (88), crosshead
(89), and the rocker arm support.
a When reusing the crosshead, install the
same intake and exhaust valves in the
same direction because the shapes of its
holes (a) and (b) are different.
9) Tighten mounting bolts (94) of holder (95)

alternately.
3 Holder mounting bolt:
8 ± 0.8 Nm {0.82 ± 0.08 kgm}
10)Tighten retaining nut (92) of inlet connector
(93).
3 Retaining nut (92) (tightening to
the specified torque):
a Check that the spherical portion of
50 ± 5 Nm {5.1 ± 0.5 kgm} adjustment screw (91) is set in the push
rod socket securely and then tighten
36 ± 5 Nm {3.7 ± 0.5 kgm}
2) Adjust the valve clearance.
a See Testing and adjusting,“Measuring
and adjusting valve clearance“ .
a Adjust the valve clearance at each
cylinder by using tool A3 to turn the
crankshaft.
3) After valve clearance adjustment, ensure
that lock nut (90) is tightened to the specified
torque.
3 Lock nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install wiring harness mounting nuts (86) to
injector assembly (96).
a Check that the wiring harness does not
interfere with the rocker arm.
50-42 PC210LC-10
a Installed positions of wiring harnesses 2) Install blowby duct (83).

Wiring harness Cylinder No. 3 Mounting bolt:
color
7 ± 2 Nm {0.7 ± 0.2 kgm}
White 1, 3, 5
3) Install spill tube (82).
Black 2, 4, 6
3 Joint bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Mounting nut:
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a If injector wiring harness connector (97) is
removed, apply liquid gasket to O-ring
(108) and flange (109) of the connector.
Apply a bead of liquid gasket, f3 mm in
diameter to the O-ring so that the ring
groove is completely covered.
If the O-ring is damaged, replace it and
the wiring harness assembly as a unit.
2 O-ring and flange face of
connector:
7. High-pressure pipe
3 Connector flange mounting bolt k Do not use high-pressure pipes with
(110): bending modification.
10 ± 2 Nm {1 ± 0.2 kgm}
k Be sure to use the genuine high-pressure
pipe fixing clamp and observe the
tightening torque.
k Install each high-pressure pipe and wiring

harness at least 10 mm apart from each
other.
a A high-pressure pipe may cause fuel leakage
if visible lengthwise slits (b) or spots (c) are
found at the joint's taper seal at part (a)
(within 2 mm from the end), or the stepped
wear at part (d) (2 mm from the end of taper
seal) is as severe as it can be felt with a
fingernail. If there is any of those defects,
replace the high-pressure pipe.
6. Head cover
1) Install the gasket and then install head cover
(85) with mounting nuts (84).
1) Tighten common rail (125) and high pressure
3 Mounting nut: pipes (34) to (39) lightly.
24 ± 4 Nm {2.45 ± 0.41 kgm}
PC210LC-10 50-43
3 Mounting bolt and sleeve nut

(tightening lightly):
0.2 to 0.8 Nm {0.02 to 0.08 kgm}
2) Tighten high-pressure pipes (34) to (39) to
the specified torque according to the
Pipe (35) connector end, Pipe (36)
Pipe (38) connector end, Pipe (39) 8. EGR cooler and exhaust manifold
connector end, Pipe (37) common rail 1) Install bracket (81).
Pipe (39) common rail end 3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Sleeve nut:
2) Lightly tighten EGR cooler (75) to bracket
35 ± 3.5 Nm {3.57 ± 0.36 kgm} (81).
3) Lightly tighten the sleeve nuts of high-
pressure pipes (40) and tube clamp. a After lightly tightening the exhaust
4) Tighten high-pressure pipe (40) in the order manifold, tighten the EGR cooler to the
of its supply pump end and its common rail specified torque.
end. 3) Install tube (79) at the lower side of the EGR
cooler.
3 Sleeve nut:
3 Mounting bolt:
35 ± 3.5 Nm {3.57 ± 0.36 kgm}
5) Tighten common rail (125) with 4 bolts. 9.5 ± 2 Nm {0.97 ± 0.2 kgm}
a Apply liquid gasket to the thread portion 3 Hose clamp:

of two bolts (P) inside engine. 5 ± 1 Nm {0.5 ± 0.1 kgm}
2 Thread portion of bolt (P):
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
6) Tighten the tube clamp to the specified
torque.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
7) Install fuel spray prevention cap (41).
k When installing the fuel spray prevention

caps, direct their slits outward and 4) Install a new gasket and lightly tighten
downward. exhaust manifold (76) to the cylinder head
and EGR cooler (75) using mounting bolts
(74) and (78).
a By loosening and tightening the mounting
bolts, adjust so that there is no phase
shift or play in the cylinder head, exhaust
manifold, and EGR cooler.
5) Tighten the exhaust manifold mounting bolts
(78) in order specified in the figure.
3 Mounting bolt:
50-44 PC210LC-10
1] Tighten the bolts to 53 ± 5 Nm {5.4 ± 0.5 3 Tube mounting bolt:

kgm} in the order of [1] to [12] shown in 9.5 ± 2 Nm {0.96 ± 0.2 kgm}
the figure. 11)Install tube clamp (71).
2] Retighten bolts [1] to [4] only shown in the
figure to 53 ± 5 Nm {5.4 ± 0.5 kgm}. 3 Mounting nut:
6) Tighten mounting bolt (74) to the specified 9.5 ± 2 Nm {0.96 ± 0.2 kgm}
torque.
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
7) Tighten EGR cooler (75) to the bracket to the
specified torque.
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
8) Install tube (77).
3 Joint bolt:
12 ± 2 Nm {1.2 ± 0.2 kgm}
3 Sleeve nut: 9. Alternator
15 ± 1 Nm {1.5 ± 0.1 kgm} 1) Install exhaust manifold pressure sensor
9) Install tube (73). connector (EXHAUST PRESSURE) (70).
3 Sleeve nut (sensor bracket side): 2) Install alternator (66).
24.5 ± 9.8 Nm {2.5 ± 1.0 kgm} 3 Mounting bolt (to bracket):
3 Sleeve nut (exhaust manifold 43 ± 6 Nm {4.4 ± 0.6 kgm}
side): 3 Mounting bolt (to plate):
18 ± 3 Nm {1.8 ± 0.3 kgm} 24 ± 4 Nm {2.45 ± 0.41 kgm}
3) Install terminal B (67) and connector E12
(68) to alternator (66).
3 Terminal B (67):
5.9 to 9.8 Nm {0.6 to 1.0 kgm}
4) Install wiring harness clamp (69).
10)Install tube (55).

3 Hose clamp (72):
5 ± 1 Nm {0.5 ± 0.1 kgm}
PC210LC-10 50-45
5) Install fan belt (64). 6) Install air conditioner compressor belt (111).
a Insert a wrench to the portion (A) (width a See Testing and adjusting, “Checking and
across flats T 12.7 mm) of the tensioner adjusting air conditioner compressor belt
assembly (65), and rotate it to the tension“.
counter-direction (R) to the winding-up
direction to decrease fan belt (64) tension,
then install.

applying turning force to the wrench.
(The spring of tensioner assembly (65)
is strong. If the wrench is loosely
inserted, the wrench can accidentally
come off and this is extremely
dangerous.)
k After installation of fan belt (64), 10.KVGT

restore tensioner assembly (65) slowly 1) Fit gasket and install tube (62) on the EGR
with care. cooler side.
k Be careful not to get your fingers 3 Mounting bolt:
caught between the pulley and fan belt 24 ± 4 Nm {2.45 ± 0.41 kgm}
(64) during work. 2) Install the tube clamp of tube (62) to the
bracket.
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
3) Install heat insulation plate (61).
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
4) Install bracket (60).
50-46 PC210LC-10
3 Sleeve nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}
5) Fit a new gasket and install KVGT (59).
4 KVGT:
25 kg
3 Mounting nut:
43 ± 6 Nm {4.4 ± 0.6 kgm}
6) Fit a new gasket and install KVGT return
tube (58).
3 Hose clamp:
5 ± 1 Nm {0.5 ± 0.1 kgm}
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
10)Install tube (52).

3 V-clamp:
7 ± 1.1 Nm {0.7 ± 0.11 kgm}
• MIKALOR clamps
a Use a new clamp.
1] Set the hose to the original (marked)
position.
a Reference
Air hose fitting length: 50 mm
(aftercooler end)
7) Install tube (57).
a The KVGT side is jointly fastened. Be (KVGT end)
careful that there is only a narrow work 2] Set the bridge (BR) under the clamp
space available. bolt and lap it over band (BD) by at
3 Sleeve nut: least 5 mm (b).
24 ± 4 Nm {2.45 ± 0.41 kgm}
8) Install tube (56). 2 Clamp bolt thread portion
(BC): Lubricant
a The KVGT side is jointly fastened.
(THREEBOND PANDO 18B)
3 Sleeve nut:
a Impact wrench is not allowed to
24 ± 4 Nm {2.45 ± 0.41 kgm} use.
9) Install tube (55) to the KVGT. • If hoses are to be reused
a The KVGT side is jointly fastened. Install the clamp to the clamp mark put on
the hose.
a Install banjo connector (80) that is jointly
fastened with tube (55) at an angle of 15
± 5 deg.
PC210LC-10 50-47
3 Clamp bolt: a V-clamp can be reused, however, replace

Min. 6 Nm {0.6 kgm} it with a new one in the following
• When using a new hose conditions.
Tighten the clamp so that BDG dimension • Deformation of V-clamp
is as follows. • Damage on T-bolt thread portion
BDG: 7 to 10 mm • Crack at V groove
• Peeling at V groove
11)Install hose (53).

3 Hose clamp: • Width across flats of V-clamp fastening
10.0 to 11.0 Nm {1.02 to 1.12 kgm} nut: 7/16 in (11.1 mm)
3 V-clamp fastening nut:
3 Hose clamp: 13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
a V-clamp mounting angle: 15°
3 Hose clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
15)Install tube (48) with V-clamp by using tool

A12 (long socket).
11.Mounting of base brackets:

1) Sling and install base bracket (42).
4 Base bracket:
25 kg
50-48 PC210LC-10
2) Install hose clamp (44), wiring harness clamp 3 Mounting nut for intake air heater
(45), and tube clamp (46) to base bracket connector:
(42). 3.4 to 4.6 Nm {0.34 to 0.47 kgm}
3) Lightly tighten tube support bracket (43). 4) Install wiring harness connector and harness
clamp (27).
side face):
24 ± 4 Nm {2.45 ± 0.41 kgm}
top):
43 ± 6 Nm {4.4 ± 0.6 kgm}
5) Install air hose (26).
12.Install KDPF assembly (116), referring to

"Removal and installation of KDPF assembly".
• MIKALOR clamps
a Use a new clamp.
1] Set the hose to the original (marked)
position.
13.EGR valve a Reference
1) Install gasket (64). Air hose fitting length: 80 mm (both
a Note the orientation of the part number upper and lower sides)
tag when installing the gasket. 2] Set the bridge (BR) under the clamp
bolt and lap it over band (BD) by at
least 5 mm (b).
4 Clamp bolt thread portion

(BC): Lubricant
(THREEBOND PANDO 18B)
a Impact wrench is not allowed to
use.
• If hoses are to be reused
Install the clamp to the clamp mark put on
the hose.
2) Install intake assembly (29). 3 Clamp bolt:

Min. 6 Nm {0.6 kgm}
3 Mounting bolt of intake assembly:
• When using a new hose
24 ± 4 Nm {2.45 ± 0.41 kgm} Tighten the clamp so that BDG dimension
3) Install intake air heater connector E01 (28) is as follows.
and the wiring harness clamp. BDG: 7 to 10 mm
PC210LC-10 50-49
6) Fit gasket and install EGR valve (25). [*2]

3 Mounting bolt for EGR valve: 3 Hose clamp:
43 ± 6 Nm {4.4 ± 0.6 kgm} 10.5 ± 0.5 Nm {1.1 ± 0.05 kgm}
7) Install tubes (22) and (23). [*3]
3 Sleeve nut: a Use an open-head type torque wrench when
25 ± 1.5 Nm {2.55 ± 0.15 kgm} installing EGR piping flange (11). It is difficult to
8) Install bracket (24) to EGR valve (25) using tighten by using a common type torque wrench.
four mounting bolts.
• Upper (EGR valve side)
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 Mounting bolt:
43 ± 6 Nm {4.4 ± 0.6 kgm}
• Middle and lower (engine side)
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
9) Install dipstick pipe (21).
3 Mounting bolt:
24 ± 4 Nm {2.45 ± 0.41 kgm}
[*4]
3 Sleeve nut:
25 ± 1.5 Nm {2.6 ± 0.15 kgm}
• Hose (16): KVGT actuator drive pressure circuit
3 Sleeve nut:
15 ± 1 Nm {1.5 ± 0.1 kgm}
Perform the following installation in the reverse

order to removal.
[*1]
When installing cover (117), insert the cover in clips
(120) (four places) shown in the figure and tighten
the mounting bolts.
• As seen from the engine.
50-50 PC210LC-10
a For the testing procedure, see Testing

and adjusting,“Checking fuel circuit for
leakage“.
2. If necessary, replace pressure limiter valve(113)
1) Before removing the pressure limiter, remove
mud, etc. from around it thoroughly and
clean it.
2) Remove the pressure limiter valve.
a If the leakage through the pressure limiter
exceeds the specified value, do not reuse
that pressure limiter valve.
[*5] 3) Check that there is no damage on high-
pressure sealing surfaces (A) on the
3 Mounting bolt:
pressure limiter valve and common rail.
34 ± 5 Nm {3.5 ± 0.5 kgm} 4) Install a new pressure limiter valve.
[*6]
2 Pressure limiter valve:
Radiator hose fitting length: 50 mm
Gear oil (#90)
3 Hose clamp:
3 Pressure limiter valve:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
100 ± 4 Nm {10.2 ± 0.4 kgm}
[*7]
a Excessive tightening can cause leakage.
a Handling of common rail pressure sensor and Take care not to tighten too strongly.
pressure limiter valve. 5) Start the engine and check that fuel does not
1. If necessary, replace common rail pressure leak.
sensor (112) according to the following
a For the testing procedure, see Testing
procedure.
and adjusting,“Checking fuel circuit for
a Do not remove common rail pressure sensor leakage“.
(112) from common rail (111) for a purpose
other than replacement.
a Be sure to replace the sensor removed from
the common rail with a new sensor.
1) Before removing the sensor, clean the area
around it to remove dirt, etc. thoroughly.
2) Remove the common rail pressure sensor.
3) Check the common rail pressure sensor
connector for crack, breakage, damage of
the seal, foreign matter on the pin and
corrosion, bend and breakage of the pin.
4) Install a new common rail pressure sensor.
2 Thread portion of common rail
pressure sensor:
Gear oil (#90)
3 Thread portion of common rail
pressure sensor:
70 ± 5 Nm {7.1 ± 0.5 kgm}
5) Connect the engine harness. At this time,
take care not to connect the connector in
reverse.
6) Start the engine and check that fuel does not
leak.
• Refilling of coolant
PC210LC-10 50-51
Supply coolant through the coolant filler to the

coolant level again.
5 Coolant(Engine coolant):
30.7 l (For details,see “Table of fuel,
coolant and lubricants“.)
50-52 PC210LC-10
Removal and installation of radiator assembly (PC220-B220-924-K-00-A)

Removal (PC200_10-B220-520-K-00-A)
10.Open hose clamps (14) and pull reservoir tank

hose (7) out of cover (15).
11.Remove cover (15).
2. Remove four cover mounting bolts (4), then

remove cover (5).
12.Remove five mounting bolts (16), then remove

bracket (17).
13.Remove two wing nuts (18) and remove net
(19).

6 Coolant:
30.7 l
4. Disconnect radiator hose (3). [*1]
a In order to indicate the original position of the
hose, put a mark of the hose-end on the
radiator.
5. Open engine hood (6) and disconnect reservoir
tank hose (7). 14.Lift and remove radiator assembly (20). [*3]
6. Disconnect hose clamp (8). a Carefully lift the radiator assembly so that its
7. Disconnect radiator hose (10) and aeration hose lower part is not caught.
(11). [*2]
8. Remove cover (12). 4 Radiator assembly:
23 kg
PC210LC-10 50-53
5 Coolant(Engine coolant):
Installation (PC200_10-B220-720-K-00-A)
Perform installation in the reverse order to removal.

[*1][*2]
a Reference
Radiator hose fitting length: 45 mm (both upper
and lower sides)
3 Radiator hose clamp:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
[*3]
a Make sure that the insulation seal (sponge) at
the radiator periphery is not damaged.
a If the heat insulation seal (sponge) is damaged,
replace it.
a When installing the radiator assembly, carefully
lower it to avoid the insulation seal (sponge) at
the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the radiator properly fits with the concaved
parts (B) of the machine from the undercover
side.
Supply coolant through the coolant filler to the
50-54 PC210LC-10
Removal and installation of hydraulic oil cooler assembly (PC220-B8P0-924-K-00-A)
a Special tools a If tools R1 and R2 are used, remove the

hydraulic tank strainer and stop oil with tools
Necessity
Symbol
R1 and R2.
Q'ty
Part No. Part Name
1 796-460-1210 Oil stopper q 1

R
2 796-770-1320 Adapter q 1
k Park the machine on a level ground, lower

the work equipment to the ground stably, and
stop the engine.
k Set the lock lever in the LOCK position.
k Release the remaining pressure in the

hydraulic circuit. For details, see Testing and
adjusting, "Releasing remaining pressure 3. Open the left side cover and remove battery
from hydraulic circuit". cover (3).

Removal (PC200_10-B8P0-520-K-00-A)
1. Remove undercovers (1) and (23).
4. Remove batteries (4). [*1]

a Disconnect the cable from the negative (-)
terminal of the battery.
2. Remove drain plug (2) to drain oil from the

hydraulic tank.
6 Hydraulic tank:
132 l
5. Disconnect wiring harness clamp (5).

6. Remove plug (7) from outlet tube (6) of the
hydraulic oil cooler to drain the remaining oil.
a After draining the oil, close plug (7).
7. Remove U-bolt (8).
8. Disconnect hydraulic oil cooler outlet tube (6).
PC210LC-10 50-55
9. Open engine hood (9) and disconnect reservoir 17.Disconnect inlet tube (21) of the hydraulic oil
tank hose (10). cooler and move it aside so that it does not
10.Remove covers (11) and (12). interfere with the hydraulic oil cooler.
11.Remove brackets (13) and (14).
18.Sling and remove hydraulic oil cooler assembly

12.Open hose clamps (15) and pull reservoir tank (22) by using eyebolts (M10) [1]. [*2]
hose (10) out of cover (16).
a Carefully lift the hydraulic oil cooler assembly
so that its lower part is not caught.
14.Remove two hydraulic oil cooler mounting bolts
(17).
4 Hydraulic oil cooler assembly:
15.Remove two wing nuts (18) and remove net
(19). 19 kg
16.Remove U-bolt (20). Installation (PC200_10-B8P0-720-K-00-A)

[*1]
a When installing the battery, tighten the double
nuts to the following torque.
50-56 PC210LC-10
3 First battery mounting nut:

1.47 to 1.96 Nm {0.15 to 0.2 kgm}
3 Battery mounting ock nut:
11.8 to 19.6 Nm {1.2 to 2.0 kgm}
[*2]
a Check that the heat insulation seal (sponge) on
the hydraulic oil cooler periphery is not
damaged.
a If the heat insulation seal (sponge) is damaged,
replace it.
a When installing the hydraulic oil cooler assembly,
carefully lower it to avoid the heat insulation seal
(sponge) on the periphery from being damaged.
a Check that the convexed parts (A) at the bottom
of the hydraulic oil cooler properly fits with the
concaved parts (B) of the machine from the
bottom side.
• Refilling of oil
a Before supplying oil, check that the oil cooler
drain plug is securely tightened.
a Supply hydraulic oil through the oil filler port to
the specified level. Run the engine to circulate
the oil through the piping. Then, check the oil
level again.
5 Hydraulic tank:
132 l
PC210LC-10 50-57
Removal and installation of aftercooler assembly (PC220-A9A0-924-K-00-A)
Removal (PC200_10-A9A0-520-K-00-A)
4 Aftercooler assembly:
1. Open engine hood (1) and remove cover (2). 10 kg
2. Sling aftercooler assembly (3) and remove

mounting bolts (4). Installation (PC220-A9A0-720-K-00-A)
3. Disconnect hoses (5) and (6) from aftercooler Perform installation in the reverse order to removal.
assembly (3). [*1] [*1]
a MIKALOR clamps 1. Reconnect the disconnected air tubes according
a Put a mark of the hose end on the tube so
that the original position of the hose can be a Use new MIKALOR clamps.
indicated. 1) Set the hose to the original (marked)
a Air hose fitting length: position.
45 mm (both R.H. and L.H. sides) a Reference
Air hose fitting length:
45 mm (both R.H. and L.H. sides)
2) With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over
with the band by dimension (b) indicated
below.
Dimension (b): Min. 5 mm
Lubricant (THREEBOND PANDO
18B)
Install the clamp to the clamp mark put on the
hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
Tighten the clamp so that BDG dimension is as
follows.
BDG: 7 to 10 mm
4. Sling and remove aftercooler assembly (3).
50-58 PC210LC-10
PC210LC-10 50-59
Removal and installation of engine and main pump assembly (PC220-R400-924-K-

00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
9 796T-401-1110 Plate q 1
10 795-799-9300 Lifting tool q 1
A
Commercially Long socket (7/16
12 in) q 1
available
1 796-460-1210 Oil stopper q 1
R
2 796-770-1320 Adapter q 1
k Park the machine on a level ground, lower 3. Drain the coolant through drain valve. (Drain
the work equipment to the ground stably, and hose: inside diameter f7 mm)
stop the engine.
6 Coolant:
30.7 l
k Release the remaining pressure in the 4. Open the R.H. side cover of the machine and
hydraulic circuit. For details, see Testing and remove rubber-lined cover (4).
adjusting, referring to "Releasing remaining
pressure from hydraulic circuit".

a Attach tags to the hoses to indicate their

installed positions to prevent any mistake when
installing.
Removal (PC200_10-R400-520-K-00-A)
1. Remove undercovers (1), (2), and (3).

5. Remove engine hood assembly. For details, see
"Removal and installation of engine hood
assembly".
6. Remove step (5) and covers (6), (7) and (8).
2. Remove the strainer of the hydraulic tank and

stop oil from flowing by using tools R1 and R2.
a If you do not use tools R1 and R2, remove
the drain plug to drain oil from the hydraulic
tank and piping.
6 Hydraulic tank:
132 l
50-60 PC210LC-10
4 Frame:
11 kg
7. Remove mounting bolts (10) for cover (9).

9. Remove eight mounting bolts (13a) of frame
(13). 11.Lift up and remove covers (9) and (11). [*1]
a Each of covers (9) and (11) can be removed
as it is, without separating it into the upper
and lower halves.
12.Remove KCCV ventilator assembly and bracket.

For details, see "Removal and installation of
KCCV assembly".
13.Remove the KDPF assembly. For details, see
"Removal and installation of KDPF assembly".
14.Removal of base brackets
1) Remove tube support bracket (14).
2) Remove tube (15). [*2]
3) Disconnect hose clamp (17), wiring harness
clamp (18), and tube clamp (19) from base
bracket (16).
4) Remove eight mounting bolts (20), then sling
and remove base bracket (16).
4 Base bracket:
25 kg
10.Remove frame (13).
PC210LC-10 50-61
24.Disconnect hoses (42) and (43).

25.Disconnect hose clamp (44).

16.Disconnect connectors V19 (22) and V11 (23).
17.Disconnect connectors V12 (24) and P22 (25).
26.Remove four mounting bolts (47) and
disconnect pump suction port tube (48).

19.Disconnect six hoses.
• (27): Case drain port hose
• (28), (29): EPC source pressure input port
• (30): Pump pressure input port
• (31): Rear load pressure input port
• (32): Front load pressure input port
20.Disconnect harness clamps (33), (34), (35), and
(36).
21.Disconnect swash plate sensor P28 (37) of the
rear pump and swash plate sensor P27 (38) of
the front pump.
22.Remove KDPF water drain tube (39).
28.Remove radiator hose (52).
23.Disconnect discharge port hose (40) of the rear

pump and discharge port hose (41) of the front
pump.
50-62 PC210LC-10
29.Disconnect hoes and tubes of KVGT. [*3]

1) Disconnect hose (53).
3) Disconnect clamp (55).
4) Disconnect tube (56).
34.Remove air conditioner compressor (67) and air

conditioner compressor belt (68). For details,
see "Removal and installation of air conditioner
compressor assembly".
30.Disconnect fuel filter hoses (59) from supply

pump. [*4]
a Pull out hose to the direction of (a) while
pressing lock (L) on both sides.
31.Disconnect fuel return hose (60). [*5]
32.Disconnect fuel supply hose (61). [*6]
35.Remove bracket (69).
36.Remove bracket (70) for the air conditioner

compressor.
33.Disconnect intake air heater E01 (62) and wiring

harness clamp (63). [*7]
PC210LC-10 50-63
37.Remove fan belt (64). [*8]

a Install a wrench to portion A (width across
flats: 12.7 mm) of the tensioner assembly
(65), and rotate it in the direction opposite to
fan belt (64) tension, then remove it.
k Make sure before turning the wrench that

it is positively inserted into portion A of
tensioner assembly (65). (Since the spring
force of tensioner assembly (65) is strong,
the wrench might come off and induce
personal injury if it is turned when not 39.Disconnect terminal B (72) and connector E12
securely attached.) (73) from alternator (66). [*10]
k After removing fan belt (64), return 41.Remove alternator (66). [*11]
tensioner assembly (65) to its original
position slowly and carefully.

during work.
42.Disconnect hose (75). [*12]

a Note that the hose mounting clips are hard to
remove or install.
38.Disconnect fan (71). [*9]
50-64 PC210LC-10
44.Disconnect engine ground strap (77) and engine

controller ground strap (78) .
46.Disconnect connector CE03 (83) from the

engine controller.
45.Disconnect connector E24 (79) from the engine a The connectors are locked with hexagonal
controller as follows. socket head bolts (84) (4 mm).
1) Roll up rubber cover (80) and slide red lever
(81) downward to unlock.
47.Disconnect terminal B (85), terminal C (86), and

harness connector (103) from the starting motor.
2) Grab and pull out connector (79) while [*13]
pressing locking tab (82).
a Locking tab (82) is provided on the farther
side of connector.
PC210LC-10 50-65
48.Disconnect connector E10 (87). 53.Sling and remove the engine and main pump
49.Disconnect connectors E08 (88) and P44 (89). assembly (94).
50.Disconnect clamp (90).
a Attach the sling to two points on the engine
and to one point on the main pump when
removing the assembly.
a Before removing the assembly, check that all
wiring and piping are disconnected.
4 Engine and main pump assembly:

840 kg

52.Remove four engine mounting bolts (92). [*14]
a Nuts except for those at the alternator
mounting side are not welded. When
removing engine mounting bolts (92), hold
tool A9 with bolt (B) to prevent nuts (93) from
rotating.
54.Remove main pump assembly (95) from the

removed engine and main pump assembly
according to the following procedure. [*15]
1) Remove drain plug (104) and drain the
damper oil.
6 Damper case:
0.65 l
50-66 PC210LC-10
2) Remove fuel filter bracket (96) and a V-clamp can be reused, however, replace it with
disconnect fuel filter (97) a new one in the following conditions.
3) Set slings to main pump assembly (95), • Deformation of V-clamp
remove housing mounting bolts (98), and • Damage on T-bolt thread portion
then remove main pump assembly (95). • Crack at V groove
4 Main pump:
190 kg
• Width across flats of V-clamp fastening nut: 7/16

in (11.1 mm)
Installation (PC200_10-R400-720-K-00-A)
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
[*1]
When installing covers (9) and (11), insert the a V-clamp mounting angle: 15°
covers in clips (102) (four places) shown in the
figure and tighten the mounting bolts.
[*3]
Install the hoses and tubes to the KVGT according
to the following procedures.
[*2] 1. Install tube (56).
Install tube (15) with V-clamp by using tool A12 3 V-clamp:
(long socket).
7 ± 1.1 Nm {0.7 ± 0.11 kgm}
• MIKALOR clamps
a Use a new clamp.
1) Set the hose to the original position
(marked position).
a Reference
(aftercooler end)
Air hose fitting length: 40 mm (KVGT
end)
PC210LC-10 50-67
2) Set the bridge (BR) under the clamp bolt When installing a connector of quick coupler type,
and lap it over band (BD) by at least 5 observe the following points.
mm (b).
a The internal parts of the fitting may be damaged
when the hose or tube is removed. Accordingly,
2 Clamp bolt thread portion (BC): do not reuse the hose or tube.
Lubricant (THREEBOND When installing, replace it with a new one.
PANDO 18B)
a Ensure that mud or dirt is not sticking to the hose
a Impact wrench is not allowed to use. joint portions in advance.
Install the clamp to the clamp mark put on a Push the connector straight (in the direction of
the hose. (b)). Do not pry it in or shake it.
If it is difficult to insert the connector, do not push
3 Clamp bolt:
it in forcibly but pull it out. Then, check the male
Min. 6 Nm {0.6 kgm} and female couplings for damage and sticking
• When using a new hose mud.
Tighten the clamp so that BDG dimension is
as follows.
BDG: 7 to 10 mm
[*5]
3 Fuel return hose mounting bolt:
2. Install hose (57). 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
3 Hose clamp: [*6]
10.0 to 11.0 Nm {1.02 to 1.12 kgm} 3 Fuel supply hose mounting bolt:
3. Install hose (58).
25.4 to 34.3 Nm {2.6 to 3.5 kgm}
3 Hose clamp: [*7]
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
3 Mounting nut for intake air heater
connector:
3 Hose clamp: 3.4 to 4.6 Nm {0.34 to 0.47 kgm}
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm} [*8]
Install fan belt (64).
a Insert a wrench to the portion (A) (width across
flats: 12.7 mm) of the tensioner assembly (65),
and rotate it to the counter-direction (R) to the
winding-up direction to decrease fan belt (64)
tension, then install.
k Firmly set the wrench on tensioner assembly
(65) at portion (A) before applying turning
force to the wrench. (The spring of tensioner
assembly (65) is strong. If the wrench is
loosely inserted, the wrench can accidentally
come off and this is extremely dangerous.)
[*4]
50-68 PC210LC-10
k After installation of fan belt (64), restore 1. Install alternator (66).

tensioner assembly (65) slowly with care.
3 Mounting bolt (to bracket):
k Be careful not to get your fingers caught 43 ± 6 Nm {4.4 ± 0.6 kgm}
between the pulley and fan belt (64) during 3 Mounting bolt (to plate):
work.
24 ± 4 Nm {2.4 ± 0.4 kgm}
2. Install terminal B (72) and connector E12 (73) to
alternator (66).
3 Terminal B (72):
5.9 to 9.8 Nm {0.6 to 1.0 kgm}
3. Install wiring harness clamp (74).
[*9]
After fan (71) is installed, check the clearance (d)
between the fan blade tips and shroud (100). If the
clearance is out of the standard value range, loosen
six mounting bolts (101) and adjust the position of
the shroud.
• Blade tip clearance (at top/bottom/left/right of [*12]
shroud) 1. Install hose (76).
d: Min. 13 mm
a Note that the hose mounting clips are hard to
remove and install.
3 Hose clamp:
10.8 to 11.8 Nm {1.1 to 1.2 kgm}
[*10][*11]
Install alternator (66) according to the following
procedure.
PC210LC-10 50-69
a Nuts except for those at the alternator mounting

side are not welded. Therefore, fix nut (93) by
using tool A9 and bolt (B) to restrict nut (93) from
turning, then install engine mounting bolt (92).
[*13]
Install terminal B (85) and terminal C (86) to the
starting motor.
3 Terminal B (85):
[*15]
17.7 to 24.5 Nm {1.8 to 2.5 kgm}
2 Main pump involute splines:
3 Terminal C (86):
Molybdenum disulfide grease (LM-G)
2.6 to 4.6 Nm {0.27 to 0.47 kgm}
2 Mating face on main pump case:
a Take care not to torque the bolts excessively
since the flywheel housing is made of aluminum.
a Reference
3 Engine mounting bracket bolts (four
places) (99):
122.5 to 147 Nm {12.5 to 15 kgm}
[*14]
a The bolt length to be used on the engine front
side is shorter than that on the rear side.
a The size of the engine mounting rubber to be
used on the engine front side is smaller than that
on rear side.
a Reference
Overview of the fitting depths of the air hoses
and radiator hoses.
3 Engine mounting bolt (4 places):

245 to 308.9 Nm {25 to 31.5 kgm}
50-70 PC210LC-10
• Filling of oil (damper case)

Supply oil through the oil filler port to the
specified level.
5 Damper case:
0.65 l
3 Damper case drain plug:
45 ± 5 Nm {4.6 ± 0.5 kgm}
• Refilling of oil (hydraulic tank)
Supply hydraulic oil through the oil filler port to
level again.
5 Hydraulic tank:
132 l
3 Hydraulic tank drain plug:
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
Supply coolant through the coolant filler port to
the coolant through the system. Then, check the
5 Coolant (Engine coolant) :

• Bleeding air
See Testing and adjusting, " Bleeding air from
hydraulic circuit".
PC210LC-10 50-71
Removal and installation of engine front oil seal (PC220-A350-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
5 790-331-1120 Wrench (Angle) q 1

A
7 795-799-6400 Seal puller t 1
Removal (PC200_10-A350-520-K-00-A)
1. Remove the radiator assembly, referring to

"Removal and installation of radiator assembly".
2. Remove the hydraulic oil cooler assembly,
referring to "Removal and installation of 8. Remove fan guards (9), (10), and (11).
hydraulic oil cooler assembly".
3. Remove the aftercooler assembly, referring to
"Removal and installation of aftercooler
assembly".
4. Remove mounting bolts, open air conditioner
condenser (1), and move it aside.
a Hold air conditioner condenser (1) using
something like a piece of string to prevent it
from closing.
9. Remove fan (12). [*1]
5. Remove mounting bolt (3) of stay (2).
10.Remove air conditioner compressor belt (17)

3) Turn jack bolt (15) and move air conditioner
loosening belt tension.
4) Loosen the tension on air conditioner
6. Remove mounting bracket (6) of the aftercooler
assembly.
7. Remove mounting bolt (7), then remove stay (2).
50-72 PC210LC-10
13.Remove dust seal (12a).

11.Remove fan belt (18). [*3]
a Insert a wrench to the portion (A) (width
across flats: 12.7 mm) of the tensioner
assembly (19), and rotate it to the opposite to
fan belt (18) tension, then remove the fan
belt.

applying turning force to the wrench. (The
spring of tensioner assembly (19) is
strong. If the wrench is loosely inserted,
the wrench can accidentally come off and
14.Remove engine front oil seal (21) as follows.
this is extremely dangerous.)
1) Install tool A5 to the crankshaft.
k After removing fan belt (18), slowly and 2) Screw in tapping screw [1] of tool A7 to the
carefully restore tensioner assembly (19). seal carrier section of engine front oil seal
(21).
3) Turn the handle clockwise and remove
engine front oil seal (21).
during work.
12.Remove six mounting bolts and remove
vibration damper (20).
a Take care in the removal so that the

crankshaft is not damaged.
PC210LC-10 50-73
Installation (PC200_10-A350-720-K-00-A) 3. Vibration damper

1. By using tool A7, install engine front oil seal (21). 1) Install vibration damper (20), aligning its
dowel hole with dowel pin (B) on the
a Before installing the seal, check that the end crankshaft.
corners and lip sliding surfaces of the 2) Tightening procedure for vibration damper
crankshaft are free from flaw, burr, and rust. mounting bolts
a When installing the seal, do not apply oil or 3 Vibration damper mounting bolt:
grease to the shaft and seal lip. Also,
thoroughly wipe off oil or grease from the 1] Tighten to 55 ± 5 Nm {5.6 ± 0.5
shaft. kgm} in a diagonal order.
2] Loosen bolts 180 deg.
3] Tighten to 55 ± 5 Nm {5.6 ± 0.5
kgm} in a diagonal order.
4] Retighten 90 ± 5 deg. in a
diagonal order.
a Use tool A5 to angle-tighten.
a Engine front oil seal (21) on cover (c):

• Protrusion (x) : Max. 0.38 mm
• Facial runout (y) : Max. 0.25 mm
• When not using angle tightening tool

Put marks on the vibration damper and
bolts with a felt-tip pen, and then tighten
the bolts an additional 90 deg. ± 5 deg.
2. install dust seal (12a).

a Check the installed dimension (L)
• Installed dimension (L): 12 +0.1/0 mm
50-74 PC210LC-10
k After installation of fan belt (18), restore

tensioner assembly (19) slowly with care.

between the pulley and fan belt (18) during
work.

order to removal.
[*1]
a After fan (12) is installed, check the clearance
between the fan blade tips and shroud (22). If
the clearance is out of the standard value range,
loosen six mounting bolts (23) and adjust the
position of the shroud.
• Blade tip clearance (at top/bottom/left/right of
shroud)
(d) : Min. 13 mm
[*2]
a See Testing and adjusting, “Checking and
adjusting air conditioner compressor belt
tension“.
[*3]
Install fan belt (18).
a Insert a wrench to the portion (A) (width across
flats: 12.7 mm) of the tensioner assembly (19),
and rotate it to the counter-direction (R) to the
winding-up direction to decrease fan belt (18)
tension, then install.
k Firmly set the wrench on tensioner assembly
(19) at portion (A) before applying turning
force to the wrench. (The spring of tensioner
assembly (19) is strong. If the wrench is
loosely inserted, the wrench can accidentally
come off and this is extremely dangerous.)
PC210LC-10 50-75
Removal and installation of engine rear oil seal (PC220-A510-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
A 8 795-799-6500 Seal puller t 1
Removal (PC220-A510-520-K-00-A)
1. Remove the main pump assembly. For details,

see "Removal and installation of main pump
7. Remove engine rear oil seal (5) as follows.
assembly".
2. Remove mounting bolt (1) and install guide bolt 1) Install tool A8 on the crankshaft.
[1]. 2) Screw tapping screw [3] of tool A8 into the
3. Remove damper assembly (2). seal carrier of engine rear oil seal (5).
3) Turn the handle clockwise to remove rear oil
seal (5).
4. Remove mounting bolts (3) and insert guide

bolts [2]. [*1]
a Width across flats of mounting bolt : 18 mm a Take care in the removal so that the
5. Sling flywheel assembly (4) and pull it out. crankshaft is not damaged.
a Be careful not to let the guide bolts drop out.
Installation (PC220-A510-720-K-00-A)
6. Sling and remove flywheel assembly (4). [*2]
4 Flywheel assembly: 1. Install the engine rear oil seal (5) according to
35 kg
a Do not remove pilot [4] which is attached to
engine rear oil seal (5) until engine rear oil
seal (5) is installed to the crankshaft.
50-76 PC210LC-10
a Before installing the engine rear oil seal,

degrease, clean and dry the crankshaft
sealing face and the seal lip face to prevent
oil leakage.

order to removal.
[*1]
a Tighten the eight flywheel assembly mounting
2. Install pilot [4] to crankshaft (6) and push engine bolts in the order shown in the figure.
rear oil seal (5) into flywheel housing (7).
3. Push in engine rear oil seal (5) further and then 3 Flywheel assembly mounting bolt:
pull out pilot [4]. 137 ± 7 Nm {13.97 ± 0.71 kgm}
4. Use tool A8 to install engine rear oil seal (5) to a Use plate [5] to prevent the flywheel assembly
the proper depth in flywheel housing (7). from rotating when tightening the bolts.
a Push in engine rear oil seal (5) with care not
to bend it.
a Extrusion of engine rear oil seal (5) from
flywheel housing (7)
X: Max. 0.38 mm
[*2]
• Measuring radial runout
a Radial runout: Max. 0.13 mm
1. Install dial gauge [6] on the stand, and set
the stand on flywheel housing (7).
PC210LC-10 50-77
2. Make the probe of dial gauge contact with

spigot joint portion (a) or outer circumference
of the flywheel at a right angle.
3. Rotate the flywheel 360 deg. and measure
the maximum swing width of the dial gauge
indicator.
a Check that the dial gauge indicator is
back in the original position after the
flywheel is rotated 360 deg.
• Measuring facial runout
a Facial runout: Max. 0.20 mm
1. Similarly to the measurement of radial runout,
make the probe of dial gauge contact at a
right angle with the end face (b) near the
outer circumference of the flywheel.
a Perform the measurement with the
crankshaft pulled to either the front or
rear side of the engine to prevent errors
caused by backlash.
2. Rotate the flywheel 360 deg. and measure
the maximum swing width of the dial gauge
indicator.
50-78 PC210LC-10
Removal and installation of fuel cooler assembly (PC220-B7W0-924-K-00-A)
a If the fuel is too much, drain the fuel in order to

stop the fuel flow from the fuel tank return hose.
Removal (PC200_10-B7W0-520-K-00-A)
1. Open the left side cover and remove plate (1).
2. Disconnect hose clamps (2).

3. Disconnect two hoses (3). [*1]
a Make sure to hold elbow (L) on the fuel
cooler by using another spanner while
disconnecting the hoses to avoid stressing
the cooler.
a If a spanner is not used, stress will be
applied to the cooler and the welded portions
(M) may come apart.
4. Remove fuel cooler mounting bolts (4).
5. Remove fuel cooler (5).
Installation (PC200_10-B7W0-720-K-00-A)

[*1]
a Make sure to hold elbow (L) on the fuel cooler by
using another spanner while connecting the
hoses to avoid stressing the cooler.
a If a spanner is not used, stress will be applied to
the cooler and the welded portions (M) may
come apart.
PC210LC-10 50-79
Removal and installation of fuel tank assembly (PC220-AD10-924-K-00-A)
k Park the machine on a level ground, swing

the upper structure by 90 deg., lower the
work equipment to the ground stably, and
stop the engine.
k Set the lock lever in the Lock position.

Removal (PC200_10-AD10-520-K-00-A)
1. Remove undercovers (1) and (2). a The lower mounting end of handrail (6) is
fixed to the inside of tool case (7).
2. Open the R.H. side cover of the machine and

open fuel tank drain valve (3) to drain the fuel. 5. Open cover (8) of tool case (7) and remove
rubber cap (9).
6 Fuel tank (when full):
400 l
6. Remove R.H. headlamp cover (10).

7. Disconnect washer hose (11).
3. Remove handrail (4) and plate (5). 8. Disconnect washer motor connector M06 (12).
4. Remove handrail (6). 9. Remove washer tank (13) and bracket together.
50-80 PC210LC-10
10.Remove grease gun (14) and grease gun 15.Remove four mounting bolts (19), then remove
mounting bracket (15). cover (27).
11.Disconnect connector L02 (16) for the R.H. 16.Remove four mounting bolts (28), then remove
headlamp wiring. cover (29).
12.Remove R.H. headlamp cover (17). [*1]
13.Remove four tool case mounting bolts (18).
14.Sling and remove tool case (7).

a Placing block [1] under tool case (7)
facilitates the lifting work.
4 Tool case:
35 kg
17.Disconnect wiring harness clamp (20) and

connector P21 (21) of the fuel level sensor.
PC210LC-10 50-81
• Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, "Bleeding air from fuel
system".
18.Disconnect fuel tank lower hoses (22), (23), and

(24).
19.Remove eight mounting bolts (25). [*2]
20.Sling and remove fuel tank assembly (26).
4 Fuel tank assembly:

180 kg
Installation (PC220-AD10-720-K-00-A)

[*1]
3 R.H. headlamp mounting nut:
17.6 to 19.6 Nm {1.78 to 2.00 kgm}
[*2]
3 Fuel tank mounting bolt:
235 to 285 Nm {23.5 to 29.5 kgm}
50-82 PC210LC-10
Removal and installation of engine hood assembly (PC220-H540-924-K-00-A)
Removal (PC200_10-H540-520-K-00-A)
1. Open engine hood (1) and support it by using a

sling.
5. Remove four mounting bolts (7) and open two

hinges (8) to disconnect them from engine hood
(1). [*1][*2]
2. Remove gas springs (2) and (3).

3. Remove stay (5).
6. Sling and remove engine hood (1).
4 Engine hood:
48 kg
4. Close engine hood (1) and remove hinge covers

(6) from the rear of the engine hood.
Installation (PC200_10-H540-720-K-00-A)

a The engine hood must be kept slung when
closing it. [*1]
Adjustment procedure for installing engine hood
1. Fasten hinges (8) of engine hood (1) with four
mounting bolts (7).
PC210LC-10 50-83
a Lightly tighten the bolts to the degree that the • As seen through hole (B), clearance (b)
engine hood does not move to the right and between bracket (13) and the engine hood
left, and back and forth when it is opened must be large enough to avoid interference.
and closed.
a Keep the engine hood slung after installation
to perform adjustments.
2. Lower engine hood (1) slowly to bring catcher

(9) near to pin (10) on the chassis and check the
engagement.
5. If either of the brackets interfere with the engine

hood, check if brackets (12) and (13) are
installed at their correct positions on frame (11).
X: 872 ± 1 mm
Y: 353 ± 1 mm
3. Adjust fore-and-aft location of engine hood (1),

so that box (14) for spring of catcher (9)
becomes nearly perpendicular.
6. If adjustment is necessary, loosen the four

engine hood mounting bolts and move the
engine hood to adjust.
a Repeat steps 2 to 5 until the engine hood is
4. Look through holes (A) and (B) in the closed
opened and closed smoothly.
engine hood to check the clearance inside the
7. When adjustment is completed, tighten
engine hood.
mounting bolts (7) for hinges (8) to the specified
• As seen through hole (A), clearance (a) torque.
between bracket (12) and the engine hood
must be 1 mm or more.
50-84 PC210LC-10
[*2] 5. Check if locking of catcher (9) is smooth.

Adjustment procedure of catcher a Repeat steps 1 to 4 until locking of catcher
a When installing the engine hood, adjust lock (9) becomes smooth.
portion of catcher (9) according to the following
procedure.
1. Loosen mounting bolts (15) of catcher (9).
2. While pulling the lever of catcher (9) to the level,

hook catcher-hook (16) to the tooth of pin (10) at
frame side.
3. While pulling up catcher (9) to the end with

keeping lever level, put a mark of lower face of
catcher pedestal.
4. Tighten mounting bolts (15) to match with the
mark.
PC210LC-10 50-85
Removal and installation of KDPF assembly (PC220-A9H0-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
1- Commercially Long socket (1/2 in) q 1

1 available
A
2 available

2. Disconnect harness clamps (3), (4), (18) and
(19).
Removal (PC200_10-A9H0-520-K-00-A)
1. Open the engine hood and disconnect

connectors E25 (1) and E26 (2).
3. Remove clamp(33) of the coolant outlet hose.

4. Disconnect wiring harness calmp(34).
a Connector disconnecting procedure

1) Slide the lever (red) of the connector to
unlock.
5. Remove V-clamp (5) by using tool A12 (long

socket) and disconnect tube (6).
a Since this is a datum location for installation,
don't loosen tube (6).
2) While pressing the knob on the upper portion • Width across flats of V-clamp fastening nut:
of the connector, pull out the connector. 7/16 in (11.1 mm)
50-86 PC210LC-10
6. Remove three mounting bolts (20) and one 10.Remove the double nuts and washers, then
mounting bolt (21). remove U-bolts (13).
7. Sling and remove KDPF bracket assembly (8).
a Loosen nuts alternately to prevent U-bolt
a When slinging, hook it to sling plate (29). thread galling.
a Pay attention to the gasket at the tube
connection that may fall away during the
removal.
4 KDPF bracket assembly:

75 kg
11.Sling and remove KDPF assembly (14) from

bracket (25).
a When slinging, hook it to hanger (30).
a Be careful not to deform eye-joint (15) when
lowering the removed KDPF assembly.
8. Disconnect sensor harness clamps (9) and (10)
4 KDPF assembly:
on the thermal guard side.
45 kg
9. Remove four mounting bolts (11) and remove

thermal guard (12).
PC210LC-10 50-87
a After the KDPF assembly is installed to the

machine, insert eye-joint (15) into the KDPF
water drain tube and install.
1) Clean exhaust pipe (17) and the outlet side
flange of KDPF assembly (14) by using parts
cleaner fluid.
2) Install a new gasket between exhaust pipe
(17) and the KDPF flange.
3) Install V-clamp (16), adjust the angle
between exhaust pipe (17) and the T-bolt of
V-clamp to 45 deg. and then fasten the V-
clamp by using tool A12 (long socket).
12.Removal of accessories from KDPF assembly a V-clamp can be reused, however, replace
a When replacing the KDPF filter, exhaust pipe it with a new one in the following
(17), eye-joint (15) and wiring harness clamp conditions.
bracket (22) must be replaced. • Deformation of V-clamp
1) Remove V-clamp (16) for the exhaust pipe by • Damage on T-bolt thread portion
using tool A12 (long socket), then remove • Crack at V groove
exhaust pipe (17) and gasket. • Peeling at V groove
• Width across flats of V-clamp fastening
nut: 7/16 in (11.1 mm)
2) Remove eye-joint (15).

nut: 7/16 in (11.1 mm)
3) Remove wiring harness clamp bracket (22). 3 V-clamp fastening nut:

13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
4) Install wiring harness clamp bracket (22).
Installation (PC200_10-A9H0-720-K-00-A)
1. Installation of accessories to KDPF assembly

a When replacing the KDPF filter, exhaust pipe
(17), eye-joint (15) and wiring harness clamp
bracket (22) must be replaced.
50-88 PC210LC-10
2. Preparatory work for installation of KDPF

3. Position adjustment of the KDPF inlet flange
bracket assembly:
connecting part
1) Sling KDPF assembly (14) to place it on
bracket (25), and lightly tighten U-bolts (13), a Since the adjustment procedure depends on
washers, and the first nut (27) of double-nuts whether the flange surface of tube (6) can be
at 4 places so that the position can be the reference point for positioning, refer to
adjusted. either procedure to perform installation.
• When the flange surface of tube (6) can be
a Use hanger (30) to sling KDPF assembly
the reference point for positioning.
(14).
(When tube (6) is not removed.)
a When nut (27) is chamfered only one side,
a Adjust the position based on tube (6)
install it with its chamfered side
flange surface so that the bellows of tube
downward.
(6) does not get any strain and KDPF
assembly can be installed with same
4 KDPF assembly:
flange position before removal.
45 kg 1) Install a new gasket on flange connecting
part of tube (6).
2) Sling KDPF bracket assembly (8) to install to
base bracket (24) by mating KDPF inlet
flange part and flange surface of tube (6).
a Use sling plate (29) to sling KDPF bracket
assembly (8).
a When installing KDPF bracket assembly
(8), take care not to drop the gasket.

75 kg
2) Move KDPF assembly (14) back or forth or 3) Install KDPF bracket assembly (8) and
rotate it to obtain correct clearance (a) to tighten three mounting bolts (20) and one
bracket (25) and set the exhaust pipe (17) mounting bolt (21).
upright. • Length of bolt (20): 30 mm
• Clearance (a): 10 mm • Length of bolt (21): 50 mm
PC210LC-10 50-89
(When tube (6) is removed.)

a If it is hard to work, you may remove step
(32).
4) Loosen V-clamp (31) of KVGT side of tube

(6) and tube support bracket (23), then adjust
the clearance between the inlet flange part of
KDPF assembly (14) and flange connecting
part of tube (6) where the gasket seats. 1) Loosen V-clamp (20) of KVGT side of tube
(6).
(32). a Adjust the position based on bracket so
that the bellows of tube (6) does not get
a The clearance between flange and the
any strain.
gasket which is in between KDPF
2) Install a new gasket on flange connecting
assembly (14) and tube (6) must be
part of tube (6).
within 5 mm all around the circumference.
3) Sling KDPF bracket assembly (8) to install it
5) While the clearance at flange is being
to base bracket (24).
adjusted, lightly tighten tube support bracket
(23). Install V-clamp (5) with pressing tube a Use sling plate (29) to sling KDPF bracket
(6) and lightly tighten by using tool A12 (long assembly (8).
socket).
a When installing KDPF bracket assembly
(8), take care not to drop the gasket.

75 kg
4) Install KDPF bracket assembly (8) and
tighten three mounting bolts (20) and one
mounting bolt (21).
• Length of bolt (20): 30 mm
• Length of bolt (21): 50 mm
5) Loosen tube support bracket (23), then

adjust the clearance between the inlet flange
part of KDPF assembly (14) and flange
• When the flange surface of tube (6) cannot connecting part of tube (6) and gasket where
be the reference point for positioning. the gasket seats.
50-90 PC210LC-10
a The clearance between flange and the

gasket which is in between KDPF
assembly (14) and tube (6) must be
within 5 mm all around the circumference.
6) While the clearance at flange is being
adjusted, lightly tighten tube support bracket
(23). Install V-clamp (5) with pressing tube
(6) and lightly tighten by using tool A12 (long
socket).
nut: 7/16 in (11.1 mm)
a KDPF side V-clamp (5) mounting angle:

30 deg.
2) Close engine hood (7) to check that the

exhaust pipe (17) stands upright. If the
exhaust pipe does not stand upright, loosen
V-clamp (26) on KDPF assembly (14) by
using tool A11 (long socket) and move the
KDPF outlet part by rotating it for fine
adjustment of exhaust pipe (17).
nut: 1/2 in (12.7 mm)
4. Tightening of each part 3 V-clamp (26) fastening nut:
1) Tighten tube (6) to the specified torque in the 18 to 22 Nm {1.8 to 2.2 kgm}
order of V-clamp (31) of KVGT side and V-
clamp (5) of KDPF side by using tool A12
(long socket).
a Do not fully tighten 2 places of KDPF U-
bolts (13) and tube support bracket (23)
before fastening V-clamp (31) and (5) so
as not to make any strain on the tube.
(32).
nut: 7/16 in (11.1 mm)
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
a KVGT side V-clamp (31) mounting angle:
15 deg.
PC210LC-10 50-91
3) Tighten first nut (27) of the double-nuts on U- a When tightening nuts (27) and (28) at
bolts (13) evenly (4 places). (A) part and (B) part, install spanner-
shaped head to torque wrench (head
3 U-bolt tightening nut (first):
exchangeable) and perform the work.
7.6 to 13.3 Nm {0.78 to 1.36 kgm}
4) Tighten second nut (28) of the double-nuts
on U-bolts (13) evenly (4 places).
a When nut (28) is chamfered only one side,
install it with its chamfered side
downward.
3 U-bolt tightening nut (second):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
5) First partially loosen support bracket (23) of

tube (6) so as not to make any strain on the
tube, then tighten it to the specified torque
with no clearance.
5. Reinstallation of KDPF surrounding components

1) Install thermal guard (12).
2) Clamp sensor wiring harnesses (9) and (10).
a The position of each wiring harness must
• Details of portion B be adjusted to maintain clearance of 20
mm or more to the surrounding
components.
50-92 PC210LC-10
3) Insert eye-joint (15) into KDPF water drain 7) Insert connectors E25 (1) and E26 (2) into
tube (18) and install it to the KDPF assembly. their mating sensor connectors, and push in
the red lever to lock them.
a Tighten bolt by holding the eye-joint so as
not to make any deformation on the tube.
• Tube insertion length (b) : 32 mm
3 eye-joint mounting bolt:
24.5 to 34.3 Nm {2.5 to 3.5 kgm}
8) Close engine hood (7) to check for

interference between exhaust pipe (17) and
engine hood hole. If necessary, loosen V-
clamp (16) for the exhaust pipe by using tool
A12 (long socket) to adjust the angle with T-
bolt to 45 deg. and retighten.
4) Install clamp(33) of the coolant outlet hose.
5) Install the wiring harness to wiring harness • Width across flats of V-clamp fastening
clamp(34). nut: 7/16 in (11.1 mm)
13.6 ± 0.5 Nm {1.38 ± 0.05 kgm}
6) Install wiring harness clamps (3), (4), (18)

and (19).
PC210LC-10 50-93
Disassembly and assembly of KDPF (PC220-A9H0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name

1 available
A
2 available
k Since the temperature of KDPF or KDOC

becomes 500 °C or higher, take care not to
get burn injury.
a Prepare block [1] referring to the figure below,
and use it with wooden plate to float the inlet
side flange from the ground.
k Stop the engine and wait until the
temperature of piping around engine drops,
then remove KDPF.
k When cleaning, replacing or disposing KDPF

and KCSF, use dust mask during the work to
prevent inhaling deposited soot, ash, mat
material or metallic powder inside KDPF.
k Install KCSF with care to the mounting

direction.
2. Put a match mark on the assembly for correct
k KDPF is fragile against shock such as falling,
alignment of inlet and outlet angles at
handle with care, and never use damaged
reassembly.
part.
a Put a marking on the V-clamp, inlet body and
outlet body in alignment with the KDPF filter
k Keep the record for each KDPF unit to and mounting portion of the differential
monitor the life, and never use the KDPF pressure sensor pipe.
exceeded its life. a The angle can be adjusted at the installation
of the KDPF assembly, slight misalignment of
a V-clamp and band used in KDPF is made of marking is allowed.
stainless steel, accordingly never use air tool for
• Inlet side
removal and installation of nut to avoid damage
on the thread part.
a Prepare new gaskets or bands when removing
them.
Disassembly (PC220-A9H0-530-K-00-A)
1. Secure the KDPF assembly at 4 places to

support its inlet body and filter assembly by
using block [1].
• Outlet side
50-94 PC210LC-10
3. Disconnect connectors of KDOC inlet 4. Remove KDOC outlet temperature sensor (2),
temperature sensor (1), KDOC outlet and KDPF outlet temperature sensor (3).
temperature sensor (2), and KDPF outlet • Width across flats of the nut for temperature
temperature sensor (3) from sensor table (13). sensor: 14 mm
a Close the sensor mounting portions with
plugs [2].
Plug [2] screw size: M12 x 1.25
a Connector disconnecting procedure

1) Slide the lever (white) of the connector to
unlock.
5. Remove differential pressure sensor pipes (5)
and (6).
1) Loosen the nuts on the filter.
• Width across flats of the nut for pipe (5):
11/16 in (17.5 mm)
• Width across flats of the nut for pipe (6):
5/8 in (15.9 mm)
2) When disconnecting connectors of
differential pressure sensor pipes (5) and (6),
pull them out while pushing lock (L) at the
fitting.
a Lock (L) at the fitting of differential
2) While pressing the knob on the upper portion
pressure sensor pipe (6) is located
of the connector, pull out the connector.
behind.
PC210LC-10 50-95
3) Remove differential pressure sensor pipes 8. When replacing KDPF filter (16), remove sensor
(5) and (6). table (13) and hanger (15) according to the
a Since the tube is inserted inside of CSF,
pull out pipe (5) upright. 1) Remove band (12) by using tool A12 (long
socket) to remove sensor table (13).
2) Remove band (14) by using tool A12 (long
socket) to remove hanger (15).
• Width across flats of band (12), (14)
tightening nut: 7/16 in (11.1 mm)
3) Remove the plug from KDPF filter assembly
(11), if so attached.
6. Remove V-clamps (7) and (8) by using tool A11

(long socket) and remove inlet body (9) and
outlet body (10).
• Width across flats of V-clamp (7), (8)
tightening nut: 1/2 in (12.7 mm)
7. Remove gaskets (17) and (18) to get KDPF filter

assembly (11).
9. When replacing differential pressure sensor (19),
remove it according to the following procedure.
1) Loosen mounting bolt (20), and remove
differential pressure sensor (19) from sensor
table (13).
2) Disconnect the fitting of differential pressure
sensor pipes (5) and (6) to remove
differential pressure sensor (19).
50-96 PC210LC-10
a When disconnecting connectors of

differential pressure sensor pipes (5) and
Assembly (PC220-A9H0-710-K-00-A)
(6), pull them out while pushing lock (L) at

the fitting. 1. Install KDPF assembly inlet body (9), KDPF filter
a Lock (L) at the fitting of differential assembly (11) and outlet body (10) in sequence.
pressure sensor pipe (6) is located a The blocks used at disassembly are used at
behind. assembly.
a Since lock nut is applied to the V-clamp,
tighten lightly until V-clamp does not move by
using tool A11 (long socket).
a V-clamp can be reused, however, replace it
with a new one in the following conditions.
• Deformation of V-clamp
• Damage on T-bolt thread portion
• Crack at V groove
1) Place new gasket (17) on end of KDPF filter

assembly (11).
10.When replacing KDOC inlet temperature sensor
(1), remove it according to the following
procedure.
1) Disconnect wiring harness clamp (4) for
KDOC inlet temperature sensor (1) from
sensor table (13).
• With across flats of clamp bolt: 10 mm
2) Remove KDOC inlet temperature sensor (1).
• Width across flats of the nut for
temperature sensor: 14 mm
2) Assemble inlet body (9) to KDPF filter

assembly (11) matching with the location of
fitting for differential pressure sensor pipe
according to the marking put before removal.
a Place V-clamp (7) to inlet body (9) before
installing them to KDPF filter assembly
(11).
a When assembling inlet body (9) and
KDPF filter assembly (11), take care that
gasket (17) does not come out.
PC210LC-10 50-97
3) Tighten V-clamp (7) lightly according to the a When assembling outlet body (10) and
marking put before removal and the angle KDPF filter assembly (11), take care that
shown below. gasket (18) does not come out.
• Width across flats of V-clamp fastening 6) Tighten V-clamp (8) lightly according to the
nut: 1/2 in (12.7 mm) marking put before removal and the angle
• Mounting angle of V-clamp T-bolt: 35 ± 5° shown below.
• Mounting angle of V-clamps (7) and (8) • Width across flats of V-clamp fastening
nut: 1/2 in (12.7 mm)
• Mounting angle of V-clamp T-bolt: 35 ± 5°
• Mounting angle of V-clamps (7) and (8)
4) Install new gasket (18) on end of KDPF filter

assembly (11).
2. Tighten V-clamps (7) and (8) according to the

1) Tighten the nuts of V-clamps (7) and (8) by
using tool A11 (long socket).
nut: 1/2 in (12.7 mm)
18 to 22 Nm {1.8 to 2.2 kgm}
2) Tap the entire periphery of the V-clamp with a
rubber hammer in the following order: aob,
cod.
5) Assemble outlet body (10) to KDPF filter 3) Tighten the nuts of V-clamps (7) and (8)
assembly (11) matching with the location of again.
fitting for differential pressure sensor pipe
according to the marking put before removal.
nut: 1/2 in (12.7 mm)
a Place V-clamp (8) to outlet body (9)
before installing them to KDPF filter
assembly (11). 18 to 22 Nm {1.8 to 2.2 kgm}
50-98 PC210LC-10
a Adjust the direction of band and its installing

place according to the marking location put
before removal and the angle shown below.
• Mounting angle of band T-bolt: 135 ± 5°
a Since lock nut is applied to the band, tighten
lightly until band does not move.
a When new KDPF filter assembly (11) is
installed, put hanger (15) at the same angle
with hanger (21) at inlet body, and adjust it
upwards when installing on the machine, and
then fasten band (14).
3. When a new KDPF filter is installed, install • Width across flats of band (14) fastening nut:
sensor table (13) and hanger (15) according to 7/16 in (11.1 mm)
3 Band (14) fastening nut (tightening to
a Once a band is tightened, it gets the folding the specified torque):
mark with the edge of the part to be fixed.
6.3 to 8.3 Nm {0.6 to 0.8 kgm}
Accordingly, do not reuse the band but
replace it with a new one.
1) Fasten hanger (15) lightly with new band (14)
by using tool A12 (long socket).
a Install hanger (15) upward and adjust it
when the V-clamp is installed.
• Width across flats of band (14) fastening
nut: 7/16 in (11.1 mm)
2) Fasten sensor table (13) lightly with new
band (12) by using tool A12 (long socket).
a Install sensor table (13) at a position that
permits easy installation of piping and
adjust it during installation of the piping. 4. Install differential pressure sensor pipes (5) and
• Width across flats of band (12) fastening (6) according to the following procedure.
nut: 7/16 in (11.1 mm) a Remove any plugs put on the mounting holes
at the removal.
1) Install differential pressure sensor pipes (5)
and (6) so that they extend horizontally, and
then lightly tighten the nuts.
a When a new KDPF filter is installed,
adjust the position of sensor table (13), at
which differential pressure sensor pipes
(5) and (6) can be installed easily, and
then fasten band (12) by using tool A12
(long socket).
PC210LC-10 50-99
• Width across flats of band (12) fastening 3 Thread portion of temperature sensor:
nut: 7/16 in (11.1 mm) Seizure prevention compound (LC-G)
3 Band (12) fastening nut: • Width across flats of the nut for temperature
6.3 to 8.3 Nm {0.6 to 0.8 kgm} sensor: 14 mm
2) Install connectors of differential pressure 3 Temperature sensor mounting nut:
sensor pipes (5) and (6) to differential
24 to 36 Nm {2.5 to 3.7 kgm}
pressure sensor (19).
a Push in fitting of connectors until locking
sound is heard.
3) Install differential pressure sensor pipes (5)
and (6).
• Width across flats of the nut for Hi side
pipe (5): 11/16 in (17.46 mm)
3 Hi side pipe (5) mounting nut:
24.5 to 36.5 Nm {2.5 to 3.7 kgm}
• Width across flats of the nut for Lo side
pipe (6): 5/8 in (15.88 mm)
3 Lo side pipe (6) mounting nut: 6. Install connectors of KDOC inlet temperature
13.6 to 19 Nm {1.39 to 1.9 kgm} sensor (1), KDOC outlet temperature sensor (2),
and KDPF outlet temperature sensor (3) to
sensor table (13).
a Do not install connectors at wrong positions.
7. When replacing differential pressure sensor (19),

install it according to the following procedure.
1) Tighten mounting bolt (20) of differential
pressure sensor (19) lightly.
2) Install connectors of differential pressure
sensor pipes (5) and (6) to differential
pressure sensor (19).
a Push in fitting of connectors until locking
sound is heard.
5. Install KDOC outlet temperature sensor (2), and
3) Tighten mounting bolt (20) of differential
KDPF outlet temperature sensor (3).
pressure sensor (19) to the specified torque.
a Remove any plugs put on the mounting holes • Width across flats of differential pressure
at the removal. sensor mounting bolt: 10 mm
a When installing the temperature sensor, 3 Differential pressure sensor
apply seizure prevention compound to thread mounting bolt:
portion.
10.9 to 16.3 Nm {1.1 to 1.7 kgm}
50-100 PC210LC-10
8. When replacing KDOC inlet sensor (1), install it

1) Install KDOC inlet sensor (1) and tighten the
nut lightly.
a When installing KDOC inlet sensor (1),
apply seizure prevention compound to
thread portion.
2 Thread portion of temperature
sensor:
Seizure prevention compound
(LC-G)
• Width across flats of the nut for
temperature sensor: 14 mm
3 Temperature sensor mounting nut:
24 to 36 Nm {2.4 to 3.6 kgm}
2) Install wiring harness clamp (4) for KDOC
inlet temperature sensor (1).
a Adjust wiring harness clamp (4) to install
as the angle and length (a) shown in the
figure.
• Adjusted wiring harness length (a): 115
mm
• Wiring harness clamp mounting angle:
90°
3) Install connector of KDOC inlet temperature
sensor (1) to sensor table (13).
PC210LC-10 50-101
Removal and installation of KCCV assembly (PC220-A180-924-K-00-A)

k After the engine is stopped, its parts are still

hot. Accordingly, wait until they have cooled
down before starting the work.
Removal (PC200_10-A180-520-K-00-A)

2. Remove step (2).
5. Disconnect stay (10).

a The engine hood is not locked any more
once the stay is disconnected. So hold the
engine hood open using something like rope
to prevent it from closing.
6. Remove two mounting bolts (11) and remove
KCCV ventilator assembly (12) and bracket (18)
together.
7. Disconnect bracket (18) from KCCV ventilator
assembly (12).
3. Disconnect clamp (4) fastening the tube.
4. Disconnect the clamps of the following hoses

first, then disconnect the hoses. [*1]
• Blowby gas inlet hose (5)
• Oil drain hose (6)
• Blowby gas outlet hose (7)
• Coolant inlet hose (8)
• Coolant outlet hose (9)
a When disconnecting each hose, take care of
dripping oil.
a Take measures to prevent dirt, dust, etc. from 8. When replacing the following hoses, remove
sticking to the disconnected hoses. them according to the following procedure. [*1]
• Blowby gas inlet hoses (5) and (19)
• Coolant outlet hoses (9) and (20)
50-102 PC210LC-10
a As replacement of the hoses is difficult with

the KDPF in position, it is recommended that
the hoses are replaced at the same time of
cleaning or replacement of the KDPF.
5) Disconnect the clamps of hoses first, then

remove hoses (5), (9), (19), and (20). [*3]
1) Remove bracket (13).
Installation (PC200_10-A180-720-K-00-A)

[*1] [*3]
2) Remove KDPF assembly (14). For details,
see "Removal and installation of KDPF a Installed dimensions of hoses are shown in the
assembly". following figure. (The numbers in the figure
indicate the clamps.)
3) Disconnect the KCCV side of KCCV blowby

gas inlet hose (5) and outlet hose (3). [*2]
4) When replacing coolant outlet hose (9),
disconnect hose clamp (16).
PC210LC-10 50-103
• Dimensions of blowby gas inlet hose (5) and • Dimension of oil drain hse (6) (KCCV ventilator
(19) (junction block side), and blowby gas outlet side) is as follows.
hose (7) (tube side) are as follows. (Figure Hose fitting length (b): 25 mm
shows blowby gas outlet hose (7) as an Between hose end and clamp (c): 5 mm
example.)
Hose fitting length (b): 30 mm
Between hose end and clamp (c): 5 mm
3 Blowby gas inlet hoses (5) and (19)

clamps:
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
• Dimensions of blowby gas inlet hose (5) and
blowby gas outlet hose (7) (KCCV ventilator 3 Blowby gas outlet hose (7) clamp:
side) are as follows. (Figure shows blowby gas 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
inlet hose (5) as an example.)
Hose fitting length (b): 25 mm 3 Oil drain hose (6) clamp:
Between hose end and clamp (c): 3 mm 3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
3 Coolant inlet hose (8) clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
3 Coolant inlet hoses (9) and (20) clamps:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
[*2]
a Fix oil drain hose (6) to blowby gas inlet hose (5)
at its red taped part (a) by using band (15).
• Dimensions of coolant inlet hose (8) and coolant

outlet hose (9) and (20) are as follows. (Figure
shows coolant inlet hose (8) as an example.)
Hose fitting length (b): 30 mm
Between hose end and clamp (c): 10 mm
50-104 PC210LC-10
a Reference
When removing, installing or replacing check
valve (17) from oil drain hose (6), install check
valve (17) with its gray part to the KCCV side as
shown on the L.H. side of the figure.
3 Hose clamp:
3.3 ± 0.49 Nm {0.34 ± 0.05 kgm}
PC210LC-10 50-105
Removal and installation of air cleaner assembly (PC220-A910-924-K-00-A)

Removal (PC200_10-A910-520-K-00-A)
1. Open the engine hood and remove cover (1)

and (2).
6. Disconnect connector P55 of mass air flow and

temperature sensor (8) and connector P23 of air
cleaner clogging sensor (9).

3. Put cover (3) aside toward engine to remove
cover (5).
7. Remove bands (10) and (11), and pull out air

cleaner assembly (12) from tube (13) to remove
it. [*2]
a Be careful about sponge (7) from being torn.
a Entering lubricant into air cleaner clogging
sensor (9) causes failure, never use lubricant
when pulling out air cleaner assembly (12)
from tube (13).
4. Remove clamp (6a) and move the hose toward

the control valve. 8. Immediately after removing air cleaner assembly
5. Remove five bolts (6) and cover (5). [*1] (12), plug the opening of tube (13) and air
cleaner with clean vinyl.
a Entering dust into air intake piping may
cause engine failure.
50-106 PC210LC-10
Installation (PC220-A910-720-K-00-A)
When replacing air cleaner

Remove intake air flow/temperature sensor (8), air
cleaner clogging sensor (9) and cover (14), then
install them to the installing air cleaner.
a Since intake air flow/temperature sensor (8) is a
precision part, neither air-blow inside nor spray
detergent liquid on it.
3 Screw for air intake flow/temperature
sensor (8):
0.98 to 1.27 Nm {0.1 to 0.13 kgm}
a Apply liquid gasket to the thread portion of air
cleaner clogging sensor (9).
2 Air cleaner clogging sensor (9):
3 Air cleaner clogging sensor (9):
1.96 to 3.92 Nm {0.2 to 0.4 kgm}
a Insert cover (14) until it touches the air cleaner.
3 Clamp fastening nut for cover (14):
3.4 to 4.4 Nm {0.35 to 0.45 kgm} [*2]
a Plug the opening of the air cleaner with vinyl till a Installation of air cleaner assembly
just before installing air cleaner to prevent the If rubber ring (16) is detached, install it to tube
dust from entering. (13) beforehand.
Perform the rest of installation in the reverse order 3 Band fastening nut (10):
to removal. 10.0 to 11.0 Nm {1.02 to 1.12 kgm}
[*1]
3 Band fastening nut (11):
a Installation of cover 8.8 to 10.8 Nm {0.9 to 1.1 kgm}
Insert covers (15) and (5) to fit mating surface of
sponge (7) and install.
PC210LC-10 50-107
50-108 PC210LC-10
Power train
Removal and installation of travel motor and final drive assembly (PC220-DF10-
924-K-00-A)
4 Travel motor and final drive assembly:

k Park the machine on a level place, lower the 300 kg
stop the engine.
k Set the lock lever in the Lock position.

adjusting, "Releasing remaining pressure
from hydraulic circuit".
Removal (PC200_10-DF10-520-K-00-A)
1. Remove the sprocket, referring to the section

"Removal and installation of sprocket(PAGE 50-
132)". Installation (PC220-DF10-720-K-00-A)
[*1]
3 Mounting bolt of travel motor and final
drive assembly:
265 to 309 Nm {27 to 31.5 kgm}
• Refilling of oil
oil through the system. Then, check the oil level
again.
• Bleeding air
Bleed air from the travel motor circuit. For details,
3. Disconnect the travel speed selector hose (2), see Testing and adjusting, “Bleeding air from
the motor hoses (3) and (4), and the drain hose hydraulic circuit“.
(5).
4. Sling the travel motor and final drive assembly

(6).
5. Remove the 18 mounting bolts and sling and
remove the travel motor and final drive assembly
(6). [*1]
a Take care that the hose mounting block is not
damaged.
PC210LC-10 50-109
Power train
Disassembly and assembly of final drive (PC220_10-DF10-926-K-00-A)
a Special tools 1) Remove No. 1 planetary carrier assembly

(3).
Necessity
Symbol
Q'ty
Part No. Part Name
1 796-427-1400 Wrench assembly t 1

2 796-427-1520 Installer t 1
796T-427-
Push tool t 1
1510
790-101-2510 Block t 1
790-101-3310 Plate t 1
790-101-2610 Leg t 2
F 790-101-2730 Adapter t 2
3
01580-11613 Nut t 2
790-101-2570 Plate t 2 2) Disassemble No. 1 planetary carrier
01643-31645 Washer t 2 assembly according to the following
Puller (294 kN {30 procedure.
790-101-2102 ton}) t 1
1] Drive pin (4) into shaft (5) to remove shaft
790-101-1102 Pump t 1 (5) from No. 1 planetary carrier (6).
4 790-331-1110 Wrench t 1 a After removing shaft (5), remove pin
Disassembly (PC220-DF10-530-K-00-A) (4) from shaft (5).
2] Remove thrust washer (7), No. 1
1. Oil draining planetary gear (8), needle bearing (9),
Remove the drain plug to drain the oil from the and thrust washer (10).
final drive case.
6 Final drive case:

5.4 l
2. Remove 20 mounting bolts. Using eyebolts [1],
sling and remove cover (1).
4 Cover:
25 kg
a If ring gear (12) is slung together with the
cover, gently tap the ring gear off the cover
by using a plastic hammer.
5. No. 1 sun gear shaft

Remove No. 1 sun gear shaft (11).
3. Washer
Remove washer (2).
4. No. 1 planetary carrier assembly
6. Ring gear
Remove ring gear (12).
50-110 PC210LC-10
Power train
4 Ring gear:
45 kg
7. Thrust washer
Remove thrust washer (13).
8. No. 2 sun gear
Remove No. 2 sun gear (14).
11.Ring nut
1) Remove lock plate (24).
2) By using tool F1, remove ring nut (25).
9. Thrust washer
Remove thrust washer (15).
10.No. 2 planetary carrier assembly
1) Remove No. 2 planetary carrier assembly
(16).
12.Hub assembly
1) Using eyebolts [2], sling and remove hub
assembly (26) from the travel motor.
4 Hub assembly:
80 kg
2) Disassemble the No. 2 planetary carrier

assembly according to the following
procedure.
1] Drive pin (17) into shaft (18) to remove
shaft (18) from No. 2 planetary carrier
(19).
a After removing shaft (18), remove pin
(17) from shaft (18).
planetary gear (21), needle bearing (22),
and thrust washer (23). 2) Remove bearing (27).
PC210LC-10 50-111
Power train
3) Remove bearing outer races (29) and (30)

from hub (28).
13.Remove floating seals (32) and (33) from travel

motor (31).
a Floating seals (32) are attached to hub
assembly (26) and travel motor.
14.Use the puller [3] and push tool [4] to remove

bearing (34).
a Bearing may come off without using the
puller.
50-112 PC210LC-10
Power train
a Install the floating seal after degreasing and

Assembly (PC220_10-DF10-710-K-00-A)
drying the O-rings and O-ring contacting
a Clean the parts completely and inspect them for surfaces completely.
any foreign material or damage. Apply power
a After installing the floating seal, check the
train oil (TO30) to the sliding surfaces before
inclination of the seal. It must be 1 mm or
assembly.
less.
1. Hub assembly
a After floating seal installation, apply a thin
1) Use push tool to press fit bearing outer races
coat of power train oil on the sliding surfaces.
(29) and (30) into hub (28).
2 Sliding surface:
Power train oil (TO30)
2) Using tool F2, install floating seal (32).

a Install the floating seal after degreasing and
drying the O-rings and O-ring contacting 4. Using eyebolts [2], place hub assembly (26) on
surfaces completely. the travel motor.
a After installing the floating seal, check the 4 Hub assembly:

inclination of the seal. It must be 1 mm or 80 kg
less.
a After floating seal installation, apply a thin
coat of power train oil on the sliding surfaces.
2 Sliding surface:
Power train oil (TO30)
5. Install bearing (27) by tapping it lightly with the

push tool.
2. Install bearing (34) to travel motor (31).

a Warm the inner race of the bearing (34) to 50
to 70°C with heater.
a Cool bearing (34) down. Tap the bearing (34)
with a wood bar and listen to the sound to
check that it is fully seated.
3. Using tool F2, install floating seal (33) to travel
motor (31).
PC210LC-10 50-113
Power train
6. Ring nut
1) Install the ring nut according to the following
procedure.
1] Rotate the hub two to three times.
2] Use tool F3 and push tool [5] to press the
inner race of bearing (27).
a Pressing force:
29.4 to 38.2 kN {3.0 to 3.9 ton}
3] Rotate the hub to the both directions at
least five times in total with the bearing
inner race pressed.
4] Release the pressing force.
5] Press the bearing again. 2) Measure the tangential force of the hub
against the motor case in the rotation
a Pressing force: direction using the push scale [6].
17.7 to 21.6 kN {1.8 to 2.2 ton} a Tangential force:
6] Rotate the hub two to three times.
Max. 490 N {50 kg}
a The tangential force denotes the
maximum force at start of the rotation.
7] Measure dimension (a) under the

condition described in 6].
a After measuring dimension (a), 3) Install lock plate (24).
remove tool F3.
a Install the lock plate so that the splines
(A) of the motor and the lock plate are in
full contact.
2 Mounting bolt threads:
Adhesive (LT-2)
a Do not apply the adhesive (LT-2) to the
thread portion of the nut.
8] Measure the thickness of ring nut (25)

and name it (b) dimension.
9] Subtract (b) from (a), and name it (c).
10]By using tool F1, tighten ring nut (25) until
dimension (d) is as shown.
Dimension (d): c (+0.06/-0.04) mm
7. No. 2 planetary carrier assembly
50-114 PC210LC-10
Power train
1) Assemble No. 2 planetary carrier according

a Replace thrust washers (20) and (23) as
well as pin (17) with new ones.
a There is trace of punching on the end
face of carrier side hole (e) which was
caused when the pin was inserted and
locked. Before pin installation, remove
the protrusion in the pin hole as a result of
punching.
1] Install needle bearing (22) to No. 2
planetary gear (21). Fit upper and lower
thrust washers (20) and (23) and set the
gear assembly to No. 2 planetary carrier
(19).
2] Align the pin holes on shaft (18) and the
carrier, and install shaft (18) by tapping it
lightly with a plastic hammer.
a Install the shaft, while rotating No. 2
planetary gear (21) with care not to
damage the thrust washer.
2) Install No. 2 planetary carrier assembly (16).

a Align the four gear shaft ends of No. 2
planetary carrier assembly (16) with the
four dimples on the motor case end face
to install.
8. Thrust washer
Install thrust washer (15).
3] Insert pin (17).

a When inserting the pin, take care that
the three claws (parts (f)) on the
periphery of the pin will not be placed
on the thin-wall parts of No. 2
planetary carrier (parts (g)). The thin-
wall part may be on the opposite side
depending on carriers. Check each
carrier and avoid setting any claw of
the pin to the thin-wall part. If there is
a groove, avoid the groove. 9. No. 2 sun gear
Install No. 2 sun gear (14).
a After assembling the No. 2 planetary
10.No. 1 sun gear shaft
carrier, check that No. 2 planetary
Install No. 1 sun gear shaft (11).
gear (21) rotates smoothly.
11.Thrust washer
a After the pin is inserted, punch the pin Install thrust washer (13).
(B) on the carrier.
PC210LC-10 50-115
Power train
12.Ring gear 2] Align the pin holes in shaft (5) and the No.
1) Install the O-ring to the hub. 1 planetary carrier, and install the shaft
2) Install ring gear (12) on the hub. (5) by tapping it lightly with a plastic
hammer.
4 Ring gear: a Install the shaft, while rotating No. 1
45 kg planetary gear (8) with care not to
damage the thrust washer.
a Degrease the mating faces of the ring gear
3] Insert pin (4).
and hub. Do not apply liquid gasket on the
mating faces. a When inserting the pin, take care that
the three claws (parts (f)) on the
a Align the bolt holes of the ring gear with
periphery of the pin will not be placed
those of the hub.
on the thin-wall parts of No. 1
planetary carrier (parts (g)). The thin-
wall part may be on the opposite side
depending on carriers. Check each
carrier and avoid setting any claw of
the pin to the thin-wall part. If there is
a groove, avoid the groove.
a After assembling the carrier, check
that No. 1 planetary gear (8) rotates
smoothly.
a After the pin is inserted, punch the
pins (C) on the carrier at 2 locations.
13.No. 1 planetary carrier assembly

1) Assemble the No. 1 planetary carrier
a Replace thrust washers (7) and (10) as
well as pin (4) with new ones. (See Pin
(4): 3].)
a There is a punching mark made when the
pin was inserted on the end face of
carrier side hole (h) and the inside wall of
the hole is swelled at that mark. Flatten
the swelled part in advance.
1] Assemble needle bearing (9) in No. 1
planetary gear (8), fit top and bottom
thrust washers (7) and (10), and then set
the gear assembly on No. 1 planetary
carrier (6).
50-116 PC210LC-10
Power train
2 Mating faces of cover and ring

gear:
a Do not apply liquid gasket (LG-6) to tap.
2) Install No. 1 planetary carrier assembly (3).

14.Washer
Install washer (2).
a After installing washer (2), measure
dimension (i) from the upper end face of No.
1 planetary gear (8) to that of ring gear (12) 2) Using tool F4, install the 20 mounting bolts.
to check for the correct assembly condition. 3 Mounting bolt
a If dimension (i) does not fall within 2.11 ± 1st time: 98 Nm {10 kgm}
0.97 mm, the assembly is built incorrectly. 2nd time: 80 to 90 deg. (rotating
Recheck. angle)
16.Refilling of oil
Tighten drain plug and supply power train oil
(TO30) from the oil filler port.
5 Final drive case:

5.4 l
a Do a final check of the oil level at the
determined position after installing the final
drive assembly to the chassis.
15.Cover
1) Using eyebolts [1], install cover (1).
4 Cover:
25 kg
PC210LC-10 50-117
Power train
Removal and installation of swing motor and swing machinery

assembly (PC220-J120-924-K-00-A)
the work equipment to the ground, and stop
the engine.

adjusting, “Releasing remaining pressure
from hydraulic circuit”.
a Note connector numbers and installed positions

before disconnecting wiring and hoses.
a Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out. 4. Remove the return filter and the accumulator
Removal (PC200_10-J120-520-K-00-A)
mounting bracket assembly according to the
following procedure. (machines equipped with
1. Remove cover (1) (four bolts). attachment)
1) Disconnect hoses (4) and (6) (four bolts),
hose (5) (two bolts) at its connection to the
relay block, hoses (7) and (8) (four bolts) at
their connections to the control valve, and
hose (9) (two bolts) at its connection to the
tube.
• Hose (4): To attachment work equipment
• Hose (5): To return oil filter
• Hose (6): To attachment work equipment
• Hose (7): To control valve (port (A-1))
• Hose (8): To control valve (port (B-1))
• Hose (9): To control valve (port (ATT))
2. Remove drain hose (2) (two bolts). 2) Disconnect hoses (10) and (11) at their
connections to the relay block.
• Hose (10): To hydraulic tank
• Hose (11): To cuntol valve (port (BP5))
3. Open the engine hood, then remove step (3)

(five bolts).
3) Sling return oil filter mounting bracket

assembly (12).
4) Remove four bolts (13) and two bolts (14),
then sling and remove return oil filter and
bracket assembly (12).
50-118 PC210LC-10
Power train
a Return oil filter bracket assembly (12) is

rather difficult to lift in its horizontal
position, as the center of gravity cannot
easily be located. Keep the assembly
horizontal by attaching the sling to three
points on it.
7. Remove 12 mounting bolts (25) of the swing

machinery. [*2]
5) Sling accumulator mounting bracket

assembly (15).
6) Remove four bolts and then sling and
remove accumulator mounting bracket
assembly (15).
8. Sling and remove the swing motor and swing

machinery assembly (26).
a Keep hose (H) away from the assembly by
pulling it with rope [1] to prevent the hose
from interference.
a Sling the assembly carefully and slowly to
prevent the drain hose at the bottom from
being caught on other parts.
5. Disconnect hoses (16) to (22) at their a Sling the assembly carefully and slowly until
connections to the swing motor. [*1] it gets clear of hose (H) of the center swivel
• Hose (16): Port (MA) joint.
• Hose (17): Port (MB)
• Hose (18): Port (S) 4 Swing motor and swing machinery
• Hose (19): Port (T) assembly (26):
• Hose (20): Port (T) 229 kg
• Hose (21): Port (B)
• Hose (22): Port (SI)
6. Disconnect clamp (23) and nipple (24).
PC210LC-10 50-119
Power train
Installation (PC220-J120-720-K-00-A)

[*1]
Hoses are connected as follows.
• Hose (16): Control valve port (B4)
• Hose (17): Control valve port (A4)
• Hose (18): Control valve port (TSW)
• Hose (19): Center swivel joint port (DR2)
• Hose (20): To hydraulic tank
• Hose (21): Swing holding brake solenoid valve
• Hose (22): 2-stage relief solenoid valve
[*2]
3 Swing machinery mounting bolt (25):
490 to 608 Nm {50 to 62 kgm}
5 Hydraulic tank (refilling only):

(For details, see “Table of fuel, coolant
and lubricants“.)
50-120 PC210LC-10
Power train
Disassembly and assembly of swing machinery (PC200_10-J120-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
1 796T-426-1410 Push tool t 1

2 796-426-1120 Push tool t 1
G 796T-426-1130 Plate t 1
3 790-101-5421 Grip t 1
01010-81240 Bolt t 1
a The figures show the equipment on PC200-8.

They are basically the same on PC210LC-10 but 2) Disassemble No. 1 planetary carrier
the different figures are noted in the texts. assembly according to the following
procedure.
Disassembly (PC200_10-J120-530-K-00-A)
1] Remove snap ring (8), thrust washer (9),
1. Set the swing motor and swing machinery No. 1 planetary gear (10), bearing (11),
assembly on block [1]. and thrust washer (12) in that order.
2. Loosen oil drain plug (1) of the swing machinery 2] Remove plate (13).
to drain the oil from the swing machinery case. 3] Reverse carrier (14) and remove snap
ring (15).
6 Swing machinery case: a PC210LC-10
7.1 l
3. Remove oil level gauge/ oil filler cap (2).
4. Remove drain hose (3).
5. Remove the six swing motor mounting bolts to
sling and remove swing motor (4).
4 Swing motor:
55 kg
a Put match marks on swing motor (4) and
swing machinery assembly (5) for correct
matching during reassembly.
3) Using push tool [2], remove shaft (16) from

carrier (14).
• Shaft press-fitting force (reference):
11.2 to 25.8 kN {1,140 to 2,630 kg}
6. Remove No. 1 sun gear (6).

7. Disassembly of No. 1 planetary carrier assembly
1) Remove No. 1 planetary carrier assembly
(7).
8. Remove No. 2 sun gear (17).

9. Remove 22 bolts (18) and sling and remove ring
gear (19).
PC210LC-10 50-121
Power train
2) Remove 12 cover mounting bolts (30).
10.Remove bolt (20).

11.Disassembly of No. 2 planetary carrier assembly
3) Reverse shaft and case assembly (29) again
1) Remove No. 2 planetary carrier assembly and set it to the press.
(21). 4) Using push tool [3], remove shaft assembly
(32) from shaft and case assembly (29).
2) Disassemble the No. 2 planetary carrier

assembly according to the following
procedure.
1] Push in pin (22) and drive out shaft (23)
from No. 2 planetary carrier (24).
a After removing shaft (23), remove pin
(22).
planetary gear (26), and needle bearing
(27).
3] Remove plate (28).
a PC210LC-10
13.Disassembly of shaft assembly

1) Using push tools [4] and [5], remove shaft
(33).
2) Remove bearing (35) and oil seal (36) from
cover (34).
12.Disassembly of shaft and case assembly

1) Reverse shaft and case assembly (29).
50-122 PC210LC-10
Power train
2 Outer periphery of oil seal:

a Take care that the liquid gasket (LG-6) does
not stick to the oil seal lip at the time of
press-fitting.
a If tool G3 is not to be used, use a push tool

that can press outer periphery (A) of oil seal
(1) evenly.
a Take care not to slant oil seal (1).
14.Remove bearing (39) from case (40).

a Apply an adequate tool to the outer periphery
(broad line: part Q) of the outer race and tap
the outer periphery of the tool.
2. Using push tool [9], press fit bearing (3) to case

(4).
Assembly (PC200_10-J120-710-K-00-A)
a Clean all the parts thoroughly, check them for

dirt and flaw, and apply power train oil to the
sliding surfaces before assembling.
5 Power train oil:

TO30
a Do not reuse the removed bearings and oil seals 3. Install cover assembly (6) to case assembly (5).
but replace them with new ones.
2 Cover mounting face:
1. Assembly of oil seal
Using tool G3, install oil seal (1) to cover (2). Liquid gasket (LG-6)
a Take care of the direction (top and bottom) of

the oil seal.
PC210LC-10 50-123
Power train
3 Cover assembly (6) mounting bolt: a Just before oil seal (14) enters shaft (B),
59 to 74 Nm {6.0 to 7.5 kgm} hold case assembly (13) horizontally so
that it is aligned with the center of shaft
a Take care that gasket sealant (LG-6) does (9), thereby the oil seal lip is prevented
not stick to drain port (DP). from being damaged.
a Match the drain portion of the cover with
drain port (DP).
4. Assembly of shaft and case assembly

1) Set case assembly (10) on shaft (9).
2 Oil seal lip:
Grease (G2-LI)
a Set case assembly (10) on with care not
to touch the oil seal.
2) Using tool G1, push tool [10], and hammer
[11], press fit the inner race of bearing (12)
into position by tapping.
5. Assembly of bearing
k Press fit to such an extent that shaft Using tool G2 and push tool [15], press fit
(9) does not drop when it is lifted. bearing (15).
a Stack sling [12]. a Press fit bearing (15) by pushing the inner
race and outer race of the bearing
simultaneously. Do not push only the inner
race.
a Press-fit force of bearing:
9.4 to 35.5 kN {960 to 3,620 kg}
a After press-fitting bearing (15), check that the
case rotates smoothly.
3) Set the assembly to the press.

4) Using tool G1 and push tools [13] and [14],
press fit bearing (12).
a Arrange push tool [14] for the event that
case assembly (13) slants.
a If case assembly (13) slants, correct it by
hitting the flange lightly.
6. Assembly of No. 2 planetary carrier
50-124 PC210LC-10
Power train

a There is a trace of punching made when
the pin was inserted at side hole (h) of No.
2 planetary carrier (16) and the inside
wall of the hole is swelled at that mark.
Flatten the swelled part in advance. (See
5].)
1] Install plate (17) to No. 2 planetary carrier
(16).
2] Install needle bearing (19) and two thrust
washers (20) at the top and bottom to No.
2 planetary gear (18). 2) Install No. 2 planetary carrier assembly (23)
3] Set the No. 2 planetary gear assembly to and secure it in position with bolt (24).
No. 2 planetary carrier (16).
2 No. 2 planetary carrier assembly
a PC210LC-10 (23) mounting bolt threads:
Adhesive (LT-2)
3 No. 2 planetary carrier assembly
(23) mounting bolt:
157 to 196 Nm {16 to 20 kgm}
3) Install O-ring (25) to case (26).
4] Align the pin holes in shaft (21) and

carrier (16) by lightly tapping with a
plastic hammer, and then install shaft
(21).
a When installing shaft (21), rotate No. 2
planetary gear. Be careful not to 7. Install No. 2 sun gear (27).
damage the thrust washers. 8. Assembly of ring gear
5] Insert pin (22). Using eyebolts (M10 x 1.5), install ring gear (28)
a When inserting pin (22), do not allow in position.
the three claws (part a) on the outer a Degrease the mating faces of ring gear (28)
periphery to be placed on the thin wall and case (26).
part of the carrier (part b). The thin
wall part may be on the opposite side a Do not deposit liquid gasket on the mating
dependoing on carriers, however. faces of ring gear (28) and case (26).
Check each carrier and avoid setting a When installing ring gear (28), match its
any claw of the pin to the thin wall match mark (c) with convex part (d) of the
part. flange as shown in the figure.
a After inserting the pin, punch two 3 Ring gear (28) mounting bolt (29):
places (c) around the pin hole of the
carrier. 157 to 196 Nm {16 to 20 kgm}
a PC210LC-10
PC210LC-10 50-125
Power train
washer (39), and snap ring (40) in that

order.
a PC210LC-10
9. Install O-ring (30).
2) Install No. 1 carrier assembly (41).
10.Assembly of No. 1 planetary carrier

1] Press fit shaft (31) to carrier (33) until the 11.Install No. 1 sun gear (42).
snap ring (32) groove is seen from the
direction of the arrow (1st direction). a Install No. 1 sun gear (42) with longer
2] After installing snap ring (32) , push it shouldered portion (g) facing up.
back from the opposite side (2nd
direction) until snap ring (33) contacts
tightly with face (P) of the carrier. Take
care not to push too hard.
a Press-fit force of shaft:
11.2 to 25.8 kN {1,140 to 2,630 kg}
3] Install plate (34) to carrier (35).

4] Install thrust washer (36), needle bearing
(37), No. 1 planetary gear (38), thrust
50-126 PC210LC-10
Power train
12.Assembly of swing motor 13.Check the mounting angle and tightening torque
Install swing motor assembly (43) to ring gear of the drain elbow (44).
(28).
3 Elbow:
4 Swing motor: 128 to 186 Nm {13.0 to 19.0 kgm}
55 kg a Elbow mounting angle: 15°
a Degrease the mating faces of swing motor
assembly(43) and ring gear (28).
a Do not deposit liquid gasket on the mating
faces of swing motor assembly (43) and ring
gear (28).
a During installation, match the match marks
put during disassembly.
3 Swing motor mounting bolt:
59 to 74 Nm {6.0 to 7.5 kgm}
14.Install the drain hose.

a Install the drain hose so that the drain plug
faces down.
3 Drain hose:
128 to 186 Nm {13.0 to 19.0 kgm}
15.Tighten the drain plug and supply power train oil
(TO30) through the oil filler port to the specified
level.
3 Drain plug:
19.6 to 24.5 Nm {2.0 to 2.5 kgm}
a When installing a new swing motor assembly,
position drain elbow (44) and dipstick pipe/ 5 Swing machinery case:
filler port cap (45) as shown in the figure
7.1 l
below.
a PC210LC-10
PC210LC-10 50-127
Power train
Removal and installation of swing circle assembly (PC220-J110-924-K-00-A)
Installation (PC220-J110-720-K-00-A)
Removal (PC220-J110-520-K-00-A)
1. Remove the revolving frame assembly referring [*1]
to the section “Removal and installation of
revolving frame assembly“. a Position the soft zone position S mark of an
2. Remove swing circle assembly mounting bolts inner race: (a) and the soft zone position S mark
(2) and sling swing circle assembly (1). [*1] of an outer race: (b) in the R.H. side of the
machine as shown below and install it on the
a Leaving one mounting bolt each in the front track frame.
and rear, sling swing circle assembly (1) by
3-point lifting method. 2 Amount of grease filled in grease bath:
3. Remove the remaining mounting bolts to remove Grease (G2-LI) 15.8 l
swing circle assembly (1).
2 Swing circle mounting bolt threaded
4 Swing circle assembly (1): portion:
295 kg Adhesive (LT-2)
• In case of angle tightening:
3 Swing circle mounting bolt:
1. Initial torque: 294.2 ± 29.4 Nm {30 ±
3 kgm}
2. Then tighten the bolt by 60 ± 6 deg.
• In case of torque tightening:
3 Swing circle mounting bolt:
716 to 814 Nm {73 to 83 kgm}
50-128 PC210LC-10
Separation and connection of track shoe assembly (PC220-DTL0-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
Remover and
1 791-630-3000 t 1
installer
N 2 790-101-1300 Cylinder (980 kN t 1
{100 ton})
3 790-101-1102 Hydraulic pump t 1
Separating track (PC220-DTL0-520-K-00-A)
1. Turn the upper structure by 90 deg. 4. By using tool N, remove master pin (2). [*2]
2. Loosen lubricator (1), and then slacken the a With guide pin (GP), push out master pin (2).
tension of the track. [*1]
k Since the internal pressure of the

adjustment cylinder is very high, do not
loosen the lubricator more than one turn.
If the grease does not come out
sufficiently, start the engine and move the
machine backwards and forwards.
5. Change the location of guide pin (GP).

1) Lift the tracks with the work equipment
extended against ground.
2) Move away blocks [1] that were set under the
track below the idler and sprocket.
3) Move guide pin (GP) to the front of the idler.
4) Relieve the extended work equipment, and
3. Position master pin (2). lower the machine.
5) Place block [1] under track (3) in front of the
1) Lift the tracks with the work equipment idler.
extended against ground.
2) Position master pin (2) in around the center
of lower track and between two track rollers.
3) Put blocks [1] under the track below the idler
and sprocket.
6. Pull out guide pin (GP), and move the machine

back slowly to separate track (3). [*3]
PC210LC-10 50-129
a Put some blocks between the track and the

track frame to prevent damages.
Connecting track (PC220-DTL0-720-K-00-A)
Perform connection in the reverse order to

separation.
[*1]
a See Testing and adjusting, "Testing and
adjusting track shoe tension".
[*2]
a Apply grease to master pin (2). (in the area
where bushing (4) and master pin (2) come
contact: shown hatched)
2 Between bushing and master pin
(hatched area):
Grease
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equivalent
a When replacing dust seals, apply grease to the

end surfaces of bushing and the contact surface
(B) of dust seals.
2 Contact surface (B portion) between
bushing and dust seal:
Grease
NIGTIGHT LYK-2 from Nippon Grease
Co., Ltd.: part no. 44392708 or equivalent
a Press fit master pin (2) and push guide pin (GP)
out.
a Using tool N, press fit master pin (2), so that the
protrusion amount (a) of the master pin is the
dimension designated below.
Protruding amount of master pin
a: 2.5 ± 1 mm
50-130 PC210LC-10
[*3]
1. Using bar [2], roll up track (3) while the machine
moves forward slowly.
2. As for latter half of the operation, use a forklift

truck or the work equipment, to pull wire [3] to fix
the track.
PC210LC-10 50-131
Removal and installation of sprocket (PC220-DT60-924-K-00-A)
Removal (PC220-DT60-520-K-00-A)
Installation (PC220-DT60-720-K-00-A)
1. Separate the track shoe assembly. For details,
see “Separation and connection of track shoe
assembly“. [*1]
2. Swing the work equipment 90 deg., push up the 2 Threads of sprocket mounting bolt:
chassis with the work equipment and place
Adhesive (LT-2)
blocks [1] between the track frame and the track.
3. Remove sprocket (2), by slinging according to 3 Sprocket mounting bolt:
the following procedure. 441 to 490 Nm {45 to 50 kgm}
1) Remove mounting bolts (1). [*1]
a Before removing the final mounting bolt,

place block [2] under sprocket (2).
2) Put sprocket (2) on block [2], make a
clearance from final drive (3), and lead sling
[3] in between.
4 Sprocket:
40 kg
50-132 PC210LC-10
Removal and installation of idler and idler cushion assembly (PC220-DTA0-924-K-00-

A)
Removal (PC200_10-DTA0-520-K-00-A)
1. Separate the track shoe assembly. For details,

see “Separation and connection of track shoe
assembly“.
2. By using bar [1], move idler and idler cushion
assembly (1) forward to a position where it can
be lifted.
Installation (PC220-DTA0-720-K-00-A)
3. Lift idler and idler cushion assembly (1), pull it

forward to remove it from track frame (2).
4 Idler and idler cushion assembly:

235 kg
4. Disconnect idler cushion assembly (4) from idler

assembly (3).
4 Idler assembly:
105 kg
4 Idler cushion assembly:

130 kg
PC210LC-10 50-133
Disassembly and assembly of idler assembly (PC200_10-DT90-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
J 791-530-1510 Installer t 1
Figure of structure
5. Remove dowel pin (8), and then remove support

(7) from shaft (5).
6. Remove bushings (9) and (10) from idler (4).
Assembly (PC200_10-DT90-710-K-00-A)
1. Press fit bushings (9) and (10) to idler (4).
Disassembly (PC200_10-DT90-530-K-00-A)
1. Remove dowel pin (1) to remove support (2).

2. Remove floating seals (3) from support (2) and
idler (4).
3. Remove idler (4) from the assembly of shaft (5)
and support (7).
a Since approximately 250 cc of oil is filled in,
drain it at this timing, or underlay some cloth
against any careless smearing.
4. Remove floating seals (6) on the other side from 2. Install shaft (5) with O-ring (12) to support (2),
idler (4) and the assembly of shaft (5) and and insert dowel pin (1).
support (7).
50-134 PC210LC-10
3. By using tool J, install floating seals (3) to idler 5. Turn it over, and supply oil between shaft (5) and
(4) and the assembly of shaft (5) and support idler (4).
(2).
5 Amount of oil to be sealed (EO-30DH):
a Completely clean, degrease, and dry the
contact surfaces (hatched area shown in the 245 to 255 cc
figure) of the floating seal and the O-ring.
a Apply oil to the sliding surface of the floating
seal, and take care not to have any dirt stuck
on it.
a After inserting the floating seals, check that
the inclination is less than 1 mm and the
protrusion (a) is within the range of 7 to 11
mm.
6. By using tool J, install floating seal (6) to idler (4)

and support (7).
contact surfaces (hatched area shown in the
on it.
a After inserting the floating seals, check that
the inclination is less than 1 mm and the
protrusion (a) is within the range of 7 to 11
mm.
4. Install the assembly of shaft (5) and support (2)

to idler (4).
PC210LC-10 50-135
7. Install shaft (5) with O-ring (11) to support (7),

and insert dowel pin (8).
a See figure of structure.
8. Supply oil and tighten plug (13).
3 Plug (13):
157 to 255 Nm {16 to 26 kgm}
a When mounting the idler assembly on the

machine, make sure that plug (13) faces right
side of the machine.
50-136 PC210LC-10
Disassembly and assembly of idler cushion (PC200_10-DTBP-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
791-600-2001 Compressor (A) t 1

or
791-685-8006 Compressor (B) t 1
790-201-2780 Spacer 1
1 791-635-3160 Extension t 1
Cylinder (686 kN {70
790-101-1600 t 1
ton})
790-101-1102 Pump t 1 2) Apply hydraulic pressure gradually to
compress the spring and remove lock plate
M 790-640-2180 Guide-bolt t 1
(3) and nut (4).
790-101-5201 Push tool kit (B) q 1
790-101-5241 • Plate 1 a Compress the spring until the nut
2 becomes loose.
790-101-5221 • Grip 1
01010-51225 • Bolt 2 a Release the hydraulic pressure slowly to
790-201-1500 Push tool KIT q 1 release the compression of the spring.
790-101-1620 • Plate 1
3 a Free length of spring: 556 mm
790-101-5021 • Grip 1 3) Remove yoke (6), plate (7a) and cylinder (7)
01010-50816 • Bolt 2 from spring (5).
4) Remove snap ring (8), dust seal (9) and
k Since the load at installed length of the
bushing (10), in turn from cylinder (7).
spring is large and dangerous, set the spring
3. Further disassembly of piston assembly (2)
securely to the tool.
1) Remove lock plate (12) from piston (11), and
a Figure of structure then remove valve (13).
2) Remove snap ring (14), then remove U-
packing (15) and ring (16).
Assembly (PC200_10-DTBP-710-K-00-A)
1. Assembly of piston (2)

1) Install ring (16) and U-packing (15) to piston
(11), and secure them with snap ring (14).
2) Tighten valve (13) lightly, and secure it with
lock plate (12).
2. Assembly of idler cushion
1) Using tool M2, press fit bushing (10) into
cylinder (7).
2) Using tool M3, install dust seal (9) to cylinder
Disassembly (PC200_10-DTBP-530-K-00-A)
(7).
3) Secure them by using snap ring (8).
1. Remove piston assembly (2) from idler cushion
assembly (1).
2. Disassembling idler cushion assembly
1) Set idler cushion assembly (1) to tool M1.
a Load at installed length of spring: 137.3
kN {14,010 kg}
PC210LC-10 50-137
a Install the piston assembly with the valve

installed position facing outward.
a Pump 300 cc of grease (G2-LI) into the
cylinder and bleed air. Check that grease
comes out of the grease hole.
4) Install cylinder (7) and yoke (6), plate (7a) to

spring (5). Install the assembly to tool M1.
2 Sliding surface of cylinder:
Grease (G2-LI)
5) Apply hydraulic pressure slowly to compress

the spring, and then tighten nut (4) so that
the installed length of the spring is dimension
(a) and secure it with lock plate (3)
a Installed length (a) of spring: 433 mm
6) Remove idler cushion assembly (1) from tool

M1.
3. Install piston assembly (2) to idler cushion
assembly (1).
2 Sliding surface of cylinder: :
Grease (G2-LI)
2 Wear ring:
Grease (G2-LI)
50-138 PC210LC-10
Disassembly and assembly of track roller assembly (PC200_10-DTD0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
K 796-670-1020 Installer t 1
a Figure of structure
Assembly (PC200_10-DTD0-710-K-00-A)
1. By using push tool [1], press fit bushings (9) and

(10) to roller (4).
2. Install O-ring (11), install collar (8) on shaft (5),
and install pin (7).
3. By using tool K, install floating seal (6a) to collar

(8).
Disassembly (PC200_10-DTD0-530-K-00-A)
contact surfaces (hatched area shown in the
1. Remove pin (1), then remove collar (2).
2. Remove floating seals (3) from collar (2) and a Take care that dirt does not stick to the
roller (4). contact face of the floating seal.
3. Remove roller (4) from the assembly of shaft (5) a After inserting the floating seals, check that
and collar (8). the inclination is less than 1 mm and the
a Since approx. 195 cc of oil is filled in, drain it protrusion (a) is within the range of 7 to 11
at this timing, or underlay some cloth against mm.
any careless smearing. 4. By using tool K, install floating seals (6b) and
4. Remove floating seal (6) on the other side from (3b) to roller (4).
roller (4), and the assmbly of shaft (5) and collar a As to precautions for installation of floating
(8). seals (6b) and (3b), refer to a marked
5. Remove pin (7) and then collar (8) from shaft (5). comments in step 3.
6. Remove bushings (9) and (10) from roller (4).
PC210LC-10 50-139
9. Supply oil and tighten plug (13).
5 Amount of oil to be sealed (EO30-DH):

190 to 200 cc
3 Plug (13):
10 to 20 Nm {1 to 2 kgm}
a When mounting the track roller assembly on
the machine, make sure that plug (13) faces
outward.
5. Assemble shaft (5) to roller (4).

6. Reverse the assembly of roller (4) and shaft (5).
7. By using tool K, install floating seal (3a) to collar

(2).
a For installation of floating seal (3a), see a
marked comments in step 3.
on it.
8. Install O-ring (12) and install collar (2) to shaft
(5) with pin (1).
50-140 PC210LC-10
Disassembly and assembly of carrier roller (ALL-DTJ0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
L 790-434-1660 Installer t 1
3. Remove ring (5) from roller (4).

4. Remove floating seal (6) from ring (5).
a Take care not to damage the sealing surface.
Disassembly (ALL-DTJ0-530-K-00-A)
1. Remove plug (9) and drain the oil from carrier

roller assembly (1).
6 Amount of oil:
75 to 85 cc
5. Remove floating seal (7) from roller (4).
a Take care not to damage the sealing surface.
2. Using push tool [1], push the end surface of the

shaft to remove shaft (2) from carrier roller
assembly (1) to separate the following parts.
6. By using push tools [2] and [3], remove bushing
• The assembly of roller (4) and ring (5), shaft (8) from roller (4).
(2) and cover (3).
• Press fitting force (reference): 59 kN {6,000
kg} min.
a The press fit between shaft (2) and ring (5),
and also between roller (4) and cover (3) are
disengaged.
a Shaft (2) and cover (3) under the shaft are
removed together.
PC210LC-10 50-141
Assembly (ALL-DTJ0-710-K-00-A)
1. By using push tools [3] and [4] , press fit bushing

(8) to roller (4).
a Press fit it from the side of cover (3).
2. Floating seal
1) By using tool L, install floating seal (7) to
roller (4).
2) By using tool L, install floating seal (6) to ring
(5).
contact surfaces (hatched area shown in
the figure) of the floating seal and the O-
ring.
Take care that dirt or other foreign matter
does not stick to the contact face of the
floating seal.
a When installing floating seals, use tool L
and make sure to press the O-ring.
a After inserting the floating seals, check
that the inclination is less than 1 mm and
the protrusion (a) is within the range of 7
to 11 mm.
50-142 PC210LC-10
5. By using push tool [8], press fit cover (3) to roller

(4).
a Degrease, wash and dry the surfaces where
roller (4) and cover (3) fit tight.
• Press fit force (reference): Min. 59 kN {6,000
kg}
3. Install roller (4) and ring (5) to shaft (2).

on it.
6. Fill carrier roller assembly (1) with oil and tighten

plug (9).
5 Amount of oil to be sealed (EO30-DH):

75 to 85 cc
3 Plug (9):
10 to 20 Nm {1 to 2 kgm}
4. Place washers [7] between push tool [6] and

roller (4). Press fit ring (5) to shaft (2) until the
height difference between roller (4) and ring (5)
becomes 1.8 ± 0.2 mm.
a Thickness of washer [7]:
1.8 ± 0.2 mm
a Use push tool [5] to support shaft (2).
PC210LC-10 50-143
Removal and installation of revolving frame assembly (PC220-H110-924-K-00-A)

the engine.


before disconnecting wirings and hoses.
a Fit a plug or flange to the disconnected hydraulic
hose to prevent oil from flowing out. 7. Disconnect hoses (6) to (11) from center swivel
Removal (PC220-H110-520-K-00-A)
joint (5). [*1]
• Hose (6): Port (DR2)
1. Remove the work equipment assembly, referring
• Hose (7): Port (E2)
to “Removal and installation of work equipment
• Hose (8): Port (B2)
assembly“.
• Hose (9): Port (D2)
2. Remove the counterweight assembly, referring
• Hose (10): Port (A2)
to “Removal and installation of counterweight
• Hose (11): Port (C2)
assembly“.
8. Pulling out pin (12) from center swivel joint (5)
3. Remove the engine hood assembly, referring to
side and disconnect stopper plate (13) from
“Removal and installation of engine hood
center swivel joint (5).
assembly“.
4. Disconnect hoses (1) of the boom cylinder. a Remove the cotter pin at the lower end of pin
(12) beforehand.
5. Sling the boom cylinder assembly (2).

6. Remove plate (3) and pin (4), then sling and 9. Sling revolving frame assembly (14).
remove boom cylinder assembly (2).
a Use two of the holes for counterweight
3 Boom cylinder assembly (2): mounting bolts and two of the holes for the
210 kg boom cylinder foot pins to lift revolving frame
assembly (14) at 4 places.
10.Remove 32 mounting bolts, then lift and remove
revolving frame assembly (14). [*2]
a First adjust the longitudinal and lateral
balance of revolving frame assembly (14)
using a lever block, etc. with two or three
mounting bolts left unremoved each at the
front and rear locations of the assembly.
Remove these remaining bolts after the
assembly is horizontally balanced.
50-144 PC210LC-10
a Lift revolving frame assembly (14) slowly,

taking care not to let it hit against center
Installation (PC220-H110-720-K-00-A)
swivel joint assembly (5). Perform installation in the reverse order to removal.
[*1]
4 Revolving frame assembly (14):
Hoses are connected to the following places.
6,500 kg
• Hose (6): Swing motor port (T)
• Hose (7): Travel speed increase solenoid valve
[*2]
2 Swivel circle mating surface:
2 Threads of revolving frame mounting
bolt:
Adhesive (LT-2)
• In case of torque tightening
3 Revolving frame assembly mounting
bolt:
716 to 814 Nm {73 to 83 kgm}
• In case of angle tightening
3 1st time:
294.2 ± 29.4 Nm {30 ± 3 kgm}
3 2nd time:
60 ± 6 deg.
again.
• Bleeding air
Bleed air from the hydraulic pump circuit. For
details, see Testing and adjusting, "Bleeding air
PC210LC-10 50-145
Removal and installation of counterweight assembly (PC220-H700-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
Commercially Eyebolt (M48 x 3)

1 q 2
available
Commercially Impact wrench
Z 2 q 1
available
Commercially Socket wrench (width
3
available across flats: 46 mm) q 1
4. By using socket wrench Z3, remove four
k Park the machine on a level ground, lower mounting bolts (4).
the work equipment to the ground, and stop a For bolts using shims, check their locations
the engine. and the quantities of shims. [*1]
Removal (PC220-H700-520-K-00-A)
1. Open right side cover (1) of the machine.
5. Lift and disconnect counterweight assembly (3).

[*2]
a Remove carefully so that it does not hit the
machine.
4 Counterweight assembly (3):

2. Disconnect connector (2).
4,920 kg
• Connector (2): Intermediate connector (A40)
of the rear view camera
Reference: Removal of rear view camera

3. Sling counterweight assembly (3) by using assembly
eyebolts Z1 installed in the eyebolt holes in the 1. Remove cover (1).
assembly.
50-146 PC210LC-10
4. Disconnect connector (4) and remove rear view

camera assembly (5).
• Connector (4): Rear view camera (A45)
2. Remove bolts (2) to remove cover (6).

a For bolts using shims (7), check their
locations and the quantities of shims.
(Shims are put on cover (6), be careful not to Installation (PC220-H700-720-K-00-A)
drop them.)

[*1]
2 Counterweight assembly (3) mounting
bolt (4) threads:
Adhesive (LT-2)
3 Counterweight assembly (3) mounting
bolt (4):
1.72 to 1.91 Nm {175 to 195 kgm}
[*2]
Installing and adjusting counterweight
a Adjust the level difference (vertical clearance)
among the exterior parts with shims.
• Shim part No.: 206-46-31450
a Install counterweight (6) so that the clearances
between side cover (5) and counterweight (6),
and revolving frame (7) and counterweight (6) in
the direction of front and rear are even and
within the limit of 10 ± 5 mm . However, the
difference between the clearance at point (S)
and the clearance at point (T) must be less than
3 mm.
3. Remove two bolts (3). a The horizontal clearance in right to left direction
between side cover (5) and counterweight (6)
must be 9 ± 4 mm.
a The horizontal clearance in right to left direction
between revolving frame (7) and counterweight
(6) must be less than 5 mm.
a The vertical clearance between upper cover (8)
and counterweight (6) must be less than 5 mm.
a Reference (enlarged view of R.H. side seen from
rear of machine)
PC210LC-10 50-147
[*3]
Installation and adjustment of rear view camera
cover
a Using shims (7), adjust the vertical clearance
between the counterweight and cover (6) to 2
mm or less.
a Hook shim (7) to cover (6) or insert it from
outside after inserting the bolt temporarily.
50-148 PC210LC-10
Hydraulic system
Removal and installation of center swivel joint assembly (PC220-J8E0-924-K-00-A)

the engine.


a Fit a plug or flange in the place of the hydraulic
hose is disconnected from to prevent oil from 3. Disconnect lower hoses (3) to (8). [*2]
flowing out.
Removal (PC220-J8E0-520-K-00-A) • Hose (5): Port (B1)
1. Stop the upper structure after swinging it 45 deg. • Hose (6): Port (D1)
clockwise, and remove two undercovers (1). • Hose (7): Port (A1)
• Hose (8): Port (C1)
a The upper structure must be swung to the
position for draining oil from the hydraulic
tank.
a For the work method in which an oil stopper
is used and the oil does not need to be
drained from the hydraulic tank, see
“Removal and installation of main pump
assembly“.
4. Disconnect lower hoses (9) and (10). [*2]

5. Remove cotter pin (13) from pin (12) of stopper
plate (11).
a Work from the underside of the machine.
a Slightly push up pin (12) for easy removal of
2. Remove drain plug (2) to drain oil from the the pin from above.
hydraulic tank. [*1]
6 Hydraulic tank:
132 l
PC210LC-10 50-149
Hydraulic system
6. Disconnect upper hoses (14) to (19). [*2]

Installation (PC220-J8E0-720-K-00-A)
• Hose (15): Port (E2) Perform installation in the reverse order to removal.
• Hose (16): Port (B2) [*1]
• Hose (17): Port (D2) • Refilling of oil (hydraulic tank)
• Hose (18): Port (A2) Supply oil through the oil filler port to the
• Hose (19): Port (C2) specified level. Run the engine to circulate the
7. Pull out pin (12), then disconnect stopper plate oil through the system. Then, check the oil level
(11) from center swivel joint (20). again.
5 Hydraulic tank:
132 l
3 Drain plug (2):
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
[*2]
Hoses are connected to the following places.
• Hose (3): L.H. travel motor port (T)
• Hose (4): R.H. travel motor port (T)
• Hose (5): L.H. travel motor port (PA)
• Hose (6): R.H. travel motor port (PB)
8. Remove four mounting bolts (21) of center • Hose (7): L.H. travel motor port (PB)
swivel joint (20).[*3] • Hose (8): R.H. travel motor port (PA)
• Hose (9): L.H. travel motor port (P)
• Hose (10): R.H. travel motor port (P)
• Hose (14): Swing motor port (T)
• Hose (15): Travel speed increase solenoid valve
[*3]
If center swivel joint base (22) was removed, install
it, four bolts (23), eight washers (24), and four nuts
(25) to the dimensions shown in the figure to set
center of swing (C).
9. Sling and remove center swivel joint (20).
4 Center swivel joint (20):

40 kg
50-150 PC210LC-10
Hydraulic system
• Bleeding air
details, see Testing and adjusting, “Bleeding air
from hydraulic circuit“.
PC210LC-10 50-151
Hydraulic system
Disassembly and assembly of center swivel joint (PC220-J8E0-926-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
790-101-2501 Push-puller q 1
790-101-2510 • Block 1
790-101-2520 • Screw 1
791-112-1180 • Nut 1
S 790-101-2540 • Washer 1
790-101-2630 • Leg 2
790-101-2570 • Plate 4
790-101-2560 • Nut 2 5. Remove slipper seals (10) and O-rings (11) from
rotor (8).
790-101-2680 • Adapter 2
6. Remove dust seal (12) from cover (13).
a Figure of structure Assembly (PC220-J8E0-710-K-00-A)
1. Install plug (14) to shaft (9).

3 Plug (14):
33.3 ± 3.9 Nm {3.4 ± 0.4 kgm}
a Before installing plug (14), clean, degrease,
and dry its thread portion.
a After installing plug (14), check that its head
is lower than the end face of shaft (9).
2. Install slipper seals (10) and O-rings (11) to rotor
(8).
3. Install dust seal (12) to cover (13).
4. Install cover (13) to shaft (9).
5. Place shaft (9) on the block. Using the push tool,
install rotor (8) to the shaft while tapping the
rotor lightly with a plastic hammer.
2 Contact surfaces on rotor and shaft:
Grease (G2-LI)
a When installing rotor (8), take care not to
damage dust seal (12) and O-rings (11).
6. Install ring (7) and secure it with snap ring (6).
7. Install cover (4) with O-ring (5).
3 Cover (4) mounting bolt:
31.4 ± 2.9 Nm {3.2 ± 0.3 kgm}
8. Install elbows (1), (2) and tee (3).
Disassembly (PC220-J8E0-530-K-00-A)
3 Elbow (1):
1. Remove elbows (1) and (2) and remove tee (3). 128 to 186 Nm {13 to 19 kgm}
3. Remove snap ring (6) and ring (7). 3 Elbow (2) and tee (3):
4. Using tool S, push shaft (9) out of rotor (8). 35 to 63 Nm {3.5 to 6.5 kgm}
50-152 PC210LC-10
Hydraulic system
Removal and installation of hydraulic tank assembly (PC220-PM30-924-K-00-A)

the engine.


a Fit a plug or flange to disconnected hydraulic
hose to prevent oil from flowing out. 4. Remove step (4), handrail (5) (six bolts), plate
Removal (PC200_10-PM30-520-K-00-A)
(6) which is fastened together with the handrail,
and covers (7) (three bolts), (8a) (five bolts), and
1. Stop the upper structure after swinging it 45 (8b) (four bolts).
degrees clockwise, and remove two
undercovers (1). a After removing KCCV hose clamp (4a)
mounting bolt, remove four bolts (4b), then
a Leave the upper structure in the swung remove step (4).
position in order to remove the hydraulic tank
mounting bolts and the suction tube.
2. Remove drain plug (2) to drain oil from the

hydraulic tank. [*1]
6 Hydraulic tank:
132 l
3. Open the R.H. side cover of the machine and

remove rubber-lined cover (3) (four bolts).
PC210LC-10 50-153
Hydraulic system
5. Remove three mounting bolts (10) of cover (9) 7. Remove cover (13) (four bolts).
and four mounting bolts (12) of cover (11).
as it is without separating it into the upper
and lower halves.
a Remove covers (9) and (11) after removing
frame (14).
6. Remove nine mounting bolts (14a) for frame
(14).
8. Remove frame (14) (nine bolts).
4 Frame (14):
11 kg
9. Lift up and remove covers (9) and (11). [*2]

50-154 PC210LC-10
Hydraulic system
10.Remove clamps (15) (one bolt each) and move 13.Remove four mounting bolts (31) of the suction
them away from hydraulic tank (16). tube and six mounting bolts (32) of the hydraulic
tank. [*3]
a Be sure to place a container to collect the
hydraulic oil that remains undrained and
flows out when the suction tube is
disconnected.
11.Disconnect hoses (20) to (25).

• Hose (20): To attachment circuit
• Hose (21): To control valve
• Hose (22): To solenoid valve
• Hose (23): To center swivel joint
• Hose (24): To PPC valve 14.Sling and remove hydraulic tank (16) .
• Hose (25): To main pump
4 Hydraulic tank (16):
140 kg
a Use eyebolts to sling and remove hydraulic
tank (16) in order to keep the tank horizontal.
• Eyebolt: M12 x 1.75
12.Remove hoses (26) to (28) and brackets (29)

and (30).
• Hose (28): To oil cooler
Installation (PC200_10-PM30-720-K-00-A)

[*1]
PC210LC-10 50-155
Hydraulic system

again.
5 Hydraulic tank:
132 l
3 Drain plug (2):
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
[*2]
When installing covers (9) and (11), engage each
cover with clips (1) (four places) shown in the figure,
and then tighten the mounting bolts.
[*3]
3 Suction tube mounting bolt (31):
29.4 to 49.0 Nm {3 to 5 kgm}
3 Hydraulic tank mounting bolt (32):
235 to 285 Nm {23.5 to 29.5 kgm}
• Bleeding air
details, see Testing and adjusting, "Bleeding air
50-156 PC210LC-10
Hydraulic system
Removal and installation of main pump assembly (PC220-C200-924-K-00-A)
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
1 796-460-1210 Oil stopper q 1

R
2 796-770-1320 Adapter q 1
k Park the machine on a level place, swing the

upper structure by 45 deg. clockwise, lower
stop the engine. a When tools R1 and R2 are available, remove
the hydraulic tank strainer and use the tools
k Set the lock lever in the LOCK position. to stop the oil.


a Tag the hoses to show their installed positions

for the prevention of wrong installation.
Removal (PC200_10-C200-520-K-00-A)
1. Remove undercover (1). 3. Remove drain plug (3) and drain the damper oil.
6 Damper case:
0.65 l
2. Remove drain plug (2) to drain the hydraulic oil.
6 Hydraulic tank:
132 l 4. Remove the KCCV ventilator assembly and
bracket, referring to “Removal and installation of
KCCV assembly“.
5. Remove the KDPF assembly, referring to
“Removal and installation of KDPF assembly“.
6. Removal of base brackets
1) Remove tube support bracket (4).
2) Disconnect hose clamp (6), harness clamp
(7), and tube clamp (8) from base bracket
(5).
PC210LC-10 50-157
Hydraulic system
3) Remove eight mounting bolts (9), then sling

and remove base bracket (5).
4 Base bracket:
25 kg

12.Disconnect six hoses.
• (21): Case drain port hose
• (22), (23): EPC source pressure input port
• (24): Pump pressure input port
• (25): Rear load pressure input port
7. Removal of covers
• (26): Front load pressure input port
1) Remove five mounting bolts (10), then 13.Disconnect harness clamps (27), (28), (29), and
remove rubber-lined cover (11). (30).
2) Remove the four mounting bolts, then 14.Disconnect swash plate sensor P28 (31) of the
remove cover (12). rear pump and swash plate sensor P27 (32) of
the front pump.
15.Remove KDPF water drain tube (33).
3) Remove two mounting bolts (13), then

remove cover (14). [*1]
a Cover (14) can be removed as it is, 16.Disconnect discharge port hose (34) of the rear
without separating it into the upper and pump and discharge port hose (35) of the front
lower halves. pump.
17.Sling hose bracket (39) and remove two
18.Sling and remove hose bracket (39) together
with hoses (36) and (37).
8. Disconnect harness clamp (15).

9. Disconnect connectors V19 (16) and V11 (17).
10.Disconnect connectors V12 (18) and P22 (19).
50-158 PC210LC-10
Hydraulic system
19.Remove four mounting bolts (41) and Installation (PC220-C200-720-K-00-A)

disconnect pump suction port tube (42).

[*1]
a When installing cover (14), engage the cover
with clip (49) shown in the figure, and then
tighten the mounting bolts.

21.Remove engine oil filter bracket (45) and
reposition it downward..
a Harness clamp (46) is tightened together.
[*2]
2 Main pump involute splines:
Molybdenum disulfide grease (LM-G)
2 Mating face on main pump case:
a Take care not to torque the bolts excessively
since the flywheel housing is made of aluminum.
22.Sling main pump assembly (47) and remove • Filling of oil (damper case)
mounting bolts (48). Supply oil through the oil filler port to the
23.Sling and remove main pump assembly (47). specified level.
[*2]
5 Damper case:
4 Main pump assembly:
0.65 l
190 kg
3 Damper case drain plug:
45 ± 5 Nm {4.6 ± 0.5 kgm}
PC210LC-10 50-159
Hydraulic system

again.
5 Hydraulic tank:
132 l
3 Hydraulic tank drain plug:
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
• Bleeding air
See Testing and adjusting, "Bleeding air from
hydraulic circuit".
50-160 PC210LC-10
Hydraulic system
Removal and installation of control valve assembly (PC220-C030-924-K-00-A)

the engine.



before disconnecting wiring and hoses. 3. Disconnect clamp (3).
4. Pull connector (4) of each solenoid valve out of
a Fit a plug or flange to the disconnected hydraulic the clip.
hose ends to prevent oil from flowing out.
a Connectors (4) are arranged in the following
Removal (PC200_10-C030-520-K-00-A) order from the bottom.
1. Remove undercover (1) and drain oil from the • Connector (V01): PPC oil pressure lock
hydraulic tank. [*1] solenoid valve
• Connector (V02): 2-stage relief solenoid
a The upper structure must be positioned at a
valve
swing angle of approximately zero degree for
• Connector (V03): Swing holding brake
the work in Steps 3 to 6 and removal of the
solenoid valve
mounting bolts of the control valve.
• Connector (V04): Travel speed increase
solenoid valve
6 Hydraulic tank: • Connector (V05): Travel junction solenoid
132 l valve
a For the work method in which an oil stopper • Connector (V06): Swing 2-stage relief
is used and the oil does not need to be solenoid valve
drained from the hydraulic tank, see • Connector (V07): Attachment circuit
“Removal“ . selector solenoid valve (for machines
equipped with attachment)

5. Disconnect solenoid valve hoses (5) to (12).
PC210LC-10 50-161
Hydraulic system
a The hose bands are colored as follows:

• Hose (5): Red (to PPC valve)
• Hose (6): Without band (to control valve)
• Hose (7): Without band (to control valve)
• Hose (8): Blue (to swing motor)
• Hose (9): Red and yellow (to travel motor)
• Hose (10): Brown (to control valve)
• Hose (11): White (to swing motor)
• Hose (12): Green (to attachment circuit
selector solenoid valve) (for machines
9. Open the engine hood, remove mounting bolt of

KCCV hose clamp (17a), and remove step (17)
(four bolts), covers (18) (five bolts), and (19)
(four bolts).
a If the machine is equipped with a return oil
filter and accumulator, remove them referring
to Step 4 of “Removal and installation of
swing motor and swing machinery assembly“.
(for machines equipped with attachment)
6. Disconnect connector (13) and detach the

harness from two clamps (14).
• Connector (13): Variable back pressure EPC
valve (V25)
7. Remove two solenoid valve mounting bolts (15).
a Move the solenoid valve aside to allow
removing the mounting bolts of the control
valve.
8. Open the right side cover and remove rubber-

lined cover (16) (five bolts).
10.Remove three mounting bolts (21) of cover (20)
and five mounting bolts (24) of cover (22).
as it is without separating it into the upper
and lower halves.
a Remove covers (20) and (22) after removing
frame (25).
11.Remove eight mounting bolts (25a) of frame
(25).
50-162 PC210LC-10
Hydraulic system

14.Disconnect hoses (26) and (27) and connectors

(28) to (30) .
a The bands are colored as follows:
• Hose (26): Without band (port (PLS1))
• Hose (27): Red (port (PLS2))
• Connector (28): Red (merge-divider EPC
valve (V23))
• Connector (29): White (merge-divider
EPC valve (V24))
• Connector (30): Rear pump pressure
sensor (P26)
12.Remove frame (25) (seven bolts).

15.Remove clamps (31) to (33).
4 Frame (25):
11 kg
a Hose (34) is disconnected here to make it
movable and thus facilitate the work.
• Hose (34): Port (T1)
13.Remove covers (20) and (22) by raising them.

[*2]
PC210LC-10 50-163
Hydraulic system
17.Disconnect hoses (35) to (41) on the right of the a The hose bands are colored as follows:
control valve. [*3] • Hose (43): Without band (port (PX1))
a The bands are colored as follows: • Hose (44): Without band (port (P-1))
• Hose (45): Without band (port (BP5)) (for
• Hose (35): Without band (port (P-2)) (for
machines equipped with attachment)
• Hose (46): Without band (port (BP5)) (for
• Hose (36): White (port (P2))
• Hose (37): Red (port (P4))
• Hose (47): Black (port (P1))
• Hose (38): Brown (port (P6))
• Hose (48): Without band (port (P3))
• Hose (39): Without band (port (P8))
• Hose (49): Green (port (P5))
• Hose (40): Green (port (P10))
• Hose (50): Red (port (P7))
• Hose (41): Blue (port (P12))
• Hose (51): Blue (port (P9))
• Hose (52): Yellow (port (P11))
• Hose (53): Without band (port (BP1))
• Hose (54): Without band (port (PX2))
a Disconnect hose (53) from the front of the
control valve.
• Hose (55): Port (TSW)
a Disconnect hose (55) from the swing
motor, because the hose is difficult to
disconnect from the control valve.

• Hose (42): Brown (port (PST))
21.Disconnect hoses (56) and (57) at the rear of the

control valve. [*3]
a The bands are colored as follows:
• Hose (56): Yellow (port (PR))
• Hose (57): Blue (port (PPS2))
19.Disconnect hoses (43) to (54) on the left of the
22.Disconnect tubes (58) and (59). [*4]
control valve. [*3]
• Tube (58): Port (PP1)
• Tube (59): Port (PP2)
23.Disconnect connector (60).
• Connector (60): Pressure sensor (P25)
50-164 PC210LC-10
Hydraulic system
26.Remove bracket (65) (one bolt).
27.Disconnect boom hoses (66).
24.Remove tubes (61) to (63). [*4]

• Tube (61): Port (T)
• Tube (62): Port (ATT) (for machines
28.Remove boom tube mounting clamps (67) to
(70) .
• Tube (63): Port (C)
29.Remove horn (71) from the bracket.
a The horn is removed here to facilitate the
removal of tubes (84) and (85) in Step 30.
25.Remove bracket (64) (one bolt).
PC210LC-10 50-165
Hydraulic system
30.Disconnect hoses (72) to (83) and tubes (84) 32.Sling and remove control valve assembly (87).
and (85) on the front of the control valve. [*3]
• Hose (72): Port (A-1) (for machines equipped 4 Control valve assembly (87):
with attachment) 265 kg
a Using eyebolts, lift and remove control valve
assembly (87), keeping it horizontal.
• Hose (76): Port (A5) • Eyebolt: M12 x 1.75
• Hose (78): Port (B-1) (for machines equpped
with attachment)
• Tube (84): Port (A3)
• Tube (85): Port (B3)
Installation (PC200_10-C030-720-K-00-A)

[*1]
again.
5 Hydraulic tank: 132 l

3 Drain plug:
68.6 ± 9.8 Nm {7.0 ± 1.0 kgm}
[*2]
When installing covers (20) and (22), engage each
cover with clips (120) (4 places) shown in the figure,
and then tighten the mounting bolts.
31.Remove four mounting bolts (86) . [*5]
50-166 PC210LC-10
Hydraulic system
• Hose (73): Bucket cylinder head end

• Hose (74): Center swivel joint port (A2)
• Hose (75): Swing motor port (MB)
• Hose (76): Center swivel joint port (C2)
• Hose (77): Arm cylinder head end
• Hose (78): Attachment (for machines equipped
with attachment)
• Hose (79): Bucket cylinder bottom end
• Hose (80): Center swivel joint port (B2)
• Hose (81): Swing motor port (MA)
• Hose (82): Center swivel joint port (D2)
• Hose (83): Arm cylinder bottom end
• Tube (84): Boom cylinder bottom end
[*3]
• Tube (85): Boom cylinder head end
Hoses and tubes are connected to the following
• Bleeding air
places.
• Hose (35): Attachment PPC valve (for machines details, see Testing and adjusting, "Bleeding air
equipped with attachment) from hydraulic circuit".
• Hose (36): Relay block (bucket CURL PPC
valve)
• Hose (37): L.H. travel forward PPC valve
• Hose (38): Relay block (bucket LOWER PPC
valve)
• Hose (39): Relay block (swing LEFT PPC valve)
• Hose (40): R.H. travel forward PPC valve
• Hose (41): Relay block (arm IN PPC valve)
• Hose (42): Travel junction solenoid valve
• Hose (44): Attachment PPC valve (for machines
• Hose (45): Attachment circuit selector solenoid
valve (for machines equipped with attachment)
• Hose (46): Attachment circuit selector solenoid
valve (for machines equipped with attachment)
• Hose (47): Relay block (bucket DUMP PPC
valve)
• Hose (48): L.H. travel reverse PPC valve
• Hose (49): Relay block (boom RAISE PPC
valve)
• Hose (50): Relay block (swing RIGHT PPC
valve)
• Hose (51): R.H. travel reverse PPC valve
• Hose (52): Relay block (arm OUT PPC valve)
• Hose (53): Control valve port (P5) (boom RAISE
PPC valve)
• Hose (55): Swing motor port (S)
• Hose (56): Solenoid valve, PPC valve, EPC
valve
• Hose (57): Front pump LS valve
• Tube (58): Front pump discharge port (PAF)
• Tube (59): Rear pump discharge port (PAR)
• Tube (61): Hydraulic tank
• Tube (62): Attachment (for machines equipped
with attachment)
• Tube (63): Oil cooler
• Hose (72): Attachment (for machines equipped
with attachment)
PC210LC-10 50-167
Hydraulic system
Disassembly and assembly of control valve (PC220-C030-926-K-00-A)
a This section explains only the precautions for

assembling the contol valve assembly.
a Special tools
Necessity
Symbol
Q'ty
Part No. Part Name
796-946-1310 Guide f21.8 mm

t 1
(For 723-46-40100)
796-946-1610 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1810 Guide f21.2 mm
(For 723-46-43100 and 723-46- t 1
1 43400)
796-946-1910 Guide f21.0 mm
(For 723-46-46101 and 723-46- t 1
46300)
796-946-2210 Guide f20.6 mm
(For 723-46-45100 and 723-46- t 1
45700)
796-946-1320 Guide f21.8 mm
t 1
(For 723-46-40100)
796-946-1620 Guide f21.4 mm
t 1
(For 723-46-41100)
796-946-1820 Guide f21.2 mm
(For 723-46-43100 and 723-46- t 1
43400)
T 2
796-946-1920 Guide f21.0 mm
(For 723-46-46101 and 723-46- t 1
46300)
796-946-2220 Guide f20.6 mm
t 1
(For 723-46-45100)
796-946-1420 Guide f21.6 mm
t 1
(For 723-46-42700)
796-946-1330 Sleeve
t 1
(For 723-46-40100)
796-946-1630 Sleeve
t 1
(For 723-46-41100)
796-946-1830 Sleeve
(For 723-46-43100 and 723-46- t 1
43400)
3
796-946-1930 Sleeve
(For 723-46-46101 and 723-46- t 1
46300)
796-946-2230 Sleeve
t 1
(For 723-46-45100)
796-946-1430 Sleeve
t 1
(For 723-46-42700)
50-168 PC210LC-10
Hydraulic system
Procedure for replacing pressure compensation valve seal (PC220-L6D4-924-K-00-A)
a Since many types of pressure compensation

valves are installed, put a mark on each and
record the installed position when removing
them.
1. Remove piston (2), plug (3) and spring (4) from
pressure compensation valve (1).
2. Remove seals (5) and (6) from piston (2).
5. Install settling tool T3 on piston (2) and keep it

installed for approximately one minute so that
seals (5) and (6) fit in.
a Check that there is no extrusion or cut on the
seal.
a There are many types of pistons.

3. Place tool T1 on piston (2), put seal (5) on the
tool, and then push the seal down slowly in such
a way that it expands evenly to install it in
position.
a Put the seal on the tool and push it down to
the flat part of the tool. Then you may install
the tool to the piston to push in the seal
further.
6. Fit plug (3) and spring (4) to piston (2), then

install pressure compensation valve (1).
a After the installation, push piston (2) by hand
and check that the piston returns with the
spring force alone.
4. Repeat the same process to install another seal

(6). Place tool T2 on the same end of piston (2).
Slowly push seal (6) down in such a way that it
expands evenly to install it in position.
a Put the seal on the tool and push it down to
the flat part of the tool. Then you may install
the tool to the piston to push in the seal
further.
PC210LC-10 50-169
Hydraulic system
Assembly of control valve (PC200_10-C030-530-K-00-A)
a Assemble filter (9) installed to the bottom ports

(PLS1) and (PLS2) in the direction shown in the
figure below. (Pay attention to the position of
caulked portion (10).)
a Apply engine oil to the sliding surfaces before

assembling.
a When installing spool (7) to the valve chamber,
set drilled hole (H1) to the direction shown in the
following figure.
a Do the same with section L-L.
• When installing spool (8) to the valve chamber,

set drilled hole (H2) to the direction shown in the
following figure.
a Do the same with H-H, K-K and M-M shown in
the sectional view.
50-170 PC210LC-10
Hydraulic system
PC210LC-10 50-171
Hydraulic system
• Upper and lower control valve covers 3 Mounting bolt of arm quick return
valve:
2 Mating face of upper and lower
control valve cover blocks (11): 58.8 – 73.6 Nm {6 – 7.5 kgm}
• Arm drift prevention valve
Loctite 222 or equivalent
a Tighten the mounting bolts of the arm
a Tighten the mounting bolts of the control
hydraulic drift prevention valve in the same
valve upper and bottom cover blocks in the
order as that for the control valve cover
following order. (A o D o C o B)
block.
3 Mounting bolts for control valve upper
3 Mounting bolt of arm hydraulic drift
and lower cover blocks:
prevention valve:
156.9 – 176.5 Nm {16 – 18 kgm}
58.8 – 73.6 Nm {6 – 7.5 kgm}
a After assembling, put stoppers to prevent
cleaning solvent from entering through f12
holes (13).
• Pressure compensation valve
a Install each pressure compensation valve
paying attention to the matchmark that was
put when removing it.
3 Pressure compensation valve:
372.7 – 411.9 Nm {38 – 42 kgm}
• Main relief valve assembly
• Merge-divider valve a After installing to the control valve, check and

adjust them. For details, see Testing and
2 Merge-divider valve mating face (12): adjusting, "Measuring and adjusting oil
Loctite 222 or equivalent pressure in work equipment, swing, and
travel circuits".
a Tighten the mounting bolts of merge-divider
valve in the same order as that for the control 3 Main relief valve assembly:
valve cover block. 49 to 58.8 Nm {5 to 6 kgm}
3 Merge-divider valve mounting bolt:
156.9 – 176.5 Nm {16 – 18 kgm}
• Variable back pressure valve
a Tighten the mounting bolts of the variable
back pressure valve in the same order as
that for the control valve cover block.
3 Variable back pressure valve
mounting bolt:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• Boom drift prevention valve
a Tighten the mounting bolts of the boom
hydraulic drift prevention valve in the same
order as that for the control valve cover
block.
3 Mounting bolt of boom hydraulic drift
prevention valve:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• Arm quick return valve
a Tighten the mounting bolts of the arm quick
return valve in the same order as that for the
control valve cover block.
50-172 PC210LC-10
Hydraulic system
Disassembly and assembly of work equipment PPC valve (ALL-PL28-926-K-00-A)
Disassembly (ALL-PL28-530-K-00-A)
a This section contains only the precautions for

disassembling the work equipment PPC valve
assembly.
a Each of springs (6) and (7), consists of two
springs having different load at installed length.
Note their installed positions (hydraulic ports)
and identify them with tags to ensure correct
installation.
Assembly (ALL-PL28-710-K-00-A)
a Only precautions for assembling the work a When installing plug (3) to valve body (1), check
equipment PPC valve assembly are described the insertion depth so that the tip of the plug
below. does not protrude into the f20 hole in the valve
body.
a Before assembly, thoroughly clean the parts and
check them for any dirt, rust or damage to 3 Plug (3):
prevent failures. 4 to 9 Nm {0.4 to 0.9 kgm}
a The head of plug (2) must not be projected from a Install spring (5) with its small diameter end
the surface of valve body (1). facing shim (4).
3 Plug (2): • Diameter of spring end tum (inside diameter)
6 to 11 Nm {0.6 to 1.1 kgm} Small diameter end: f 4.9 mm
Large diameter end: f 5.55 mm
PC210LC-10 50-173
Hydraulic system
a When installing springs (6) and (7), note that 3 Nut (14):
their installed positions are determined by the 69 to 88 Nm {7 to 9 kgm}
hydraulic ports.
• Installed height is 31.9 mm for all springs.
• Load at installed length
Spring (6) (P1, P2): 35.3 N {3.6 kg}
Spring (7) (P1, P2): 21.6 N {2.2 kg}
a Before installing piston (8), apply grease (G2-LI)
to the periphery of the piston and the bore in the
valve body.
3 Bolt (11):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a When installing joint (12) to valve body (1), apply
Loctite according to the following procedure.
1. When installing the joint, apply a drop (approx.
0.02 g) of Loctite (No. 262) to each female
thread portion (A) (2 places) of the valve body.
Before installing the joint, degrease its male
threads and the female threads of the valve
body with Drysol and dry them.
2. Drop Loctite to the following positions.
2 Female thread (A) of valve body:
Loctite No. 262
3 Joint (12):
39 to 49 Nm {4 to 5 kgm}
a Apply grease (G2-LI) to the rocking parts of joint

(12) and to the contact surfaces on disc (13) and
piston (8).
2 Grease (G2-LI)
• Rocking parts of joint: 2 to 4 cc/entire periphery
• Contact surfaces on disc and piston: 0.3 to 0.8
cc/part
a Install disc (13), refering to Testing and adjusting,
"Adjusting play of work equipment and swing
PPC valves".
a Lever play:
0.5 to 3 mm (at 200 mm from lever pivot point)
50-174 PC210LC-10
Hydraulic system
Disassembly and assembly of travel PPC valve (PC220-C6V0-926-K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part Name
bol
1 796T-416-1010 Push tool t 1

Q 2 796T-416-1030 Push tool t 1
3 796T-416-1020 Push tool t 1
Disassembly (PC220-C6V0-530-K-00-A)
1. Remove screws (22) and remove damper a Note the installed position, quantity and
assemblies (21). thickness of shims (3) and keep them.
2. Remove mounting bolt (19) and remove case 8. Remove valves (2) from valve body (1).
(18), shafts (16) and levers (13) as a unit.
3. Remove pins (17).
4. Remove levers (13), bushings (14) and (14a),
and shafts (16) from case (18).
5. Remove mounting bolts (11) to remove plate
(10).
a Note the thickness and installed position of
washer (12).
a Remove pin (24) from valve body (1).
6. Remove seals (9) and collars (8).
7. Remove pistons (7), and then to remove
retainers (6), springs (5) and (4), and shims (3).
PC210LC-10 50-175
Hydraulic system
Assembly (PC220-C6V0-710-K-00-A)
a Only precautions for assembly are described. a Do not drive the pin directly with a hammer,
etc.
a Before assembly, thoroughly clean the parts and
check them for dirt, rust, or damage to prevent
failure. Assemble the parts with utmost care.
a When installing piston (7), apply grease (G2-LI)
to its periphery and the inside of the valve body
hole.
a Install spring (4) with its small diameter end
facing shim (3).
• Diameter of spring (inside diameter)
Small diameter end: f 4.9 mm
Large diameter end: f 5.55 mm
a Install shaft (16) according to the following
procedure. 3. Install lever (13).
1. Using tool Q1, install bushing (14) to the case. 4. Install shaft (16).
5. Using tool Q3, install pin (17).
a Install the bushing with its 10 deg. chamfered
side ahead. a Installed dimension (C) of pin (17) should be
as follows.
a Install the bushing so that dimension (A) is
• Dimension (C): 0 to 0.5 mm
as follows.
• Dimension (A): 20.4 ± 0.3 mm a Do not drive the pin directly with a hammer,
etc.
a Do not drive the pin directly with a hammer,
etc.
a Apply grease (G2-LI) to the rocking parts of

2. Using tool Q2, install bushing (14a) to the case. shaft (16), contact surfaces on lever (13) and
piston (7), and contact surfaces on damper
a Insert bushing (14a) with its 10-deg. (21) and pin (20).
chamfered side ahead.
2 Grease (G2-LI)
a Install bushing (14a) so that dimension (B) is
Rocking parts of shaft (16): 4 to 8 cc/
as follows (bushing end face is flush with the
entire periphery
case end face).
Contact surfaces on lever (13) and
• Dimension(B): 0 mm
piston (7): 0.3 to 0.8 cc/part
Contact surfaces on damper (21) and
pin (20): 0.3 to 0.8 cc/part
50-176 PC210LC-10
Hydraulic system
a For washer (12), install the one 16 mm in

thickness (t) first. If the difference in the lever
angle between right and left when the lever is
at full stroke position exceeds 0.7 degree,
change the thickness of the washer to make
the difference 0.7 degree or smaller.
a If the thickness of the washer is reduced by
0.3 mm, the full stroke angle of the lever
increases by 0.39 deg.
• Settings of thickness (t) of washer (12):
1.0, 1.3, 1.6, 1.9, 2.2 mm
a Tighten each part to the following torque.
3 Screw (22):
0.441 to 0.588 Nm {0.045 to 0.06 kgm}
3 Bolt (19):
25 to 30 Nm {2.5 to 3.2 kgm}
3 Bolt (11):
27 to 34 Nm {2.8 to 3.5 kgm}
PC210LC-10 50-177
Work equipment
Removal and installation of work equipment assembly (PC220-L410-924-K-00-A)
a Lower the cylinder head on a stand with the

piston rod tied by using wire to prevent it
a Special tools
from coming out, or support the cylinder
head with a block to prevent it from lowering.
Necessity
Symbol
When supporting it with a block etc., remove
Q'ty
Part No. Part Name
the grease nipple at the cylinder bottom.
a Remove the boom cylinder on the other side
796-900-1200 Remover t 1 in the same manner.
796-900-1210 • Sleeve 1
792-900-1520 • Plate 1 a If bumping of the lifting hook against the
working lamp is anticipated in lifting the work
799-900-1230 • Screw 1
equipment, the lamp must be removed.
796-900-1240 • Adapter 1
6. Stop the engine, and release the pressure
V 01643-33080 • Washer 1 remaining in the circuit. For details, see Testing
01803-13034 • Nut 1 and adjusting, “Releasing remaining pressure
Puller (490 kN {50 from hydraulic circuit“.
790-101-4000 ton} long) t 1
7. Disconnect two bucket cylinder hoses (6) and
Pump (294 kN {30 two arm cylinder hoses (7).
790-101-1102 ton}) t 1
a Plug the hose and then fix it to the valve side
k Fully extend the arm and bucket and with rope.
completely lower the work equipment to the 8. Disconnect working lamp intermediate
ground. connector A13 (8).

Removal (PC200_10-L410-520-K-00-A)
1. Disconnect greasing hose (1).

2. Sling the boom cylinder assembly (2).
3. Remove lock bolt (3).
4. Remove plate (4) and remove the boom cylinder
head pin. [*1]
a Shims are installed, so note their quantity 9. Open tool case (9), remove rubber caps (10),
and thickness. and remove the mounting bolts.
4 Boom cylinder head pin:
30 kg
10.Remove mounting bolt (11) and remove cover

(12).
5. Start the engine and then retract the piston rod.
50-178 PC210LC-10
Work equipment
11.Sling the work equipment assembly, remove Installation (PC220-L410-720-K-00-A)

plate (13) and boom foot pin (14). [*2]
[*1]
2 Inner surface of bushing when installing
pin:
Molybdenum disulphide lubricant (LM-P)
2 Pin after installed in position:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust clearance (b) between cylinder rod (16)

• Removal by using tool V and plate (4) to 1.5 mm or less by using shims.
Remove plate (13) and remove boom foot a Install one shim or more on each end face.
pin (14) by using tool V.
a Shim thickness (resin shim)
a Shims are installed, so note their quantity
• Shim (17): adjust by combining 1.0 mm and
and thickness.
2.0 mm shims
4 Boom foot pin: • Shim (18): 1.0 mm
• Shim (19): 1.0 mm
55 kg • Shim (20): 1.0 mm
12.Remove work equipment assembly (15).

[*2]
4 Work equipment assembly:
2 Inner surface of bushing when installing
4,500 kg pin:
Molybdenum disulphide lubricant (LM-P)
2 Pin after installed in position:
Grease (LM-G)
PC210LC-10 50-179
Work equipment
a Adjust clearance (c) between the foot end face

of boom (21) and bracket (22) to 1 mm or less by
using shims.
a Install one shim or more on each end face.
a Shim thickness (resin shim)
• Shim (23): 2.0 mm
• Shim (24): adjust by combining 2.0 mm, 2.5
mm, 3.0 mm, or 3.5 mm shims

Supply hydraulic oil through the oil filler port to
level again.
• Bleeding air
Bleed the air. See Testing and adjusting
"Bleeding air from hydraulic circuit".
50-180 PC210LC-10
Work equipment
Disassembly and assembly of work equipment cylinder (PC220-PPZ0-926-K-00-A)
a Special tools Disassembly of piston rod

1. Set piston rod assembly (2) on tool U1.
Necessity
Symbol
Q'ty
Part No. Part Name
790-502-1003 Cylinder repair stand q 1

1
790-101-1102 Pump q 1
790–102–4300 Wrench assembly t 1
2
790–102–4310 Pin t 2
3 790–720–1000 Expander q 1
Rubber band (for
796–720–1670 boom and bucket) q 1
07281–01279 Clamp q 1
4
Rubber band (for
796–720–1680 arm) q 1
2. Using a hexagonal wrench (6 mm), remove lock
07281–01589 Clamp q 1 screw (3) at the end of piston assembly (4).
790–201–1702 Push tool kit t 1
U a Above operation is common to the boom,
• Push tool (for
790-201–1841 boom and bucket) 1 arm and bucket cylinder.
5 • Push tool (for • Screw size: M12 x 1.75 mm (16 mm in
790–201–1851 arm) 1 length)
790–101–5021 • Grip 1
01010–50816 • Bolt 2
790–201–1500 Push tool kit t 1
• Plate (for boom
790–201–1650 and bucket) 1
6 • Plate(For arm)
790–201–1660 1
790–101–5021 • Grip 1
01010–50816 • Bolt 2
Disassembly (PC220-PPZ0-530-K-00-A)
Disconnecting cylinder assembly and piston rod
assembly
1. Remove the piping from the cylinder assembly.
2. Remove 12 mounting bolts and disconnect a If screw (3) is caulked too firmly to be
cylinder head assembly (1). loosened, squeeze the screw further once
3. Pull out piston rod assembly (2). and then apply tap (T) to the threaded portion
a Place a container under the cylinder to to ease the caulking.
collect oil from the cylinder.
3. Using tool U2, remove piston assembly (4).
PC210LC-10 50-181
Work equipment
a When not using tool U2, use the drilled holes

(H) (f10 mm, two places) to loosen the
piston assembly.
Disassembling cylinder head

1. Remove the O-ring and backup ring (15).
2. Remove snap ring (16), then remove dust seal
(17).
4. Remove plunger (5) and collar (6). 3. Remove rod packing (18) and buffer ring (19).
a Only for the arm and boom cylinders 4. Remove snap ring (30).
5. Remove cylinder head assembly (7). 5. Remove bushing (20).
6. Remove cap (8) to remove 12 balls (9), and Disassembling cylinder (arm cylinder only)
remove plunger (10). 1. Remove plug (21).
a Arm cylinder only 2. Remove spring (22) and valve (23).
Disassembling piston
1. Remove two rings (11).
2. Remove two wear rings (12).
3. Remove piston ring (13).
4. Remove the O-ring and two backup rings (14).
50-182 PC210LC-10
Work equipment
Assembly (PC200_10-PPZ0-710-K-00-A)
a Be careful not to damage the packings, dust

seals, O-rings, etc.
a Clean each part. After assembling the cylinder,
cover the piping ports and pin holes to prevent
entering of dirt.
a Before installing the backup ring, warm it in hot
water of approximately 50 to 60 °C. Do not
attempt to force it into position.
Assembly of cylinder (only for arm cylinder)

1. Install valve (23) and spring (22).
2. Install plug (21) with O-ring (24). Assembly of piston
1. Set piston ring (13) on tool U3. Expand piston
a Clean, degrease, and dry the thread portion ring (13) by turning the handle 8 to 10 turns.
of the plug, and then apply liquid gasket to 2. Remove piston ring (13) from tool U3. Install the
the entire periphery of the thread portion. ring to the piston.
3 Plug (21): 3. Using tool U4, compress piston ring (13).
83.4 – 102.9 Nm {8.5 – 10.5 kgm}
2 Plug (21):
Liquid gasket (LG–5)
4. Install two backup rings (14) and the O-ring.

a Install the backup rings and O-ring as shown
in the figure below.
5. Install wear rings (12) (2 pieces).
Assembly of cylinder head 6. Install wear rings (11) (2 pieces).
1. Using tool U5, press fit bushing (20). a Be careful not to open the end gap of the ring
2. Install snap ring (30). too wide.
3. Install buffer ring (19) and rod packing (18).
4. Install dust seal (17) using tool U6, and install
snap ring (16).
5. Install backup ring (15) and the O-ring.
Assembly of piston rod

1. Set piston rod assembly (2) to tool U1.
PC210LC-10 50-183
Work equipment
both of them are to be replaced with new ones,

see Step 7.)
1) Using tool U2, install piston assembly (4) to
piston rod assembly (2).
a Any burrs or sharp edges on threaded
portions must be removed using files
before installation.
2. Install cylinder head assembly (7).

3. Install the O-ring and the backup rings to collar
(6) and install the collar to the piston rod.
a Install the two backup rings, one each in the
front and rear of the O-ring.
a Only the boom and arm cylinders
4. Install plunger (5).
a Only the boom and arm cylinders a Fully tighten piston assembly (4) until it
contacts with end face (b) of the rod.
Then, at around this position, align screw
holes (H) in the piston and piston rod end
face
a For a cylinder with a head cushion,
ensure that there is a small play in
plunger (5) with piston assembly (4)
installed.
• Only the boom and arm cylinders
5. Place plunger (10) on piston rod assembly (2).

Install 12 balls (9) and cap (8).
a After installing the plunger, check that there
is a little play at its end.
a Arm cylinder only
2) Install screw (3) to lock piston assembly (4)

and piston rod assembly (2).
2 Screw (3) thread portion:
Adhesive (Loctite #262)
3 Screw (3):
58.9 – 73.6 Nm {6 – 7.5 kgm}
a After installing screw (3), caulk the screw
at four peripheral places (a).
6. If both of piston rod assembly (2) and piston
assembly (4) are to be reused, assemble them
according to the following procedure. (If either or
50-184 PC210LC-10
Work equipment
Tap drill diameter 10.3

Tap drill hole depth 27
Screw hole size 12 x 1.75
Screw hole depth 20
a After tapping the screw hole, remove

chips and other dirt and thoroughly clean
the area.
7. When replacing either or both of piston rod

assembly (2) and piston assembly (4) with new
ones, assemble the new ones according to the
1) Using tool U2, screw in piston assembly (4)
until it comes into contact with end face (b) of
the rod.
a If the cylinder has the bottom cushion, put
a mark on the rod end face to indicate the 3) Install screw (3) to lock piston assembly (4)
tightening position of the ball cap. and piston rod assembly (2).
3 Piston assembly (4): a After installing screw (3), caulk the screw
at four peripheral places (a).
294 ± 29.4 Nm {30 ± 3.0 kgm}
2 Screw (3) thread portion:
a For a cylinder with a head cushion,
ensure that there is a little play in plunger Adhesive (Loctite #262)
(5) with piston assembly (4) installed. 3 Screw (3):
• Only the boom and arm cylinders 58.9 – 73.6 Nm {6 – 7.5 kgm}
2) Drill a screw hole across the threads of

piston rod assembly (2) and piston assembly Connecting cylinder assembly and the piston
rod assembly
(4).
1. Install piston rod assembly (2) to tool U1.
a With a drill aligned with the V groove
where the threads of piston assembly (4)
and piston rod assembly (2) are mated,
drill a hole straight.
a The cylinder with the bottom cushion
must not be machined in the cushion cap
machining hole position.
• Dimensions of screw hole (mm):
PC210LC-10 50-185
Work equipment
2. Install the cylinder assembly to piston rod 4. Install piping.

assembly (2).
3 Piping fixing band mounting bolt:
a Align axial center of the cylinder tube, then Boom cylinder: 27.4 ± 6.9 Nm {2.8 ±
insert. 0.7 kgm}
a Check that the ring is not broken and has not Arm cylinder and Bucket cylinder: 89
come out, then push in fully. ± 34 Nm {9.0 ± 3.5 kgm}
3. Tighten the mounting bolts for cylinder head

assembly (1).
3 Cylinder head assembly (1) mounting
bolt:
Boom cylinder: 270 ± 39 Nm {27.5 ±
4.0 kgm}
Arm cylinder: 373 ± 54 Nm {38.0 ± 5.5
kgm}
Bucket cylinder: 270 ± 39 Nm {27.5 ±
4.0 kgm}
Bucket cylinder (Demolition spec):
373 ± 54 Nm {38.0 ± 5.5 kgm}
50-186 PC210LC-10
Removal and installation of operator's cab assembly (PC220-K000-924-K-00-A)

stop the engine.


a Positions of the controllers are shown below.
5. Remove box (9) (five bolts).
• A: Pump controller assembly
• B: Air conditioner controller assembly a Disconnect the hose located under box (9).
• C: KOMTRAX terminal 6. Remove box (10) (three bolts).
a Be careful about connectors (11) and (12)
located behind box (10) (for machines
equipped with 12 V power socket).
• Connector (11): 12 V power socket
intermediate harness (M13A)
intermediate harness (M13B)
7. Remove cover (13) (three bolts).
Removal (PC220-K000-520-K-00-A)
1. Remove the machine monitor assembly. For

details, see " Removal and installation of
machine monitor assembly(PAGE 50-239)".
2. Remove the floor mat.
3. Remove cover (1) first, and then remove cover
(2).
4. Remove cover and duct assembly (3).
a Remove harness (4) by passing it through
the space between cover (5) and duct (6).
8. Remove cover (14) (seven bolts).

a Disconnect connector (15) located behind
cover (14).
• Connector (15): Cigarette lighter (M04)
PC210LC-10 50-187
9. Remove duct (16). 13.Remove ducts (23) and (24).

10.Remove cover (17). 14.Disconnect connector (25).
a Disconnect connectors (18) and (19) located • Connector (25): Room lamp (L03)
behind cover (17). a Cut the cable ties holding the ducts and
• Connector (18): R.H. console connectors.
intermediate harness (H14)
• Connector (19): R.H. console
intermediate harness (H15)
15.Disconnect connectors (26) to (29) from

KOMTRAX terminal (C).
• Connector (26): Communication antenna
(GPS)
• Connector (27): Machine main harness
(CK01) .
(CK02) .
a Neatly arrange and place the disconnected
connectors on the floor apart from the
operator's cab.
11.Remove plate (20).

12.Pull up lock pin (21) to unlock and remove duct
(22).
50-188 PC210LC-10
16.Remove connector (30) from the clip at the

operator's cab.
• Connector (30): L.H. console intermediate
harness (H16)
a Neatly arrange and place the disconnected
connector on the floor apart from the
operator's cab.
17.Release connectors (31) to (35) from the clips at
the operator's cab and disconnect the
connectors.
intermediate harness (M10) (for machines
20.Disconnect connectors (38) to (40) from air
equipped with 12 V power socket)
conditioner controller assembly (B).
• Connector (32): Handsfree microphone
intermediate harness (M46) (for machines • Connector (38): Air conditioner compressor
equipped with handsfree microphone) electromagnetic clutch relay (R21)
• Connector (33): AUX intermediate connector • Connector (39): Machine main harness
(M01B) (AC02)
• Connector (34): Operator's cab roof • Connector (40): Machine main harness
intermediate connector (H09) (AC01)
• Connector (35): Loudspeaker intermediate a Air conditioner controller assembly (B) can
connector (H08) be easily removed after the above
a Neatly arrange and place the disconnected connectors are disconnected.
connectors on the floor apart from the a Neatly arrange and place the disconnected
operator's cab. connectors on the floor apart from the
18.Disconnect radio antenna (36). operator's cab.
a Cut the cable ties holding the antenna. 21.Remove two bolts (41) and remove air
conditioner controller assembly (B). Neatly
a Neatly arrange and place the removed arrange and place the assembly on the floor
antenna on the floor apart from the operator's apart from the operator's cab.
cab.
22.Remove ducts (42) and (43).

19.Remove four mounting bolts (37) and remove
pump controller assembly (A). Neatly arrange a Cut the cable ties holding the ducts.
and place the assembly on the floor apart from 23.Disconnect connector (44).
the operator's cab. • Connector (44): Front window wiper motor
(M05)
PC210LC-10 50-189
24.Remove ducts (45) to (47). 28.Remove bolt (53) from under the operator's cab
and remove lock plate (54). [*1]
29.Remove cab tipping stopper (55). (width across
flats : 46 mm) [*2]
25.Remove clamp (49).
30.Remove operator's cab mounting bolts (56) and

nuts (57). [*3]
a Bolt (56): 6 places
a Nut (57): 4 places
26.Disconnect window washer hose (50).

27.Cut cable ties (52) holding window washer hose
(50) and harness (51).
a Arrange them neatly and place window
washer hose (50) and harness (51) on the
floor.
31.Sling and remove operator's cab assembly (58).
a Lift up the operator's cab little by little while
checking that every hose, connector, and
clamp is disconnected.
4 Operator's cab assembly (58):

430 kg
50-190 PC210LC-10
Installation (PC220-K000-720-K-00-A)
• Perform installation in the reverse order to

removal.
[*1]
3 Lock plate mounting bolt (53):
98 to 123 Nm {10.0 to 12.5 kgm}
[*2]
3 Cab tipping stopper (55):
245 to 309 Nm {25.0 to 31.5 kgm}
[*3]
3 Operator's cab mounting bolt (56):
98.1 to 122.6 Nm {10 to 12.5 kgm}
PC210LC-10 50-191
Removal and installation of operator cab glass (adhered glass) (PC220-K183-924-

K-00-A)
a Special tools
Necessity
Sym-
Q'ty
Part No. Part Name
bol
2 793-498-1210 Lifter (suction cup) t 2

X
3 20Y-54-13180 Stopper rubber t 2
a Although some of the figures depict another

model, the replacement procedure is basically
the same.
a Among the glass panels on the four sides of the
operator's cab, five panes (1) to (4) and (18) are
adhered.
a In this section, the procedures for replacing the
adhered glass are explained.
a When replacing front window glass (4), remove
front window assembly (5). (It is impossible to
replace only the front window glass while the
front window assembly is installed to the
operator's cab.)
a For the procedure for replacing the front window
assembly, see "Removal and installation of front
window assembly".
50-192 PC210LC-10
(1): Right side window glass

(2): Left side rear window glass
(3): Door lower window glass
(4): Front window glass
(5): Front window assembly (front window glass and front frame)
(6): Dam rubber
(17): Center trim seal
(18): Rear window glass
PC210LC-10 50-193
Removal (PC220-K183-520-K-00-A)
a Remove the window glass to be replaced

1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).
a If the window glass is broken into small

pieces, they may be removed with knife [4]
and a flat-head screwdriver.
a Widening the cut with a flat-head screwdriver,
cut the adhesive and dam rubber with knife
[4].
2. Remove the window glass.
50-194 PC210LC-10
1. Using a knife and scraper [5], remove the a Use the primer within two hours after opening
remaining adhesive and dam rubber from the container.
sheet metal (adhesion surfaces) of the
a Even if the container of the primer is capped
operator's cab.
again just after it is opened, use it out within
a Remove the adhesive and dam rubber to a 24 hours after it is opened for the first time.
degree that they will not affect adhesion of (Discard the primer which is left unused 24
the new adhesive. Take care not to scratch hours after it is opened.)
the painted surfaces. (If the painted surfaces 1) Stir the primers for painted surface and glass
are damaged, adhesion will be lowered.) sufficiently before using them.
(The figure shows the operator's cab of a wheel
loader.) a If the primer is stored in a refrigerator,
leave it at the room temperature for at
least half a day before stirring it. (If the
primer is opened just after taken out of
the refrigerator, water will be condensed.
Accordingly, leave the primer at the room
temperature for a sufficient time.)
2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and contaminants.
a Prepare respective brushes for the
painted surface primer and glass primer.
2. Remove oil, dust, dirt, etc. from the adhesion
surfaces on cab (8) and window glass (9) with
white gasoline.
a If the adhesion surfaces are not cleaned well,
the window glass may not be bonded
perfectly.
a Clean all the black part on the back of the
window glass.
a After cleaning the adhesion surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a wheel
loader.) 3) Evenly apply the painted surface primer to
the surfaces on operator's cab (8); the
surface where dam rubber (6) is bonded on
and its outside surfaces where the adhesive
is applied to.
2 Primer for painted surface:
Sunstar Primer 580 Super for
painted surfaces
a Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
3. Apply primer (10).

a The primer is good for four months after the
date of manufacture. Do not use the primer
after the expiration date.
PC210LC-10 50-195
a Places to apply: Apply over the entire a Never apply wrong primer. If the paint
circumference with dimension (a). primer is applied by mistake, wipe it off
• Primer applying dimension (a): 30 mm with white gasoline. If glass primer, etc. is
applied by mistake, wipe it off with white
gasoline.
4) Evenly apply the glass primer to the
adhesion surfaces of glass (9).
2 Primer for glass:
Sunstar Primer 453-41 for glass
a Do not apply the primer more than two
times. (Applying primer more than twice
will degrade the performance.)
a In addition to the above places, apply

primer to right side window glass (1) and
lower door glass (3).
• Area to apply additional primer for right
side window glass (1): (b)
• Area to apply additional primer for lower
door window glass (3): (c)
a After applying the primer, leave it in air for
at least five minutes (maximum eight
hours) to dry. a Places to apply: Apply the primer to
adhesion surface (d) on window glass (9)
along its circumference, which is
determined by the installed position of
dam rubber (6) and operator's cab (8).
• Primer applying dimension (d): 30 mm
a Do not apply the primer to the boarder
area of about 5 mm wide between the
black portion and transparent portion of
the glass.
a After applying the primer, leave it in air for
at least 5 minutes (maximum 8 hours) to
dry.
a Never apply wrong primer. If painted
surface primer is applied by mistake,
wipe it off with white gasoline.
50-196 PC210LC-10
a Stick additional dam rubber (6a) for right

side window glass (1).
• Positions to stick additional dam rubber
for right side window glass:
(f): 50 mm
(g): 90 mm
(h): 250 mm
4. Stick dam rubber (double-sided tape) (6) to the

operator's cab as follows.
a Do not remove the release tape of dam
rubber on the glass sticking side before
sticking the window glass.
a When sticking the dam rubber, do not touch
the cleaned surface. 2) Stick dam rubber (6) for left side rear window
a Care should be taken not to slacken the dam glass (2) to the position as shown in the
rubber of each sticking corner. figure.
3) Stick dam rubber (6) for door lower window

a When sticking dam rubber (6) all around, do glass (3) to the position as shown in the
not overlap the ends. Or, provide a clearance figure.
of approximately 5 mm between ends (e).
1) Stick dam rubber (6) for right side window
glass (1) to the position as shown in the
figure.
a Stick additional dam rubber (6b) for door

lower window glass (3).
• Positions to stick additional dam rubber
for door lower window glass:
(j): 110 mm
PC210LC-10 50-197
(k): 90 mm a For accurate positioning, stick tape [6]

(m): 200 mm across the left, right, and bottom edges of
the right side window glass, left side rear
window glass, and door lower window
glass.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, etc. and then
remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab (8)
before installing the window glass.
4) Stick dam rubber (6) for front window glass

(4) to the position shown in the figure.
a Stick lower dam rubber (6c) for the front

window glass along the outside edge of
the lower frame, differently from other
dam rubbers (6). (If it is stuck along the
inside, it will be seen through the
transparent portion of the glass.)
a When positioning front glass (4),

• set right and left installing positions to
the frame width.
• set its vertical position to make the
height difference (p) between the
frame top and the front window glass
(4) 3 mm.
5. Position the new window glass.

1) Check the clearances between the window
glass and the operator's cab on the right, left,
upper, and lower sides, and then position the
window glass so that it is centered.
2) Stick tapes [6] between window glass (9) and
operator's cab (8). Draw a positioning line (n)
on each tape.
50-198 PC210LC-10
6. Apply adhesive.
a Use either of the two types of adhesives
according to the season.
2 Adhesive (summer):
Sunstar penguine seal 580 super "S"
or equivalent
2 Adhesive (winter):
Sunstar penguine seal 580 super "W"
or equivalent
a The using limit of the adhesive is four months
after the date of manufacture. Do not use the 4) Remove the release tape from dam rubber
adhesive after the period. (6) on the glass sticking side.
5) Apply adhesive (15) to the outside of dam
a Keep the adhesive in a dark place where the
rubber (6) on the operator's cab.
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove all the
hardened part from the nozzle tip.
1) Remove aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the
nozzle.
a Adjacent to dam rubber (6) on operator's cab

(8), apply adhesive (15) in dimensions (s)
and (t) as shown in the figure.
• Dimension (s): 10 mm
• Dimension (t): 15 mm
a Apply adhesive (15) thicker than dam rubber
2) Cut the tip of the adhesive nozzle (14) so that (6).
dimensions (q) and (r) are as follows. a Apply the adhesive evenly in height.
• Dimension (q): 10 mm
• Dimension (r): 15 mm
a Apply adhesive (15) adjacent to additional

3) Set adhesive cartridge (12) to caulking gun dam rubber (6a) for right side window glass
[7]. and additional dam rubber (6b) for lower door
window glass.
a An electric caulking gun is more efficient.
PC210LC-10 50-199
a After installing front window glass (4) fill

the clearances between the window glass
and center trim seal (16) with caulking
material in range (s) with dimensions (t)
and (u).
a After applying the primer to the part of
window glass (4) shown in section A-A,
apply the adhesive as caulking material.
• Caulking dimension (t): 2 mm
• Caulking dimension (u): 5 mm
a When caulking, apply masking to the
7. Install the window glass. window glass and form the adhesive with
1) Install window glass (9) while aligning the a rubber spatula as shown in the figure.
lines drawn on the positioning tapes in step a Wipe off the squeezed adhesive.
5.
2 Primer for glass:
a Since the window glass cannot be
Sunstar Primer 580 Super for
removed and installed again, install it with
glass
utmost caution.
2 Adhesive:
a Install the window glass within 5 minutes
after applying the adhesive. Sikaflex 250-2
2) After installing window glass (9), press entire
circumferential area until it adheres firmly to
the dam rubber.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by

pulling window glass (9) from inside of the
operator's cab using suction cup X2.
50-200 PC210LC-10
2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass to the dam
rubber to bond them completely.
9. After installing the window glass, remove any

excess of the primer and adhesive on the
operator's cab and window glass.
a Use white gasoline to wipe off the remaining
adhesive before it dries up.
a When cleaning the glass, do not give an
impact to it.
10.Cure the stuck window glass.
1) Keep the stopper rubbers, styrene foam
8. Fix the glass. blocks, and rubber bands installed for ten
hours as a curing period. (at temperature of
1) After installing right side window glass (1) to 20℃ and humidity of 60%)
the operator's cab, install stopper rubbers X3 2) After removing the stopper rubbers, styrene
to 2 places (v) at the bottom of the window foam blocks, and rubber bands, wait at least
glass to fix it. fourteen hours, at least twenty four hours in
total, before operating the machine actually.
PC210LC-10 50-201
Removal and installation of front window assembly (PC220-K181-924-K-00-A)

the engine.
k Removal and installation must be done by a

pair of two workers.
a To replace the front window glass, the front

window assembly must be removed from the
operator's cab.
Removal (PC220-K181-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling

and lock it. 4. Release the lock of front window asembly (1).
a Make sure that the assembly is certainly

locked.
2. Remove front lower window (2).
3. Remove bracket (3) at the left corner (two

screws) and bracket (4) at the right corner (two
screws). [*1]
a Leave mounting screws (5) and washers (6)
for bracket (3) at the left corner in position.
They are used to hook the pull-up assist
cable in Step 6.
5. Carefully slide front window assembly (1) down

until the lower part of front window assembly (1)
is detached from the operator's cab through the
ends from which the corner brackets are
removed in Step 2 (rail missing ends) and
support the lower part of the front window
assembly.
a Right and left rollers (8) and (7) are insertion-
fitted, so they easily become detached.
Handle them carefully.
50-202 PC210LC-10
7. Lower front window assembly (1) completely.

a Take care not to let front window assembly
(1) touch machine monitor (12).
6. Remove pin (9). [*2]

a Removal of pin (9) allows plate (11) at the
end of pull-up assist cable (10) to come off.
a Hook plate (11) on screw (5) of left corner 8. Carefully slide front window assembly (1) down
bracket (3) to hold the plate (used washer (6) to detach the top of the front window assembly
as well). from the operator's cab through the ends from
which the left and right corner brackets are
removed in Step 2 (rail missing ends).
k Pull-up assist cable (10) is under a return
load of 58.8 N {6 kg} that is working a Right and left rollers (14) and (13) are
toward the rear of the operator's cab. So insertion-fitted, so they easily become
be fully careful when removing pin (9) detached. Handle them carefully.
during the disconnection of the cable.

removal.
[*1]
PC210LC-10 50-203
• Adjust opening and closing of front window

assembly (1) according to the following
procedure.
1. Open and close front window assembly (1) to
check that it does not interfere with the rails and
that the rollers are not caught.
2. If there is any problem in opening or closing of
front window assembly (1), loosen mounting
bolts (16) of roller adjustment bracket (15) and
adjust the condition of the front window, and
then tighten the mounting bolts again.
a Make sure that bracket (15) is not slanted
when mounted.
3 Mounting bolt (16) of bracket (15):
19.6 to 25.0 Nm {2.0 to 2.5 kgm}
5. Install left corner bracket (3).

a Tighten lightly for the meantime. Bolts are
tightened to the specified torque after
adjusting the locks for the front window
3. Pull up front window assembly (1) to the ceiling assembly (1) in its "closed" position in the
and lock it. following step 6.
a Make sure that the assembly is certainly a Install left corner bracket (3) so that
locked. clearance (b) between rail (18) and left
4. Install right corner bracket (4). corner bracket (3) becomes 0 to 2.0 mm.
a Tighten lightly for the meantime. Bolts are a There must be no level difference on rolling
tightened to the specified torque after surface (R) for the roller (same as the right
adjusting the locks for the front window corner bracket).
assembly (1) in its "closed" position in the
following step 6.
a Install right corner bracket (4) so that
clearance (a) between rail (17) and right
corner bracket (4) becomes 0 to 2.0 mm.
a There must be no level difference on rolling
surface (R) for the roller.
6. Adjust the locks for the front window assembly

(1) in its "closed" position according to the
1) Install right and left corner brackets (4) and
(3) in roughly right positions so that front
50-204 PC210LC-10
window glass (19) is closely attached to cab-

side trim seal (20).
7. After the adjustment, splash water heavily over

the front window glass and check that the water
does not leak into the cab.
2) Check the working condition of right and left
8. Adjust the locks for front window assembly (1) in
locks (22) and (21) when opening and
its "open" position.
closing front window assembly (1).
1) After adjusting the locks for the front window
a If right and left locks (22) and (21) rattle; assembly (1) in its "closed" position in steps
1] Loosen lock fixing bolt (23) inside the 6 and 7, pull up front window assembly (1) to
cover, move lock (21) forward, and then the ceiling.
tighten the bolt again. (The same applies 2) Check the locks at the rear right and left of
to the right side.) the operator's cab on the following items with
2] After moving the lock, check the contact front window assembly (1) in its "open"
between front window glass (19) and cab- position.
side trim seal (20) which was checked in • Check the working condition of right and
step 1). left locks (22) and (21) (as explained
3] Repeat the work in 1] and 2] until the above).
contact of front window glass (19) and the • Front window assembly (1) must be in
working condition of right and left locks contact with the right and left rubber
(22) and (21) are both acceptable, and stoppers (24), and furthermore, must be
then tighten the mounting bolts of the pushing them backward by 1.5 to 3.0
right and left corner brackets (tighten to mm.
the specified torque). • Check that limit switch (25) is pushed
back 4 to 7 mm by front window assembly
(1).
a Since the position of limit switch (25)
cannot be adjusted, the "open" position of
front window assembly (1) is decided
within the functioning range of this switch.
a Limit switch (25) prohibits wiper operation
if the wiper switch is turned ON by
mistake while the front window assembly
is "open".
a The wiper falls into the operator's cab and
breaks if operated when front window
assembly (1) is open.
a To check whether limit switch (25) is
working, turn the starting switch to ON
position and see that, even if the wiper
switch is turned on, the wiper does not
operate when front window assembly (1)
is in the "open" position.
PC210LC-10 50-205
• When adjustment is needed after 6) Adjustment of right and left rubber stoppers
performing check in step 8; (24)
3) Close front window assembly (1). • Bring right and left rubber stoppers (24)
4) Loosen locknuts (26) of right and left rubber into contact with front window assembly
stoppers (24) and move the stoppers (1) (locked in "open" position).
backward so that front window assembly (1)
does not touch the stoppers when it is locked
in its "open" position.
• Close front window assembly (1).

• Turn right and left rubber stoppers (24) to
the left one and a half rotation.
5) Loosen lock nut (27) at both sides, and
adjust the position of striker bolt (28). a One turn of rubber stopper (24) to the left
is equivalent to squashing the rubber by
• Striker bolt (28): M10
approximately 1.5 mm.
• Diameter of hole in plate (29): 14.5 mm
a When front window assembly (1) is
locked in "open" position, front window
assembly (1) must be pushing right and
left rubber stoppers (24) by 1.5 to 3.0
mm.
• Front window assembly (1) (locked in

"open" position) must be pushing the limit
switch (25) backward by 4 to 7 mm.
• Working condition of lock (31).
• Tighten lock nuts (26) of right and left

rubber stoppers (24).
50-206 PC210LC-10
9. Adjust anti-vibration stoppers (30) of front

a Also check the latching efforts of right and
window assembly (1).
left locks (33) and (34) for the front window
1) Adjust and lock anti-vibration stopper (30) at assembly in its "closed" position (at front side
both sides so that surface (d) of stopper (D) of the operator's cab).
is in contact with surface (c) of anti-vibration
stopper (30) when front window assembly (1)
is pulled up.
[*2]
3 Pin (9):
27 to 34 Nm {2.8 to 3.5 kgm}
2 Thread portion of pin (9):
Adhesive (LT-2)
10.Check the latching efforts of front window

assembly (1).
a After finishing the adjustment of steps 6 to 9,
check that latching efforts of both right and
left locks (32) and (31) are even.
PC210LC-10 50-207
Removal and installation of floor frame assembly (PC220-H1H0-924-K-00-A)
k Park the machine on a level ground, lower a Refrigerant to be collected:

the work equipment to the ground, and stop 930 ± 50 g
the engine. 3. Remove cover (2).


k If you drain the coolant or disconnect the

heater hose when the radiator coolant
temperature is high, you may be scalded. In
such case, wait until the coolant temperature
lowers and then drain the coolant or 4. Loosen drain valve (3) to drain coolant. (Drain
disconnect the heater hose. hose: inside diameter f7 mm)
k If refrigerant gas (R134a) gets in your eyes,
you may lose your sight. And if it touches 6 Coolant:
your skins, you may suffer from frostbite. 30.7 l
Accordingly, put on the protective
eyeglasses, gloves and working suits with
long sleeves while you are collecting or
filling refrigerant (R134a).
a Never release the refrigerant (R134a) to the

atmosphere.
a Ask a qualified person for collecting, adding, and
filling operations of the refrigerant (R134a).
a Note the connector numbers and installed
positions before disconnecting wiring and hoses.
a Fit a plug or flange to the disconnected hydraulic 5. Remove cover (4).
hose ends to prevent oil from flowing out.
Removal (PC200_10-H1H0-520-K-00-A)
1. Remove operator's cab assembly (1), referring

to “Removal and installation of operator's cab
assembly“.
6. Disconnect ground cables (5).
2. Collect the refrigerant (R134a) from the air

conditioner circuit. [*1]
50-208 PC210LC-10

• Hose (18): Black (port (P1))
• Hose (19): Brown (port (P2))
7. Disconnect connectors (7) to (10) from travel

PPC valve (6).
• Connector (7): L.H. travel reverse oil
pressure sensor (P10)
11.Disconnect connectors (21) and (22) from 1-way
• Connector (8): L.H. travel forward oil
attachment PPC valve (20). (for machines
pressure sensor (P09)
• Connector (9): R.H. travel forward oil
pressure sensor (P11) • Connector (21): Pedal rear inclination oil
• Connector (10): R.H. travel reverse oil pressure switch (P14)
pressure sensor (P12) • Connector (22): Pedal front inclination oil
8. Disconnect hoses (11) to (14) from travel PPC pressure switch (P15)
valve (6). 12.Disconnect hoses (23) and (24) from 1-way
a The hose bands are colored as follows: equipped with attachment)
• Hose (11): Red (L.H. travel forward port
(P2))
• Hose (12): Without band (L.H. travel • Hose (23): Yellow (port (P1))
reverse port (P1)) • Hose (24): Without band (port (P2))
• Hose (13): Blue (R.H. travel reverse port 13.Disconnect connectors (25) and (26). (for
(P3)) machines equipped with attachment)
• Hose (14): Green (R.H. travel forward • Connector (25): Attachment oil flow rate
port (P4)) adjuster EPC valve (V30)
• Connector (26): Intermediate connector
(P13) of attachment oil pressure switch
a Cut all cable ties that hold the harnesses to
the floor frame.
9. Disconnect connectors (16) and (17) from 2-way

• Connector (16): Pedal front inclination oil
pressure switch (P16) 14.Disconnect clamps (27) (two bolts).
• Connector (17): Pedal rear inclination oil
pressure switch (P30)
10.Disconnect hoses (18) and (19) from 2-way
PC210LC-10 50-209
15.Disconnect ground cables (28). 19.Disconnect hose (35).

a Ground cable arrangement (from left to right): • Hose (35): Port (T) (drain circuit to the
(T04), (T05), (T06), (T07), (T09), (T10) hydraulic tank)
16.Remove clamps (29) and (30). 20.Disconnect connector (36).
• Connector (36): Dual pressure switch (P17)
of air conditioner
a Cut all cable ties that hold the harnesses to
the floor frame.
21.Remove bolt (37), then disconnect tubes (38) of
the air conditioner. [*2]
22.Remove clamp (39) (one bolt) fastening tubes
(38).
23.Disconnect heater core hoses (40). [*3]
24.Remove clamp (41) (one bolt) (with a spacer)
fastening hoses (40).
17.Pull connectors (31) to (33) out of the clips.

(A41) (for machines equipped with a 2nd
camera)
(A42) (for machines equipped with a 3rd
camera)
(A08) (for machines equipped with
attachment)
• Hose (34): Port (P) (circuit from PPC 25.Remove clamps (42) and (43) (two bolts each).
hydraulic lock solenoid valve) 26.Cut cable tie (44).
27.Remove clamp (45) (one bolt). (for machines
a Disconnect work equipment PPC valve
hoses (P) from the relay block. (See Step
34.)
50-210 PC210LC-10
28.Disconnect connector (46) and remove air

conditioner controller (B) from the main harness.
(AC04)
32.Open the engine hood, then remove cover (52)

(four bolts).
29.Disconnect connectors (47) to (49).

• Connector (47): R.H. console intermediate
harness (H14)
harness (H15)
• Connector (49): L.H. console intermediate
harness (H16)
33.Remove clamps (53) to (55) fastening the

hoses.
a Move the hoses toward the control valve to
allow disconnecting the work equipment
PPC valve hoses from the relay block.
a Cut the cable tie that bundles the hoses.
34.Disconnect work equipment PPC valve hoses

(57) to (64) from relay block (56).
a Be sure to place a container to receive
30.Disconnect ground cable (T01) (50).
hydraulic oil before disconnecting the hoses.
31.Disconnect all clamps that fasten main harness
(51) to the floor frame.
a Separate the pump controller assembly and
main harness from the floor frame and move
them toward the boom.
PC210LC-10 50-211

• Hose (57): White (bucket CURL circuit)
• Hose (58): Brown (boom LOWER circuit)
• Hose (59): Without band (swing RIGHT
circuit)
• Hose (60): Blue (arm IN circuit)
• Hose (61): Black (bucket DUMP circuit)
• Hose (62): Green (boom RAISE circuit)
• Hose (63): Red (swing LEFT circuit)
• Hose (64): Yellow (arm OUT circuit)
Reference: Precautions for removing work

equipment lever
Using a flat-head screwdriver and the like, push lock
(69) of resin frame (68) in boot (67) to remove boot
(67) from console resin cover (70).
a Do not forcibly pull out any parts other than lock
(69) of resin frame (68) when carrying out this
operation. Doing so may damage the resin
frame.
35.Open the left side cover of the machine and pull

out hose assembly (65).
36.Sling and remove floor frame assembly (66).

a Lift the assembly little by little while checking
that every hose, connector, and clamp is
disconnected.
4 Floor frame assembly (66):

250 kg
Installation (PC200_10-H1H0-720-K-00-A)

[*1]
• Filling air conditioner circuit with refrigerant
(R134a)
Fill the air conditioner circuit with refrigerant
(R134a).
50-212 PC210LC-10
a Filling quantity: a Cab mounts must be installed with the mount

930 ± 50 g rubber groove (1) oriented as shown in the figure.
• Refilling of air compressor oil (Top view. Left side of figure is the front side of
For details, see Others, "Filling compressor oil". machine)
• Refilling of coolant (radiator)
Supply the coolant through the coolant filler port
to the specified level. Run the engine to circulate
the coolant through the system. Then, check the
5 Coolant (engine coolant):

30.7 l (For details, see“Table of fuel,
coolant and lubricants“ .)
[*2]
a When installing the air conditioner hoses and
tubes, take care so that dust, dirt, or water does
not enter them.
a When connecting the air conditioner hoses and
tubes, check that O-rings are fitted to their joints.
a Do not reuse an O-ring since it is deformed and
deteriorated once it is used.
a When removing O-rings, use a soft tool to avoid
damaging hoses and tubes.
a Check that there is no defect or deterioration on
the O-ring.
a Apply compressor oil (Denso: ND-OIL8) for
R134a refrigerant to O-rings.
3 Hose clamp (M6 bolt):

8 to 12 Nm {0.8 to 1.2 kgm}
[*3]
a When installing the hoses of heater core, make
white line (marking) of heater hoses straight to
prevent kink of heater hoses.
Reference: Precautions for installing cab mount

a The type of damper differs by the installed
position. Note the identification labels before
removing them. (See Structure and
Function,“Cab mount and cab tipping stopper“.)
PC210LC-10 50-213
Removal and installation of air conditioner unit assembly (PC220-K500-924-K-00-A)

6 Coolant:
work equipment to the ground stably, and 30.7 l
stop the engine. 3. Pull up front window assembly (1) to the ceiling
and lock it.
k Turn the battery disconnect switch to the a Make sure that the assembly is certainly
OFF position and remove the key. locked.
k If you drain the coolant or disconnect the 5. Remove floor mat (3).
heater hose when the coolant temperature is
high, you may be scalded. In this case, wait
until the coolant temperature lowers and
then drain the coolant or disconnect the
heater hose.

you may lose your sight. And if it touches
your skins, you may suffer from frostbite.
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to the 6. Remove box (8) (five bolts).
atmosphere. a Disconnect the hose located under box (8).
a Ask a qualified person for collecting, adding, and 7. Remove box (9) (three bolts).
filling operations of the refrigerant (R134a). a Be careful about connectors (10) and (11)
a Note connector numbers and installed positions located behind box (9) (for machines
before disconnecting wiring and hoses. equipped with 12 V power socket).
a Positions of the controllers are shown below. intermediate harness (M13A)
• A: Pump controller assembly • Connector (11): 12 V power socket
• B: Air conditioner controller assembly intermediate harness (M13B)
• C: KOMTRAX terminal controller assembly 8. Pull up cover (12) (three bolts) to remove.
a The connectors and harnesses at the rear
must not be caught.
Removal (PC200_10-K500-520-K-00-A)

a Refrigerant to be collected:
930 ± 50 g
2. Drain the coolant.
50-214 PC210LC-10
9. Remove cover (13) (seven bolts). 12.Remove plate (19).

13.Pull up lock pin (20) to unlock and remove duct
a Disconnect connector (14) located behind
(21).
cover (13).
14.Remove ducts (24) to (28). [*2]
10.Remove duct (15) (two bolts). a Cut the cable ties holding the ducts.
11.Remove cover (16) (three bolts) and bracket
(41) (two bolts).
a Disconnect connectors (17) and (18) located
behind cover (16) .
harness (H14)
harness (H15)
15.Remove cable tie (39) of the left console wiring

harness.
PC210LC-10 50-215
16.Remove cable tie (40) of the floor wiring 19.Disconnect connectors (42) to (45).
harness. • Connector (42): Communication antenna
(GPS)
(CK01).
(CK02).
20.Remove KOMTRAX terminal (C) (four bolts).
17.Remove four bolts (29) and remove pump

controller assembly (A). Arrange the assembly
neatly and place it on the floor apart from the
operator's cab.
18.Disconnect connectors (30) to (32) from air

conditioner controller assembly (B).
(AC01)
• Connector (31): Machine main harness 22.Remove bolt (34), then disconnect tubes (35) of
(AC02) the air conditioner. [*3]
• Connector (32): Machine main harness 23.Disconnect hoses (36) of the heater core. [*4]
(AC04)
50-216 PC210LC-10
24.Remove six mounting bolts (37), then remove [*3]

air conditioner unit assembly (38).
a When installing air conditioner hoses and tubes,
take care so that dust, dirt or water does not
enter them.
a When connecting the air conditioner hoses and
deteriorated once it is used.
damaging hoses and tubes.
the O-ring.
Installation (PC200_10-K500-720-K-00-A) a Apply compressor oil (Denso: ND-OIL8) for
[*1]
• Filling air conditioner circuit with refrigerant
(R134a)
(R134a).
a Filling quantity:
930 ± 50 g
• Refilling of air compressor oil
For details, see Others "Filling compressor oil".
• Refilling of coolant (radiator)
Supply the coolant through the coolant filler port
to the specified level. Run the engine to circulate
the coolant through the system. Then, check the 3 Hose clamp (M6 bolt):
coolant level again. 8 to 12 Nm {0.8 to 1.2 kgm}
[*4]
5 Coolant (engine coolant):
30.7 l (For details, see“Table of fuel, a When installing the hoses of heater core, make
coolant and lubricants“.) white line (marking) of heater hoses straight to
prevent kink of heater hoses.
[*2]
Removing cover (48) makes easier to install ducts
(24) and (26) .
a Since the mounting bolts of cover (48) are
hidden by cover (47), remove cover (47) first.
PC210LC-10 50-217
Removal and installation of operator's seat (PC220-K2Q0-924-K-00-A)

stop the engine.

k Removal and installation work must be done

by a pair of two workers.

3. Pull lever (1) again and move operator's seat (2)

Removal (PC220-K2Q0-520-K-00-A) forward and fold the backrest forward.
1. Pull lever (1) and move operator's seat (2) 4. Remove two bolts (5) (with hexagonal socket)
backward. and two reinforcing plates (7), on the seat rail at
the rear side of operator's seat. [*1]
5. Disconnect connector (6) of the operator's seat.
• Connector (6): Seat belt caution switch (S19)
2. Remove two bolts (3) (with hexagonal socket)

and two reinforcing plates (4), on the seat rail at
the front side of operator's seat. [*1]
a For the heated seat

Remove wiring harness fixing band (8) and
disconnect connector (9).
(Connector (9) is located under the seat rail
mounting frame.)
• Connector (9): Heated sheet (M35)
50-218 PC210LC-10
4. Slide adjusters (11) and (12) backward and

forward approximately three times to make sure
that they slide smoothly.
5. Make sure that they are locked at the midpoint of
the sliding move, then tighten four bolts (13).
49 Nm {5.0 kgm}
6. Slide the seat assembly backward and forward
approximately three times. After making sure
that they are locked in the rearmost position,
tighten two bolts (15) of the front side.
6. Remove the operator's seat. 3 Mounting bolt (15) (front side):

49 Nm {5.0 kgm}
4 Operator's seat: 7. Slide the seat assembly backward and forward
21 kg approximately three times again. After making
sure that they are locked in the rearmost position,
Installation (PC220-K2Q0-720-K-00-A) tighten two bolts (15) of the rear side.
• Perform installation in the reverse order to 3 Mounting bolt (15) (rear side):
removal.
49 Nm {5.0 kgm}
[*1]
8. If a large operating effort is required (target is
3 Mounting bolts (3) and (5) of operator's max.15 kg), repeat adjustment and make sure
seat (hexagonal socket head): right and left locks work properly at respective
25.5 Nm {2.6 kgm} positions.
Reference: Assembly and adjustment procedure

for operator’s seat adjuster
1. Using four bolts (13), install adjusters (11) and
(12) loosely to frame (10). At the same time,
install two wires (14) for releasing slide lock.
a Check that right and left locks work properly.
2. Slide adjusters (11) and (12) backward and

install them loosely to base (16) using two bolts
(15).
a Place washer (17) between adjusters (11),
(12) and base (16).
3. Slide adjusters (11) and (12) forward and install
them loosely to base (16) using two bolts (15).
49 Nm {5.0 kgm}
PC210LC-10 50-219
Removal and installation of seat belt (PC220-K2Q3-924-K-00-A)

the engine.

k Removal and installation work must be done

by a pair of two workers.

6. Remove operator seat (2).

Removal (PC220-K2Q3-520-K-00-A)
1. Pull lever (1) and move operator's seat (2) 4 Operator's seat (2):
backward. 21 kg
7. Remove mounting bolt (6) of seat belt (7) (one
on each side) to remove seat belt (7). [*2]
2. Remove two hexagonal socket head bolts (3)

from the seat rails. [*1]
3. Pull lever (1) again and move operator's seat (2)

forward and fold the backrest forward.
4. Remove two hexagonal socket head bolts (4)
Installation (PC220-K2Q3-720-K-00-A)
from the seat rails. [*1] • Perform installation in the reverse order to
5. Disconnect connector (5). removal.
• Connector (5): Seat belt caution switch (S19) [*1]
3 Mounting bolts (hexagonal socket head)
(3) and (4) of operator's seat (2):
25.5 Nm {2.6 kgm}
[*2]
50-220 PC210LC-10
3 Mounting bolt (6) of seat belt (7):

19.6 – 29.4 Nm {2.0 to 3.0 kgm}
PC210LC-10 50-221
Removal and installation of front wiper assembly (PC220-K710-924-K-00-A)

the engine.
k Set the work equipment lock lever in the

LOCK position.

Removal (PC220-K710-520-K-00-A)
1. Check that wiper blade (1) is at stowed position

(to the R.H. stay).
2. Pull lever (3) to release the lock while holding

handle (2) at right and left of upper part of front
window.
3. Hold lower handle (4) with left hand and upper

handle (5) with right hand, and pull up the front
window, and push it against lock cap (6) at the
rear of cab to lock.
4. Check lever (3) is securely locked.

a Check that the position of arrows on lock
case (7) and lever (3) match.
50-222 PC210LC-10
8. Disconnect connector P31 (14) inside cover

5. Remove lower window (9) by pulling up at knobs
(12).
(8).
9. Remove covers (15) and (16).

6. Remove cover (10) and floor mat (11).

a Insert a flat-head screwdriver in slit (18) at
a One of four mounting screws is covered with left bottom, and pull it upward to remove
cap (13). cover (17) while releasing lug (19).
PC210LC-10 50-223
13.Move wiring harness (23) and remove connector

M05 (24).
14.Open cap (25), remove nut (26) and remove

wiper arm (27).
15.Remove cap (28), nut (29), washer (30) and
packing (31).
11.Remove duct (20).
16.Remove six mounting bolts (32) and remove

wiper motor assembly (33).
12.Remove the mounting bolts of bracket (21) and

keep the bracket with machine monitor (22) at
rear side.
a Ii is not necessary to disconnect the
connectors of machine monitor.
1. Install wiper motor assembly (33).

Adhesive (LT-2)
50-224 PC210LC-10
2. Install packing (31), washer (30) and tighten nut

(29) to the specified torque.
a Install washer (30) with its chamfered face
toward cab front.
3 Nut (29):
10.8 to 12.7 Nm {1.10 to 1.30 kgm}
5. Check the operation of the wiper arm according

1) Connect connector M05 (24) and P31 (14).
3. Install cap (28) and wiper arm (27).

a Install wiper arm (27) so that clearance "a"
between washer nozzle (34) and wiper blade
(35) becomes following dimension.
• Dimension "a": 7 mm
4. Tighten nut (26) and close cap (25).
3 Nut (26):
11.8 to 15.7 Nm {1.20 to 1.60 kgm}
2) Install lower window (9) by holding knobs (8).
PC210LC-10 50-225
3) Pull lever (3) down to release the lock while 5) When the bottom of front window touches the
holding handle (2) at right and left of front top of lower window, push the upper portion
window stowed in the ceiling. of front window against lock catcher (36) at
the front of the cab to lock.
4) Hold lower handle (4) with left hand and

upper handle (5) with right hand securely, 6) Check lever (3) is securely locked.
and push down the window forward slowly. a Check that the position of arrows on lock
case (7) and lever (3) match.
7) Turn the battery disconnect switch to the ON

position.
8) Check that the work equipment lock lever is
in the LOCK position, and then start the
engine.
9) Check the operation of wiper arm while the
front window is dry.
1] Push wiper switch (37) 3 times
consecutively, check that wiper arm (27)
makes one round trip and then be stowed
to the R.H. stay.
50-226 PC210LC-10
2] Repeat Step 1] again. 3] Repeat Step 1] again.

4] Check that wiper arm (27) makes round
a Rotating direction of motor crank
trips in odd number and then be stowed
defers between Step 1] and Step 2].
to the R.H. stay
Accordingly, check twice.
5] Keep pushing window washer switch (39)
3] Push wiper switch (37), and check
to operate the wiper, and check following.
clearance "b" with trim seal (38) becomes
following dimension when the tip of wiper • No interference between wiper slider
blade (35) reaches to the highest point. (40) and stopper (41) when the tip of
• Dimension "b": 130 mm or less wiper blade (35) reaches to the
highest point. (If interferes, click
sound is heard.)
• No interference between wiper blade
(35) and front window seal (42) when
the tip of wiper blade (35) reaches to
the lowest point.
10)Check the operation of wiper arm while the

front window is wet with washing fluid.
1] Keep pushing window washer switch (39)
for few seconds to wet the front window
throughout, then hand off the switch.
2] Check that wiper arm (27) makes two
round trips and then be stowed to the R.H. 11)If any abnormality is found in the above
stay checks, perform the installation adjustment
of wiper arm in Step 3.
PC210LC-10 50-227
6. Perform the subsequent installation in the

reverse order to removal.
50-228 PC210LC-10
Electrical system
Removal and installation of air conditioner compressor assembly (PC220-

K590-924-K-00-A)



atmosphere.
4. Disconnect two air conditioner hoses (5) and (6).
a Ask a qualified person for collecting, adding, and [*3]
filling operations of the refrigerant (R134a).
a Plug the hose to prevent any dirt, dust and
water from entering.
Removal (PC200_10-K590-520-K-00-A)
a Take care not to damage or lose the O-rings.
1. Collect the refrigerant (R134a) from the air 5. Disconnect magnetic clutch connector AC03 (7)
conditioner circuit. [*1] for the air conditioner compressor.
930 ± 50 g
2. Open the engine hood and remove fan guards
(1), (2), and (3).
6. Remove air conditioner compressor belt (12)

3. Remove air hose (4). [*2] 3) Turn jack bolt (10) and move air conditioner
a Put marks on the hose end and tube to loosening belt tension.
indicate their fitting positions. 4) Loosen the tension on air conditioner
PC210LC-10 50-229
Electrical system

Lubricant (THREEBOND PANDO 18B)
Install the clamp to the clamp mark put on the
hose.
3 Clamp bolt:
Min. 6 Nm {0.6 kgm}
Tighten the clamp so that BDG dimension is as
follows.
7. Remove four air conditioner compressor BDG: 7 to 10 mm
mounting bolts (13) and remove air conditioner
compressor (11). [*5]
[*3]
a When installing air conditioner hoses and tubes,
Installation (PC200_10-K590-720-K-00-A) take care so that dust, dirt or water does not
enter them.
Perform installation in the reverse order to removal. a When connecting the air conditioner hoses and
[*1]
• Filling air conditioner circuit with refrigerant a Do not reuse an O-ring since it is deformed and
(R134a) deteriorated once it is used.
Fill the air conditioner circuit with refrigerant a When removing O-rings, use a soft tool to avoid
(R134a). damaging hoses and tubes.
a Filling quantity: a Check that there is no defect or deterioration on
930 ± 50 g the O-ring.
• Refilling of air compressor oil a Apply compressor oil (Denso: ND-OIL8) for
For details, see Others, " Filling compressor oil". R134a refrigerant to O-rings.
[*2]
Reconnect the disconnected air tubes according to 3 Hose clamp (M6 bolt):
the following procedure. 8 to 12 Nm {0.8 to 1.2 kgm}
a Use new MIKALOR clamps.
1. Set the hose to the original (marked) position.
a Reference
Air hose fitting length:
80 mm (both R.H. and L.H. sides)
2. With bridge (BR) set under the clamp bolt,
tighten the bolt so that bridge (BR) laps over
with the band by dimension (b) indicated below.
50-230 PC210LC-10
Electrical system
[*4]
a See Testing and adjusting, " Checking and
adjusting air conditioner compressor belt
tension".
3 Lock nut (9):
108 to 132 Nm {11 to 13.5 kgm}
59 to 74 Nm {6.0 to 7.5 kgm}
[*5]
3 Air conditioner compressor assembly
mounting bolt :
24.5 to 29.4 Nm {2.5 to 3.0 kgm}
PC210LC-10 50-231
Electrical system
Removal and installation of air conditioner condenser assembly (PC220-K580-

924-K-00-A)



atmosphere.
a Ask a qualified person for collecting, adding, and
filling operations of the refrigerant (R134a). Perform installation in the reverse order to removal.
[*1]
Removal (PC220-K580-520-K-00-A) • Filling air conditioner circuit with refrigerant
(R134a)
(R134a).
a Filling quantity:
930 ± 50 g
930 ± 50 g
• Addition of air compressor oil
2. Open the left rear cover and disconnect hoses
For details, see Others, "Filling compressor oil".
(1) and (2) from air conditioner condenser
[*2]
assembly (4). [*2]
3. Remove mounting bolts (3) and open air a When installing air conditioner hoses, take care
conditioner condenser (4). so that dust, dirt or water does not enter the
hose.
a Make sure before the installation that there is an
O-ring in the piping connector of the air
conditioner hose.
deteriorated after the first time it was used.
damaging hoses.
the O-ring.
a Apply compressor oil (Denso: ND-OIL8) for
4. Remove 4 mounting bolts (5) for the air
conditioner condenser and then remove air
conditioner condenser (4). [*3] 3 Hose clamp (M6 bolt):
a In this removal operation, take care not to 8 to 12 Nm {0.8 to 1.2 kgm}
damage the core part.
50-232 PC210LC-10
Electrical system
[*3]
a Mount the air conditioner condenser assembly
by inserting cushions in place.
2 Air conditioner condenser assembly
mounting bolt threads:
Adhesive (LT-2)
3 Air conditioner condenser assembly
mounting bolt:
10 to 15 Nm {1.2 to 1.5 kgm}
PC210LC-10 50-233
Electrical system
Removal and installation of engine controller assembly (PC220-AP70-924-K-00-A)
2) Grab the connector (5) and pull it down while

pressing locking tab (8) to disconnect the
connector.
a Locking tab (8) is provided on the farther
Removal (PC220-AP70-520-K-00-A) side of connector (5).
2. Remove two mounting nuts (2), disconnect

harness clamp (3), and remove bracket (4). [*1]
4. Disconnect connectors ECM (9) and CE03 (10)

from the engine controller.
a Clean the surrounding area to remove mud
3. Disconnect connector E24 (5) from the engine and other contamination to prevent them
controller according to the following procedure. from entering the connector hole.
a Clean the surrounding area to remove mud a The connectors are locked with hexagonal
and other contamination to prevent them socket head bolts (11) (4 mm). [*2]
from entering the connector hole. 5. Remove four mounting bolts (12) and remove
1) Roll up rubber cover (6) and slide red lever engine controller (13). [*3]
(7) downward to unlock. a Ground cable (14) is tightened together.
50-234 PC210LC-10
Electrical system
Installation (PC220-AP70-720-K-00-A)

[*1]
When installing bracket (4), tighten harness clamp
(3) together.
3 Bracket mounting nut:
10 ± 2 Nm {1.0 ± 0.2 kgm}
[*2]
3 Hexagon socket head bolt (11):
3 ± 1 Nm {0.31 ± 0.1 kgm}
[*3]
When installing mounting bolt (12), tighten ground
cable (14) together.
3 Engine controller mounting bolt:
24 ± 4 Nm {2.4 ± 0.4 kgm}
PC210LC-10 50-235
Electrical system
Removal and installation of pump controller assembly (PC220-C3V1-924-K-00-A)

the engine.


a The position of the pump controller is shown in
the figure.
• A: Pump controller
3. Disconnect connectors (4) and (5) according to
a While pressing lock (L1), move lock (L2) to
the other side.
a Slider (B) comes out and the lock is
released.
• Connector (4): Pump controller (CP01)
• Connector (5): Pump controller (CP02)
4. Remove four bolts (6) to remove pump controller
(A).
Removal (PC220-C3V1-520-K-00-A)
1. Pull up cover (1) (three bolts) to remove.

a The connectors and harnesses at the rear
must not be caught.
2. Remove bolts (2) to remove plate (3).
Installation (PC220-C3V1-720-K-00-A)

removal.
Reference: Procedure for removing connector
cover (1)
1. Cut and remove cable tie (2).
50-236 PC210LC-10
Electrical system
2. Move lever (3) upward.
a Right and left sliders (4) are pushed in as far

3. Lightly press part (A) on both sides of connector as they go. (See the left figure shown below.)
cover (1) to release tabs (B). 2. Move lever (3) on connector cover (1) from the
4. Arc connector cover (1) around tab (C) to top position to the left position (locked position)
remove the cover. as shown in the following figure.
a (B) and (C): Tab
a If the sliders and lever are not set as shown
in the following figure, the connector is not
disconnected or locked securely with the
lever. Accordingly, check their positions
again.
a The figure below shows the connector

without connector cover (1).
3. Set tab (C) to the connector and place connector

cover (1).
a Take care that wiring harness (5) be not
caught.
Reference: Procedure for installing connector

cover (1)
1. Push in right and left sliders (4) as far as they
go.
4. Put tabs (B) in to install connector cover (1).
PC210LC-10 50-237
Electrical system
5. Using a new cable tie (2), bind connector cover

(1) and harness (6).
50-238 PC210LC-10
Electrical system
Removal and installation of machine monitor assembly (PC220-Q170-924-K-00-A)

the engine.


Removal (PC220-Q170-520-K-00-A)
1. Pull up front window assembly (1) to the ceiling 5. Remove connector (6) and then remove cover
and lock it. (4).
• Connector (6): Sunlight sensor (P31)
a Check that the front window is securely
locked.
6. Remove duct (10) (one bolt).
3. Remove rubber panel (3) (two bolts).
7. Insert a flat-head screwdriver in slit (7) and pull it

upward to remove cover (9) while releasing lug
(8).
4. Remove three mounting screws of cover (4).
a One of the three screws is covered with cap
(5).
PC210LC-10 50-239
Electrical system
10.Disconnect connectors (13) to (16).

a Hook (17) beneath cover (9) unites cover (9).
a Disconnecting connector (15) first makes
easier to disconnect the other connectors.
• Connector (13): Machine monitor (CM01)
• Connector (14): Machine monitor (CM02)
• Connector (15): Machine monitor (not used)
(CM03)
• Connector (16): Machine monitor (for camera
connection) (CM04)
8. Loosen mounting bolts (19) of cover and duct

assembly (18).
a Loosening mounting bolts (19) first makes
easier to remove machine monitor mounting
bolts.
9. Remove four mounting bolts (11) of machine

monitor (12).
Installation (PC220-Q170-720-K-00-A)

removal.
50-240 PC210LC-10
Electrical system
Removal and installation of pump swash plate sensor (PC220-C3WG-924-K-00-A)

the engine.


Removal (PC220-C3WG-520-K-00-A)
1. Open the right side cover and remove rubber-

lined cover (1) (five bolts).
Installation (PC220-C3WG-720-K-00-A)

3 Pump swash plate sensor mounting bolt:
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
a Adjust the pump swash plate sensor. For details,
see Testing and adjusting, "Special function of
machine monitor", "Adjustment (Cal F pump
swash plate sensor)" and "Adjustment (Cal R
pump swash plate sensor)".
2. Remove harness (2) from clip (3).

3. Disconnect connectors (4) and (5).
• Connector (4): Front pump swash plate
sensor (P27)
• Connector (5): Rear pump swash plate
sensor (P28)
4. Remove clamp (6) (one bolt) holding the swash

plate sensor harness.
5. Remove two swash plate sensor mounting bolts
(7), then remove front pump swash plate sensor
(8) and rear pump swash plate sensor (9).
PC210LC-10 50-241
Electrical system
Removal and installation of mass air flow and temperature sensor (PC220-
A96H-924-K-00-A)

Removal (PC200_10-A96H-520-K-00-A)
1. Open the engine hood and remove cover (1).
2. Disconnect connector P55 (3) of intake air flow/

temperature sensor.
3. Remove intake air flow/temperature sensor (2).
[*1]
a Be careful about dust from entering into air
cleaner.
Installation (PC220-A96H-720-K-00-A)

[*1]
3 Screw (4) for air intake flow/temperature
sensor:
0.98 to 1.27 Nm {0.1 to 0.13 kgm}
50-242 PC210LC-10
Electrical system
Removal and installation of KOMTRAX terminal assembly (PC220-Q210-924-K-00-A)

the engine.


a The position of the KOMTRAX terminal is shown
below.
• C: KOMTRAX terminal
a Be careful about connector (7) located
behind cover (6).
Removal (PC220-Q210-520-K-00-A)
1. Remove box (1) (five bolts).

a Disconnect the hose located under box (1).
5. Disconnect connectors (8) to (11).
2. Remove box (2) (three bolts).
a Be careful about connectors (3) and (4) (GPS)
located behind box (2) (for machines • Connector (9): Machine main harness
equipped with 12 V power socket). (CK01).
• Connector (3): 12 V power socket • Connector (10): Machine main harness
intermediate harness (M13A) (CK02).
• Connector (4): 12 V power socket • Connector (11): Communication antenna
intermediate harness (M13B) 6. Remove KOMTRAX terminal (C) (four bolts).
PC210LC-10 50-243
Electrical system
Installation (PC220-Q210-720-K-00-A)

removal.
50-244 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
60 Maintenance standard
8 60 Maintenance standard
PC210LC-10 60-1
Table of contents

60 Maintenance standard................................................................................................................... 60-1
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Power train................................................................................................................................. 60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery ................................................................................................................. 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Idler .................................................................................................................................. 60-14
Track roller ........................................................................................................................ 60-16
Carrier roller ...................................................................................................................... 60-17
Track shoe ........................................................................................................................ 60-18
Hydraulic tank.................................................................................................................... 60-24
Main pump ........................................................................................................................ 60-25
Control valve ..................................................................................................................... 60-26
Swing motor ...................................................................................................................... 60-36
Travel motor ...................................................................................................................... 60-38
Work equipment and swing PPC valve................................................................................. 60-41
Travel PPC valve ............................................................................................................... 60-44
1st-line attachment PPC valve (with EPC valve) ................................................................... 60-47
2nd-line attachment PPC valve ........................................................................................... 60-50
Solenoid valve ................................................................................................................... 60-52
Attachment circuit selector valve (for high-pressure circuit) .................................................... 60-53
Attachment circuit selector valve (for low-pressure circuit) ..................................................... 60-54
Center swivel joint .............................................................................................................. 60-55
Work equipment ....................................................................................................................... 60-56
Work equipment................................................................................................................. 60-56
Boom cylinder (large diameter piston) .................................................................................. 60-65
Arm cylinder ...................................................................................................................... 60-66
Bucket cylinder .................................................................................................................. 60-67
60-2 PC210LC-10
Engine mount
Engine mount (PC200_10-H320-034-K-00-A)
PC210LC-10 60-3
Cooling system
Cooling system (PC200_10-B000-034-K-00-A)
60-4 PC210LC-10
Swing circle
Swing circle (PC200_10-J110-034-K-00-A)
Unit mm
No. Item Criteria Remedy
Axial clearance of Standard clearance Allowable clearance
1 bearing (when mounted Replace
on machine) 0.5 to 1.6 3.2
PC210LC-10 60-5
Swing machinery
Swing machinery (PC200_10-J130-034-K-00-A)
60-6 PC210LC-10
Swing machinery
Unit mm
Backlash between Standard clearance Allowable clearance
1 swing motor shaft and
No.1 sun gear 0.18 to 0.28 —
Backlash between No.
2 1 sun gear and No. 1 0.16 to 0.50 1.00
planetary gear
Backlash between No.1
3 planetary gear and ring 0.18 to 0.59 1.10
gear
4 planetary carrier and 0.39 to 0.71 1.40
No. 2 sun gear
5 2 sun gear and No. 2 0.16 to 0.50 1.00
planetary gear
Replace
6 2 planetary gear and 0.18 to 0.59 1.20
ring gear
7 2 planetary carrier and 0.07 to 0.23 —
swing pinion
Backlash between
8 swing pinion and swing 0.22 to 1.32 2.00
circle
Clearance between
9 plate and No. 2 0.9 ± 0.24 —
planetary carrier
Clearance between
10 plate and No. 2 sun 2.3 ± 0.64 —
gear
Standard Repair by
Outside diameter of oil Tolerance Allowable dimension
dimension hard chrome-
11 seal contact surface of
0 plating or
spacer 125 —
-0.100 replace
PC210LC-10 60-7
Final drive
Final drive (PC220_10-DF10-034-K-00-A)
60-8 PC210LC-10
Final drive
Unit:mm
Backlash between Standard clearance Allowable clearance
1 travel motor and No. 2
planetary carrier 0.06 to 0.25 —
ring gear
No. 2 sun gear
Replace
4 planetary gear and ring 0.16 to 0.56 1.10
gear
No. 1 sun gear shaft
6 planetary carrier and 0.38 to 0.68 1.00
No. 2 sun gear
Amount of wear on Build-up
7 Repair limit 6
sprocket tooth welding for
Standard dimension Repair limit rebuilding or
8 Width of sprocket tooth replace
71 68
PC210LC-10 60-9
Sprocket
Sprocket (PC-DT60-034-K-00-A)
Unit mm
Standard dimension Repair limit
1 Wear of tooth tip
294.5 282.5 Build-up
2 Thickness of tooth root 17 11 welding for
3 Width of tooth 71 68 rebuilding or
Repair limit 6 replace
4 Wear of tooth shape
(use a full-scale drawing of sprocket tooth shape to judge)
Full-scale drawing of sprocket tooth shape

a Duplicate the full-scale drawing onto an OHP sheet
60-10 PC210LC-10
Sprocket
PC210LC-10 60-11
Track frame and idler cushion (PC200_10-DT20-034-K-00-A)
60-12 PC210LC-10
Unit:mm
Standard dimension Tolerance Repair limit
+3
Height of idler Track 107 111
1 guide frame -1
Build-up
Idler
105 ±0.5 103 welding for
support
rebuilding or
Track +4 replace
250 255
Width of idler frame -1
2 guide Idler
247.4 — 245.4
support
Free length Load at Load at
Installed
x Outside installed Free length installed
3 Recoil spring length Replace
diameter length length
126.5 kN 101 kN
561.4 x 237 433 534
{12,900 kg} {10,300 kg}
PC210LC-10 60-13
Idler
Idler (PC220-DT90-034-K-00-A)
60-14 PC210LC-10
Idler
Unit:mm
Outside diameter of Standard dimension Repair limit
1 protrusion 538 —
Outside diameter of Build-up
2 500 488
tread welding for
3 Thickness of tread 26 20 rebuilding or
4 Depth of tread 19 25 replace
5 Ovevall width 159 —
6 Width of tread 37.5 —
Standard Tolerance Standard Allowable
Clearance between dimension Shaft Hole clearance clearance
7 shaft and bushing -0.250 + 0.164 0.176 to
65 —
-0.350 - 0.074 0.514
Tolerance Standard Allowable
Standard
interfer- interfer- Replace
Interference between dimension Shaft Hole
8 ence ence bushing
idler and bushing
+ 0.108 - 0.032 0.040 to
72 —
+ 0.008 - 0.062 0.170
Clearance between Standard dimension Repair limit
9 bushing and support
0.5 to 1.0 —
(Total of both sides)
PC210LC-10 60-15
Track roller
Track roller (PC200_10-DTD0-034-K-00-A)
Unit:mm
1 flange 188 —
Outside diameter of Build-up
2 156 144
tread welding for
3 Thickness of tread 44.5 38.5 rebuilding or
4 Ovevall width 225 — replace
5 Width of tread 44.5 —
6 Width of flange 25.5 —
Clearance between dimension Shaft Hole clearance clearance
7 shaft and bushing –0.215 +0.195 0.215 to
60 —
–0.315 0 0.510 Replace
Tolerance Standard Allowable bushing
Standard
interfer- interfer-
8 ence ence
roller and bushing
+0.153 +0.030 0.023 to
67 —
+0.053 0 0.153
Clearance between Standard dimension Repair limit
9 bushing and collar Replace
0.5 to 1.0 —
(Total of both sides)
60-16 PC210LC-10
Carrier roller
Carrier roller (PC200_10-DTJ0-034-K-00-A)
Unit mm
1 flange 143 —
Outside diameter of
2 120 106
tread
3 Width of tread 43 —
4 Thickness of tread 23 16
5 Width of flange 14 —
Clearance between dimension Shaft Hole clearance clearance Replace
6 shaft and bushing -0.170 +0.301 0.338 to
40 —
-0.190 +0.168 0.491
Tolerance Standard Allowable
Standard
interfer- interfer-
7 ence ence
roller and bushing
+0.061 0 0.016 to
47 —
+0.016 -0.040 0.101
End play of roller (play Standard clearance Allowable clearance
8 of shaft end) 0.44 to 0.76 —
PC210LC-10 60-17
Track shoe
Track shoe (PC200_10-DTL0-034-K-00-A)
a Portion P shows the link on the side where the bushing is press-fitted.
*1: Triple grouser shoe
*2: Road liner
*3: Swamp shoe
*4: Flat shoe
60-18 PC210LC-10
Track shoe
Unit:mm
1 Link pitch
190.3 193.3 Turn 180
Outside diameter of Standard dimension Repair limit deg. or
2 bushing replace
59.4 54.4
3 Thickness of bushing 10.4 5.4
4 Link height
105 97 Repair or
Thickness of link replace
5 (bushing press fit part) 28.5 20.5
6 160.4
7 Shoe bolt pitch 124.4
8 62
Inside
9 84.8
width
Overall
10 Link 45.4
width
Tread
11 39.6
width
Adjust or
Protrusion of Regular 2.5
12 pin replace
Master 2.5
Protrusion of Regular 4.85
13 bushing
Master 0.0
Overall length Regular 212
14 of pin
Master 212
Overall length Regular 138.5
15 of bushing
Master 128.7
16 Thickness of spacer —
17 Bushing 88.2 to 245 kN {9 to 25 ton}
Regular
18 Press-fitting 127.4 to 274.4 kN {13 to 28 ton}
pin —
force
(*1) Master
78.4 to 147 kN {8 to 15 ton}
19 pin
Tightening torque Retightening angle
(Nm {kgm}) (deg.)
a. 490 ± 49
Regular Triple grouser
120 ± 10
link shoe {50 ± 5}
20 Shoe bolt 549 ± 59 Retighten
Road liner —
{56 ± 6}
Tightening torque Retightening angle Lower limit torque
b.
Master (Nm {kgm}) (deg.) (Nm {kgm})
link —
— —
PC210LC-10 60-19
Track shoe
Unit:mm
Standard Tolerance Standard
Interference between dimension Shaft Hole interference
21 bushing and link +0.434 +0.074
59 0.320 to 0.434
+0.394 0
Interference between +0.222 –0.138
22 regular pin and link 38 0.300 to 0.422
+0.162 –0.200
Clearance between dimension Shaft Hole clearance
23 regular pin and bushing +0.222 +0.902 Adjust or
38 0.180 to 0.740 replace
+0.162 +0.402
(*1) Interference between dimension Shaft Hole interference
24 master pin and link +0.280 +0.062
37.8 0.188 to 0.280
+0.250 0
(*1) Clearance between dimension Shaft Hole clearance
25 master pin and bushing –0.150 +0.902
38 0.552 to 1.252
–0.350 +0.402
*1: For the dry type track
60-20 PC210LC-10
Track shoe
Triple grouser shoe (PC200_10-DTL8-034-K-00-A)
Unit:mm
1 Grouser overall height
26 16
Shoe overall 36 26
2 height (*) 34.5 26
10 Build-up
Plate
3 welding for
thickness (*) 8.5 rebuilding or
4 26 replace
Grouser base length
5 19
6 20
7 Grouser tip length 14
8 19
*: 600 mm width shoe.
PC210LC-10 60-21
Track shoe
Swamp shoe (PC-DTLA-034-K-00-A)
Unit: mm
Standard dimension Repair limit Build-up
1 Shoe height welding for
102.5 90.5
rebuilding or
2 Shoe thickness 17 5 replace
60-22 PC210LC-10
Track shoe
Road liner (PC-DTLK-034-K-00-A)
Unit: mm
1 Height 70 Replace
PC210LC-10 60-23
Hydraulic tank
Hydraulic tank (PC200_10-PM30-034-K-00-A)
60-24 PC210LC-10
Main pump
Main pump (PC-C200-034-K-00-A)
PC210LC-10 60-25
Control valve
Control valve (PC200_10-C030-034-K-00-A)
60-26 PC210LC-10
Control valve
PC210LC-10 60-27
Control valve
Unit: mm
Free length Installed Load at Load at
1 Spool return spring length
407 N 326 N
55.2 x 34.4 51.2 — If damaged
{41.5 kg} {33.2 kg} or deformed,
393 N 315 N replace
2 Spool return spring 54.5 x 34.8 51.2 —
{40.1 kg} {32.1 kg} spring
375 N 300 N
{38.2 kg} {30.6 kg}
421 N 336 N
{42.9 kg} {34.3 kg}
60-28 PC210LC-10
Control valve
PC210LC-10 60-29
Control valve
Unit: mm
x Outside installed Free length installed If damaged
1 Suction valve spring length
diameter length length or deformed,
5.5 N 4.4 N replace
46.8 x 7.5 40.6 —
{0.56 kg} {0.45 kg} spring
1.5 N 1.2 N
2 Check valve spring 11.5 x 4.6 8.5 —
{0.15 kg} {0.12 kg}
60-30 PC210LC-10
Control valve
PC210LC-10 60-31
Control valve
Unit: mm
Variable back pressure x Outside installed Free length installed
1 length
valve return spring diameter length length
14.7 N 11.8 N
59.3 x 14.4 43 —
{1.5 kg} {1.2 kg}
13.7 N 11 N
2 Check valve spring 33.8 x 6 29 — If damaged
Quick return valve 170 N 135 N replace
3 60.2 x 20 36 —
spring {17.3 kg} {13.8 kg} spring
Regeneration circuit 5.9 N 4.71 N
4 31.5 x 10.3 19.5 —
check valve spring {0.6 kg} {0.48 kg}
Cooler check valve 157 N 126 N
5 88.2 x 28.4 65 —
spring {16 kg} {12.8 kg}
52.7 N 42.2 N
6 Pilot piston spring 22.35 x 9.3 13.4 —
{5.37 kg} {4.30 kg}
60-32 PC210LC-10
Control valve
PC210LC-10 60-33
Control valve
Unit: mm
Merge-divider valve x Outside installed Free length installed
1 length
spring (for LS) diameter length length
121 N 96.5 N
36.4 x 21.8 33.0 —
{12.3 kg} {9.84 kg}
250 N 200 N
2 Sequence valve spring 70.9 x 18.0 56.0 —
{25.5 kg} {20.4 kg}
Merge-divider valve 178 N 142 N If damaged
3 64.5 x 32.3 63.0 — or deformed,
spring (main) {18.1 kg} {14.5 kg}
replace
Hydraulic drift 35.3 N 28.2 N spring
4 prevention valve check 33.0 x 12.0 26.0 —
valve spring {3.6 kg} {2.88 kg}
13.7 N 11.0 N
{1.4 kg} {1.12 kg}
Regeneration circuit 5.9 N 4.71 N
6 31.5 x 10.3 19.5 —
check valve spring {0.6 kg} {0.48 kg}
Travel junction valve 50.0 N 40.0 N
7 30.7 x 20.5 23 —
spring {5.1 kg} {4.08 kg}
60-34 PC210LC-10
Control valve
PC210LC-10 60-35
Swing motor
Swing motor (PC200_10-J610-034-K-00-A)
60-36 PC210LC-10
Swing motor
Unit: mm
1 Check valve spring length
3.43 N 2.75 N replace
57.2 x 20 30.9 —
{0.35 kg} {0.28 kg} spring
13.7 N 11.0 N
2 Shuttle valve spring 16.4 x 8.9 11.5 —
{1.4 kg} {1.12 kg}
PC210LC-10 60-37
Travel motor
Travel motor (PC200_10-C400-034-K-00-A)
60-38 PC210LC-10
Travel motor
PC210LC-10 60-39
Travel motor
Unit: mm
1 Regulator piston spring length
223 N 179 N
46.9 x 20.3 37.1 —
{22.8 kg} {18.2 kg}
69.6 N 55.7 N
2 Regulator piston spring 51.1 x 13.5 39.1 — If damaged
54.9 N 43.9 N replace
3 Regulator valve spring 21.5 x 11.1 17.1 —
{5.6 kg} {4.48 kg} spring
2.55 N 2.04 N
{0.26 kg} {0.21 kg}
Suction safety valve 7.16 N 5.96 N
5 32.5 x 6.5 24.2 —
spring {0.73 kg} {0.58 kg}
Counterbalance valve 410 N 328 N
6 58.4 x 30.0 42.6 —
spring {41.9 kg} {33.5 kg}
60-40 PC210LC-10
Work equipment and swing PPC valve
Work equipment and swing PPC valve (PC200_10-PL28-034-K-00-A)
PC210LC-10 60-41
60-42 PC210LC-10
Unit:mm
Centering spring x Outside installed Free length installed
1 length
(for ports P3 and P4) diameter length length
If damaged
17.7 N 14.1 N or deformed,
42.5 x 15.5 34.0 —
{1.80 kg} {1.44 kg} replace
Centering spring 29.4 N 23.5 N spring
2 44.5 x 15.5 34.0 —
(for ports P1 and P2) {3.0 kg} {2.40 kg}
16.7 N 13.3 N
3 Metering spring 26.5 x 8.15 24.9 —
{1.70 kg} {1.36 kg}
PC210LC-10 60-43
Travel PPC valve
Travel PPC valve (PC-C6V0-034-K-00-A)
60-44 PC210LC-10
Travel PPC valve
PC210LC-10 60-45
Travel PPC valve
Unit:mm
1 Centering spring length
48.57 x 108 N 86.3 N replace
32.5 —
15.5 {11 kg} {8.8 kg} spring
26.53 x 16.7 N 13.3 N
2 Metering spring 24.9 —
8.15 {1.7 kg} {1.36 kg}
60-46 PC210LC-10
1st-line attachment PPC valve (with EPC valve)
1st-line attachment PPC valve (with EPC valve) (PC200_10-PL29-034-K-00-A)
(if equipped)
PC210LC-10 60-47
Unit:mm
1 Centering spring length
125 N 100 N replace
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg} spring
16.7 N 13.3 N
{1.70 kg} {1.36 kg}
60-48 PC210LC-10
EPC valve (PC200_10-PL2B-034-K-00-A)
(if equipped)
Unit:mm
Load at Load at If damaged
Installed or deformed,
Free length installed Free length installed
1 Metering spring length replace the
length length
PPC valve
3.1 N 2.5 N assembly
9.5 8.4 —
{0.32 kg} {0.26 kg}
PC210LC-10 60-49
2nd-line attachment PPC valve
2nd-line attachment PPC valve (PC-PL2A-034-K-00-A)
(if equipped)
Unit:mm
Standard dimension Repair limit If damaged
Free length Installed Load at Load at or deformed,
1 Centering spring
x Outside installed Free length installed replace
length spring
60-50 PC210LC-10
2nd-line attachment PPC valve
Unit:mm
125 N 100 N
33.9 x 15.3 28.4 —
{12.7 kg} {10.2 kg}
16.7 N 13.3 N
{1.70 kg} {1.36 kg}
PC210LC-10 60-51
Solenoid valve
Solenoid valve (PC-PQPT-034-K-00-A)
a The figure shows the type for a machine ready for installing attachments.
60-52 PC210LC-10
Attachment circuit selector valve (for high-pressure
circuit)
Attachment circuit selector valve (for high-pressure circuit) (PC-PQJ5-034-K-00-A)
(if equipped)
Unit mm
Free length Installed Load at Load at If damaged
x Outside installed Free length installed or deformed,
diameter length length replace
28.7 N 22.9 N spring
33.4 x 11.2 27.3 —
{2.93 kg} {2.34 kg}
PC210LC-10 60-53
Attachment circuit selector valve (for low-pressure
circuit)
Attachment circuit selector valve (for low-pressure circuit) (PC-PQJ3-034-K-00-A)
(if equipped)
Unit mm
Free length Installed Load at Load at If damaged
x Outside installed Free length installed or deformed,
diameter length length replace
834 N 667 N spring
132 x 29 114.5 —
{85.0 kg} {68.0 kg}
60-54 PC210LC-10
Center swivel joint
Center swivel joint (PC-J8E0-034-K-00-A)
Unit: mm
Allowable
Clearance between Standard dimension Standard clearance
1 clearance Replace
rotor and shaft
80 0.056 to 0.105 0.111
PC210LC-10 60-55
Work equipment
Work equipment (PC200_10-L410-034-K-00-A)
60-56 PC210LC-10
Work equipment
PC210LC-10 60-57
Work equipment
Unit:mm
Criteria
No. Item Standard Tolerance Standard Allowable Remedy
dimension Shaft Hole clearance clearance
Clearance between pin
and bushing connecting -0.036 +0.135 0.110 to
1 90 1.0
revolving frame and -0.071 +0.074 0.206
boom
Clearance between pin -0.036 +0.137 0.113 to
2 and bushing connecting 90 1.0
-0.071 +0.077 0.208
boom and arm
3 and bushing connecting 70 1.0 Replace pin
-0.076 +0.078 0.232
arm and link and bushing
-0.076 +0.074 0.213
arm and bucket
-0.076 +0.086 0.242
link and bucket
-0.076 +0.086 0.230
links
60-58 PC210LC-10
Work equipment
Unit:mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
Connecting 0 +1 Adjust shim
625.5 632 4.5 to 8.0
part of -0.5 -2 so that
7 revolving L7: Adjust with the combination of shim thickness 2.0 mm (2), clearance will
(*2) 2.5 mm (1), 3.0 mm (1), and 3.5 mm (1).
frame and be 1.0 mm or
boom 500 hours R7: Insert 2.0 mm thickness shim (1). less
(*1) +1.5
96 ±1.2 99.3 2.1 to 6.0
Connecting 0 Adjust shim
part of so that
8 revolving L8: Adjust with the combination of shim thickness 1.0 mm (1) clearance will
(*2) and 2.0 mm (2).
frame and be 1.5 mm or
boom 500 hours R8: Insert 1.0 mm thickness shim (1). less
cylinder
+3
695 ±2.4 701 2.6 to 11.4
Connecting -1 Adjust shim
part of L9-1: Adjust with the combination of shim thickness 1.0 mm (1) so that
9 boom and and 2.0 mm (2). clearance will
boom (*2) L9-2: Insert 1.0 mm thickness shim (1). be 1.5 mm or
cylinder 500 hours R9-1: Insert 1.0 mm thickness shim (1). less
R9-2: Insert 1.0 mm thickness shim (1).
+1.5 Adjust shim
Connecting 96 ±1.2 99.3 2.1 to 6.0
0 so that
part of
10 L10: Insert 1.0 mm thickness shim (1). clearance will
boom and (*2)
arm cylinder 500 hours R10: Adjust with the combination of shim thickness 1.0 mm (1) be 1.5 mm or
and 2.0 mm (2). less
0 +0.5 Adjust shim
Connecting 305.5 310 4.5 to 6.5
-0.5 0 so that
part of L11: Insert 2.0 mm thickness shim (1).
11 clearance will
boom and (*2)
R11: Adjust with either shim thickness 2.0 mm (1) or 2.5 mm be 1.0 mm or
arm 500 hours (1) or 3.0 mm (1). less
Connecting +1.5
106 ±1.2 109.3 2.1 to 6.0
part of arm 0 Replacement
12 L12: Insert 1.0 mm thickness shim (1).
cylinder and (*2) of shim
arm 500 hours R12: Insert 1.0 mm thickness shim (1).
+1.5 Adjust shim
Connecting 96 ±1.2 99.3 2.1 to 6.0
0 so that
part of arm
13 L13: Insert 1.0 mm thickness shim (1). clearance will
and bucket (*2)
cylinder R13: Adjust with the combination of shim thickness 1.0 mm (1) be 1.5 mm or
500 hours and 2.0 mm (2). less
Connecting 325 ±0.5 326.5 ±1 0 to 3.0
14 part of link (*2) L14: — —
and bucket 500 hours R14: —
Connecting 96 ±1.2 100.2 +0.5 2.5 to 5.9
part of
15a bucket (*2) L15a: Insert 1.0 mm thickness shim (1). —
cylinder and 500 hours R15a: Insert 1.0 mm thickness shim (1).
link
0 Adjust shim
280 — — —
Connecting -0.5 so that
15b part of link L15b: Insert 1.0 mm thickness shim (1). clearance will
(*2)
and link R15b: Adjust with the combination of shim thickness 1.0 mm be 1.5 mm or
500 hours (1) and 2.0 mm (1). less
PC210LC-10 60-59
Work equipment
Unit:mm
Criteria
Greasing Width of boss Width of hinge Remedy
No. Item Standard
interval Standard Standard
Tolerance Tolerance clearance
dimension dimension
0 Adjust shim
280 — — —
Connecting - 0.5 so that
16 part of arm L16: Adjust with the combination of shim thickness 1.0 mm (1) clearance will
(*2) and 2.0 mm (1).
and link be 1.5 mm or
500 hours R16: Insert 1.0 mm thickness shim (1). less
0 +2.2 Adjust shim
325 327.5 2.3 to 5.2
Connecting -0.5 -0.2 so that
17 part of arm L17: — clearance will
(*3)
and bucket R17: Adjust with the combination of shim thickness 0.5 mm (4) be 0.5 to 1.0
500 hours and 1.0 mm (12). mm
*1: The criteria indicates the L.H. boom cylinder. The position for shim adjustment of R.H. boom cylinder
becomes opposite to that of L.H. boom cylinder.
*2: Use plastic shims (with flange).
*3: Use separated iron shims.
a The number in ( ) next to the shim thickness shows the quantity of shims to be prepared.
60-60 PC210LC-10
Work equipment
Dimensions of arm (PC200_10-L412-034-K-00-A)
PC210LC-10 60-61
Work equipment
Unit: mm
PC210LC–10
No. Tolerance
Measurement point Standard dimension
Shaft Hole
-0.030 +0.100
1 — 80
-0.076 0
+1.5
Arm side 109.3
2 0
Cylinder head side 106 ±1.2
+0.5
Boom side 310
0
3
0
Arm side 305.5
-0.5
-0.036 +0.054
4 — 90
-0.071 0
5 — 402.1 ±1.0
6 — 187.2 ±0.5
7 — 829.1 ±1.0
8 — 2,919 —
9 — 2,630.5 ±1.0
10 — 410 ±1.0
11 — 640 ±0.2
12 — 600 ±0.5
13 — 458.1 —
14 — 1,486 —
-0.030 +0.100
15 — 80
-0.076 0
Link side 325 ±0.5
16
Bucket side 326.5 ±1.0
-0.030 +0.100
17 — 80
-0.076 0
0
(without bushing) 311
-0.5
18
(with bushing press-
325 —
fitted)
(Min.) 1,680 —
19
(Max.) 2,800 —
60-62 PC210LC-10
Work equipment
Dimensions of bucket (PC200_10-LBK0-034-K-00-A)
PC210LC-10 60-63
Work equipment
Unit: mm
PC210LC–10
No.
Measurement point Standard dimension Tolerance
1 — 457.6 ±0.5
2 — 22 ±0.5
3 — 92°45′ —
4 — 458.1 —
5 — 1,477.3 —
6 — 158.6 —
7 — — —
8 — 15°54′ —
+0.1
9 — 80
0
10 — 326.5 ±1.0
11 — 56 —
12 — 106 —
13 — 470 —
14 — 23.5 —
15 — 140 —
16 — 190 —
17 — 133.2 —
18 — 131.6 —
19 — 107 —
20 — 85 —
+2.0
21 — 348.5
0
22 — 38 —
60-64 PC210LC-10
Boom cylinder (large diameter piston)
Boom cylinder (large diameter piston) (PC200_10-L541-034-K-01-A)
Unit:mm
1 piston rod and bushing bushing
-0.036 +0.257 0.084 to
90 0.437
-0.090 +0.048 0.347
Clearance between -0.030 +0.190
piston rod support shaft 0.100 to
2 80 1.0
and bushing -0.060 +0.070 0.250
Replace pin
Clearance between and bushing
-0.030 +0.165 0.075 to
3 cylinder bottom support 70 1.0
shaft and bushing -0.060 +0.045 0.225
Tightening torque of
4 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
6 cylinder piston fix 58.9 to 73.6 Nm {6.0 to 7.5 kgm}
screw
PC210LC-10 60-65
Arm cylinder
Arm cylinder (PC200_10-L950-034-K-00-A)
Unit:mm
– 0.036 + 0.222 0.083 to
95 0.412
– 0.090 + 0.047 0.312
Clearance between – 0.030 + 0.190
2 80 1.0
and bushing – 0.076 + 0.070 0.266
Replace pin
– 0.030 + 0.190 0.100 to
shaft and bushing – 0.076 + 0.070 0.266
4 373 ± 54.0 Nm {38.0 ± 5.5 kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
screw
60-66 PC210LC-10
Bucket cylinder
Bucket cylinder (PC200_10-LCD0-034-K-00-A)
Unit:mm
-0.030 +0.258 0.078 to
80 0.434
-0.076 +0.048 0.334
Clearance between -0.030 +0.170
2 70 1.0
and bushing -0.060 +0.070 0.230
Replace pin
-0.030 +0.165 0.075 to
shaft and bushing -0.060 +0.045 0.225
4 270 ± 39 Nm {27.5 ± 4.0kgm}
cylinder head
5 294 ± 29.4 Nm {30.0 ± 3.0 kgm} Retighten
cylinder piston
screw
PC210LC-10 60-67
Bucket cylinder
60-68 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
80 Appendix
9 80 Appendix
PC210LC-10 80-1
80 Appendix
Table of contents

80 Appendix...................................................................................................................................... 80-1
Air conditioner components ......................................................................................................... 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-17
Air conditioner controller ..................................................................................................... 80-18
Compressor....................................................................................................................... 80-19
Air conditioner condenser ................................................................................................... 80-20
Sunlight sensor .................................................................................................................. 80-22
Outer temperature sensor (outside air temperature sensor) ................................................... 80-23
Procedure for testing and troubleshooting ............................................................................ 80-24
Circuit diagram and arrangement of connector pins............................................................... 80-26
System diagram................................................................................................................. 80-28
Input and output signals of the air conditioner controller ......................................................... 80-29
Parts and connectors layout................................................................................................ 80-31
Testing air leakage (duct) .................................................................................................... 80-35
Testing with self-diagnosis function ...................................................................................... 80-38
Testing vent (mode) changeover.......................................................................................... 80-40
Testing FRESH/RECIRC air changeover.............................................................................. 80-42
Testing sunlight sensor ....................................................................................................... 80-43
Testing (dual) pressure switch for refrigerant......................................................................... 80-44
Testing relays .................................................................................................................... 80-45
Failure code list related to air conditioner.............................................................................. 80-51
Failure code [879AKA] A/C Inner Sensor Open Circuit .......................................................... 80-52
Failure code [879AKB] A/C Inner Sensor Short Circuit........................................................... 80-53
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-54
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-56
Failure code [879CKA] Ventilating Sensor Open Circuit ......................................................... 80-58
Failure code [879CKB] Ventilating Sensor Short Circuit ......................................................... 80-59
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-60
Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-62
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-63
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-64
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)................................................ 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-70
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-72
Troubleshooting with gauge pressure................................................................................... 80-74
Connection of service tool................................................................................................... 80-77
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-79
Handling of compressor oil.................................................................................................. 80-81
Desiccant replacement ....................................................................................................... 80-83
80-2 PC210LC-10
80 Appendix
Precautions for refrigerant
Air conditioner components (ALL-K500-001-K-02-A)
Precautions for refrigerant (ALL-K512-012-K-00-A)
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
PC210LC-10 80-3
80 Appendix
Air conditioner component
Air conditioner component (PC200LC_10-K500-04D-K-00-A)
80-4 PC210LC-10
80 Appendix
1. Compressor
2. Condenser
3. Modulator (with desiccant)
4. Hot water piping
5. Hot water return piping
6. Refrigerant piping
7. Dual pressure switch
8. Sight glass
9. Air conditioner controller
11. Recirculation air filter
12. Fresh air filter
13. Machine monitor
14. Sunlight sensor
A. Front vent
B. Rear vent
C. Foot vent
D. Defroster vent
E. Recirculation air inlet
PC210LC-10 80-5
80 Appendix
F. Fresh air inlet

Specification (ALL-K500-030-K-00-A)
Refrigerant R134a
Refrigerant refilling level (g) 930 ± 50
80-6 PC210LC-10
80 Appendix
Configuration and function of refrigeration cycle
Configuration and function of refrigeration cycle (ALL-K500-042-K-00-A)
Cycle Compression Condensation Expansion Evaporation

(Component) (Compressor) (Condenser) (Expansion valve) (Evaporator)
In operator's cab In operator's cab
Engine
Location compartment Front of radiator (Built in air conditioner (Built into air
unit) conditioner unit)
Circulates Lowers temperature
By evaporating
refrigerant gas and Condenses and pressure of
refrigerant, absorb
increases its refrigerant to refrigerant liquid and
heat from the air
temperature and discharge heat gas for easy
around the evaporator,
Function pressure so that it absorbed in evaporation with
and cools the
can be liquefied evaporator. throttle. Controls flow
surrounding air.
easily in condenser. (condensation of rate, too.
(Evaporation of
(Compression of refrigerant) (Throttle action of
refrigerant)
refrigerant) refrigerant)
Gas o gas Gas o liquid Liquid, gas o gas
State of Liquid o liquid, gas
refrigerant Adiabatic Constant pressure Constant pressure
Adiabatic expansion
compression change change
PC210LC-10 80-7
80 Appendix
Outline of refrigeration cycle
Outline of refrigeration cycle (ALL-K500-04A-K-00-A)
• The refrigerating cycle performs the following four processes. The refrigerant is liquefied and gasified
repeatedly while it is circulated in the cycle.
Compression (Compressor)
• The compressor sucks in the refrigerant that has been vaporized in the evaporator and compresses it into
a state where it can be easily liquefied at the ambient temperature.
• The gaseous refrigerant sucked into the compressor cylinder is compressed to a temperature and
pressure at which it can be easily liquefied when cooled to the ambient temperature.
Condensation (Condenser)
• The condenser cools and liquefies the high pressure and high-temperature gaseous refrigerant sent from
the compressor.
• The heat released to the outside from the condenser is called condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in
the cab and the quantity of the work applied (the value converted into a heat quantity) by compression of
the compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency.
• In the compression cycle, the gaseous refrigerant and liquid refrigerant coexist.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the
gaseous refrigerant is liquefied are proportional to each other.
(The condensation pressure varies depending on the condensation temperature of the refrigerant)
Expansion (Expansion valve)

• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be
easily evaporated by the throttle action (*1).
• The action of reducing the liquid refrigerant pressure to a level where it can be easily evaporated before it
is sent to the evaporator is called expansion.
• The expansion valve, which reduces the refrigerant pressure, also adjusts the refrigerant flow rate
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant feed rate so that the optimum quantity of liquid refrigerant is
supplied to the evaporator.
*1: Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow will be generated.
The liquid expands when it passes through the narrow section and rushes into the passage where the
sectional area is larger, and consequently, its pressure and temperature are reduced.
• No heat is transferred from or to the outside during the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• After the heat has been removed, the cooled air is sent into the cab by the blower fan, reducing the
temperature inside the cab.
• The mist refrigerant that has been sent from the expansion valve coexists with the evaporated refrigerant
in the evaporator
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid
refrigerant is evaporated are proportional to each other.
• The compressor sucks in the evaporated refrigerant in order to keep the pressure level in the evaporator
as low as possible so that the liquid refrigerant can be evaporated at a much lower temperature.
Relationship between refrigerant and defective air conditioning

• The refrigerant circulates in the refrigeration circuit while repeating the refrigeration cycle to expel the heat
from inside the cab.
80-8 PC210LC-10
80 Appendix
Outline of refrigeration cycle
• If there is an insufficient quantity of refrigerant, all of it will be evaporated while it is passing through the
evaporator. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it will be evaporated and part of it will be sucked into the
compressor in liquid form, which will cause the compressor to compress the liquid and may damage the
components.
• If water gets into the refrigeration circuit, it will freeze at a small hole in the expansion valve, lower the
refrigerant flow, and may result in defective air conditioning.
PC210LC-10 80-9
80 Appendix
Air conditioner unit
Air conditioner unit (ALL-K540-041-K-00-A)
a This air conditioner unit is auto temperature control type.
A: Refrigerant inlet (from condenser)

B: Refrigerant outlet (to compressor)
80-10 PC210LC-10
80 Appendix
C: Hot water inlet

D: Hot water outlet
E: Recirculation air hole
F: Fresh air hole
G: Front air vents
H: Rear air vents
J: Foot level air vents
K: Defroster vents
1. Evaporator
2. Heater core
3. Expansion valve
4. Blower fan, blower motor
5. Air mix servomotor
6. Air mix door
7. Vent (mode) changeover servomotor
Vent (mode) changeover door
8. Rear door
9. Foot door
10. Defroster door
11. FRESH/RECIRC air changeover servomotor
12. FRESH/RECIRC air changeover door
13. Power transistor
14. Evaporator temperature sensor
15. Insidel air temperature sensor
a The door is the same as the damper.
Function (ALL-K540-042-K-00-A)
• The air conditioner unit consists of evaporator (1) and heater core (2), and is used to cool down or warm
up the air in the cab.
Temperature control
• When the temperature control switch on the machine monitor is operated, the set temperature data is sent
to the air conditioner controller that is located at the rear of the operator's seat.
• The air conditioner controller controls air mix servomotor (5) to change the angle of air mix door (6) so that
the set temperature is reached
Over-cooling (Freezing) prevention

• Evaporator temperature sensor (14) varies the resistance of its resistor according to temperature.
• The air conditioner controller converts the change in resistance of evaporator temperature sensor (14) into
the change in voltage to determine the temperature of evaporator (1).
• The air conditioner controller performs control to prevent freezing of the evaporator (1) by operating the
compressor clutch relay (*) to stop the compressor.
*: For details of compressor clutch relay, see "Parts and connectors layout".
Air flow adjustment

• When the air flow adjusting switch on the machine monitor is operated, the set air flow data is sent to the
air conditioner controller. The air conditioner controller controls blower motor (4) by using power transistor
(13) in order to adjust the air flow.
Vent (mode) changeover

• When a vent switch on the machine monitor is operated, mode data is sent to the air conditioner controller.
The air conditioner controller controls mode changeover servomotor (7) to adjust the opening and closing
angles of mode changeover doors (8) to (10) so that the selected vents are available.
PC210LC-10 80-11
80 Appendix
FRESH/RECIRC air changeover

• When the FRESH/RECIRC air selector switch on the machine monitor is operated, the set data of
FRESH/RECIRC air changeover is sent to the air conditioner controller. The air conditioner controller
controls FRESH/RECIRC air changeover servomotor (11) to open or close FRESH/RECIRC air
changeover door (12).
Automatic mode of air conditioner

• Inside air temperature sensor (15) detects the temperature inside operator's cab based on changes in
resistance. The air conditioner controller converts the change in resistance of inside air temperature
sensor (15) into the change in voltage to determine the room temperature.
The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the
room temperature so that it matches the setting made on the machine monitor.
The air conditioner controller also takes into consideration data from the sunlight sensor and the outer
sensor (outside air temperature sensor) when adjusting the room temperature.
Changeover pattern of the vent (mode) changeover door
Rear door (8) Foot door (9) Defroster door (10)
Opening Opening Opening
and closing Angle and closing Angle and closing Angle
door door door
Front Close 0 Close 0 Close 0
Front and rear Open 25 Close 0 Close 0
Front, rear and Open Open
25 35 Close 0
Air vent foot
mode Foot Open 25 Open 53 Close 0
Foot and Open Open Open
25 23 38
defroster
Defroster Open 25 Open 0 Open 38
Selection pattern of air mix door (6)
Set temperature Opening and closing door Angle (°C)
Max. Cool Close 0
Max. Hot Open 80
80-12 PC210LC-10
80 Appendix
Functions of major components (ALL-K540-001-K-00-A)
a For details of the numbers in the following sentence, see “Air conditioner unit”.
Evaporator (ALL-K549-042-K-00-A)
• Evaporator (1) is cooled by the low-pressure, low-temperature refrigerant gas being sent from expansion
valve (3).
• Air from blower motor (4) is cooled and dehumidified when passing through the evaporator fins.
Heater core (ALL-K547-042-K-00-A)

• Heater core (2) is warmed by the hot water (engine coolant) being sent from the engine. Air from blower
motor (4) is warmed when passing through fins of the heater core (2).
Evaporator temperature sensor (ALL-K5FF-042-K-00-A)

• Evaporator temperature sensor (14) is installed to evaporator (1) with the holder. Its resistance changes in
accordance with the temperature change of the evaporator. The air conditioner controller determines the
temperature of evaporator (1) from voltage changes of evaporator temperature sensor (14) to prevent
freeze of the evaporator.
PC210LC-10 80-13
80 Appendix
Servomotor (ALL-K5D2-042-K-00-A)
a Servomotors are used to adjust the temperature (air mix) and to perform vent (mode) changeover.
• When a switch on the machine monitor is operated, the air conditioner controller applies 24V power
between servomotor terminal B (6) and servomotor terminal A (7). (Rotation direction switches according
to the polarity of supply voltage.) )
• The servomotor contains a variable resistor, and its resistance value changes as the motor rotates.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor
rotation angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• When the air conditioner controller cannot recognize the potential difference that corresponds to the
command to the servomotor, it generates a air conditioner failure code to inform the machine monitor of
failure in air conditioner system. Failure code [879EMC] or [879FMC] is displayed on the electrical system
failure record screen of the machine monitor.
a FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore,
does not have a self-diagnosis function.
a Do not try to drive a servomotor by supplying power directly between servomotor terminals (6) and (7)
during inspection.
80-14 PC210LC-10
80 Appendix
Expansion valve (ALL-K548-041-K-00-A)
A: When evaporator outlet temperature is high

B: When evaporator outlet temperature is low
C: From capacitor (high-pressure refrigerant)
D: To compressor (low-pressure refrigerant)
1. Expansion valve
1a. Needle valve
1a-1. Diaphragm
1a-2. Thermoprobe
1b. Spring
2. Refrigerant gas
3. Evaporator
Outline
• The expansion valve(1) converts high-pressure and high-temperature liquid refrigerant from the receiver
drier to low-pressure, low-temperature misty refrigerant through the throttle action.
• It controls the flow rate of refrigerant by changing the level of throttling depending on the temperature in
the cab.
• The temperature of the air blown out of the air vent is adjusted depending on the flow rate of refrigerant
circulating in the evaporator (3).
Structure (ALL-K548-042-K-00-A)
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• Refrigerant gas (2) is sealed in the diaphragm chamber (hatched area) outside diaphragm (1a-1) of
needle valve (1a).
• The opening level of needle valve (1a) is determined based on the balance between the reaction force
exerted by spring (1b) in a rightward direction, and force (Fg) of refrigerant gas (2) pushing needle valve
(1a) through diaphragm (1a-1) in a leftward direction.
PC210LC-10 80-15
80 Appendix
• The refrigerant flow rate flowing from the receiver drier to evaporator (3) is determined based on the
opening level of needle valve (1a).
Operation (ALL-K548-044-K-00-A)
• Thermoprobe (1a-2) senses the refrigerant temperature after it passes through the evaporator (3).
• After the refrigerant passes through evaporator (3), its temperature is transferred to the refrigerant gas (2)
in the diaphragm chamber (hatched area) through the thermoprobe (1a-2).
• The pressure of the refrigerant gas (2) sealed in the diaphragm chamber (hatched area) changes in
response to the temperature change of the thermoprobe (1a-2), which therefore changes the force (Fg)
pushing the needle valve (1a).
• The opening level of the needle valve (1a) is determined based on the balance between the reaction force
exerted by the spring (1b) in a rightward direction, and the force (Fg) of the refrigerant gas (2) pushing the
needle valve (1a) through the diaphragm (1a-1) in a leftward direction.
When evaporator (3) outlet temperature is high: [When not cooled yet: Condition (A) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is high and the volume is increased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is increased, and the needle valve
(1a) moves leftward.
• As a result, the opening level of the needle valve (1a) is increased and the refrigerant flow rate to the
evaporator (3) is increased to improve cooling capacity. (Condition (A) in previous figure)
When evaporator (3) outlet temperature is low: [When cooled already: Condition (B) in the figure]
• The pressure of the refrigerant gas (2) in the diaphragm chamber is low and the volume is decreased.
• The force (Fg) of the refrigerant gas (2) pushing the needle valve (1a) is reduced, and the needle valve
(1a) is moved rightward by the reaction force of spring (1b).
• The opening level of the needle valve (1a) is reduced and the refrigerant flow rate to the evaporator (3) is
reduced to lower the cooling capacity. (Condition (B) in previous figure)
80-16 PC210LC-10
80 Appendix
Dual pressure switch
Dual pressure switch (ALL-K5FG-044-K-00-A)
a The dual pressure switch is mounted on the air conditioner hose under the floor.
• The dual pressure switch turns “OFF“ when the refrigerant circuit pressure becomes abnormally low or
abnormally high.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch
relay “OFF“. As a result, the compressor's magnet clutch is released and air conditioner components are
protected.
Function (ALL-K5FG-042-K-00-A)
a LA or lower: Abnormally low pressure

a HA or higher: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
PC210LC-10 80-17
80 Appendix
Air conditioner controller
Air conditioner controller (ALL-K5G4-041-K-00-A)
a See "System Diagrams" for details regarding input/output signals.
80-18 PC210LC-10
80 Appendix
Compressor
Compressor (ALL-K590-041-K-00-A)
A: Refrigerant inlet (from air conditioner unit)

B: Refrigerant outlet (to condenser)
1. Pulley
2. Magnetic clutch
3. Relief valve
Number of cylinders - Bore x Stroke (mm) 10 - 32 x 20.8

Piston capacity (cc/rev) 157.3
Max. allowable speed (rpm) 6,000
Compressor oil DENSO: ND-OIL8 (For R134a)
Compressor oil refill capacity (cc) 180
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator
into a misty refrigerant at high pressure and high temperature so that it will be easily regenerated
(liquefied) at the normal temperature.
• Calling into account of the evaporator temperature and refrigerant pressure, the air conditioner controller
activates magnetic clutch (2) built in the compressor.
• When magnetic clutch (2) is engaged, the power of the engine rotates the compressor shaft along with
pulley (1) to drive the compressor.
PC210LC-10 80-19
80 Appendix
Air conditioner condenser
Air conditioner condenser (ALL-K580-041-K-00-A)
A: Refrigerant inlet (from compressor)

B: Refrigerant outlet (to air conditioner unit)
1. Condenser
2. Modulator
3. Desiccating agent
4. Filter
5. Seal cap
6. O-ring
7. Snap ring
Fin pitch (mm) 4.0

Total heat dissipation surface (m2) 3.58
Max. working pressure (MPa{kg/cm2}) 3.53{36}
Weight of desiccating agent (g) 290
• The condenser cools and liquefies the high pressure and high temperature misty refrigerant sent from the
compressor.
• The sub-cool section of condenser (1) further cools liquefied refrigerator, which came to this section after
passing through modulator (2), to increase the cooling efficiency.
• Modulator (2) stores the high-pressure and high-temperature liquefied refrigerant from the condenser. It is
capable of completely liquefying the refrigerant even when bubbles are contained in the refrigerant due to
the condenser condition in heat dissipation.
• Filter (4) and desiccating agent (3) contained in modulator (2) eliminate foreign substances in the
circulation circuit and water in the refrigerant.
80-20 PC210LC-10
80 Appendix
Air conditioner condenser
a If the fin is crushed or is clogged with dust, heat exchange efficiency is reduced and complete liquefaction
of refrigerant becomes impossible. Since increase of pressure in the refrigerant circulation circuit applies
extra load to the engine and reduces the cooling effect, you must take care not to crush or damage the fins
when handling them or during daily inspection.
a For the replacement procedure of desiccating agent (3) in modulator (2), see "Desiccant replacement".
PC210LC-10 80-21
80 Appendix
Sunlight sensor
Sunlight sensor (ALL-K5FH-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K5FH-042-K-00-A)
• The sunlight sensor is mounted on top of the machine monitor.

• It detects the strength of incident sunlight and sends signals to the air conditioner controller.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the sunlight sensor in order to adjust the temperature and air flow.
80-22 PC210LC-10
80 Appendix
Outer temperature sensor (outside air temperature
sensor)
Outer temperature sensor (outside air temperature sensor) (ALL-K55C-041-K-00-A)
1. Connector
2. Sensor
Function (ALL-K55C-042-K-00-A)
• The outside (air) temperature sensor is installed in the cooling unit.

• The outside air temperature sensor has feature of change in resistance by temperature change, therefore,
can detect the ambient temperature.
• The air conditioner controller detects the ambient temperature by converting the changes in the resistance
of the outside air temperature sensor into voltage changes.
• When performing automatic air conditioning, the air conditioner controller controls the blower motor and
the air mix servomotor with the data of the outside (air) temperature sensor in order to adjust the
temperature and air flow.
PC210LC-10 80-23
80 Appendix
Procedure for testing and troubleshooting
Procedure for testing and troubleshooting (ALL-K500-422-K-00-A)
The air conditioner is provided with self-diagnosis functionality in order to provide for inspection of its main
components. Specifically, the operation of sensors and servomotors can be examined.
If a troubled section is detected, every part of that section must be inspected.
1. After basic check, find the troubled section according to the detected trouble of the air conditioner.
2. Narrow down the sections with the self-diagnosis function (See “Check with self-diagnosis”).
If, however, the entire air conditioner unit fails to operate, inspect for problems with the supply of power to
the air conditioner controller and with CAN communication between the machine monitor and the air
conditioner controller.
If any part of the air conditioner unit can operate, it will indicate that the air conditioner controller is
receiving power normally and that CAN communication between the machine monitor and the air
conditioner controller is normal.
3. After finding out the troubled section, inspect the component parts in that section and repair the troubled
part.
Basic testing and troubleshooting sequence
*1: By error display or abnormal display on "Electrical Systems" screen on the machine monitor.
*2: Simple checking of refrigerant volume through sight glass.
Start up the engine, set the air conditioner switch to ON, and then wait for five minutes before proceeding with
the inspection.
A) If the continuous stream of bubbles can be seen, the system contains insufficient refrigerant.
B) If the bubbles can be seen intermittently, the refrigerant volume is sufficient.
80-24 PC210LC-10
80 Appendix
Procedure for testing and troubleshooting
C) If no bubbles can be seen (i.e., the liquid is perfectly clear), the system contains too much refrigerant or no
refrigerant at all.
The above should be treated as general guidelines as certain exceptions do exist.
See "Troubleshooting with gauge pressure" and use gauge pressure to determine whether or not the
condition is normal.
S: Sight glass condition
R: Receiver drier internal condition
LR: Liquid refrigerant
*3: If any leakage of refrigerant is occurring, the compressor oil circulating within the air conditioner circuit will
definitely be leaking from the same point.
In such a case, retighten in accordance with the table of retightening torques from "Precautions for
disconnecting and connecting air conditioner piping."
*4: Start the engine and perform the check with the air conditioner switch set to ON.
PC210LC-10 80-25
80 Appendix
Circuit diagram and arrangement of connector pins
Circuit diagram and arrangement of connector pins (PC220-K500-051-K-01-A)
80-26 PC210LC-10
80 Appendix
Circuit diagram and arrangement of connector pins
a The diffuser servomotor means the vent (mode) changeover servomotor.

a The Fresh/recirculated air servomotor means the FRESH/RECIRC air changeover servomotor.
a The frost sensor means the evaporator temperature sensor.
PC210LC-10 80-27
80 Appendix
System diagram
System diagram (PC220-K5F0-051-K-00-A)
a This air conditioner unit is auto temperature control type.
80-28 PC210LC-10
80 Appendix
Input and output signals of the air conditioner controller
Input and output signals of the air conditioner controller (ALL-K5G4-03C-K-00-A)
Controller connector: AMP 025 - 32PM

Wiring harness connector: ACECU
AMP025 - 32PF
Input/Output
Pin No. Symbol Signal name
signal
1 +Bback Backup power supply Input
2 – (*1) –
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 V Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/output
11 CAN_L CAN communication signal (L) Input/output
12 – (*1) –
13 MRFA Fresh/recirculated air servomotor terminal A Output
14 MRFB Fresh/recirculated air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24 V 24 V power supply Input
18 – (*1) –
19 SAM Air mix servomotor potentiometer signal Input
20 SVI Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input
22 – (*1) –
23 – (*1) –
24 – (*1) –
25 GNDS Sensor GND Input
26 GND GND Input
27 – (*1) –
28 – (*1) –
29 RLCC Compressor clutch relay Output
30 – (*1) –
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
Function (ALL-K5G4-042-K-00-A)
• Operation of air conditioner controller

1. Performing CAN communication with the machine monitor, the air conditioner controller controls the air
conditioner unit by inputting switches associated with air conditioning.
2. The air conditioner controller controls three servomotors located inside the air conditioner unit in order to
adjust the temperature (airmix), perform vent (mode) changeover, and perform FRESH/RECIRC air
changeover.
3. The air conditioner controller controls the ON/OFF condition of the compressor clutch relay (i.e., a switch
for activating the compressor).
4. The air conditioner controller controls the air flow volume using the power transistor.
a The power transistor has an overcurrent prevention fuse in it.
PC210LC-10 80-29
80 Appendix
Input and output signals of the air conditioner controller
5. The air conditioner controller detects the evaporator temperature using the evaporator temperature
sensor.
6. In order to prevent freezing of the evaporator, the air conditioner controller controls the compressor by
turning the compressor clutch relay ON and OFF.
a When the dual pressure switch detects a pressure abnormality (i.e., turns OFF), the air conditioner
controller turns the compressor clutch relay OFF, and therefore, the compressor stops operating.
7. When performing automatic air conditioning, the air conditioner controller controls the inside (air)
temperature to the set temperature and adjust the air flow according to the data from the sunlight sensor,
the outside air temperature sensor, and the inside air temperature sensor.
8. The air conditioner controller has the self-diagnosis function. If any abnormality is detected, the controller
notifies it to the machine monitor by the CAN communication. Then, failure code [879***] is displayed on
the "Electrical Systems" screen of the electrical system on the machine monitor.
80-30 PC210LC-10
80 Appendix
Parts and connectors layout
Parts and connectors layout (PC220-K500-055-K-00-A)
• Three fuses related to the air conditioner are in the fuse box at the right rear of the operator's seat.
• The air conditioner unit is mounted inside the rear cover of the operator's seat.
k Park the machine on a level surface, swing the upper structure by 90 degrees, lower the work
equipment to the ground so that it is stable, and stop the engine.
k Turn the battery disconnect switch to the "OFF" position and pull out the key.
a Note the connector numbers and installed positions before disconnecting wiring and hoses.
Connector Reference
Remarks Location
No. item
AC01 Intermediate connector Right rear of cab 2.
AC02 Intermediate connector Right rear of cab 2.
AC03 Air conditioner compressor Engine 7.
ACECU Air conditioner controller Rear of cab 2.
CM01* Machine monitor Front of cab 5.
CM02 Machine monitor Front of cab 5.
F01 Fuse box Right rear of cab 1.
Dual pressure switch
P17 Under cab 6.
a Swing upper structure 90 deg.
P18 Outside air temperature sensor Cooling unit 8.
P31 Sunlight sensor Machine monitor 4.
R21 Relay Rear of cab 2.
[2] Power transistor Air conditioner unit 3.
[5]* FRESH/RECIRC air changeover
Air conditioner unit 3.
servomotor
[6]* Inside air temperature sensor Air conditioner unit 3.
Evaporator temperature sensor
[7]* Air conditioner unit 3.
(Frost sensor)
*: Connector that does not appear during troubleshooting
Details (PC200LC_10-K500-04D-K-01-A)
1. Each fuse in fuse box F01

Open the cover of the fuse box at the right rear of the operator's cab.
• No. 10 (20 A): Fuse for power supply of blower (fan) and air conditioner compressor
• No. 14 (5 A): Fuse for primary power supply of air conditioner unit, air conditioner controller, and air
conditioner compressor electromagnetic clutch relay
• No. 19 (5 A): Fuse for power supply (backup power supply) of air conditioner controller
PC210LC-10 80-31
80 Appendix
2. Air conditioner controller: *1

• AC01: Intermediate connector
• AC02: Intermediate connector
• ACECU: Air conditioner controller connector
• R21: Connector for air conditioner compressor electromagnetic clutch relay

a Connectors [2], [5], [6], and [7] do not have labels.
a Rear side of air conditioner unit (only connector [2] can be removed while installed on machine)
[2]: Power transistor (*2) connector
[5]: FRESH/RECIRC air changeover servomotor connector
[6]: Inner sensor (inside air temperature sensor) connector
[7]: Evaporator temperature sensor connector
*2: Power transistor
80-32 PC210LC-10
80 Appendix
4. Sunlight sensor
P31: Sunlight sensor connector
5. Machine monitor
• CM01 to CM04: Machine monitor connector
a Connector CM03: (Not used)
a Connector CM04: (For camera connection)
6. Dual pressure switch

a Rotate cab undercover 90 degrees and remove it.
• P17: Dual pressure switch connector
PC210LC-10 80-33
80 Appendix
7. Air conditioner compressor

a Open up the engine hood.
• AC03: Air conditioner compressor connector
8. Outside (air) temperature sensor

P18: Outside (air) temperature sensor connector
80-34 PC210LC-10
80 Appendix
Testing air leakage (duct)
Testing air leakage (duct) (ALL-K5D0-001-K-00-A)
k Place the machine on a level ground, lower the work equipment to the ground and stop the engine.
k Turn the battery disconnect switch to the OFF position and remove the key.
a Note the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
Check (ALL-K5D0-360-K-00-A)
1. Lift front window assembly (1) to the ceiling and lock it.
a Check that the front window is securely locked.
3. Remove floor mat (3).
4. Remove cover (4) first, and then remove cover (5).
6. Remove cap (7-1).

a Disconnect the sunlight sensor connector from the rear of cover (7).
8. Remove drink box (8) (five bolts).

a Disconnect the hose under drink box (8).
9. Remove magazine box (9) (three bolts).
a Be careful about connectors (10) and (11) behind magazine box (9). (for machines equipped with 12 V
power socket)
• Connector (10): 12 V power socket intermediate harness (M13A)
• Connector (11): 12 V power socket intermediate harness (M13B)
10.Pull up cover (12) (three bolts) to remove.
a The connectors and wiring harnesses at the rear must not be caught.
PC210LC-10 80-35
80 Appendix
11.Remove cover (13) (seven bolts).

a Be careful about connector (14) behind cover (13).
12.Check the following ducts and pins for disconnection.

• Front duct (15)
• Defroster duct (16)
• Rear duct (17)
• Fresh air inlet duct (18) and pin (19)
80-36 PC210LC-10
80 Appendix
PC210LC-10 80-37
80 Appendix
Testing with self-diagnosis function
Testing with self-diagnosis function (ALL-Q19Y-001-K-00-A)
Outline (ALL-Q19Y-360-K-00-A)
On the air conditioner operation screen of the machine monitor, the system performs self-diagnosis to the
communication with the air conditioner controller, FRESH/RECIRC air temperature sensor, outside (air)
temperature sensor, evaporator temperature sensor, temperature control, vent (mode) changeover, and
refrigerant pressure with the pressure switch, and if a problem is detected, the "Air conditioner system
condition monitor" is displayed.
a Even if the cause of a detected problem is restored to normal, the self-diagnosis failure condition will not
automatically be reset. To reset the failure condition, the starter switch must be set to OFF.
a On the "Electrical System" screen in the service mode of the machine monitor, the system performs self-
diagnosis for various sensors. If a problem is detected, failure information is displayed.
a FRESH/RECIRC air changeover servomotor is not checked with self-diagnosis function.
How to open the electrical system abnormality record screen in service mode
of the machine monitor (PC220-Q19Y-100-K-00-A)
• Overview of machine monitor operating procedure
Normal screen
O While pressing [4], press [1], [2], and [3] in this order.
Service menu (Mode)
O Press [F3] twice. Press [F6].
03 Abnormality record
O Press [F3] once. Press [F6].
02 Electrical Systems screen
• Detailed description of machine monitor operating procedure
1. On the normal operation screen, while pressing number key [4], press [1], [2], and [3] in this order.
2. On the service menu screen, press [F3] twice, and then select "03 Abnormality Record".
3. Press [F6] to confirm.
80-38 PC210LC-10
80 Appendix
Testing with self-diagnosis function
4. On the Abnormality Record screen, press [F3] once, and then select "02 Electrical Systems".
5. Press [F6] to confirm.
a For details, see the failure code list related to air conditioner
Failure code Failure (Displayed on screen) Remarks
879AKA A/C Inner Sensor Open Circuit
*
879AKB A/C Inner Sensor Short Circuit
879BKA A/C Outer Sensor Open Circuit
879BKB A/C Outer Sensor Short Circuit
879CKA Ventilating Sensor Open Circuit
*
879CKB Ventilating Sensor Short Circuit
879DKZ Sunlight Sensor Open or Short Circuit
879EMC Ventilation Damper Abnormality *
879FMC Air Mix Damper Abnormality *
879GKX Refrigerant Abnormality
DAZ9KQ A/C Model Selection Abnormality See Chapter 40, "Troubleshooting by
failure code"
DAZQKR CAN2 Discon (Aircon ECU)
**
*: Troubleshooting cannot be performed while the controller is mounted on the machine since the connector
cannot be checked.
**: Troubleshooting is not performed by the air conditioner unit but by the machine monitor.
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The air mix damper means the temperature adjustment (air mix) damper (door).
PC210LC-10 80-39
80 Appendix
Testing vent (mode) changeover
Testing vent (mode) changeover (ALL-K5FR-001-K-00-A)
Testing (ALL-K5FR-360-K-00-A)
1. Remove drink box (1) (five bolts).

a Disconnect the hose under drink box (1).
2. Remove magazine box (2) (three bolts).
a Be careful about connectors (3) and (4) behind magazine box (2). (for machines equipped with 12 V
power socket).
• Connector (3): 12 V power socket intermediate harness (M13A)
• Connector (4): 12 V power socket intermediate harness (M13B)

a Be careful about connector (7) behind cover (6).
80-40 PC210LC-10
80 Appendix
Testing vent (mode) changeover
5. Remove ducts (8) and (9).
6. Turn the battery disconnect switch to the “ON“ position.

7. Start the engine and turn the air conditioner power “ON“.
8. Operate the vent changeover switch on the machine monitor.
9. Check the opening/closing operation of rear door (11) and defroster door (12) of air conditioner unit (10).
10.After finishing the inspection, turn the starting switch to the OFF position.
PC210LC-10 80-41
80 Appendix
Testing FRESH/RECIRC air changeover
Testing FRESH/RECIRC air changeover (ALL-K5D2-001-K-00-A)
Testing (ALL-K5D2-360-K-00-A)
1. Open outside air filter cover (1) and remove outside air filter (2).
2. Start the engine and turn the air conditioner power "ON".
3. Operate the FRESH/RECIRC air selector switch on the machine monitor.
4. Check the opening/closing operation of FRESH/RECIRC air changeover rear door (3) through the fresh
air inlet on the left side of the cab.
5. After finishing the inspection, turn the starting switch to the OFF position.
80-42 PC210LC-10
80 Appendix
Testing sunlight sensor
Testing sunlight sensor (PC220-K5FH-001-K-00-A)
Testing (PC220-K5FH-360-K-01-A)
1. Remove the machine monitor cover. For details, see "Testing air leakage (duct)", Steps 6 and 7.
2. Check connector P31 at the rear of the sunlight sensor. (Check whether the connector is coming off.)
3. Disconnect connector P31, remove the sunlight sensor, and measure the voltage between the terminals
on the sensor side using a circuit tester in voltage range.
• Approximate voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoors
PC210LC-10 80-43
80 Appendix
Testing (dual) pressure switch for refrigerant
Testing (dual) pressure switch for refrigerant (PC220-K5FG-001-K-00-A)
Testing (PC220-K5FG-360-K-01-A)
1. Swing by 90 ° .
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector P17.
4. Ensure that the resistance between the switch-side terminals from connector P17 is shorted (ON). (If not
shorted (OFF), the dual pressure switch will detect a refrigerant pressure abnormality.)
a When the dual pressure switch is OFF, connect a pressure gauge to the high-pressure side of the air
conditioner compressor and check the refrigerant pressure. See "Connection of service tool" and
"Troubleshooting with gauge pressure."
a If the refrigerant pressure is normal, the dual pressure switch is defective.
• (Dual) pressure switch
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
k When replacing the dual pressure switch, refrigerant must be collected in advance.
a If resistance between the switch-side terminals from connector P17 is shorted (ON), perform
"Troubleshooting for compressor and refrigerant system".
80-44 PC210LC-10
80 Appendix
Testing relays
Testing relays (PC220-K5FE-001-K-00-A)
Testing (PC220-K5FE-360-K-03-A)
1. Check contact R21 of connector (for disconnection).

2. Turn the starting switch ON (do not start the engine), turn the main power of the air conditioner ON, and
turn the air conditioner switch. If the compressor relay is normal, it is turned ON. Check whether it clicks.
a The air conditioner controller will not turn on the compressor clutch relay in the following cases.
1) When the evaporator temperature is below 3 °C (depending on the input voltage from the evaporator
temperature sensor).
2) When the pressure switch detects abnormality (it is turned OFF).
• Checking relay unit

a Since no T-adapter is available, it is impossible to check the relay while the voltage is applied to the coil
actually.
Compressor clutch relay (CCRL), connector (AC04)
1. The coil resistance between terminals (1) and (2) is approximately 300 to 500 z.
2. While voltage (DC 20 to 30 V) is not applied between terminals (1) (+) and (2), terminals (3) and (4) are
connected.
3. While voltage (DC 20 to 30 V) is applied between terminals (1) (+) and (2), terminals (3) and (5) are
connected.
PC210LC-10 80-45
80 Appendix
Troubleshooting chart 1
Troubleshooting chart 1 (PC220-3840-421-A-00-A)
Numbers in T represent the item numbers in the troubleshooting quick reference table.
1. Lowered cooling performance
2. Lowered heating performance
80-46 PC210LC-10
80 Appendix
Troubleshooting chart 2 (PC220-3840-421-A-01-A)
1. During cooling, the blower fan motor does not operate or the rotation speed does not match the air flow
setting.
Probable cause Check method Remedy
Check the connector for disconnection. Repair broken parts
Wire breakage or defective and connect
connection See "Parts and connectors layout". correctly
Operate the fan switches in order and check the fan
Defective blower fan motor speed. Replace
See "Air conditioner unit".
Defective power transistor Operate the fan switches in order and check the fan
Replace
(PTR) speed.
2. During cooling, the blower fan motor is normal but the flow of air is very light.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check duct joints.
Repair
joints See "Testing air leakage (duct)".
Obstruction at evaporator Check evaporator for stain and obstruction Remove obstruction
inlet and clean
Defective evaporator Evaporator is frozen.
temperature sensor, Sensor fixing clip inspection, sensor contaminated
defective contact of Repair or replace
evaporator temperature Inspect the air conditioner hose around the pressure
switch for frost.
sensor, defective expansion
valve* (when freezing has advanced even further)
*: The evaporator temperature sensor and expansion valve are located inside the air conditioner unit.
3. Pressure abnormality (high-pressure/low-pressure) during cooling.
Repair leaking part,
then charge with
Insufficient refrigerant
proper quantity of
Check the refrigerant volume through sight glass. refrigerant again
Specifically, perform checking with the gauge manifold Collect refrigerant,
connected. then fill up with
Overcharge with refrigerant
proper quantity of
refrigerant again
Normal pressure range
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to 2.0 kg/
cm2 }
Judgment by pressure at See Troubleshooting
inlet/outlet of compressor High pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2 with gauge pressure
}
Temperature in operator's cab: 30 to 35 °C , Engine
speed: Approx. 1,500 rpm
PC210LC-10 80-47
80 Appendix
4. During cooling, the compressor will not operate smoothly, or at all.

a See "Troubleshooting of compressor system (Air is not cooled)".
Troubled
part
Deflection of belt is large.
Compressor See "Checking and adjusting air
belt
Slack of belt conditioner compressor belt tension" in Adjust tension
the "Testing and adjusting" in Chapter
30.
Trouble in compressor Slip of belt Repair or replace
Compressor Insufficient compressor oil See "Handling
Heating of compressor
Seizing on compressor compressor oil".
Drop of battery voltage Slip of clutch Charge battery
Open or short circuit in coil Inspect with multimeter (10 to 20 z) Replace
Magnet
Check ground cable and joints.
clutch Wire breakage or defective
connection of ground wire See "Troubleshooting for compressor Repair
and refrigerant system".
Defective compressor clutch
Relay See "Testing relays" Replace
relay
See
Refrigerant Low/high pressure (Operation See "Troubleshooting with gauge "Troubleshooting
pressure of pressure switch) pressure". with gauge
pressure".
See "Troubleshooting for compressor
Pressure and refrigerant system".
Defective pressure switch Replace
switch See "Testing refrigerant (dual) pressure
switch".
5. During heating, blower fan motor is normal but air flow alone is insufficient.
Large duct resistance Check the filter for clogging and the duct for crushing. Repair
Air leakage through duct Check the duct joints by referring to "Testing air leakage
Repair
joints (duct)."
Clogging of heater core fins Check heater core fins for clogging Clean
6. Engine coolant temperature or volume abnormalities during heating or cooling
Low engine coolant Warm up engine, and then check engine coolant
temperature temperature Find out cause
Low engine coolant level Check coolant level in radiator Add coolant
Insufficient circulation of Check engine coolant piping for clogging.
engine coolant Bleed air and correct
(Hose, pipe and core)
The connection of IN and
OUT heater hoses is in Check the destination of heater hoses Correct
reverse.
7. Fan speed abnormalities during cooling
See "Replacing fan belt" in "Testing and adjusting" in
Fan speed is low Replace
Chapter 30.
80-48 PC210LC-10
80 Appendix
8. Other abnormalities
Probable cause Check method Remarks
Temperature cannot be Select manual mode and change temperature setting.
controlled
Vent (mode) changeover is Common to cooling
See "Testing vent (mode) changeover".
not possible. and heating
FRESH/RECIRC air cannot
See "Testing FRESH/RECIRC air changeover".
be changed over
Excessive compressor oil See "Handling of compressor oil".
Cooling only
Water leakage into the cab Clogging of drain hole
PC210LC-10 80-49
80 Appendix
Information in troubleshooting table
Information in troubleshooting table (ALL-5170-421-A-03-A)

Information in troubleshooting table
Failure Failure symptom that appears on machine
Related information Information on occurred failure or troubleshooting
[Information described]
• Procedure
• Measuring location
1
a "Between A and B" denotes measuring voltage or resistance, etc.
Probable cause of failure between A and B.
(Perform troubleshooting • Criteria to determine probable causes
according to these.) • Remarks for judgment of Good or No good
[Notes on troubleshooting]
2 (1) pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus (-) tester leads
as shown below unless otherwise specified.
• Connect the plus (+) lead to a pin or harness indicated in the
front.
• Connect the minus (-) lead to a pin or harness indicated in the
rear.
3 Defective — (2) Example of troubleshooting done by testing multiple items
a Normal in 1 but abnormal in 2
At this time, "Defective component" shown at left 3 is applied.
a If a wiring harness is burnt, replace it.

[Defective wiring harness]
• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A harness not to be connected to the ground (earth) circuit comes into contact with the ground (earth)
circuit or chassis accidentally.
• Hot short circuit
A harness not to be connected to the power (24V) circuit comes into contact with the power (24V) circuit
accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with another independent wire. (poor
insulation at connector and others)

This is the extracted circuit diagram related to failure
• Indicates connector No., and pin No.
• See "Circuit diagram and arrangement of connector pins" and "Parts and connectors layout" for
connector location
• The circuit diagram shows the size and colors of wires.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
a When there are two colors
Example: WY: Yellow line on white background
a The number before the wire color indicates the wire size.
• N.C.: Normally closed (Normally ON)
• [1], [2], ... are numbers of unlabeled connectors.
• The arrow (io) indicates their rough installation position on the machine.
80-50 PC210LC-10
80 Appendix
Failure code list related to air conditioner
Failure code list related to air conditioner (ALL-K500-441-K-00-A)

Compo-
Failure Failure (Displayed on screen) nent in Action Category
Remarks
code charge level of record
A/C Inner Sensor Open Electrical Troubleshooting cannot be
879AKA MON –
Circuit system performed while the controller
is mounted on the machine
A/C Inner Sensor Short Electrical
879AKB MON – since the connector cannot
Circuit system
be checked.
A/C Outer Sensor Open Electrical
879BKA MON –
Circuit system
A/C Outer Sensor Short Electrical
879BKB MON –
Circuit system
Ventilating Sensor Open Electrical Troubleshooting cannot be
879CKA MON –
Circuit system performed while the controller
Ventilating Sensor Short Electrical
879CKB MON – since the connector cannot
Circuit system
be checked.
Sunlight Sensor Open or Electrical
879DKZ MON –
Short Circuit system
Ventilation Dumper Electrical Troubleshooting cannot be
879EMC Abnormality MON L01 system performed while the controller
Electrical
879FMC Air Mix Dumper Abnormality MON L01 since the connector cannot
system
be checked.
Electrical
879GKX Refrigerant Abnormality MON L01 system
A/C Model Selection Electrical
DAZ9KQ Abnormality MON –
system See Chapter 40,
"Troubleshooting by failure
Electrical
DAZQKR CAN2 Discon (Aircon ECU) MON L01 code"
system
a The air conditioner inner sensor means the inside (air) temperature sensor.
a The air conditioner outer sensor means the outside (air) temperature sensor.
a The ventilating sensor means the evaporator temperature sensor (frost sensor).
a The vent damper means the vent (mode) changeover damper (door).
a The Air Mix Damper means the temperature adjustment (air mix) damper (door).
a Troubleshooting for the troubles which do not display failure codes is explained after failure code
[879GKX].
• Troubleshooting for power supply system (Air conditioner does not operate)
• Troubleshooting for compressor and refrigerant system (Air is not cooled)
• Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
• Troubleshooting for FRESH/RECIRC air changeover
PC210LC-10 80-51
80 Appendix
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKA] A/C Inner Sensor Open Circuit (D155-879AKA-400-A-00-A)
Action level Failure code Open circuit in air conditioner inside air temperature sensor
Failure
- 879AKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed on the "Electrical Systems" screen in service
Related mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
Defective air conditioner Air conditioner controller may be defective. (Since this is an internal
controller
Air conditioner unit may be defective. (Since this is an internal defect,
2 Defective air conditioner unit troubleshooting cannot be performed.)
80-52 PC210LC-10
80 Appendix
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit (D155-879AKB-400-A-00-A)
Action level Failure code Short circuit in air conditioner inside air temperature sensor
Failure
- 879AKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in inside (air) temperature sensor.
failure
• The air conditioner controller sends information about the inside (air) temperature sensor
Action of short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner if it is in automatic mode.
• The air conditioner does not operate in automatic mode because of a short circuit in the
Problem on air conditioner inside air temperature sensor.
machine (The air conditioner can be operated in manual mode)
• Check whether this failure code is displayed on the electrical system abnormality record
Related screen in service mode of the machine monitor.
information • Troubleshooting cannot be performed since the connector portion of the air conditioner
inside (air) temperature sensor cannot be checked while the controller is installed on the
machine.
controller
PC210LC-10 80-53
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit (PC220_10-879BKA-400-A-00-A)
Action Air conditioner outside air temperature sensor disconnection

Failure code
level Failure
— (Machine monitor system)
879BKA
Details of • Air conditioner controller detected disconnection in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor disconnection to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since the air conditioner outside temperature sensor has a disconnection, outside
Problem on temperature is not counted in automatic mode.
machine (The air conditioner is not affected in manual mode)
• Check whether this failure code is displayed in the "Electrical Systems" screen of the
electrical system in the service mode of the machine monitor.
• For connectors and other parts, see “Parts and connectors layout“.
• Since connector ACECU of the air conditioner controller has small pins and does not
Related have a T-adapter, carry out troubleshooting by using the intermediate connector
information (Although the intermediate connector does not have a T-adapter either, it does have large
pins).
• If the air conditioner wiring harness between connector ACECU of the air conditioner
controller and the intermediate connector needs to be replaced, the air conditioner unit
must be replaced.
1. Turn starting switch to “OFF“ position.
Defective outside
1 air temperature
sensor Between P18
Resistance 25°C Approx 1.7 kz
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
a If cause 2 is not the cause for the failure, this check is not required.
harness 2. Disconnect connectors P18 and AC01.
3 (Wire breakage or Between AC01 (female) (7) and P18
Between AC01 (female) (8) and P18
Defective air If no failures are found by the above checks, the air conditioner controller may be
4 conditioner defective.
If no failures are found by the above checks, the air conditioner unit may be
Defective air defective.
5
conditioner unit
80-54 PC210LC-10
80 Appendix
Failure code [879BKA] A/C Outer sensor Open Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC210LC-10 80-55
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit (PC220_10-879BKB-400-A-00-A)
Action Air conditioner outside air temperature sensor short circuit

Failure code
level Failure
879BKB
Details of • Air conditioner controller detected short circuit in outside (air) temperature sensor.
failure
• The air conditioner controller sends information about the outside (air) temperature
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Continues control of air conditioner in automatic mode, ignoring data of outside (air)
temperature sensor.
• Since air conditioner outside temperature sensor has short circuit, outside temperature is
Problem on not counted in automatic mode.
pins).
must be replaced.
1. Turn starting switch to “OFF“ position.
Defective outside
1 air temperature
sensor Between P18
(male) (1) and (2)
Open circuit or 2. Disconnect connector AC01.
2 short circuit in a Same as above, if resistance is normal
wiring harness
Between AC01
a If cause 2 is not the cause for the failure, this check is not required.
Short-circuiting of 1. Turn starting switch to OFF position.
3 2. Disconnect connectors P18 and AC01.
harness
Between AC01 (female) (7) and (8), or
Resistance between P18 (female) (1) and (2) Min. 1 Mz
harness 2. Disconnect connectors P18 and AC01.
4
(Contact with GND Between ground and AC01 (female) (8)
circuit) Resistance or P18 (female) (1) Min. 1 Mz
6
conditioner unit
80-56 PC210LC-10
80 Appendix
Failure code [879BKB] A/C Outer sensor Short Circuit
Circuit diagram related to air conditioner outside air temperature sensor
PC210LC-10 80-57
80 Appendix
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit (D155-879CKA-400-A-00-A)
Action level Failure code Open circuit in evaporator temperature (frost) sensor
Failure
- 879CKA (Machine monitor system)
Detail of • Air conditioner controller detected open circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor open circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to an open circuit in the evaporator temperature
machine (frost) sensor.
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
controller
80-58 PC210LC-10
80 Appendix
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit (D155-879CKB-400-A-00-A)
Action level Failure code Short circuit in evaporator temperature (frost) sensor
Failure
- 879CKB (Machine monitor system)
Detail of • Air conditioner controller detected short circuit in evaporator temperature (frost) sensor.
failure
• The air conditioner controller sends information about the evaporator temperature (frost)
Action of sensor short circuit to the machine monitor via CAN communication.
controller • Stops the air conditioner.
Problem on • The air conditioner does not operate due to a short circuit in the evaporator temperature
machine (frost) sensor.
• Method of reproducing failure code: Starting switch ON
information • Troubleshooting cannot be performed since the connector portion of the evaporator
temperature (frost) sensor cannot be checked while the air conditioner unit is installed on
the machine.
controller
PC210LC-10 80-59
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit (PC220_10-879DKZ-

400-A-00-A)
Action Sunlight sensor disconnection or short circuit
Failure code
level Failure
879DKZ
Details of • Air conditioner controller detected disconnection or short circuit in sunlight sensor.
failure
• The air conditioner controller sends information about sunlight sensor disconnection or
Action of short circuit to the machine monitor via CAN communication.
controller • Continues control of the air conditioner in automatic mode, ignoring sunlight sensor data.
• Since the air conditioner sunlight sensor has a disconnection or short circuit, sunlight
Problem on strength is not counted in automatic mode.
pins).
must be replaced.
1. See “Testing sunlight sensor“.
Defective sunlight Direct sunlight Approx. 0.55 V
1 Between sunlight
sensor Voltage Cloudy Approx. 0.45 V
sensor terminals
Indoor Approx. 0.4 V
Breaking of 2. Disconnect connector P31.
harness a See “Testing sunlight sensor“.
2 (Wire breakage or Between P31 (female) (1) and AC01
Between P31 (female) (2) and AC01
4
conditioner unit
80-60 PC210LC-10
80 Appendix
Failure code [879DKZ] Sunlight sensor Open or Short
Circuit
Circuit diagram related to sunlight sensor
PC210LC-10 80-61
80 Appendix
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879EMC] Ventilation Damper Abnormality (D155-879EMC-400-A-00-A)
Action level Failure code Abnormality in vent (mode) changeover damper servomotor
Failure
L01 879EMC (Machine monitor system)
Detail of • Air conditioner controller judged from potentiometer voltage of servomotor that vent
failure (mode) changeover damper servomotor is not operating.
Action of • The air conditioner controller sends information about the abnormality in vent (mode)
controller changeover damper to the machine monitor via CAN communication.
Problem on • Vent (mode) cannot be changed but air conditioner can be operated.
machine
information • Troubleshooting cannot be performed since the connector portion of vent (mode)
changeover damper servomotor cannot be checked while the air conditioner unit is
installed on the machine.
controller
80-62 PC210LC-10
80 Appendix
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality (D155-879FMC-400-A-00-A)
Action level Failure code Abnormality in air mix (temperature control) damper
Failure servomotor
L01 879FMC
Detail of • The air conditioner controller judged from the potentiometer voltage of the servomotor that
failure the air mix (temperature regulation) damper servomotor is not operating.
Action of • The air conditioner controller sends information about the air mix damper abnormality to
controller the machine monitor via CAN communication.
Problem on • The air conditioner does not operate since temperature cannot be regulated.
machine
Related
screen in service mode of the machine monitor.
information
• Troubleshooting cannot be performed since the connector portion of the air mix damper
servomotor cannot be checked while the air conditioner unit is installed on the machine.
controller
PC210LC-10 80-63
80 Appendix
Failure code [879GKX] Refrigerant Abnormality
Failure code [879GKX] Refrigerant Abnormality (PC220_10-879GKX-400-A-00-A)
Action Refrigerant (dual) pressure switch abnormality

Failure code
level Failure
L01 879GKX
Details of • Air conditioner controller detected that dual pressure switch was OFF (abnormal).
failure
• The air conditioner controller sends information about the refrigerant pressure
abnormality to the machine monitor via CAN communication.
Action of • The air conditioner controller turns OFF compressor clutch relay, since refrigerant
controller pressure is abnormal.
(The air conditioner compressor stops)
Problem on • The air conditioner (cooling) does not operate.
machine
• For each connector and other parts, see “Parts and connectors layout“.
pins).
must be replaced.
Defective 1. See “Testing (dual) pressure switch for refrigerant“.
1 refrigerant (dual)
k When replacing the dual pressure switch, be sure to collect refrigerant in
pressure switch
advance. See “Precautions for refrigerant“.
Breaking of
2. Disconnect connector AC01 and P17.
harness
Between P17 (female) (1) and AC01
2 (Wire breakage or (female) (6) Max. 1 z
defective contact of Resistance Between P17 (female) (2) and ground
connectors) Max. 1 z
a Looseness and rust of T06
4
conditioner unit
Circuit diagram related to (dual) pressure switch for refrigerant
80-64 PC210LC-10
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)
A-1 Troubleshooting for power supply system (Air conditioner does not
operate) (PC220_10-FJ0-400-A-00-A)
Failure • Trouble: Air conditioner does not operate due to power supply system failure.
• If failure code [DAZQKR] is displayed on machine monitor, perform this troubleshooting
first.
a The machine monitor, engine controller, pump controller, and air conditioner controller are
connected via CAN communication.
• "DAZQKR" is displayed on operation screen of machine monitor in the following cases. In
this section, 1) and 2) of the following are explained.
1) The air conditioner controller is receiving no power.
2) The air conditioner controller is malfunctioning.
3) No communication is possible between the air conditioner controller and the machine
monitor.
a For 3), see failure code [DAZQKR].
• Turn starting switch to ON position and check whether failure code [DAZQKR] is
displayed on machine monitor and whether CAN communication condition is abnormal.
Related This type of abnormal status indicates that CAN communication cannot be performed
information between the air conditioner controller above the air conditioner unit and the machine
monitor.
• Referring to “Parts and connectors layout“, check fuse No. 14 (5 A) in fuse box F01 for
breakage.
• Ground cable of air conditioner is connected in machine wiring harness together with
electrical equipment of machine.
• In cases where fuses are blown when the A/C switch is pressed, see "Troubleshooting for
compressor and refrigerant system."
have a T-adapter, carry out troubleshooting by using the intermediate connector
(Although the intermediate connector does not have a T-adapter either, it does have large
pins).
must be replaced.
Defective wiring 2. Set battery disconnect switch to OFF position.
1 harness (ground) 3. Disconnect connector AC02.
Between (1) (black) on harness side of
Resistance connector AC02 and chassis ground Max. 1 z

2 Blown fuse 2. Referring to “Parts and connectors layout“, check fuse No. 14 (5 A) in fuse box
F01 for breakage.
a If fuse described in related information is broken, replace it.
2. Set battery disconnect switch to OFF position.
Defective wiring 3. Disconnect connector AC02.
3
harness 4. Set battery disconnect switch to ON position.
Between connector AC02 (female) (4) 20 to 30 V
Voltage
(red) and (1) (black)
PC210LC-10 80-65
80 Appendix
A-1 Troubleshooting for power supply system (Air
conditioner does not operate)

a If the fuse is blown again during the above test, carry out the following
procedure.
Ground fault in
machine wiring
2. Set battery disconnect switch to OFF position.
4 harness
3. Disconnect connector AC02.
(Contact with GND 4. Remove fuse No. 14 of fuse box F01.
circuit) Between connector AC02 (female) (4)
Resistance (red) and ground, or between F01-14 Min. 1 Mz
and ground
Breaking of 1.Turn starting switch to OFF position.
harness 2.Set battery disconnect switch to OFF position.
3.Disconnect connector AC02.
5 (Wire breakage or
4.Remove fuse No. 14 of fuse box F01.
Between connector AC02 (female) (4)
connectors) Resistance Max. 1 Mz
(red) and F01-14
Defective air Replace air conditioner controller.
6 conditioner
controller
7
conditioner unit
Defective machine If no abnormality is found in the checkup of potential causes 1 - 7, the machine
8
monitor monitor is defective.
Circuit diagram related to power supply
80-66 PC210LC-10
80 Appendix
A-2 Troubleshooting of compressor system (Air is not
cooled)
A-2 Troubleshooting of compressor system (Air is not cooled) (PC220_10-FKE-400-

A-00-A)
Failure • Trouble: Air is not cooled due to compressor or refrigerant system failure.
• Referring to "Testing with self-diagnosis function", display "Electrical Systems" screen on
the machine monitor and check to see if the refrigerant pressure is abnormal by checking
whether failure code [879GKX] is displayed. If the refrigerant pressure is abnormal, the
compressor will not be turned ON and air will not subsequently be cooled.
a Abnormal refrigerant pressure indicates that "Signal ((21) of connector ACECU) from the
dual pressure switch is not grounded".
• In certain cases, the air conditioner will not turn on at 3°C or lower (normal).
• If no air comes out, see "Troubleshooting for blower motor system".
Related • For each connector and fuse, see “A-3 Troubleshooting for blower motor system (No air
information comes out or air flow is abnormal)“ and “Parts and connectors layout“.
a A T-adapter is provided only for the connector AC03.
pins).
must be replaced.
a Perform this check when failure code [879GKX] is displayed on "Electrical
Systems" screen of machine monitor.
See failure code [879GKX].
Defective dual a In certain cases, the dual pressure switch may be operating normally and set to
1 pressure switch OFF, therefore, if abnormality is indicated (i.e., switch OFF), attach a pressure
system gauge to the air conditioner compressor and check the refrigerant pressure.
(See “Troubleshooting with gauge pressure“.)
k If the pressure switch is to be replaced, refrigerant must be collected in
advance.
2. Disconnect the connector AC03 from the air conditioner compressor and
connect a T-adapter to the male side.
Defective air
2 conditioner a Ensure connection of air conditioner compressor ground cable (E).
compressor (See “Parts and connectors layout“.)
Between connector AC03 (male) (1) and
Resistance the chassis ground (i.e., air conditioner Approx. 15 z
compressor coil resistance)
• Referring to "Testing relays", check sound when compressor clutch relay is
turned ON.
Click is heard.: A
a When A above is abnormal and B below is abnormal and C is normal (if the
relay is normal), go to cause 4.
compressor clutch 2. Disconnect connector R21.
3 relay(Does not turn 3. Use a wire to short-circuit (3) (white) and (5) (red on yellow) of connector R21
ON) (wiring harness side). (This forces the compressor to operate without using the
relay.)
Air is cooled.: B
2. Disconnect connector R21 and troubleshoot in that condition.
PC210LC-10 80-67
80 Appendix
cooled)

Between R21
(male) (1) and (2) (i. Approx. 300 to 500
Resistance C
e., coil resistance) z

2. Disconnect connector R21 and carryout troubleshooting without turning
starting switch ON.
a Ensure that test result for cause 2 (air conditioner compressor is normal) is
normal.
Between connector R21 (female) (5) and
Breaking of F01-10 Max. 1 z
4 (Pressure switch is turned ON)
harness
Resistance the chassis ground
Approx. 15 z
(Air conditioner compressor coil
resistance)
Between F01-14 and AC01 (female) (4)
300 to 500 z
a Relay coil resistance
a If the fuse is not blown, skip troubleshooting.
Ground fault in
harness
5 2. Disconnect connectors AC03 and R21, and connect a T-adapter to the female
(Contact with GND side of AC03.
circuit) Between AC03 (female) (1) and chassis
Resistance ground Min. 1 Mz

2. Disconnect connectors AC01, AC02, and R21.
Short-circuiting of a Ensure that test result for cause 2 is normal.
6
harness Between wiring harness side (2) of
Resistance connector R21 and AC02 (female) (2), Min. 1 Mz
(3), and (4)
2. Disconnect connector R21.
Defective air 3. Turn starting switch to ON position.
7 conditioner 4. Display the air conditioner operation screen on the machine monitor and press
controller the A/C switch.
Voltage Max. 1 V
ground
Defective machine 2. Display the air conditioner operation screen on the machine monitor.
8
monitor
Press A/C switch. "A/C ON" is displayed.
9
conditioner unit
80-68 PC210LC-10
80 Appendix
cooled)
Circuit diagram related to compressor and refrigerant system
PC210LC-10 80-69
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
A-3 Troubleshooting for blower motor system (No air comes out or air
flow is abnormal) (PC220_10-FK3-400-A-00-A)
Failure No air comes out or air flow is abnormal due to blower motor system failure.
• This failure is not checked with self-diagnosis function.
• In cases where the blown-air volume begins to behave in an unpredictable manner after a
certain while during cooling, freezing of the evaporator is a likely cause.
This may be due to the followings.
1. Defective compressor clutch relay (i.e., stuck in ON position) (see item 3 A from
"Troubleshooting for compressor and refrigerant system")
2. Detachment of the evaporator temperature sensor's mounting holder (Replace the air
conditioner unit)
3. Incorrect adjustment of expansion valve (Replace air conditioner unit)
• If air comes out, fuse and motor are normal, and also wiring harness is normal.
• For connectors and power transistor, see “Parts and connectors layout“.
Related
information a The power transistor is on the rear side of the air conditioner unit.
• If air comes out but its flow is abnormal in heating mode, replace power transistor. (When
no air comes out, the power transistor may also be defective.)
a The blower motor cannot be replaced unless the air conditioner unit is removed once.
pins).
must be replaced.
Defective fuse No. If fuse is blown, circuit probably has ground fault.
1
10 in fuse box F01
Defective power 2. Replace power transistor.
2
transistor a If air comes out and air flow can be adjusted, the original power transistor is
defective.
harness 2. Disconnect connector AC02.
3 (Wire breakage or 3. Remove fuse No. 10 of fuse box F01.
Resistance Between AC02 (female) (2) and F01-10 Max. 1 z
connectors)
harness 2. Disconnect connectors AC02 and R21.
4 3. Remove fuse No. 10 of F01.
(Contact with GND
Between AC02 (female) (2) or F01-10
circuit) Resistance Max. 1 z
and ground
5 conditioner defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
6
conditioner unit
80-70 PC210LC-10
80 Appendix
A-3 Troubleshooting for blower motor system (No air
comes out or air flow is abnormal)
Circuit diagram related to blower motor system
PC210LC-10 80-71
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
A-4 Troubleshooting for FRESH/RECIRC air changeover (PC220_10-FKF-400-A-00-A)
Failure • Trouble: FRESH/RECIRC air cannot be selected

• FRESH/RECIRC air changeover is not checked with self-diagnosis function.
• Referring to "Testing FRESH/RECIRC air selector", operate the FRESH/RECIRC air
selector switch and check operation of FRESH/RECIRC air changeover door (damper).
• For connectors, see “Parts and connectors layout“.
a The T-adapter is not prepared for the connector.
Related (Although the intermediate connector does not have a T-adapter either, it does have large
information pins).
must be replaced.
• Troubleshooting cannot be performed since the connector portion of the servomotor
cannot be checked while it is installed on machine.
Defective fuse No. If fuse is blown, circuit probably has ground fault.
1
19 in fuse box F01
Breaking of a Connector [5] installed on machine cannot be disconnected since it is on the
harness rear side of the air conditioner unit.
2 (Wire breakage or 1. Turn starting switch to OFF position.
defective contact of 2. Disconnect connector AC02.
connectors) 3. Remove fuse No. 19 of F01.
Resistance Between F01-19 and AC02 (female) (3) Max. 1 z
harness 2. Disconnect connector AC02.
3 3. Remove fuse No. 19 of F01.
(Contact with GND
Between F01-19 and ground, or
circuit) Resistance Max. 1 z
between AC02 (female) (3) and ground
4 conditioner defective. (Since this is an internal defect, troubleshooting cannot be performed.)
controller
5
conditioner unit
2. Display the air conditioner operation screen on the machine monitor.
Defective machine
6 Press FRESH/
monitor
RECIRC air Display of Recirc/Fresh changes.
selector switch.
80-72 PC210LC-10
80 Appendix
A-4 Troubleshooting for FRESH/RECIRC air changeover
Circuit diagram related to FRESH/RECIRC air changeover
PC210LC-10 80-73
80 Appendix
Troubleshooting with gauge pressure
Troubleshooting with gauge pressure (PC220-3840-362-A-00-A)
Perform troubleshooting according to the high and low gauge pressures of the cooling cycle. For details, see
"Connection of service tool".
a The gauge pressure varies largely with the weather condition and operating condition of the machine.
Check the gauge pressure under the pressure measurement conditions.
• Pressure of high-pressure line is too high: Approximately 2.5 MPa {25 kg/cm 2} minimum
• Pressure of high-pressure line is too low: Approximately 1 MPa {10 kg/cm 2} maximum
• Pressure of low-pressure line is too high: Approximately 0.3 MPa {3 kg/cm 2} minimum
• Pressure of low-pressure line is too low: Approximately 0.05 MPa {0.5 kg/cm 2} maximum
a Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure
or low-pressure line is abnormal.
[Measurement condition for pressure]
Item Condition value
Ambient temperature 25 to 50°C
Engine speed 1,500 rpm
Air conditioner switch ON
Fan switch HI
Set temperature Cool-Max
• Dual pressure switch
a The switch is normally "ON", and becomes "OFF" when it detects abnormal pressure for compressor
operation.
LA: 0.20 MPa {2 kg/cm2 }

LB: 0.02 MPa {0.2 kg/cm2 }
HA: 3.14 MPa {32 kg/cm2 }
HB: 0.59 MPa {6 kg/cm2 }
80-74 PC210LC-10
80 Appendix
Indicated gauge pressure Cause Check method Remedy

Air conditioner cycle is operating normally.
If any cooling trouble (poor cooling) is recognizes, the
cause is in other system.
Pressure is normal Pressure of high-pressure line: Approx. 1.5 to 1.7 -
MPa {15 to 17 kg/cm2}
Pressure of low-pressure line: Approx. 0.13 to 0.2
MPa {1.3 to 2.0 kg/cm2 }
Collect refrigerant, then fill
Bubbles can be seen
Insufficient refrigerant up with proper quantity of
through sight glass. *1, *3
refrigerant again. *2
Temperature difference is
recognized between inlet
Clogging of receiver drier and outlet pipes of Replace *2
receiver drier.
Tank is frosty.
Clogging of expansion Expansion valve is frosty. Clean or replace *2
valve
Gas leakage at
<Pressure of both high- Low-pressure line gauge Replace *2
thermoprobe of expansion
pressure and low- reads vacuum.
valve
pressure lines are too
Evaporator is frozen.
low>
Flow rate of refrigerant is Repair or replace
Low-pressure line gauge Defective evaporator
reduced due to freezing.
reads vacuum temperature sensor or Replace receiver drier.
defective contact of (If air conditioner is set to
sensor (coming off of Cool Max. and HI fan
up with proper quantity of
mounting clip) speed modes, later its
cooling performance
lowers.)
Piping between receiver
drier and compressor is
clogged or crushed.
Clogged or crushed piping Clean or replace *2
If clogged completely, low-
pressure line gauge reads
vacuum
Filling of too much
Connect gauge manifold. up with proper quantity of
refrigerant
Check condenser for dirt, Clean condenser, repair
Defective cooling of fins for clogging or fins, or repair or replace
condenser crushing, and cooling fan cooling fan *2
<Pressure of both high- for defective rotation.
pressure and low- Defective adjustment of
pressure lines are too expansion valve Bubbles can be seen
high> Replace *2
(Valve is excessively through sight glass. *3
opened.)
Evacuate air from air
Bubbles can be seen conditioner and then fill up
Air in cycle parts
through sight glass. *3 with proper quantity of
PC210LC-10 80-75
80 Appendix
Indicated gauge pressure Cause Check method Remedy

<Pressure of high-
Clogged or crushed piping Remarkable temperature Clean inside of cooling
pressure line is too high
between compressor and difference is recognized cycle parts or replace
and that of low-pressure across clogged part.
condenser them.*2
line is too low>
Pressures of high-
pressure and low-
<Pressure of high- pressure lines are almost
Defective compressor
pressure line is too low the same while
(compression trouble of Replace *2
and that of low-pressure compressor is running.
compressor)
line is too high>
Compressor has seized
and is extremely hot.
*1: If refrigerant leaks, (compressor) oil in the air conditioner circuit always leaks, as well. Accordingly, perform
the check mainly on pipe joints and dirty parts with oil.
*2:
k When replacing cooling cycle parts, be sure to collect refrigerant. For details, see "Precautions for
refrigerant". After replacing parts, fill the air conditioner circuit with refrigerant.
*3: Sight glass is on the refrigerant piping near the condenser.
80-76 PC210LC-10
80 Appendix
Connection of service tool
Connection of service tool (PC300-K500-061-K-00-A)
a Following service tool kit is used for work with refrigerant R134a.
Symbol Part No. Part name
X 799-703-1200 Service tool kit
a Use the service tool kit for R134a.

Service tool kit X
(1): Gauge manifold
(2): Red high-pressure line charging hose
(3): Blue low-pressure line charging hose
(4): Large diameter quick joint (HI side)
(5): Small diameter quick joint (LO side)
(a): Note that the threads are coarse pitch and hoses are relatively easy to loosen.
Connect the gauge manifold, hoses and other service tools according to the following procedure.
1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (HI side) and blue low-pressure
line charging hose (3) to the gauge manifold (LO side).
3. Connect quick joints (4) and (5) to each hose.
4. Connect quick joints (4) and (5) to service valves (8) and (9) of high- and low-pressure piping respectively.
PC210LC-10 80-77
80 Appendix
Connection of service tool
A: From operator's cab

B: To condenser
80-78 PC210LC-10
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
Precautions for disconnecting and connecting air conditioner

piping (PC200_10-K5B0-924-K-00-A)
Precautions for connecting
k Collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before
disconnecting the air conditioner hoses to replace the air conditioner unit or condenser, the air
conditioner compressor, receiver drier, etc.
a Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a). (Only registered person can work.)
a Never release the refrigerant (R134a) to the atmosphere.
k If refrigerant gas (R134a) gets in your eyes, you may lose your sight. And if it touches your skin,
you may suffer from frostbite. Put on protective eyeglasses, gloves and working clothes with long
sleeves while collecting the refrigerant or filling the air conditioner circuit with the refrigerant.
• When loosening the air conditioner hose nuts after collecting the refrigerant, be sure to use 2 wrenches.
Use one wrench to fix and use the other one to loosen the nuts.
• When disconnecting conditioner hoses and tubes, cover so that dust, dirt or water dose not enter them.
Precautions for connecting

• Once an O-ring is used, it is deformed and deteriorated. Accordingly, do not reuse it.
• When removing it, use a soft tool (such as a toothpick) so that the piping will not be damaged.
• Check that there is no defect or deterioration on the O-ring.
• Apply compressor oil (ND-OIL8) for R134a to the O-rings. (See item 4 of "Handling compressor oil")
a Do not apply oil to the threads of a bolt, nut or union, however.
• Push in each pipe to the stopper and tighten the bolt or nut fully with your fingers.
• Be sure to use two wrenches to tighten each nut. Use one wrench to fix and tighten the nut with the other
wrench to the specified torque (Use a torque wrench for tightening).
a Example of fitting of O-ring
• Every joint portion of the air conditioner piping has an O-ring/
PC210LC-10 80-79
80 Appendix
Precautions for disconnecting and connecting air
conditioner piping
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque Nm {kgm}
M6 x 1.0 8 to 12 {0.8 to 1.2}
1. Engine
2. Compressor
3. Condenser
4. Modulator
80-80 PC210LC-10
80 Appendix
Handling of compressor oil
Handling of compressor oil (PC200_10-K594-212-K-00-A)

1. Compressor oil management (DENSO: ND-OIL8 for R134a)
Although compressor oil differs from engine oil in that it does not need regular checking or filling, the following
types of problem can occur if the amount in the system is too high or too low.
Condition Content
Insufficiency of oil Lubrication trouble and seizure of compressor
Cooling trouble (Excessive oil stick to parts and lower heat exchange
Excess of oil performance)
Accordingly, compressor oil must be filled to the specified level, similarly to refrigerant.
2. Filling compressor oil

k Refrigerant is potentially hazardous to health and to the environment. Before disconnecting air
conditioner hoses, therefore, refrigerant should be collected in accordance with “Precautions for
disconnecting and connecting air conditioner piping“.
a If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or seized.
Be sure to use an oil suitable for R134a (DENSO: ND-OIL8).
a Oil for use with R134a is extremely hygroscopic, and therefore, the cap must be immediately closed after
use to limit contact with air.
Store the oil can in a dry and ventilated place.
a Precautions for using oil
Do not allow oil for use with R134a to come into contact with acrylic plastic or polystyrene surfaces (except
a baked finish) as it may dissolve these plastics.
Check compressor oil in the following cases, and then add new oil if necessary.
• When much refrigerant is discharged because of leakage.
• When the compressor is troubled and replaced.
(See 3 below)
• When a cycle parts such as air conditioner unit, condenser, modulator, refrigerant piping, etc. is replaced.
• Quantity of oil to be added when cycle part is replaced
Air conditioner part Quantity to be added (cc)
Air conditioner unit, evaporator Approx. 40
Condenser (including modulator) Approx. 60
Modulator (desiccant) Approx. 20
Hose (between compressor and cab) Approx. 35
Hose (between condenser and compressor) Approx. 30
Hose (between condenser and cab) Approx. 10
3. Replacement of compressor
• In case of compressor seizure or breakage.
Metal chips will circulate through the air conditioner circuit and contaminate the compressor oil extremely.
PC210LC-10 80-81
80 Appendix
Handling of compressor oil
In this case, flush the air conditioner circuit and replace the compressor and receiver drier.
The compressor oil is removed from the air conditioner circuit by flushing. Accordingly, install a new
compressor with the oil of the specified quantity (180 cc) filled in it.
• Other cases
a New compressor contains compressor oil of 180 cc in it.
1. Prepare an oil container and drain oil from the old compressor.
2. Measure the quantity of the drained oil with a measuring cylinder, and note the quantity or mark the level.
3. Drain below-mentioned quantity of oil from the new compressor.

Quantity to be drained = 180 cc - "Noted quantity"
Example: If 30 cc was drained from the removed compressor, the quantity to be drained from the new
compressor would be 150 cc (i.e., 180 - 30 cc).
4. Applying compressor oil to O-rings

Whenever connecting piping or hoses, the compressor oil (ND-OIL8) must be applied to O-rings in order to
prevent the leakage of refrigerant.
80-82 PC210LC-10
80 Appendix
Desiccant replacement
Desiccant replacement (ALL-K523-923-K-00-A)
a Prepare desiccating agent replacement kit (20Y-810-1250).
k When replacing the desiccating agent, be sure to collect the refrigerant from the air conditioning
cycle. If the desiccating agent is replaced without collecting the refrigerant, the refrigerant may
blind you or cap (C) may fly out and injure you because of the refrigerant pressure in the cycle.
1. Condenser
2. Modulator
a The desiccanting agent is in modulator (2).
Taking out desiccanting agent (D)

1. Remove snap ring (SR) from modulator (2).
2. Hold boss (B) of cap (C) with pliers etc. to remove it from modulator (2).
a Cap (C) may be hard to remove. When removing it, exercise care not to damage or deform the seal or
modulator (2).
3. Remove filter (F) from modulator (2).
4. Remove desiccanting agent (D) from modulator (2).
a Replace snap ring (SR), cap (C), O-ring (OR), filter (F), and desiccanting agent (D) with the new parts
in the desiccanting agent replacement kit.
PC210LC-10 80-83
80 Appendix
Installing new desiccanting agent (D)

1. Apply compressor oil (ND-OIL8) to the periphery of O-ring (OR) of cap (C).
2. Install filter (F) to cap (C).
3. Insert desiccanting agent (D) in modulator (2).

4. Install cap (C) with filter (F) to modulator (2).
5. Fit snap ring (SR) to modulator (2) to fix cap (C).
a If snap ring (SR) is not fitted to the groove in modulator (2) securely, cap (C) may be come off.
80-84 PC210LC-10
80 Appendix
PC210LC-10 80-85
80 Appendix
80-86 PC210LC-10
SHOP MANUAL
HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number
PC210LC-10 450001 and up
90 Diagrams and drawings

10 90 Diagrams and drawings
PC210LC-10 90-1
Table of contents

90 Diagrams and drawings................................................................................................................. 90-1
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electric circuit diagram........................................................................................................ 90-13
Electric circuit diagram for air conditioner unit ....................................................................... 90-25
90-2 PC210LC-10
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram (ALL-C000-001-K-90-A)
Symbols in hydraulic circuit diagram (PC220-0000-007-K-00-A)
(Rev. 2010/03)
PC210LC-10 90-3
90-4 PC210LC-10
PC210LC-10 90-5
90-6 PC210LC-10
Hydraulic circuit diagram Hydraulic circuit diagram
PC210LC-10
PC210LC-10
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
PC210LC-10 90-7
Symbols in electric circuit diagram
Electric circuit diagram (ALL-0000-001-K-90-A)
Symbols in electric circuit diagram (PC220-0000-008-K-00-A)
(Rev. 2010/03)
PC210LC-10 90-9
90-10 PC210LC-10
PC210LC-10 90-11
90-12 PC210LC-10
Electrical circuit diagram (1/6) Electrical circuit diagram (1/6)
PC210LC-10
PC210LC-10
PC210LC-10 90-13
PC210LC-10
PC210LC-10
PC210LC-10 90-15
PC210LC-10
PC210LC-10
PC210LC-10 90-17
PC210LC-10
PC210LC-10
PC210LC-10 90-19
PC210LC-10
PC210LC-10
PC210LC-10 90-21
PC210LC-10
PC210LC-10
PC210LC-10 90-23
Electrical circuit diagram for air conditioner unit Electrical circuit diagram for air conditioner unit
PC210LC-10
PC210LC-10
a In the drawing, full line shows air conditioner wiring harness, and dashed line shows cab and chassis wiring harness. (For the detail of cab and chassis harness, see "Electrical circuit diagram")
a In the drawing, dot and dash line shows machine monitor wiring, and using twisted line (AVS 0.5 x 2, pitch 45 mm or less).
PC210LC-10 90-25
INDEX
INDEX
1st-line attachment PPC valve (with EPC Compressor ................................................. 80-19

valve)......................................................... 60-47 Configuration and function of refrigeration
2nd-line attachment PPC valve ...................... 60-50 cycle ............................................................ 80-7
Connection of service tool ............................. 80-77
Connector contact identification ..................... 40-59
A Connector list and layout ............................... 40-48
A-1 Troubleshooting for power supply system Control valve ...................................... 10-74, 60-26
(Air conditioner does not operate) ................. 80-65 Conversion table .......................................... 00-57
A-2 Troubleshooting for compressor and Cooling system.....................................10-27, 60-4
refrigerant system (Air is not cooled) ............. 80-67
A-3 Troubleshooting for blower motor system
(No air comes out or air flow is abnormal) ...... 80-70
D
A-4 Troubleshooting for FRESH/RECIRC air Desiccant replacement.................................. 80-83
changeover ................................................ 80-72 Diagnostic procedure for wiring harness open
Accumulator ............................................... 10-188 curcuit of pressure sensor system ................ 40-46
Adjusting mirrors........................................... 30-75 Disassembly and assembly of carrier roller ... 50-141
Adjusting play of work equipment and swing Disassembly and assembly of center swivel
PPC valves ................................................ 30-66 joint.......................................................... 50-152
Adjusting rearview camera angle ................. 30-148 Disassembly and assembly of control valve .. 50-168
Adjustment (Pump calibration: Matching speed Disassembly and assembly of final drive....... 50-110
check)...................................................... 30-138 Disassembly and assembly of idler............... 50-134
Air conditioner condenser .............................. 80-20 Disassembly and assembly of idler cushion .. 50-137
Air conditioner controller ................................ 80-18 Disassembly and assembly of KDPF .............. 50-94
Air conditioner unit ........................................ 80-10 Disassembly and assembly of swing
Arm cylinder ................................................. 60-66 machinery ................................................ 50-121
Attachment circuit selector valve (for high Disassembly and assembly of track roller ..... 50-139
pressure circuit) ........................................ 10-181 Disassembly and assembly of travel PPC
Attachment circuit selector valve (for low valve ........................................................ 50-175
pressure circuit) ........................................ 10-183 Disassembly and assembly of work equipment
Attachment circuit selector valve (for high- cylinder .................................................... 50-181
pressure circuit) .......................................... 60-53 Disassembly and assembly of work equipment
Attachment circuit selector valve (for low- PPC valve ................................................ 50-173
pressure circuit) .......................................... 60-54 Dual pressure switch..................................... 80-17
B E
Bleeding air from fuel system ......................... 30-34 E-1 Engine does not start (Engine does not
Bleeding air from hydraulic circuit ................... 30-72 crank) ...................................................... 40-553
Bucket cylinder ............................................. 60-67 E-2 Manual preheating system does not work .....40-
Bucket play adjustment shim ....................... 10-191 559
E-3 Automatic preheating system does not
work......................................................... 40-562
C E-4 Preheating monitor does not light up when
Carrier roller ................................................. 60-17 preheater is operated ................................ 40-564
Center swivel joint............................. 10-186, 60-55 E-5 When starting switch is turned to ON
Checking and adjusting air conditioner position, machine monitor displays nothing.. 40-566
compressor belt tension............................... 30-39 E-6 When starting switch is turned to ON
Checking cab tipping stopper......................... 30-74 position (before starting engine), engine oil
Checking fuel circuit for leakage..................... 30-36 level monitor lights up in yellow .................. 40-569
Circuit diagram and arrangement of connector E-7 When starting switch is turned to ON
pins ........................................................... 80-26 position (before starting engine), radiator
Classification and procedure for coolant level monitor lights up in yellow ....... 40-570
troubleshooting ........................................... 40-38 E-8 Coolant temperature monitor lights up in
CLSS........................................................... 10-44 white while engine is running...................... 40-571
Coating materials list....................................... 50-6
PC210LC-10 1
INDEX
E-9 Hydraulic oil temperature monitor lights up E-38 When swing brake cancel switch is set to
in white while engine is running .................. 40-572 CANCEL position, machine cannot swing ... 40-603
E-10 Charge level monitor lights up while E-39 Swing brake does not operate while
engine is running....................................... 40-573 swing brake cancel switch is locked ............ 40-605
E-11 Fuel level monitor lights up in red while E-40 One-touch power maximizing function
engine is running....................................... 40-574 does not work or monitor is not displayed .... 40-607
E-12 Air cleaner clogging monitor lights up in E-41 One-touch power maximizing function is
yellow while engine is running .................... 40-575 not cancelled ............................................ 40-609
E-13 Water separator monitor lights up while E-42 Travel alarm does not sound when
engine is running....................................... 40-576 machine travels ........................................ 40-610
E-14 Coolant temperature monitor lights up in E-43 Alarm does not stop sounding while
red while engine is running......................... 40-577 machine is stopped ................................... 40-611
E-15 Hydraulic oil temperature monitor lights E-44 Horn does not sound ........................... 40-612
up in red while engine is running................. 40-578 E-45 Horn does not stop sounding ............... 40-614
E-16 Engine oil pressure monitor lights up in E-46 Wiper monitor does not light up or go out
red while engine is running......................... 40-579 when wiper switch is operated.................... 40-615
E-17 Fuel gauge indicates either full or empty E-47 Wiper does not operate when wiper
and does not move.................................... 40-580 switch is operated ..................................... 40-616
E-18 Fuel gauge indicates incorrect amount E-48 Window washer does not operate when
(indicates neither full nor empty) ................. 40-581 window washer switch is operated .............. 40-618
E-19 Coolant temperature gauge indicates E-49 BOOM LOWER indication is not
either Min. or Max. and does not move........ 40-582 displayed properly with monitoring function . 40-619
E-20 Coolant temperature gauge indicates E-50 ARM DUMP indication is not displayed
incorrect temperature (indicates neither Min. properly with monitoring function ................ 40-620
nor Max.).................................................. 40-583 E-51 ARM IN indication is not displayed
E-21 Hydraulic oil temperature gauge indicates properly with monitoring function ................ 40-621
either Min. or Max. and does not move........ 40-584 E-52 BOOM RAISE indication is not displayed
E-22 Hydraulic oil temperature gauge indicates properly with monitoring function ................ 40-622
incorrect temperature (indicates neither Min. E-53 BUCKET CURL indication is not
nor Max.).................................................. 40-586 displayed properly with monitoring function . 40-623
E-23 Content of display on machine monitor is E-54 BUCKET DUMP indication is not
different from that of actual machine ........... 40-587 displayed properly with monitoring function . 40-624
E-24 Machine monitor does not display some E-55 SWING indication is not displayed
items........................................................ 40-588 properly with monitoring function ................ 40-625
E-25 Function switch does not work ............. 40-589 E-56 TRAVEL indication is not displayed
E-26 Automatic preheating system does not properly with monitoring function ................ 40-626
work (In cold season) ................................ 40-590 E-57 Service is not displayed properly with
E-27 Auto-deceleration monitor does not light monitoring function.................................... 40-627
up or does not go out when auto-deceleration E-58 Attachment hydraulic circuit cannot be
switch is operated ..................................... 40-591 changed ................................................... 40-630
E-28 Auto-deceleration is not actuated or E-59 KOMTRAX system does not operate
canceled when lever is operated ................ 40-592 properly.................................................... 40-631
E-29 Working mode selection screen is not EGR cooler .................................................. 10-18
diplayed when working mode switch is EGR system circuit diagram .......................... 10-14
operated................................................... 40-593 EGR system piping drawing........................... 10-12
E-30 Engine or hydraulic pump setting does EGR valve ................................................... 10-16
not change when working mode is changed 40-594 Electric circuit diagram .................................. 90-13
E-31 Travel speed monitor does not change Electric circuit diagram for air conditioner unit .. 90-25
when travel speed switch is operated.......... 40-595 Engine mount ................................................. 60-3
E-32 When travel speed selection is changed, Engine related parts ........................................ 10-3
actual travel speed does not change........... 40-596 Explanation of terms for maintenance standard ...00-
E-33 Alarm buzzer does not stop sounding ... 40-597 23
E-34 When starting switch is turned to OFF
position, service meter is not displayed ....... 40-598
E-35 Service mode cannot be selected......... 40-599
F
E-36 Any of work equipment, swing and travel Fabrication of dummy temperature sensor (for
does not work ........................................... 40-600 KDOC and KDPF temperature sensors)...... 40-106
E-37 All of work equipment, swing, and travel Fabrication of short-circuit connector (for
mechanism do not lock .............................. 40-602 CA1883 and CA3135) ............................... 40-107
2 PC210LC-10
INDEX
Failure code [879FMC] Air Mix Damper Failure code [CA2288] Turbo Speed High Error
Abnormality .............................................. 40-125 1.............................................................. 40-281
Failure code [A1U0N3]: KDPF Dry Request Failure code [CA2349] EGR Valve Solenoid
(HC Release)............................................ 40-130 Open Error ............................................... 40-283
Failure code [A1U0N4] KDPF Dry Request Failure code [CA2353] EGR Valve Solenoid
(HC Release)............................................ 40-132 Short Error................................................ 40-285
Failure code [AA10NX] Air Cleaner Clogging. 40-134 Failure code [CA2357] EGR Valve Servo Error ....40-
Failure code [B@BAZK] Eng Oil Level Low ... 40-139 287
Failure code [CA1117] Persistent Data Lost Failure code [CA2373] Exhaust Manifold Press
Error ........................................................ 40-238 Sens High Error ........................................ 40-288
Failure code [CA122] Chg Air Press Sensor Failure code [CA2374] Exhaust Manifold Press
High Error................................................. 40-145 Sens Low Error ......................................... 40-290
Failure code [CA123] Chg Air Press Sensor Failure code [CA2375] EGR Orifice Temp Sens
Low Error ................................................. 40-147 High Error................................................. 40-292
Failure code [CA144] Coolant Temp Sens High Failure code [CA238] Ne Speed Sensor
Error ........................................................ 40-153 Supply Volt Error ....................................... 40-169
Failure code [CA145] Coolant Temp Sens Low Failure code [CA2381] KVGT Pos Sens High
Error ........................................................ 40-155 Error ........................................................ 40-296
Failure code [CA153] Chg Air Temp Sensor Failure code [CA2382] KVGT Pos Sens Low
High Error................................................. 40-157 Error ........................................................ 40-298
Failure code [CA154] Chg Air Temp Sensor Failure code [CA2383] KVGT Solenoid Open
Low Error ................................................. 40-159 Error ........................................................ 40-301
Failure code [CA1664] KDOC Malfunction .... 40-239 Failure code [CA2386] KVGT Solenoid Short
Failure code [CA1691] Regeneration Error ........................................................ 40-303
Ineffective................................................. 40-241 Failure code [CA2387] KVGT Servo Error ..... 40-305
Failure code [CA1843] Crankcase Press Sens Failure code [CA2554] Exh Manifold Press
High Error................................................. 40-248 Sens In Range Error.................................. 40-306
Failure code [CA1844] Crankcase Press Failure code [CA2555] Grid Htr Relay Volt Low
Sensor Low Error ...................................... 40-250 Error ........................................................ 40-307
Failure code [CA187] Sensor 2 Supply Volt Failure code [CA2556] Grid Htr Relay Volt High
Low Error ................................................. 40-161 Error ........................................................ 40-309
Failure code [CA1879] KDPF Delta Pressure Failure code [CA2637] KDOC Face Plugging 40-311
Sensor High Error ..................................... 40-252 Failure code [CA2639] Manual Stationary
Failure code [CA1881] KDPF Delta Pressure Regeneration Request............................... 40-313
Sensor Low Error ...................................... 40-254 Failure code [CA271] IMV/PCV1 Short Error . 40-171
Failure code [CA1883] KDPF Delta P Sens In Failure code [CA272] IMV/PCV1 Open Error . 40-173
Range Error.............................................. 40-256 Failure code [CA295] Ambient Press Sens In
Failure code [CA1921] KDPF Soot Load High Range Error.............................................. 40-175
Error 1...................................................... 40-259 Failure code [CA2973] Chg Air Press Sensor
Failure code [CA1922] KDPF Soot Load High In Range Error .......................................... 40-317
Error 2...................................................... 40-262 Failure code [CA3133] KDPF Outlet Press
Failure code [CA1993] KDPF Delta Pressure Sens High Error ........................................ 40-318
Low Error ................................................. 40-268 Failure code [CA3134] KDPF Outlet Press
Failure code [CA2185] Throt Sensor Sup Volt Sens Low Error ......................................... 40-320
High Error................................................. 40-271 Failure code [CA3135] KDPF Outlet Press
Failure code [CA2186] Throt Sensor Sup Volt Sens In Range Error.................................. 40-322
Low Error ................................................. 40-273 Failure code [CA322] Inj #1(L#1) Open/Short
Failure code [CA221] Ambient Press Sens Error ........................................................ 40-176
High Error................................................. 40-163 Failure code [CA323] Inj #5(L#5) Open/Short
Failure code [CA222] Ambient Press Sens Low Error ........................................................ 40-178
Error ........................................................ 40-165 Failure code [CA324] Inj #3(L#3) Open/Short
Failure code [CA2249] Rail Press Very Low Error ........................................................ 40-180
Error 2...................................................... 40-275 Failure code [CA325] Inj #6(L#6) Open/Short
Failure code [CA227] Sensor 2 Supply Volt Error ........................................................ 40-182
High Error................................................. 40-167 Failure code [CA3251] KDOC Inlet Temp High
Failure code [CA2271] EGR Valve Pos Sens Error ........................................................ 40-326
High Error................................................. 40-276 Failure code [CA3253] KDOC Temp Error -
Failure code [CA2272] EGR Valve Pos Sens Non Regeneration..................................... 40-329
Low Error ................................................. 40-278
PC210LC-10 3
INDEX
Failure code [CA3254] KDOC Outlet Temp Failure code [CA515] Rail Press Sens Sup Volt
High Error 1 .............................................. 40-332 High Error................................................. 40-211
Failure code [CA3255] KDPF Temp Error - Non Failure code [CA516] Rail Press Sens Sup Volt
Regeneration............................................ 40-335 Low Error ................................................. 40-213
Failure code [CA3256] KDPF Outlet Temp Failure code [CA553] Rail Press High Error... 40-215
High Error 1 .............................................. 40-338 Failure code [CA559] Rail Press Low Error ... 40-218
Failure code [CA331] Inj #2(L#2) Open/Short Failure code [CA687] Turbo Speed Low Error .....40-
Error ........................................................ 40-184 221
Failure code [CA3311] KDOC Outlet Temp Failure code [CA689] Eng Ne and Speed
High Error 2 .............................................. 40-341 Sensor Error ............................................. 40-223
Failure code [CA3312] KDPF Outlet Temp Failure code [CA691] Intake Air Temp Sens
High Error 2 .............................................. 40-344 High Error................................................. 40-225
Failure code [CA3313] KDOC Inlet Temp Failure code [CA692] Intake Air Temp Sens
Sensor Low Error ...................................... 40-347 Low Error ................................................. 40-227
Failure code [CA3314] KDOC Inlet Temp Failure code [CA731] Eng Bkup Speed Sens
Sensor High Error ..................................... 40-350 Phase Error .............................................. 40-231
Failure code [CA3315] KDOC Inlet Temp Sens Failure code [CA778] Eng Bkup Speed Sensor
In Range Error .......................................... 40-353 Error ........................................................ 40-233
Failure code [CA3316] KDOC Outlet Temp Failure code [D19JKZ] Personal Code Relay
Sens Low Error ......................................... 40-357 Abnormality .............................................. 40-386
Failure code [CA3317] KDOC Outlet Temp Failure code [D8ALKA] System Operating
Sens High Error ........................................ 40-360 Lamp Disconnection (KOMTRAX) .............. 40-391
Failure code [CA3318] KDOC Outlet Temp Failure code [D8ALKB] System Operating
Sens In Range Error.................................. 40-364 Lamp Short Circuit (KOMTRAX) ................. 40-393
Failure code [CA3319] KDPF Outlet Temp Failure code [DA25KP] 5V Sensor1 Power
Sens High Error ........................................ 40-368 Abnormality .............................................. 40-398
Failure code [CA332] Inj #4(L#4) Open/Short Failure code [DA29KQ] Model Selection
Error ........................................................ 40-186 Abnormality .............................................. 40-401
Failure code [CA3321] KDPF Outlet Temp Failure code [DA2LKA] System Operating
Sens Low Error ......................................... 40-372 Lamp Disconnection (Pump Con) ............... 40-403
Failure code [CA3322] KDPF Outlet Temp Failure code [DA2LKB] System Operating
Sens In Range Error Failure code [CA3322] Lamp Short Circuit (Pump Con).................. 40-405
KDPF Outlet Temp Sens In Range Error ..... 40-375 Failure code [DA2QKR] CAN2 Discon ( Pump
Failure code [CA3419] Mass Air Flow Sensor Con) ........................................................ 40-406
Sup Volt High Error.................................... 40-379 Failure code [DA2RKR] CAN1 Discon ( Pump
Failure code [CA3421] Mass Air Flow Sensor Con) ........................................................ 40-409
Sup Volt Low Error .................................... 40-381 Failure code [DAF9KQ] Model Selection
Failure code [CA352] Sensor 1 Supply Volt Abnormality .............................................. 40-414
Low Error ................................................. 40-190 Failure code [DAFLKA] Operating Lamp Open
Failure code [CA356] Mass Air Flow Sensor Circuit(Monitor) ......................................... 40-416
High Error................................................. 40-192 Failure code [DAFLKB] System Operating
Failure code [CA357] Mass Air Flow Sensor Lamp Short Circuit (Monitor) ...................... 40-418
Low Error ................................................. 40-194 Failure code [DAZ9KQ] AC Model Selection
Failure code [CA3741] Rail Press Valve Trip Abnormality .............................................. 40-420
Error ........................................................ 40-383 Failure code [DAZQKR] CAN2 Discon (AC) .. 40-421
Failure code [CA386] Sensor 1 Supply Volt Failure code [DB2QKR] CAN2 Discon (Engine
High Error................................................. 40-196 Con) ........................................................ 40-426
Failure code [CA428] Water in Fuel Sensor Failure code [DGH2KB] Hyd Oil Sensor Short .....40-
High Error................................................. 40-197 435
Failure code [CA429] Water in Fuel Sensor Failure code [DHS3MA] Arm IN PPC Sen.
Low Error ................................................. 40-199 Abnormality .............................................. 40-444
Failure code [CA449] Rail Press Very High Failure code [DHS9MA] Boom LOWER Press
Error ........................................................ 40-205 Sensor Abnormality................................... 40-452
Failure code [CA451] Rail Press Sensor High Failure code [DHSDMA] Bucket DUMP PPC
Error ........................................................ 40-206 Press Sensor Abnormality ......................... 40-464
Failure code [CA452] Rail Press Sensor Low Failure code [DKR0MA] F pump S/P sensor
Error ........................................................ 40-208 Abnormality .............................................. 40-479
Failure code [CA488] Chg Air Temp High Failure code [DKR1MA] R pump S/P sensor
Torque Derate........................................... 40-210 Abnormality .............................................. 40-481
4 PC210LC-10
INDEX
Failure code [DW43KA] Travel Speed Sol Failure code [B@BCZK] Radiator Coolant
Open Circuit ............................................. 40-489 Level Low................................................. 40-141
Failure code [DW45KA] swing holding brake Failure code [B@HANS] Hyd Oil Overheat.... 40-143
Sol Open Circuit........................................ 40-493 Failure code [CA115] Eng Ne and Bkup Speed
Failure code [DW45KB] Swing Brake Sol Short Sens Error ................................................ 40-144
Circuit ...................................................... 40-496 Failure code [CA131] Throttle Sensor High
Failure code [DXA8KA] PC-EPC (F) Sol Open Error ........................................................ 40-149
Circuit ...................................................... 40-519 Failure code [CA132] Throttle Sensor Low
Failure code [DXA8KB] PC-EPC (F) Sol Short Error ........................................................ 40-151
Circuit ...................................................... 40-521 Failure code [CA234] Eng Overspeed........... 40-168
Failure code [DXA9KA] PC-EPC (R) Sol Open Failure code [CA239] Ne Speed Sens Supply
Circuit ...................................................... 40-523 Volt High Error .......................................... 40-170
Failure code [DXA9KB] PC-EPC (R) Sol Short Failure code [CA343] ECM Critical Internal
Circuit ...................................................... 40-525 Failure ..................................................... 40-188
Failure code [DXE0KA] LS-EPC Sol Open Failure code [CA351] Injectors Drive Circuit
Circuit ...................................................... 40-527 Error ........................................................ 40-189
Failure code [DXE5KA] Merge-divider Main Sol Failure code [CA435] Eng Oil Press Sw Error......40-
Open Circuit ............................................. 40-535 201
Failure code [DXE5KB] Merge-divider Main Sol Failure code [CA441] Battery Voltage Low
Short Circuit ............................................. 40-537 Error ........................................................ 40-202
Failure code [DXE6KA] Merge-divider LS Sol Failure code [CA442] Battery Voltage High
Open Circuit ............................................. 40-539 Error ........................................................ 40-204
Failure code [879AKA] A/C Inner Sensor Open Failure code [CA555] Crankcase Press High
Circuit ............................................ 40-117, 80-52 Error 1...................................................... 40-216
Failure code [879AKB] A/C Inner Sensor Short Failure code [CA556] Crankcase Press High
Circuit ............................................ 40-118, 80-53 Error 2...................................................... 40-217
Failure code [879BKA] A/C Outer sensor Open Failure code [CA697] ECM Int Temp Sensor
Circuit ........................................................ 80-54 High Error................................................. 40-229
Failure code [879BKA] A/C Outer Sensor Failure code [CA698] ECM Int Temp Sensor
Open Circuit ............................................. 40-119 Low Error ................................................. 40-230
Failure code [879BKB] A/C Outer sensor Short Failure code [CA1695] Sensor 5 Supply Volt
Circuit ........................................................ 80-56 High Error................................................. 40-244
Failure code [879BKB] A/C Outer Sensor Short Failure code [CA1696] Sensor 5 Supply Volt
Circuit ...................................................... 40-120 Low Error ................................................. 40-246
Failure code [879CKA] Ventilating Sensor Failure code [CA1942] Crankcase Press Sens
Open Circuit ................................... 40-121, 80-58 In Range Error .......................................... 40-267
Failure code [879CKB] Ventilating Sensor Failure code [CA2311] IMV Solenoid Error .... 40-282
Short Circuit ................................... 40-122, 80-59 Failure code [CA2376] EGR Orifice Temp Sens
Failure code [879DKZ] Sunlight sensor Open Low Error ................................................. 40-294
or Short Circuit............................................ 80-60 Failure code [CA2961] EGR Orifice Temp High
Failure code [879DKZ] Sunlight Sensor Open Error 1...................................................... 40-316
or Short Circuit.......................................... 40-123 Failure code [CA595] Turbo Speed High Error
Failure code [879EMC] Ventilation Damper 2.............................................................. 40-220
Abnormality .................................... 40-124, 80-62 Failure code [D110KB] Battery Relay Output
Failure code [879FMC] Air Mix Damper Voltage..................................................... 40-384
Abnormality ................................................ 80-63 Failure code [D811MC] KOMTRAX Error ...... 40-389
Failure code [879GKX] Refrigerant Failure code [D862KA] GPS Antenna Open
Abnormality .................................... 40-126, 80-64 Circuit ...................................................... 40-390
Failure code [989L00] Engine Controller Lock Failure code [D8AQKR] CAN2 Discon
Caution1 .................................................. 40-127 (KOMTRAX) ............................................. 40-394
Failure code [989M00] Engine Controller Lock Failure code [DA20MC] Pump Controller ...... 40-395
Caution2 .................................................. 40-128 Failure code [DA22KK] Pump Solenoid Power
Failure code [989N00] Engine Controller Lock Low Error ................................................. 40-396
Caution3 .................................................. 40-129 Failure code [DAF0MB] Monitor ROM
Failure code [AB00KE] Charge Voltage Low . 40-136 Abnormality .............................................. 40-410
Failure code [B@BAZG] Engine Oil Pressure Failure code [DAF0MC] Monitor Error ........... 40-411
Low ......................................................... 40-138 Failure code [DAF8KB] Camera Power Supply
Failure code [B@BCNS] Engine Coolant Short Circuit ............................................. 40-412
Overheat .................................................. 40-140 Failure code [DAFGMC] GPS Module Error .. 40-415
PC210LC-10 5
INDEX
Failure code [DAFQKR] CAN2 Discon Failure code [DXE4KB] Attachment Flow EPC
(Monitor) .................................................. 40-419 Short Circuit ............................................. 40-533
Failure code [DB2RKR] CAN1 Discon (Engine Failure code [DXE6KB] Merge-divider LS Sol
Con) ........................................................ 40-431 Short Circuit ............................................. 40-541
Failure code [DHA4KA] Air Cleaner Clog Failure code [DY20KA] Wiper Working
Sensor Open Circuit .................................. 40-437 Abnormality .............................................. 40-543
Failure code [DHPAMA] F Pump Press Sensor Failure code [DY20MA] Wiper Parking
Abnormality .............................................. 40-438 Abnormality .............................................. 40-545
Failure code [DHPBMA] R Pump Press Sensor Failure code [DY2CKB] Washer Drive Short
Abnormality .............................................. 40-441 Circuit ...................................................... 40-547
Failure code [DHS4MA] Bucket Curl PPC Failure code [DY2DKB] Wiper Drive (Fwd)
Press Sensor Abnormality ......................... 40-446 Short Circuit ............................................. 40-549
Failure code [DHS8MA] Boom Raise PPC Failure code [DY2EKB] Wiper Drive (Rev)
Press Sensor Abnormality ......................... 40-449 Short Circuit ............................................. 40-551
Failure code [DHSAMA] Swing RH PPC Press Failure code list related to air conditioner ........ 80-51
Sensor Abnormality................................... 40-455 Failure mode and cause table ...................... 40-636
Failure code [DHSBMA] Swing LH PPC Press Final drive ............................................10-34, 60-8
Sensor Abnormality................................... 40-458 Fuse location table...................................... 40-101
Failure code [DHSCMA] Arm Dump PPC
Press Sensor Abnormality ......................... 40-461
Failure code [DHSFMA] Travel Fwd LH PPC
H
Press Sensor Abnormality ......................... 40-467 H-1 All of work equipment, swing and travel
Failure code [DHSGMA] Travel Fwd RH PPC operation lacks speed or power .................. 40-644
Press Sensor Abnormality ......................... 40-470 H-2 Engine speed lowers significantly or
Failure code [DHSHMA] Travel Rev LH PPC engine stalls ............................................. 40-647
Press Sensor Abnormality ......................... 40-473 H-3 All work equipment, swing and travel does
Failure code [DHSJMA] Travel Rev RH PPC not work ................................................... 40-650
Press Sensor Abnormality ......................... 40-476 H-4 Unusual sound is heard from around
Failure code [DR21KX] Camera 2 Picture Rev. hydraulic pump ......................................... 40-651
Drive Abnormality...................................... 40-483 H-5 Fine control performance or response is
Failure code [DR31KX] Camera 3 Picture Rev. poor ......................................................... 40-652
Drive Abnormality...................................... 40-485 H-6 Speed or power of boom is low .............. 40-654
Failure code [DV20KB] Travel Alarm Short H-7 Speed or power of arm is low................. 40-658
Circuit ...................................................... 40-487 H-8 Speed or power of bucket is low............. 40-663
Failure code [DW43KB] Travel Speed Sol H-9 Work equipment does not move in single
Short Circuit ............................................. 40-491 operation.................................................. 40-666
Failure code [DW91KA] Travel Junction Sol H-10 Hydraulic drift of boom is large ............. 40-667
Open Circuit ............................................. 40-499 H-11 Hydraulic drift of arm is large ................ 40-668
Failure code [DW91KB] Travel Junction Sol H-12 Hydraulic drift of bucket is large............ 40-669
Short Circuit ............................................. 40-501 H-14 When part of work equipment is relieved
Failure code [DWA2KA] Attachment Sol Open singly, other parts of work equipment move . 40-672
Circuit ...................................................... 40-503 H-15 One-touch power maximizing function
Failure code [DWA2KB] Attachment Sol Short does not operate ....................................... 40-673
Circuit ...................................................... 40-505 H-16 In combined operation of work
Failure code [DWK0KA] 2-Stage Relief Sol equipment, equipment having heavier load
Open Circuit ............................................. 40-507 moves slower ........................................... 40-674
Failure code [DWK0KB] 2-stage Relief Sol H-17 In combined operations of swing and
Short Circuit ............................................. 40-509 boom RAISE, boom rising speed is low....... 40-675
Failure code [DWK2KA] Variable Back Press H-18 In combined operations of swing and
Sol Open Circuit........................................ 40-511 travel, travel speed drops largely ................ 40-676
Failure code [DWK8KA] Swing Press C/O Sol H-19 Machine does not travel straight........... 40-677
Open Circuit ............................................. 40-515 H-20 Travel speed is slow............................ 40-680
Failure code [DWK8KB] Swing Press C/O Sol H-21 Machine is hard to steer or travel power
Short Circuit ............................................. 40-517 is low ....................................................... 40-682
Failure code [DXE0KB] LS-EPC Sol Short H-22 Travel speed does not change, or travel
Circuit ...................................................... 40-529 speed is too slow or fast ............................ 40-685
Failure code [DXE4KA] Attachment Flow EPC H-23 One of tracks does not run................... 40-686
Open Circuit ............................................. 40-531 H-24 Upper structure does not swing to the
right or left ................................................ 40-688
6 PC210LC-10
INDEX
H-25 Upper structure swing only to the right or KOMTRAX system ..................................... 10-267
left ........................................................... 40-689 KVGT ............................................................ 10-5
H-26 Swing acceleration or swing speed is low
in both directions (right and left).................. 40-690
H-27 Swing acceleration performance is poor
L
or swing speed is slow in only one direction. 40-691 List of abbreviation........................................ 00-52
H-28 Upper structure overruns excessively
when it stops swinging (both right and left) .. 40-692
H-29 Upper structure overruns excessively
M
when it stops swinging (either right or left) ... 40-693 Machine monitor system.................. 10-194, 10-245
H-30 Shock is large when upper structure Main pump ......................................... 10-49, 60-25
stops swinging .......................................... 40-694 Measuring and adjusting valve clearance........ 30-13
H-31 Large unusual noise is heard when upper Measuring fuel delivery, return and leakage..... 30-29
structure stops swinging ............................ 40-695 Measuring fuel pressure ................................ 30-23
H-32 Swing drift on a slope is large while swing Method of disconnecting and connecting of
holding brake is applied ............................. 40-696 push-pull type coupler ................................. 00-29
H-33 Swing drift on a slope is large while swing
holding brake is released ........................... 40-697
H-34 Attachment hydraulic circuit cannot be O
changed while attachment is installed ......... 40-698 Outer temperature sensor.............................. 80-23
H-35 Oil flow in attachment circuit cannot be Outline of refrigeration cycle ............................ 80-8
controlled ................................................. 40-699
Handling battery disconnect switch .............. 30-151
Handling cylinder cutout mode operation ........ 30-37 P
Handling equipment of fuel system devices..... 00-25 Parts and connectors layout .......................... 80-31
Handling no injection cranking operation......... 30-38 Pm clinic service......................................... 30-153
Handling of compressor oil ............................ 80-81 Power train system ....................................... 10-29
Handling of electrical equipment .................... 00-32 PPC valve.................................................. 10-156
Handling of hydraulic equipment .................... 00-27 Practical use of KOMTRAX............................ 00-47
Handling of intake system parts ..................... 00-26 Precautions for disconnecting and connecting
Handling voltage circuit of engine controller .. 30-150 air conditioner piping ................................... 80-79
How to open the electrical system abnormality Precautions for KDPF (KCSF and KDOC)
record screen in service mode of the machine Cleaning and Replacement........................ 40-103
monitor....................................................... 80-38 Precautions for refrigerant ............................... 80-3
How to read electric wire code ....................... 00-40 Precautions when performing operation.......... 00-43
How to read the shop manual ........................ 00-21 Preparation work for troubleshooting of
How to read this manual .................................. 50-4 electrical system ......................................... 40-34
Hydraulic circuit diagram ................................. 90-7 Procedure for testing and troubleshooting ....... 80-24
Hydraulic equipment layout drawing ............... 10-38
Hydraulic tank .................................... 10-42, 60-24
R
I Releasing remaining pressure from hydraulic
circuit ......................................................... 30-44
Idler ............................................................. 60-14 Removal and installation of air conditioner
Important safety precautions.......................... 00-14 compressor assembly ............................... 50-229
Information described in troubleshooting table Removal and installation of air conditioner
(H-mode).................................................. 40-633 condenser assembly ................................. 50-232
Information in troubleshooting table ...... 40-44, 80-50 Removal and installation of air conditioner unit
Information mentioned in troubleshooting table assembly.................................................. 50-214
(S mode) .................................................. 40-700 Removal and installation of center swivel joint
Inspection procedure before troubleshooting... 40-15 assembly.................................................. 50-149
Isolating the parts causing hydraulic drift in Removal and installation of control valve
work equipment .......................................... 30-68 assembly.................................................. 50-161
Removal and installation of counterweight
K assembly.................................................. 50-146
Removal and installation of cylinder head
KCCV layout drawing .................................... 10-19 assembly.................................................... 50-33
KCCV ventilator............................................ 10-21
KDPF .......................................................... 10-23
PC210LC-10 7
INDEX
Removal and installation of engine and main Removal and installation of work equipment
pump assembly .......................................... 50-60 assembly.................................................. 50-178
Removal and installation of engine controller Replacing fan belt ......................................... 30-41
assembly.................................................. 50-234 ROPS cab.................................................. 10-193
Removal and installation of engine front oil
seal ........................................................... 50-72
Removal and installation of engine hood
S
assembly.................................................... 50-83 S-1 When starting switch is turned to START
Removal and installation of engine rear oil seal ...50- position, engine does not crank .................. 40-701
76 S-2 Engine cranks but no exhaust smoke
Removal and installation of floor frame comes out ................................................ 40-702
assembly.................................................. 50-208 S-3 Fuel is being injected but engine does not
Removal and installation of front window start (misfiring: engine cranks but does not
assembly.................................................. 50-202 start) ........................................................ 40-703
Removal and installation of front wiper S-4 Engine startability is poor....................... 40-704
assembly.................................................. 50-222 S-5 Engine does not pick up smoothly .......... 40-706
Removal and installation of fuel cooler S-6 Engine stops during operation................ 40-708
assembly.................................................... 50-79 S-7 Engine runs rough or is unstable ............ 40-710
Removal and installation of fuel tank assembly....50- S-8 Engine lacks power............................... 40-711
80 S-9 Exhaust smoke is black (KDPF clogs up
Removal and installation of hydraulic oil cooler early) ....................................................... 40-713
assembly.................................................... 50-55 S-10 Engine oil consumption is excessive..... 40-715
Removal and installation of hydraulic tank S-11 Engine oil becomes contaminated early 40-716
assembly.................................................. 50-153 S-12 Fuel consumption is excessive............. 40-717
Removal and installation of idler and idler S-13 Oil is in coolant (or coolant spurts or
cushion assembly ..................................... 50-133 coolant level goes down) ........................... 40-718
Removal and installation of injector assembly . 50-24 S-14 Engine oil pressure drops .................... 40-719
Removal and installation of KCCV assembly . 50-102 S-15 Fuel is contaminated in engine oil......... 40-720
Removal and installation of KDPF assembly ... 50-86 S-16 Coolant is contaminated in engine oil (Oil
Removal and installation of KOMTRAX becomes cloudy white) .............................. 40-721
terminal assembly ..................................... 50-243 S-17 Coolant temperature rises too high
Removal and installation of machine monitor (overheating) ............................................ 40-722
assembly.................................................. 50-239 S-18 Unusual noise is heard ........................ 40-723
Removal and installation of main pump S-19 Vibration is excessive.......................... 40-724
assembly.................................................. 50-157 S-20 Air cannot be bled from fuel circuit ........ 40-725
Removal and installation of mass air flow and S-21 Active regeneration is executed
temperature sensor ................................... 50-242 frequently ................................................. 40-726
Removal and installation of operator cab glass S-22 Active regeneration takes time ............. 40-727
(adhered glass)......................................... 50-192 S-23 White smoke is exhausted during active
Removal and installation of operator's cab regeneration ............................................. 40-728
assembly.................................................. 50-187 Sensor....................................................... 10-270
Removal and installation of pump controller Separation and connection of track shoe
assembly.................................................. 50-236 assembly.................................................. 50-129
Removal and installation of pump swash plate Sequence of events in troubleshooting ........... 40-11
sensor...................................................... 50-241 Sketch of tools for testing and adjusting ............ 30-7
Removal and installation of radiator assembly . 50-53 Sketches of special tools ............................... 50-15
Removal and installation of revolving frame Solenoid valve.................................. 10-178, 60-52
assembly.................................................. 50-144 Special functions of machine monitor.............. 30-77
Removal and installation of seat belt............. 50-220 Specification drawing ...................................... 01-3
Removal and installation of sprocket ............ 50-132 Specifications .........................................01-3, 01-5
Removal and installation of supply pump Sprocket ...................................................... 60-10
assembly.................................................... 50-19 Standard tightening torque table .................... 00-48
Removal and installation of swing circle Standard value table for electrical system ....... 20-18
assembly.................................................. 50-128 Standard value table for engine........................ 20-3
Removal and installation of swing motor and Standard value table for machine ..................... 20-5
swing machinery assembly ........................ 50-118 Sunlight sensor............................................. 80-22
Removal and installation of travel motor and Swing circle..........................................10-31, 60-5
final drive assembly................................... 50-109 Swing machinery ..................................10-32, 60-6
Swing motor ..................................... 10-131, 60-36
8 PC210LC-10
INDEX
Symbols in electric circuit diagram.................... 90-9 Work equipment and swing PPC valve ........... 60-41
Symbols in hydraulic circuit diagram................. 90-3 Work equipment shim ................................. 10-190
Symptom of probable failure and Working range drawings.................................. 01-4
troubleshooting No. ..................................... 40-41
System chart for hydraulic system ................ 40-634
System diagram ........................................... 80-28
T
T-branch box and T-branch adapter table........ 40-95
Table of fuel, coolant and lubricants .................. 01-9
Testing air leakage (duct)............................... 80-35
Testing and adjusting oil pressure in pump LS
control circuit .............................................. 30-55
Testing and adjusting oil pressure in pump PC
control circuit .............................................. 30-52
Testing and adjusting oil pressure in work
equipment, swing, and travel circuits............. 30-45
Testing and adjusting track shoe tension......... 30-43
Testing before troubleshooting ....................... 40-13
Testing blowby pressure ................................ 30-20
Testing boost pressure .................................... 30-9
Testing compression pressure ....................... 30-16
Testing diodes ............................................ 30-152
Testing (dual) pressure switch for refrigerant ... 80-44
Testing EGR valve and KVGT oil pressures..... 30-22
Testing engine oil pressure ............................ 30-21
Testing engine speed ...................................... 30-8
Testing exhaust gas color .............................. 30-11
Testing FRESH/RECIRC air changeover ........ 80-42
Testing oil leakage ........................................ 30-69
Testing oil pressure of control circuit ............... 30-49
Testing output pressure of solenoid valve........ 30-60
Testing PPC valve output pressure................. 30-64
Testing pump swash plate sensor................... 30-67
Testing relays ............................................... 80-45
Testing sunlight sensor.................................. 80-43
Testing swing circle bearing clearance............ 30-42
Testing vent (mode) changeover .................... 80-40
Testing with self-diagnosis function................. 80-38
Tools for testing and adjusting.......................... 30-3
Track frame and idler cushion .............. 10-36, 60-12
Track roller ................................................... 60-16
Travel motor ..................................... 10-143, 60-38
Travel PPC valve .......................................... 60-44
Troubleshooting chart 1................................. 80-46
Troubleshooting chart 2................................. 80-47
Troubleshooting points .................................... 40-9
Troubleshooting with gauge pressure ............. 80-74
Truck shoe ................................................... 60-18
V
Valve control ................................................ 10-40
W
Weight table ................................................... 01-8
Work equipment ............................... 10-189, 60-56
PC210LC-10 9
PC210LC-10 HYDRAULIC EXCAVATOR
Form No. SEN05842-01
©2012 KOMATSU
All Rights Reserved
Printed in Japan 06–12

PC210 10

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SEN05842-01

HYDRAULIC PC210LC -10

PC210LC-10 450001 and up

00 Index and foreword

Attachment circuit selector valve (for low pressure circuit).................................................... 10-183

Bleeding air from hydraulic circuit ........................................................................................ 30-72

Failure code [CA131] Throttle Sensor High Error................................................................. 40-149

Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)........................ 40-391

Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-521

E-35 Service mode cannot be selected .............................................................................. 40-599

Power train............................................................................................................................. 50-109

Track roller ........................................................................................................................ 60-16

Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-62

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

General precautions knowledge of welding perform the work. When

k Slinging with one rope may cause turning

Precautions for using mobile crane

• When installing wire ropes to an angular load,

Precautions for using overhead traveling crane Nominal

• Check that the O-ring is not damaged or

For tightening torques, see "Others",

Fire prevention (ALL-0000-001-K-27-A)

Action if fire occurs (ALL-0000-17A-K-01-A)

KDPF is a system for purifying soot in exhaust

To prevent pollution, pay full attention to the way to

Some kinds of rubber and plastics may produce

How to read the shop manual (ALL-0320-010-A-01-A)

Composition of shop manual

Symbol Item Remarks

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

Standard dimension and tolerance

• The performance and function of the products

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

Use care for working environment

How to clean parts when dirt is stuck

Precautions for replacing fuel filter cartridge

Handling of intake system parts (PC220-A900-2A4-K-00-A)

Be careful of working environment

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

Be careful of working environment

Disassembly and maintenance work in the field

Method of disconnecting and connecting of push-pull type coupler (ALL-

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

Precautions for handling electric equipment

Handling wiring harnesses and connectors

Main failures occurring in wiring harness

blow it with compressed air and spray it with

High-pressure water entering connector

Entry of water, mud or dirt when disconnecting a

• Check that there is no oil, dirt or water stick

3. Action to take after removing connectors

Deutsch connector (DT8-pin, DT12-pin)

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

3. Perform a continuity test on the connector.

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

Slide, lock type (Type 1) (FRAMATOME-3,

Push lock type (3) (AMP-3)

a If the lock is located on the underside, use

Example) Injection pressure control valve of

Connection Handling controller

• Cover the control connectors with tape or a vinyl

temperature even for a short period of time.