Sen06616 03

SEN06616-03
HYDRAULIC PC210LCI -11

EXCAVATOR SERIAL NUMBERS 500470 and up
00 INDEX AND FOREWORD
PC210LCI-11 00-1
INDEX 00 INDEX AND FOREWORD
INDEX
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ........................................................................................................................... 00-23
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-29
HOW TO READ THE SHOP MANUAL........................................................................................... 00-29
SAFETY NOTICE FOR OPERATION............................................................................................. 00-31
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-39
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-43
PRECAUTIONS FOR DEF............................................................................................................. 00-44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-57
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-59
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-73
HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-78
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-81
CONVERSION TABLE ................................................................................................................... 00-88
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
SPECIFICATION DRAWING............................................................................................................ 01-9
WORKING RANGE DRAWINGS ....................................................................................................01-11
SPECIFICATIONS ......................................................................................................................... 01-12
WEIGHT TABLE ............................................................................................................................ 01-15
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-17
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
UREA SCR SYSTEM............................................................................................................................ 10-12
LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-13
UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-18
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-19
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-36
BOOT-UP SYSTEM .............................................................................................................................. 10-45
LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-45
SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-47
BATTERY DISCONNECT SWITCH ............................................................................................... 10-49
ENGINE SYSTEM ................................................................................................................................ 10-50
LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-50
ENGINE CONTROL SYSTEM ....................................................................................................... 10-52
AUTO-DECELERATION SYSTEM ................................................................................................. 10-55
ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-57
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-59
TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-62
00-2 PC210LCI-11
00 INDEX AND FOREWORD INDEX
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-64

COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-67
COOLING SYSTEM.............................................................................................................................. 10-86
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-86
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH .................................................................... 10-88
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH........................................................... 10-90
COMPONENT PARTS OF COOLING SYSTEM............................................................................. 10-92
CONTROL SYSTEM............................................................................................................................. 10-93
LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-93
MACHINE MONITOR SYSTEM ..................................................................................................... 10-96
KomVision SYSTEM ...................................................................................................................... 10-98
KOMTRAX SYSTEM.....................................................................................................................10-102
COMPONENT PARTS OF CONTROL SYSTEM...........................................................................10-103
HYDRAULIC SYSTEM.........................................................................................................................10-144
LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-144
CLSS ............................................................................................................................................10-150
ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-169
PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-175
COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-178
WORK EQUIPMENT SYSTEM ............................................................................................................10-266
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-266
STRUCTURE OF VALVE CONTROL............................................................................................10-271
ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-273
PPC LOCK SYSTEM ....................................................................................................................10-275
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-276
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-278
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-280
ICT SYSTEM .......................................................................................................................................10-305
LAYOUT DRAWING OF ICT SYSTEM..........................................................................................10-305
ICT CONTROL SYSTEM DIAGRAM.............................................................................................10-309
BUCKET EDGE POSITION DETECTION SYSTEM......................................................................10-310
THE INTELLIGENT MACHINE CONTROL SYSTEM....................................................................10-312
CUSHION SYSTEM FOR ARM IN END........................................................................................10-333
BOOM SECONDARY DRIVE SWITCH.........................................................................................10-335
COMPONENT PARTS OF ICT SYSTEM ......................................................................................10-336
SWING SYSTEM .................................................................................................................................10-370
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-370
SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-374
COMPONENT PARTS OF SWING SYSTEM................................................................................10-378
TRAVEL SYSTEM................................................................................................................................10-392
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-392
TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-396
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-398
UNDERCARRIAGE AND FRAME........................................................................................................10-419
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-419
WORK EQUIPMENT............................................................................................................................10-421
STRUCTURE OF WORK EQUIPMENT ........................................................................................10-421
FUNCTION OF WORK EQUIPMENT ...........................................................................................10-422
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-423
BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-424
CAB AND ITS ATTACHMENTS ...........................................................................................................10-425
ROPS CAB ...................................................................................................................................10-425
CAB MOUNT ................................................................................................................................10-426
CAB TIPPING STOPPER .............................................................................................................10-427
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
PC210LCI-11 00-3
STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11 ............................................................... 20-9

STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-13
STANDARD VALUE TABLE FOR MACHINE: PC210LCI-11 .......................................................... 20-13
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-36
STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-40
STANDARD VALUE TABLE FOR ELECTRICAL ............................................................................ 20-40
30 TESTING AND ADJUSTING ..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
RELATED INFORMATION ON TESTING AND ADJUSTING ................................................................ 30-12
TOOLS FOR TESTING AND ADJUSTING..................................................................................... 30-12
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-22
ENGINE AND COOLING SYSTEM....................................................................................................... 30-23
TEST ENGINE SPEED .................................................................................................................. 30-23
TEST BOOST PRESSURE............................................................................................................ 30-26
TEST EXHAUST GAS COLOR ...................................................................................................... 30-28
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-31
TEST COMPRESSION PRESSURE.............................................................................................. 30-33
TEST BLOWBY PRESSURE ......................................................................................................... 30-38
TEST ENGINE OIL PRESSURE .................................................................................................... 30-40
TEST EGR VALVE AND VGT OIL PRESSURE ............................................................................. 30-41
TEST FUEL PRESSURE ............................................................................................................... 30-43
TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-49
BLEEDING AIR FROM FUEL SYSTEM ......................................................................................... 30-55
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-56
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-58
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-59
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-60
TEST COOLING FAN SPEED ...................................................................................................... 30-62
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-63
TEST SCR RELATED FUNCTIONS............................................................................................... 30-64
CLEAN AdBlue/DEF TANK ............................................................................................................ 30-91
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK ................................................... 30-95
POWER TRAIN..................................................................................................................................... 30-97
TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-97
UNDERCARRIAGE AND FRAME......................................................................................................... 30-98
TEST AND ADJUST TRACK TENSION......................................................................................... 30-98
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................30-100
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........
..................................................................................................................................................30-101
TEST OIL PRESSURE OF CONTROL CIRCUIT .......................................................................... 30-111
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ...................................30-113
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT....................................30-116
TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-123
TEST PPC VALVE OUTLET PRESSURE .....................................................................................30-127
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-129
TEST PUMP SWASH PLATE SENSOR........................................................................................30-130
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-131
TEST OIL LEAKAGE ....................................................................................................................30-133
BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-136
TEST CAB TIPPING STOPPER ...................................................................................................30-140
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-141
ELECTRICAL SYSTEM .......................................................................................................................30-147
SET AND OPERATE MACHINE MONITOR..................................................................................30-147
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-254
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-259
00-4 PC210LCI-11
ADJUST KomVision CAMERA ANGLE .........................................................................................30-262

ADJUST KomVision RELATED ITEMS .........................................................................................30-267
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-283
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-284
TEST DIODES ..............................................................................................................................30-285
ICT SYSTEM .......................................................................................................................................30-286
SET AND OPERATE CONTROL BOX ..........................................................................................30-286
CALIBRATE INTELLIGENT MACHINE CONTROL .......................................................................30-295
Pm CLINIC...........................................................................................................................................30-733
Pm CLINIC SERVICE ...................................................................................................................30-733
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
ABBREVIATION LIST ........................................................................................................................... 40-15
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-21
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-21
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-22
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-34
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-36
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-38
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-40
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM..................................... 40-60
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-69
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-72
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-77
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM............................................................................................................................ 40-79
CONNECTOR LIST AND LAYOUT ................................................................................................ 40-82
CONNECTOR CONTACT IDENTIFICATION ................................................................................40-105
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-145
FUSE LOCATION TABLE .............................................................................................................40-151
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..........................40-155
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135])..........................................................................................................................40-159
FAILURE CODES TABLE .............................................................................................................40-161
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-183
FAILURE CODE [879AKA]............................................................................................................40-183
FAILURE CODE [879AKB]............................................................................................................40-184
FAILURE CODE [879BKA]............................................................................................................40-185
FAILURE CODE [879BKB]............................................................................................................40-187
FAILURE CODE [879CKA]............................................................................................................40-189
FAILURE CODE [879CKB]............................................................................................................40-190
FAILURE CODE [879DKZ]............................................................................................................40-191
FAILURE CODE [879EMC] ...........................................................................................................40-193
FAILURE CODE [879FMC] ...........................................................................................................40-194
FAILURE CODE [879GKX] ...........................................................................................................40-195
FAILURE CODE [989L00] .............................................................................................................40-197
FAILURE CODE [989M00] ............................................................................................................40-198
FAILURE CODE [989N00] ............................................................................................................40-199
FAILURE CODE [A1U0N3] ...........................................................................................................40-200
FAILURE CODE [A1U0N4] ...........................................................................................................40-202
FAILURE CODE [A900FR]............................................................................................................40-204
FAILURE CODE [A900N6] ............................................................................................................40-205
FAILURE CODE [A900NY]............................................................................................................40-206
FAILURE CODE [AA10NX] ...........................................................................................................40-207
FAILURE CODE [AB00KE] ...........................................................................................................40-209
FAILURE CODE [AQ10N3] ...........................................................................................................40-212
FAILURE CODE [AS00N3]............................................................................................................40-214
FAILURE CODE [AS00R2]............................................................................................................40-216
PC210LCI-11 00-5
FAILURE CODE [AS00R3]............................................................................................................40-217

FAILURE CODE [AS00R4]............................................................................................................40-218
FAILURE CODE [AS00R5]............................................................................................................40-219
FAILURE CODE [AS00R6]............................................................................................................40-220
FAILURE CODE [AS00ZK]............................................................................................................40-221
FAILURE CODE [AS10KM]...........................................................................................................40-222
FAILURE CODE [AS10NR] ...........................................................................................................40-223
FAILURE CODE [AS10NT] ...........................................................................................................40-224
FAILURE CODE [B@BAZG] .........................................................................................................40-225
FAILURE CODE [B@BAZK]..........................................................................................................40-226
FAILURE CODE [B@BCNS] .........................................................................................................40-228
FAILURE CODE [B@BCZK] .........................................................................................................40-229
FAILURE CODE [B@HANS] .........................................................................................................40-231
FAILURE CODE [CA115] ..............................................................................................................40-232
FAILURE CODE [CA122] ..............................................................................................................40-233
FAILURE CODE [CA123] ..............................................................................................................40-235
FAILURE CODE [CA131] ..............................................................................................................40-237
FAILURE CODE [CA132] ..............................................................................................................40-239
FAILURE CODE [CA144] ..............................................................................................................40-241
FAILURE CODE [CA145] ..............................................................................................................40-243
FAILURE CODE [CA153] ..............................................................................................................40-245
FAILURE CODE [CA154] ..............................................................................................................40-248
FAILURE CODE [CA187] ..............................................................................................................40-250
FAILURE CODE [CA221] ..............................................................................................................40-252
FAILURE CODE [CA222] ..............................................................................................................40-254
FAILURE CODE [CA227] ..............................................................................................................40-256
FAILURE CODE [CA234] ..............................................................................................................40-257
FAILURE CODE [CA238] ..............................................................................................................40-258
FAILURE CODE [CA239] ..............................................................................................................40-260
FAILURE CODE [CA249] ..............................................................................................................40-262
FAILURE CODE [CA256] ..............................................................................................................40-264
FAILURE CODE [CA271] ..............................................................................................................40-266
FAILURE CODE [CA272] ..............................................................................................................40-268
FAILURE CODE [CA322] ..............................................................................................................40-270
FAILURE CODE [CA323] ..............................................................................................................40-272
FAILURE CODE [CA324] ..............................................................................................................40-274
FAILURE CODE [CA325] ..............................................................................................................40-276
FAILURE CODE [CA331] ..............................................................................................................40-278
FAILURE CODE [CA332] ..............................................................................................................40-280
FAILURE CODE [CA343] ..............................................................................................................40-282
FAILURE CODE [CA351] ..............................................................................................................40-283
FAILURE CODE [CA352] ..............................................................................................................40-284
FAILURE CODE [CA356] ..............................................................................................................40-287
FAILURE CODE [CA357] ..............................................................................................................40-289
FAILURE CODE [CA386] ..............................................................................................................40-291
FAILURE CODE [CA428] ..............................................................................................................40-292
FAILURE CODE [CA429] ..............................................................................................................40-294
FAILURE CODE [CA435] ..............................................................................................................40-296
FAILURE CODE [CA441] ..............................................................................................................40-298
FAILURE CODE [CA442] ..............................................................................................................40-300
FAILURE CODE [CA449] ..............................................................................................................40-301
FAILURE CODE [CA451] ..............................................................................................................40-302
FAILURE CODE [CA452] ..............................................................................................................40-304
FAILURE CODE [CA488] ..............................................................................................................40-306
FAILURE CODE [CA515] ..............................................................................................................40-307
FAILURE CODE [CA516] ..............................................................................................................40-309
FAILURE CODE [CA553] ..............................................................................................................40-311
FAILURE CODE [CA555] ..............................................................................................................40-312
00-6 PC210LCI-11
FAILURE CODE [CA556] ..............................................................................................................40-313

FAILURE CODE [CA559] ..............................................................................................................40-314
FAILURE CODE [CA595] ..............................................................................................................40-317
FAILURE CODE [CA687] ..............................................................................................................40-318
FAILURE CODE [CA689] ..............................................................................................................40-320
FAILURE CODE [CA691] ..............................................................................................................40-323
FAILURE CODE [CA692] ..............................................................................................................40-325
FAILURE CODE [CA697] ..............................................................................................................40-327
FAILURE CODE [CA698] ..............................................................................................................40-328
FAILURE CODE [CA731] ..............................................................................................................40-329
FAILURE CODE [CA778] ..............................................................................................................40-331
FAILURE CODE [CA1117] ............................................................................................................40-336
FAILURE CODE [CA1664] ............................................................................................................40-337
FAILURE CODE [CA1669] ............................................................................................................40-339
FAILURE CODE [CA1673] ............................................................................................................40-340
FAILURE CODE [CA1677] ............................................................................................................40-341
FAILURE CODE [CA1678] ............................................................................................................40-342
FAILURE CODE [CA1682] ............................................................................................................40-343
FAILURE CODE [CA1683] ............................................................................................................40-345
FAILURE CODE [CA1684] ............................................................................................................40-347
FAILURE CODE [CA1686] ............................................................................................................40-349
FAILURE CODE [CA1691] ............................................................................................................40-350
FAILURE CODE [CA1694] ............................................................................................................40-353
FAILURE CODE [CA1695] ............................................................................................................40-356
FAILURE CODE [CA1696] ............................................................................................................40-357
FAILURE CODE [CA1712] ............................................................................................................40-359
FAILURE CODE [CA1713] ............................................................................................................40-362
FAILURE CODE [CA1714] ............................................................................................................40-364
FAILURE CODE [CA1715] ............................................................................................................40-365
FAILURE CODE [CA1776] ............................................................................................................40-366
FAILURE CODE [CA1777] ............................................................................................................40-369
FAILURE CODE [CA1843] ............................................................................................................40-372
FAILURE CODE [CA1844] ............................................................................................................40-374
FAILURE CODE [CA1879] ............................................................................................................40-377
FAILURE CODE [CA1881] ............................................................................................................40-379
FAILURE CODE [CA1883] ............................................................................................................40-381
FAILURE CODE [CA1885] ............................................................................................................40-384
FAILURE CODE [CA1887] ............................................................................................................40-386
FAILURE CODE [CA1921] ............................................................................................................40-388
FAILURE CODE [CA1922] ............................................................................................................40-391
FAILURE CODE [CA1942] ............................................................................................................40-396
FAILURE CODE [CA1993] ............................................................................................................40-397
FAILURE CODE [CA2185] ............................................................................................................40-400
FAILURE CODE [CA2186] ............................................................................................................40-401
FAILURE CODE [CA2249] ............................................................................................................40-403
FAILURE CODE [CA2271] ............................................................................................................40-404
FAILURE CODE [CA2272] ............................................................................................................40-407
FAILURE CODE [CA2288] ............................................................................................................40-410
FAILURE CODE [CA2311] ............................................................................................................40-411
FAILURE CODE [CA2349] ............................................................................................................40-412
FAILURE CODE [CA2353] ............................................................................................................40-415
FAILURE CODE [CA2357] ............................................................................................................40-417
FAILURE CODE [CA2381] ............................................................................................................40-418
FAILURE CODE [CA2382] ............................................................................................................40-421
FAILURE CODE [CA2383] ............................................................................................................40-424
FAILURE CODE [CA2386] ............................................................................................................40-427
FAILURE CODE [CA2387] ............................................................................................................40-429
FAILURE CODE [CA2555] ............................................................................................................40-430
PC210LCI-11 00-7
FAILURE CODE [CA2556] ............................................................................................................40-433

FAILURE CODE [CA2637] ............................................................................................................40-436
FAILURE CODE [CA2639] ............................................................................................................40-438
FAILURE CODE [CA2771] ............................................................................................................40-441
FAILURE CODE [CA2777] ............................................................................................................40-447
FAILURE CODE [CA2976] ............................................................................................................40-450
FAILURE CODE [CA3133] ............................................................................................................40-452
FAILURE CODE [CA3134] ............................................................................................................40-455
FAILURE CODE [CA3135] ............................................................................................................40-457
FAILURE CODE [CA3142] ............................................................................................................40-460
FAILURE CODE [CA3143] ............................................................................................................40-461
FAILURE CODE [CA3144] ............................................................................................................40-462
FAILURE CODE [CA3146] ............................................................................................................40-464
FAILURE CODE [CA3147] ............................................................................................................40-465
FAILURE CODE [CA3148] ............................................................................................................40-466
FAILURE CODE [CA3151] ............................................................................................................40-468
FAILURE CODE [CA3165] ............................................................................................................40-474
FAILURE CODE [CA3229] ............................................................................................................40-476
FAILURE CODE [CA3231] ............................................................................................................40-478
FAILURE CODE [CA3232] ............................................................................................................40-480
FAILURE CODE [CA3235] ............................................................................................................40-484
FAILURE CODE [CA3239] ............................................................................................................40-486
FAILURE CODE [CA3241] ............................................................................................................40-489
FAILURE CODE [CA3242] ............................................................................................................40-492
FAILURE CODE [CA3251] ............................................................................................................40-495
FAILURE CODE [CA3253] ............................................................................................................40-497
FAILURE CODE [CA3254] ............................................................................................................40-500
FAILURE CODE [CA3255] ............................................................................................................40-503
FAILURE CODE [CA3256] ............................................................................................................40-507
FAILURE CODE [CA3311] ............................................................................................................40-509
FAILURE CODE [CA3312] ............................................................................................................40-511
FAILURE CODE [CA3313] ............................................................................................................40-514
FAILURE CODE [CA3314] ............................................................................................................40-516
FAILURE CODE [CA3315] ............................................................................................................40-517
FAILURE CODE [CA3316] ............................................................................................................40-519
FAILURE CODE [CA3317] ............................................................................................................40-521
FAILURE CODE [CA3318] ............................................................................................................40-522
FAILURE CODE [CA3319] ............................................................................................................40-524
FAILURE CODE [CA3321] ............................................................................................................40-525
FAILURE CODE [CA3322] ............................................................................................................40-527
FAILURE CODE [CA3419] ............................................................................................................40-529
FAILURE CODE [CA3421] ............................................................................................................40-531
FAILURE CODE [CA3497] ............................................................................................................40-533
FAILURE CODE [CA3498] ............................................................................................................40-534
FAILURE CODE [CA3543] ............................................................................................................40-535
FAILURE CODE [CA3545] ............................................................................................................40-541
FAILURE CODE [CA3547] ............................................................................................................40-543
FAILURE CODE [CA3558] ............................................................................................................40-544
FAILURE CODE [CA3559] ............................................................................................................40-546
FAILURE CODE [CA3562] ............................................................................................................40-548
FAILURE CODE [CA3563] ............................................................................................................40-550
FAILURE CODE [CA3567] ............................................................................................................40-553
FAILURE CODE [CA3568] ............................................................................................................40-556
FAILURE CODE [CA3571] ............................................................................................................40-560
FAILURE CODE [CA3572] ............................................................................................................40-562
FAILURE CODE [CA3574] ............................................................................................................40-564
FAILURE CODE [CA3575] ............................................................................................................40-566
FAILURE CODE [CA3577] ............................................................................................................40-568
00-8 PC210LCI-11
FAILURE CODE [CA3578] ............................................................................................................40-570

FAILURE CODE [CA3582] ............................................................................................................40-572
FAILURE CODE [CA3583] ............................................................................................................40-578
FAILURE CODE [CA3596] ............................................................................................................40-580
FAILURE CODE [CA3649] ............................................................................................................40-582
FAILURE CODE [CA3681] ............................................................................................................40-584
FAILURE CODE [CA3682] ............................................................................................................40-589
FAILURE CODE [CA3713] ............................................................................................................40-595
FAILURE CODE [CA3717] ............................................................................................................40-598
FAILURE CODE [CA3718] ............................................................................................................40-599
FAILURE CODE [CA3725] ............................................................................................................40-600
FAILURE CODE [CA3741] ............................................................................................................40-603
FAILURE CODE [CA3748] ............................................................................................................40-604
FAILURE CODE [CA3751] ............................................................................................................40-606
FAILURE CODE [CA3755] ............................................................................................................40-608
FAILURE CODE [CA3866] ............................................................................................................40-610
FAILURE CODE [CA3867] ............................................................................................................40-613
FAILURE CODE [CA3868] ............................................................................................................40-616
FAILURE CODE [CA3899] ............................................................................................................40-620
FAILURE CODE [CA3911] ............................................................................................................40-622
FAILURE CODE [CA3912] ............................................................................................................40-626
FAILURE CODE [CA3932] ............................................................................................................40-628
FAILURE CODE [CA3933] ............................................................................................................40-630
FAILURE CODE [CA3934] ............................................................................................................40-632
FAILURE CODE [CA3935] ............................................................................................................40-635
FAILURE CODE [CA3936] ............................................................................................................40-637
FAILURE CODE [CA4151] ............................................................................................................40-639
FAILURE CODE [CA4152] ............................................................................................................40-643
FAILURE CODE [CA4155] ............................................................................................................40-647
FAILURE CODE [CA4156] ............................................................................................................40-650
FAILURE CODE [CA4157] ............................................................................................................40-653
FAILURE CODE [CA4158] ............................................................................................................40-655
FAILURE CODE [CA4159] ............................................................................................................40-656
FAILURE CODE [CA4161] ............................................................................................................40-657
FAILURE CODE [CA4162] ............................................................................................................40-660
FAILURE CODE [CA4163] ............................................................................................................40-663
FAILURE CODE [CA4164] ............................................................................................................40-664
FAILURE CODE [CA4165] ............................................................................................................40-666
FAILURE CODE [CA4166] ............................................................................................................40-668
FAILURE CODE [CA4168] ............................................................................................................40-669
FAILURE CODE [CA4169] ............................................................................................................40-672
FAILURE CODE [CA4171] ............................................................................................................40-674
FAILURE CODE [CA4249] ............................................................................................................40-677
FAILURE CODE [CA4251] ............................................................................................................40-679
FAILURE CODE [CA4259] ............................................................................................................40-681
FAILURE CODE [CA4261] ............................................................................................................40-684
FAILURE CODE [CA4277] ............................................................................................................40-687
FAILURE CODE [CA4281] ............................................................................................................40-690
FAILURE CODE [CA4459] ............................................................................................................40-693
FAILURE CODE [CA4461] ............................................................................................................40-696
FAILURE CODE [CA4658] ............................................................................................................40-699
FAILURE CODE [CA4731] ............................................................................................................40-703
FAILURE CODE [CA4732] ............................................................................................................40-704
FAILURE CODE [CA4739] ............................................................................................................40-705
FAILURE CODE [CA4768] ............................................................................................................40-706
FAILURE CODE [CA4769] ............................................................................................................40-708
FAILURE CODE [CA4842] ............................................................................................................40-711
FAILURE CODE [CA4952] ............................................................................................................40-714
PC210LCI-11 00-9
FAILURE CODE [CA5115] ............................................................................................................40-716

FAILURE CODE [CA5179] ............................................................................................................40-719
FAILURE CODE [CA5181] ............................................................................................................40-721
FAILURE CODE [CA5383] ............................................................................................................40-723
FAILURE CODE [D110KB]............................................................................................................40-725
FAILURE CODE [D19JKZ] ............................................................................................................40-727
FAILURE CODE [D811MC] ...........................................................................................................40-730
FAILURE CODE [D862KA]............................................................................................................40-731
FAILURE CODE [D8ALKA] ...........................................................................................................40-732
FAILURE CODE [D8ALKB] ...........................................................................................................40-734
FAILURE CODE [D8AQKR] ..........................................................................................................40-736
FAILURE CODE [DA20MC] ..........................................................................................................40-738
FAILURE CODE [DA22KK] ...........................................................................................................40-739
FAILURE CODE [DA25KP] ...........................................................................................................40-742
FAILURE CODE [DA26KP] ...........................................................................................................40-745
FAILURE CODE [DA29KQ]...........................................................................................................40-747
FAILURE CODE [DA2LKA] ...........................................................................................................40-750
FAILURE CODE [DA2LKB] ...........................................................................................................40-752
FAILURE CODE [DA2QKR] ..........................................................................................................40-754
FAILURE CODE [DA2RKR] ..........................................................................................................40-757
FAILURE CODE [DAF0MB] ..........................................................................................................40-759
FAILURE CODE [DAF0MC] ..........................................................................................................40-760
FAILURE CODE [DAF8KB] ...........................................................................................................40-761
FAILURE CODE [DAF9KQ]...........................................................................................................40-763
FAILURE CODE [DAFGMC] .........................................................................................................40-764
FAILURE CODE [DAFLKA] ...........................................................................................................40-765
FAILURE CODE [DAFLKB] ...........................................................................................................40-767
FAILURE CODE [DAFQKR] ..........................................................................................................40-769
FAILURE CODE [DAZ9KQ]...........................................................................................................40-770
FAILURE CODE [DAZQKR] ..........................................................................................................40-771
FAILURE CODE [DB2QKR] ..........................................................................................................40-776
FAILURE CODE [DB2RKR] ..........................................................................................................40-781
FAILURE CODE [DB90MC] ..........................................................................................................40-786
FAILURE CODE [DB92KK] ...........................................................................................................40-787
FAILURE CODE [DB95KP] ...........................................................................................................40-789
FAILURE CODE [DB96KP] ...........................................................................................................40-793
FAILURE CODE [DB99KQ]...........................................................................................................40-797
FAILURE CODE [DB9LKA] ...........................................................................................................40-800
FAILURE CODE [DB9LKB] ...........................................................................................................40-802
FAILURE CODE [DB9QKR] ..........................................................................................................40-804
FAILURE CODE [DB9RKR] ..........................................................................................................40-811
FAILURE CODE [DBP0KM] ..........................................................................................................40-817
FAILURE CODE [DBP0KT] ...........................................................................................................40-818
FAILURE CODE [DBPQKR]..........................................................................................................40-819
FAILURE CODE [DBR0MC]..........................................................................................................40-824
FAILURE CODE [DBR2KK]...........................................................................................................40-825
FAILURE CODE [DBR5KP]...........................................................................................................40-828
FAILURE CODE [DBR6KP]...........................................................................................................40-830
FAILURE CODE [DBR9KQ] ..........................................................................................................40-832
FAILURE CODE [DBRLKA]...........................................................................................................40-835
FAILURE CODE [DBRLKB]...........................................................................................................40-837
FAILURE CODE [DBRQKR]..........................................................................................................40-839
FAILURE CODE [DBRRKR]..........................................................................................................40-846
FAILURE CODE [DBRSKB] ..........................................................................................................40-852
FAILURE CODE [DBRTKB] ..........................................................................................................40-854
FAILURE CODE [DBUSKR] ..........................................................................................................40-856
FAILURE CODE [DD20MA] ..........................................................................................................40-860
FAILURE CODE [DDNRKA]..........................................................................................................40-863
00-10 PC210LCI-11
FAILURE CODE [DDNRKY]..........................................................................................................40-865

FAILURE CODE [DDNS00]...........................................................................................................40-867
FAILURE CODE [DFB1KZ] ...........................................................................................................40-869
FAILURE CODE [DFB3L8]............................................................................................................40-873
FAILURE CODE [DFB4L8]............................................................................................................40-875
FAILURE CODE [DGH2KA] ..........................................................................................................40-881
FAILURE CODE [DGH2KB] ..........................................................................................................40-883
FAILURE CODE [DHA4KA]...........................................................................................................40-885
FAILURE CODE [DHAAMA]..........................................................................................................40-887
FAILURE CODE [DHACMA] .........................................................................................................40-889
FAILURE CODE [DHPAMA] ..........................................................................................................40-891
FAILURE CODE [DHPBMA]..........................................................................................................40-893
FAILURE CODE [DHS3MA] ..........................................................................................................40-895
FAILURE CODE [DHSAMA]..........................................................................................................40-907
FAILURE CODE [DHSBMA]..........................................................................................................40-910
FAILURE CODE [DHSCMA] .........................................................................................................40-913
FAILURE CODE [DHSDMA] .........................................................................................................40-916
FAILURE CODE [DHSFMA]..........................................................................................................40-919
FAILURE CODE [DHSGMA] .........................................................................................................40-922
FAILURE CODE [DHSHMA] .........................................................................................................40-925
FAILURE CODE [DHSJMA] ..........................................................................................................40-928
FAILURE CODE [DHUXMA] .........................................................................................................40-931
FAILURE CODE [DHUYMA] .........................................................................................................40-933
FAILURE CODE [DK80KM]...........................................................................................................40-935
FAILURE CODE [DK80KR] ...........................................................................................................40-936
FAILURE CODE [DK80KT] ...........................................................................................................40-942
FAILURE CODE [DKG1KM]..........................................................................................................40-943
FAILURE CODE [DKG1L8] ...........................................................................................................40-944
FAILURE CODE [DKR0MA] ..........................................................................................................40-945
FAILURE CODE [DKR1MA] ..........................................................................................................40-947
FAILURE CODE [DKT0KM] ..........................................................................................................40-949
FAILURE CODE [DKT0L8]............................................................................................................40-950
FAILURE CODE [DKT1KA] ...........................................................................................................40-951
FAILURE CODE [DKT1KB] ...........................................................................................................40-953
FAILURE CODE [DKT4KM] ..........................................................................................................40-959
FAILURE CODE [DKT4L8]............................................................................................................40-960
FAILURE CODE [DKTAKA]...........................................................................................................40-977
FAILURE CODE [DKTAKB]...........................................................................................................40-979
FAILURE CODE [DKTAMB] ..........................................................................................................40-981
FAILURE CODE [DKTBKX]...........................................................................................................40-982
FAILURE CODE [DKTBMC]..........................................................................................................40-984
FAILURE CODE [DKTEMB] ..........................................................................................................40-985
PC210LCI-11 00-11
FAILURE CODE [DKTFKX]...........................................................................................................40-987

FAILURE CODE [DKTFMC] ..........................................................................................................40-989
FAILURE CODE [DKTJMB]...........................................................................................................40-990
FAILURE CODE [DKTUL8] ...........................................................................................................40-992
FAILURE CODE [DKTVKA]...........................................................................................................40-993
FAILURE CODE [DKTVKB]...........................................................................................................40-995
FAILURE CODE [DKTWKA]..........................................................................................................40-996
FAILURE CODE [DKTWKB]..........................................................................................................40-998
FAILURE CODE [DKU1MA] ..........................................................................................................40-999
FAILURE CODE [DKU2MA] ........................................................................................................40-1000
FAILURE CODE [DKUGKA]........................................................................................................40-1001
FAILURE CODE [DKUGKB]........................................................................................................40-1003
FAILURE CODE [DKUGKY]........................................................................................................40-1005
FAILURE CODE [DKUHKA] ........................................................................................................40-1007
FAILURE CODE [DKUHKB] ........................................................................................................40-1009
FAILURE CODE [DKUHKY] ........................................................................................................40-1011
FAILURE CODE [DKULKA].........................................................................................................40-1013
FAILURE CODE [DKULKB].........................................................................................................40-1015
FAILURE CODE [DKULKY].........................................................................................................40-1017
FAILURE CODE [DKV0KA].........................................................................................................40-1019
FAILURE CODE [DKV0KY].........................................................................................................40-1022
FAILURE CODE [DKV4MA] ........................................................................................................40-1036
FAILURE CODE [DKVAMA] ........................................................................................................40-1054
FAILURE CODE [DKVBKA] ........................................................................................................40-1057
FAILURE CODE [DKVBKB] ........................................................................................................40-1059
FAILURE CODE [DKVBKY] ........................................................................................................40-1061
FAILURE CODE [DKVCKA] ........................................................................................................40-1063
FAILURE CODE [DKVCKB] ........................................................................................................40-1065
FAILURE CODE [DKVCKY] ........................................................................................................40-1067
FAILURE CODE [DKVDKA] ........................................................................................................40-1069
FAILURE CODE [DKVDKB] ........................................................................................................40-1071
FAILURE CODE [DKVDKY] ........................................................................................................40-1073
FAILURE CODE [DKVDMA]........................................................................................................40-1075
FAILURE CODE [DLM5KA].........................................................................................................40-1077
FAILURE CODE [DLM5MB] ........................................................................................................40-1079
FAILURE CODE [DR10KA] .........................................................................................................40-1081
FAILURE CODE [DR21KX] .........................................................................................................40-1084
FAILURE CODE [DR31KX] .........................................................................................................40-1086
FAILURE CODE [DUMBKA]........................................................................................................40-1088
FAILURE CODE [DUMBKB]........................................................................................................40-1090
FAILURE CODE [DV20KB] .........................................................................................................40-1092
FAILURE CODE [DW43KA] ........................................................................................................40-1094
FAILURE CODE [DW43KB] ........................................................................................................40-1096
FAILURE CODE [DW43KY] ........................................................................................................40-1098
00-12 PC210LCI-11
FAILURE CODE [DW4CKY]........................................................................................................40-1108

FAILURE CODE [DW4FKA] ........................................................................................................ 40-1110
FAILURE CODE [DW4FKB] ........................................................................................................ 40-1113
FAILURE CODE [DW4FKY] ........................................................................................................ 40-1115
FAILURE CODE [DW4GKA] ....................................................................................................... 40-1117
FAILURE CODE [DW4GKB] .......................................................................................................40-1120
FAILURE CODE [DW4GKY] .......................................................................................................40-1122
FAILURE CODE [DW4SKA]........................................................................................................40-1124
FAILURE CODE [DW4SKB]........................................................................................................40-1126
FAILURE CODE [DW4SKY]........................................................................................................40-1128
FAILURE CODE [DWA2KA] ........................................................................................................40-1136
FAILURE CODE [DWA2KB] ........................................................................................................40-1138
FAILURE CODE [DWA2KY] ........................................................................................................40-1140
FAILURE CODE [DWK0KA]........................................................................................................40-1142
FAILURE CODE [DWK0KB]........................................................................................................40-1144
FAILURE CODE [DWK0KY]........................................................................................................40-1146
FAILURE CODE [DWN5KA]........................................................................................................40-1160
FAILURE CODE [DWN5KB]........................................................................................................40-1162
FAILURE CODE [DWN5KY]........................................................................................................40-1164
FAILURE CODE [DXA8KA].........................................................................................................40-1166
FAILURE CODE [DXA8KB].........................................................................................................40-1168
FAILURE CODE [DXA9KA].........................................................................................................40-1170
FAILURE CODE [DXA9KB].........................................................................................................40-1172
FAILURE CODE [DXE0KA].........................................................................................................40-1174
FAILURE CODE [DXE0KB].........................................................................................................40-1175
FAILURE CODE [DXE4KY].........................................................................................................40-1181
FAILURE CODE [DXEAKA] ........................................................................................................40-1209
FAILURE CODE [DXEAKB] ........................................................................................................40-1211
FAILURE CODE [DXEAKY] ........................................................................................................40-1213
FAILURE CODE [DY20KA] .........................................................................................................40-1215
FAILURE CODE [DY20MA].........................................................................................................40-1217
FAILURE CODE [DY2CKB].........................................................................................................40-1219
FAILURE CODE [DY2DKB].........................................................................................................40-1222
FAILURE CODE [DY2EKB].........................................................................................................40-1224
PC210LCI-11 00-13
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1226

E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1226
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1232
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1235
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.....40-1237
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING................................................................................................................................40-1239
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), EN-
GINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW ...........................................................40-1242
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIA-
TOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .................................................40-1243
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1244
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1245
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...
................................................................................................................................................40-1246
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............40-1247
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................40-1248
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......40-1249
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1250
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1251
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1252
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .................40-1253
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...............................40-1255
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM.........................................................................................................................40-1256
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL-
ANT TEMPERATURE..............................................................................................................40-1257
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM ...............................................................................................................................40-1258
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM-
PERATURE .............................................................................................................................40-1260
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ......................40-1261
E-24 FUNCTION SWITCH DOES NOT OPERATE .....................................................................40-1262
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)..................40-1263
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF ....................................................................40-1264
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ....................40-1265
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ....................................................................................................................40-1266
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED ......................................................................................................................40-1267
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE .................................................................................................................................40-1268
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE .................................................................................................................................40-1269
E-32 ALARM BUZZER CANNOT BE CANCELED ......................................................................40-1271
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
................................................................................................................................................40-1272
E-34 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1273
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ....40-1274
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK........40-1277
E-37 BUCKET DOES NOT MOVE WITH AUTO TILT FUNCTION .............................................40-1279
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ....................................................................................................................................40-1280
00-14 PC210LCI-11
E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE ...............................................................................................40-1283
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDI-
CATOR NOT DISPLAYED ON MONITOR ...............................................................................40-1285
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ...........................40-1288
E-42 ALARM DOES NOT SOUND DURING TRAVEL ................................................................40-1289
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................40-1291
E-44 HORN DOES NOT SOUND................................................................................................40-1292
E-45 HORN DOES NOT STOP SOUNDING...............................................................................40-1295
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .
................................................................................................................................................40-1297
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...40-1298
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPER-
ATE .........................................................................................................................................40-1300
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ...
................................................................................................................................................40-1301
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1302
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..........
................................................................................................................................................40-1303
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1304
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
................................................................................................................................................40-1305
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1306
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.40-1307
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1308
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
................................................................................................................................................40-1309
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.......................................40-1311
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1312
E-60 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not con-
nected !] AND [Slope sensor not connected !] .........................................................................40-1313
E-61 CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected!] .....................40-1318
E-62 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link...] ...............................40-1322
E-63 CONTROL BOX DISPLAYS THE MESSAGE [Tilt Bucket Sensor Offline!] .........................40-1323
E-64 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites...]................................40-1324
E-65 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] ............40-1325
E-66 CONTROL BOX DISPLAYS THE MESSAGE [Sensors are invalid] ....................................40-1328
E-67 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize....] .................................40-1331
E-68 CONTROL BOX DISPLAYS THE MESSAGE [Initializing....]...............................................40-1332
E-69 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization...]...............................40-1333
E-70 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions...]........................................40-1334
E-71 CONTROL BOX DISPLAYS [Out of design area...].............................................................40-1335
E-72 CONTROL BOX DISPLAYS THE MESSAGE [Avoidance Area Breach!] ............................40-1336
E-73 CONTROL BOX CAN NOT BE TURNED ON .....................................................................40-1337
E-74 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN ...40-1338
E-75 CONTROL BOX DOES NOT DISPLAY HYDRAULIC EXCAVATOR IMAGE.......................40-1339
E-76 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE ..............................................40-1340
E-77 CONTROL BOX TOUCH PANEL DOES NOT RESPOND..................................................40-1341
E-78 CONTROL BOX TOUCH PANEL IS INACCURATE............................................................40-1342
E-79 WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE VALUE IS DIFFER-
ENT FROM ACTUAL MACHINE .............................................................................................40-1343
E-80 SEMI-AUTO MODE IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED40-1345
E-81 AUTO GRADE ASSIST CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DIS-
PLAYED ..................................................................................................................................40-1346
E-82 AUTO STOP CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED........
................................................................................................................................................40-1347
PC210LCI-11 00-15
E-83 BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN AUTO GRADE
ASSIST FUNCTION IS ON......................................................................................................40-1348
E-84 BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE WHEN AUTO
STOP CONTROL FUNCTION IS ON ......................................................................................40-1350
E-85 FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TARGET .......40-1352
E-86 NG OCCURS VERY OFTEN IN IMU CALIBRATION DIAGNOSIS .....................................40-1353
E-87 CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK .............................40-1354
E-88 CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK .......................................40-1355
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1358
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1358
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1359
FAILURE MODE AND CAUSE TABLE........................................................................................40-1361
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK......................................40-1373
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER ..................40-1374
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR............................................40-1377
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ..................................40-1378
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..................................................40-1379
H-6 SPEED OR POWER OF BOOM IS LOW .............................................................................40-1381
H-7 ARM SPEED OR POWER IS LOW ......................................................................................40-1385
H-8 BUCKET SPEED OR POWER IS LOW................................................................................40-1390
H-9 BUCKET DOES NOT MOVE IN SINGLE OPERATION WITH AUTO TILT FUNCTION ........40-1393
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION ...................................40-1394
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1395
H-12 HYDRAULIC DRIFT OF ARM IS LARGE ...........................................................................40-1397
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1399
H-14 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIP-
MENT MOVES ........................................................................................................................40-1400
H-15 TIME LAG OF WORK EQUIPMENT IS LARGE .................................................................40-1401
H-16 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .........................40-1402
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................40-1403
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................40-1404
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER ...................................................................................................................40-1405
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY ......
................................................................................................................................................40-1406
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW ....
................................................................................................................................................40-1407
H-22 MACHINE DOES NOT TRAVEL STRAIGHT ......................................................................40-1408
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................40-1410
H-24 TRAVEL SPEED IS LOW ...................................................................................................40-1413
H-25 ONE OF TRACKS DOES NOT RUN ..................................................................................40-1415
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ..40-1416
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .................40-1417
H-28 SWINGS ONLY IN ONE DIRECTION.................................................................................40-1418
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND
LEFT) ......................................................................................................................................40-1419
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY
ONE DIRECTION ....................................................................................................................40-1420
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH
RIGHT AND LEFT)..................................................................................................................40-1421
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE
DIRECTION EITHER RIGHT OR LEFT)..................................................................................40-1422
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .............................40-1423
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING40-1424
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)40-1425
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) ........
................................................................................................................................................40-1426
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ............................40-1427
00-16 PC210LCI-11
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1428

TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1429
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1429
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
................................................................................................................................................40-1430
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1431
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ........................................................................................................40-1432
S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1434
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1436
S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1438
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1440
S-8 ENGINE LACKS POWER.....................................................................................................40-1441
S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1443
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1445
S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1446
S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1447
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
................................................................................................................................................40-1448
S-14 OIL PRESSURE DROPS ...................................................................................................40-1449
S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1451
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1452
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1453
S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1454
S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1455
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1456
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1457
S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1459
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1460
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1461
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1463
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1464
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ........................................................ 50-14
HOW TO READ THIS MANUAL..................................................................................................... 50-14
COATING MATERIALS LIST.......................................................................................................... 50-16
SPECIAL TOOLS LIST .................................................................................................................. 50-21
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-33
ENGINE AND COOLING SYSTEM....................................................................................................... 50-39
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-39
REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-45
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-58
REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................ 50-84
REMOVE AND INSTALL EGR COOLER ASSEMBLY.................................................................... 50-87
REMOVE AND INSTALL STARTER ASSEMBLY ........................................................................... 50-96
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-100
REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-104
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-109
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-115
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY ....................................................................50-119
REMOVE AND INSTALL FAN .......................................................................................................50-127
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-128
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-149
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-156
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .................................................................50-160
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-162
PC210LCI-11 00-17
REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-169

REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-177
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-189
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-201
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-203
REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-204
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-208
REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-217
REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-221
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-233
REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-249
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-256
REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-268
REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-274
REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-280
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-293
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-296
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-301
POWER TRAIN....................................................................................................................................50-303
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-303
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-306
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-319
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-325
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-336
UNDERCARRIAGE AND FRAME........................................................................................................50-338
SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-338
REMOVE AND INSTALL SPROCKET ..........................................................................................50-343
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-345
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-347
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-352
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-355
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-359
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-363
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-368
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-375
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-380
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-383
REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-388
REMOVE AND INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL...
..................................................................................................................................................50-394
REMOVE AND INSTALL PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL .......50-401
REMOVE AND INSTALL BOOM SPOOL STROKE SENSOR ......................................................50-404
REMOVE AND INSTALL ARM SPOOL STROKE SENSOR .........................................................50-406
REMOVE AND INSTALL JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE
CONTROL.................................................................................................................................50-408
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-412
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-428
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-433
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-435
WORK EQUIPMENT............................................................................................................................50-438
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-438
DISASSEMBLE AND ASSEMBLE STROKE SENSING BOOM CYLINDER ASSEMBLY..............50-450
DISASSEMBLE AND ASSEMBLE STROKE SENSING ARM CYLINDER ASSEMBLY ................50-463
DISASSEMBLE AND ASSEMBLE STROKE SENSING BUCKET CYLINDER ASSEMBLY ..........50-477
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-494
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-512
00-18 PC210LCI-11
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-524

REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-533
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-549
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-564
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-570
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-572
ELECTRICAL SYSTEM .......................................................................................................................50-586
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-586
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-589
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY ................................50-599
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY ................................................50-603
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-605
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-612
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-614
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-616
REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-618
REMOVE AND INSTALL KomVision CAMERA .............................................................................50-622
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-628
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY ...........................................50-635
REMOVE AND INSTALL JUNCTION HARNESS OF CONTROL BOX .........................................50-641
REMOVE AND INSTALL CONTROL BOX HARNESS ..................................................................50-647
REMOVE AND INSTALL GNSS RECEIVER.................................................................................50-650
REMOVE AND INSTALL NETWORK MODEM .............................................................................50-652
REMOVE AND INSTALL GNSS RECEIVER ANTENNA ...............................................................50-653
REMOVE AND INSTALL NETWORK MODEM ANTENNA ...........................................................50-655
REMOVE AND INSTALL GNSS ANTENNA ..................................................................................50-657
REMOVE AND INSTALL IMU SENSOR .......................................................................................50-659
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ENGINE AND COOLING SYSTEM......................................................................................................... 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-9
MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................. 60-10
POWER TRAIN..................................................................................................................................... 60-12
MAINTENANCE STANDARD OF SWING CIRCLE ........................................................................ 60-12
MAINTENANCE STANDARD OF SWING MACHINERY................................................................ 60-13
MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-15
MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-17
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING......... 60-18
UNDERCARRIAGE AND FRAME......................................................................................................... 60-20
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-20
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-22
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-24
MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-25
MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-26
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-29
MAINTENANCE STANDARD OF SWAMP SHOE.......................................................................... 60-30
MAINTENANCE STANDARD OF ROAD LINER ............................................................................ 60-31
HYDRAULIC SYSTEM.......................................................................................................................... 60-32
MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-32
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-33
MAINTENANCE STANDARD OF LS-EPC VALVE ......................................................................... 60-34
MAINTENANCE STANDARD OF PC-EPC VALVE......................................................................... 60-35
MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-36
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-39
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-42
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-52
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-55
PC210LCI-11 00-19
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-58
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE ..................................... 60-61
MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-63
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRES-
SURE) ........................................................................................................................................ 60-64
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRES-
SURE) ........................................................................................................................................ 60-65
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-66
WORK EQUIPMENT............................................................................................................................. 60-67
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-67
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-76
MAINTENANCE STANDARD OF STROKE SENSING BOOM CYLINDER .................................... 60-77
MAINTENANCE STANDARD OF STROKE SENSING ARM CYLINDER....................................... 60-79
MAINTENANCE STANDARD OF STROKE SENSING BUCKET CYLINDER ................................ 60-81
MAINTENANCE STANDARD OF STROKE SENSOR FOR BOOM CYLINDER ............................ 60-83
MAINTENANCE STANDARD OF STROKE SENSOR FOR ARM CYLINDER ............................... 60-84
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER.... 60-85
80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
AIR CONDITIONER SYSTEM .............................................................................................................. 80-10
PRECAUTIONS FOR REFRIGERANT .......................................................................................... 80-10
AIR CONDITIONER COMPONENT ................................................................................................80-11
SPECIFICATIONS OF AIR CONDITIONER ................................................................................... 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................. 80-14
OUTLINE OF REFRIGERATION CYCLE ....................................................................................... 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-17
AIR CONDITIONER UNIT.............................................................................................................. 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-21
AIR CONDITIONER CONTROLLER .............................................................................................. 80-25
COMPRESSOR ............................................................................................................................. 80-26
CONDENSER ................................................................................................................................ 80-27
SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-29
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......
.......................................................................................................................................................... 80-31
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-33
AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-36
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.......................................................................................................................................................... 80-38
TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-42
METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-42
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-44
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR .......................................................................................................... 80-45
TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-46
METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-46
TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-48
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-48
TEST SUNLIGHT SENSOR.................................................................................................................. 80-49
METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-49
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-50
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-50
TEST RELAYS...................................................................................................................................... 80-51
METHOD FOR TESTING RELAYS ................................................................................................ 80-51
AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-53
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-56
00-20 PC210LCI-11
FAILURE CODE [879AKA].................................................................................................................... 80-58

FAILURE CODE [879AKB].................................................................................................................... 80-59
FAILURE CODE [879BKA].................................................................................................................... 80-60
FAILURE CODE [879BKB].................................................................................................................... 80-62
FAILURE CODE [879CKA].................................................................................................................... 80-64
FAILURE CODE [879CKB].................................................................................................................... 80-65
FAILURE CODE [879DKZ].................................................................................................................... 80-66
FAILURE CODE [879EMC] ................................................................................................................... 80-68
FAILURE CODE [879FMC] ................................................................................................................... 80-69
FAILURE CODE [879GKX] ................................................................................................................... 80-70
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-72
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...
.......................................................................................................................................................... 80-74
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-77
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-79
TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-81
CONNECTION OF SERVICE TOOL ..................................................................................................... 80-84
METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-84
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-86
HANDLE COMPRESSOR OIL .............................................................................................................. 80-88
METHOD FOR REPLACING DESICCANT ........................................................................................... 80-90
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-9
HYDRAULIC CIRCUIT DIAGRAM (1/2) ......................................................................................... 90-13
ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-21
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-21
ELECTRICAL CIRCUIT DIAGRAM (1/12)...................................................................................... 90-25
ELECTRICAL CIRCUIT DIAGRAM (10/12) .................................................................................... 90-43
PC210LCI-11 00-21
ELECTRICAL CIRCUIT DIAGRAM (12/13).................................................................................... 90-71

INDEX..................................................................................................................................................................1
00-22 PC210LCI-11
00 INDEX AND FOREWORD ABBREVIATION LIST
ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake When the tires skid (wheels stop rotating), the
ABS Anti-skid Brake System brakes are released, and when the wheels start
(HD, HM) to rotate, the brakes are applied again.
Automatic Idling Setting
AISS Engine This function automatically sets the idle speed.
System
Steering A lever is used to perform the steering operations
Advanced Joystick instead of a steering wheel. Moreover, it shifts
AJSS
Steering System (WA) gear and changes direction (FORWARD or RE-
VERSE).
Travel and brake When the accelerator pedal is released while the
Automatic Retarder Ac- machine is traveling downhill, this function auto-
ARAC
celerator Control (HD, HM) matically applies the retarder with a constant
braking force.
machine is traveling downhill, this function auto-
Automatic Retarder
ARSC matically applies the retarder to ensure that the
Speed Control (HD, HM) machine speed does not accelerate above the
speed set by the operator.
Travel and brake When the tires spin on soft ground surfaces, this
Automatic Spin Regula-
ASR function automatically uses the optimum braking
tor (HD, HM) force to drive both wheels.
A device that can be fixed onto the standard ma-
ATT Attachment Work equipment
chine in order to enable it to do different jobs.
Brake When the retarder is not being used, this valve
Brake cooling oil control
BCV bypasses part of the brake cooling oil to reduce
valve (HD) the load on the hydraulic pump.
Communication and elec- One of communication standards that is used in
CAN Controller Area Network
tronic control the network on the machine.
A regulator valve which is installed to KCCV ven-
Crankcase Depression
CDR Engine tilator. It is written as CDR valve and it is not
Regulator
used independently.
This system can simultaneously actuate multiple
Closed-center Load
CLSS Hydraulic system actuators regardless of the load (provides better
Sensing System
combined operation than OLSS).
Engine controller electronically controls supply
pump, common rail, and injector. This function
CRI Common Rail Injection Engine
maintains optimum fuel injection amount and fuel
injection timing.
PC210LCI-11 00-23
ABBREVIATION LIST 00 INDEX AND FOREWORD

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

Global Navigation Satel-
GNSS (KOMTRAX, KOMTRAX uses satellites such as GPS, GALILEO, etc. to
lite System
Plus) determine the current location on the earth.
Steering This function uses a combination of hydraulic

Hydrostatic Steering motor and bevel shaft to control difference in
HSS
System (D) travel speed of right and left tracks. Accordingly
machine can turn without using steering clutch.
Transmission This function uses a combination of hydraulic
Hydro Static Transmis-
HST pump and hydraulic motor for stepless shifting of
sion (D, WA) the speed range without using gears.
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This valve is installed at inlet port of pump, and it
adjusts fuel intake amount in order to control fuel
IMA Inlet Metering Actuator Engine
discharged volume of supply pump. (Same as
IMV)
00-24 PC210LCI-11

Abbrevia-
tion
component/system)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
IMV Inlet Metering Valve Engine
IMA)
This mechanism separates oil in blowby gas and
Komatsu Closed Crank-
KCCV Engine returns it to the intake side to combust it there. It
case Ventilation
primarily consists of filters.
Komatsu Catalyzed This filter captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
The catalyst is used for purifying exhaust gas.
Komatsu Diesel Oxida-
KDOC Engine It is built in to KDPF or assembled with the muf-
tion Catalyst
fler.
This component is used to purify the exhaust
Komatsu Diesel Particu- gas. KDOC (catalyst) and KCSF (filter to capture
KDPF Engine soot) are built-in it.
late Filter
It is installed in place of the conventional muffler.
Travel and brake This function recovers the drive force of the
wheels by braking automatically with the opti-
Komatsu Traction Con- mum force and at the same time activates the in-
KTCS
trol System (HM) ter-axle differential lock when the wheels idle
while the machine travels on the soft ground
road.
Image display equipment such as a monitor
LCD Liquid Crystal Display Machine monitor
which assembles in the liquid crystal element.
It refers to semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- One of communication standards that is used in
LIN
work tronic control the network on the machine.
Function that detects differential pressure of
LS Load Sensing Hydraulic system pump and controls discharged volume corre-
sponding to load.
Low Voltage Differential Communication and elec- One of communication standards that is used in
LVDS
Signaling tronic control the network on the machine.
This indicates engine intake air flow. It is not
used independently but it is used as combined
MAF Mass Air Flow Engine
with sensor. Mass air flow sensor can be called
as MAF sensor.
Service that allows transmission and reception of
Multimedia Messaging
MMS Communication short messages consisting of characters or voice
Service
or images between cell phones.
Characteristics of electrical or hydraulic circuits.
Electrical system, Hydraul-
NC Normally Closed Circuit is normally closed if it is not actuated, and
ic system
it opens when it is actuated.
PC210LCI-11 00-25

Abbrevia-
tion
component/system)
NO Normally Open Circuit is normally open if it is not actuated, and it
ic system
closes when it is actuated.
Open-center Load Hydraulic system that can operate multiple actua-
OLSS Hydraulic system
Sensing System tors at the same time, regardless of the load.
PC Pressure Compensation Hydraulic system A function used to correct oil pressure.
Steering System in which a controller instantly analyses
Palm command control data from each lever, pedal, and dial, and per-
PCCS
system (D) forms optimum electronic control of the engine
and transmission.
This valve is installed at inlet port of pump and it
PCV Pre-stroke Control Valve Engine adjusts fuel intake amount in order to control fuel
discharged volume of supply pump.
This system is used for controlling proportional
Proportional Pressure
PPC Hydraulic system pressure. It moves actuators in proportion to the
Control
oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism.
Power Tilt and power Work equipment This function performs hydraulic control of the tilt
PTP
Pitch dozer (D) and pitch of the bulldozer blade.
Sturcture protects the operator who wear the

seatbelt so that he will not be crushed by a ma-
Roll-Over Protective chine when it is tipped. (Operator Protective
ROPS Cab and canopy structure when tipping)
Structure
Structure which is standardized as ISO 3471 or
ISO 12117-2.
It is exhaust gas purifier using urea water con-
verts nitrogen oxides (NOx) to harmless nitrogen
Selective Catalytic Re-
SCR Urea SCR system and water by oxidation-reduction reaction. It may
duction
also be mentioned as exhaust gas purification
catalyst or part of the name of related devices.
Abbreviation for "Le Systeme International d' Uni-
Le Systeme Internation-
tes". It is the universal unit system and "a single
SI al d' Unites (Internation- Unit
unit for a single quantity" is the basic principle ap-
al unit system)
plied.
It refers to an actuator consisting of a solenoid
SOL Solenoid Electrical system and an iron core that is moved by the magnetic
force when the solenoid is energized.
Solenoid valve that switches over direction of
TWV 2-Way Valve Hydraulic system
flow.
Tip-Over Protectuive chine when it is overtuned.(Hydraulic excavator
TOPS Cab and canopy
Structure tip-over protective structure)
Structure which is standardized as ISO 12117.
00-26 PC210LCI-11

Abbrevia-
tion
component/system)
Variable Geometry Tur- The turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is made variable.
*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
PC210LCI-11 00-27

T/C Torque Converter
T/M Transmission
00-28 PC210LCI-11
00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL
FOREWORD, SAFETY, BASIC INFORMATION

HOW TO READ THE SHOP MANUAL
REMARK
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. "STRUC-
TURE AND FUNCTION" is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the ad-
justing method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in "STANDARD VALUE TABLE".
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, instal-
lation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
PC210LCI-11 00-29
HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.
Symbol Item Remark
This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.
Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.
Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.
Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.
Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.
00-30 PC210LCI-11
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION
SAFETY NOTICE FOR OPERATION

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpos-
es.
• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.
PC210LCI-11 00-31
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD
• Always wear the protective eyeglasses when hitting parts

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

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).
00-32 PC210LCI-11
• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.
• Before starting work, shut down the engine. When working

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.
PC210LCI-11 00-33
• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.
,&
Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.
00-34 PC210LCI-11
REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.
• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.
PC210LCI-11 00-35
REMARK
Weight of component whose weight is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND
ASSEMBLY".
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.
Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope ( mm) Allowable load ( kN { t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}
00-36 PC210LCI-11
Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
PC210LCI-11 00-37
REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, "Pre-
cautions for disconnection and connection of air conditioner
piping".
00-38 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE
PRECAUTIONS TO PREVENT FIRE

Fire caused by fuel, oil, coolant or window washer fluid
Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.
PC210LCI-11 00-39
PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD
• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.
00-40 PC210LCI-11
00 INDEX AND FOREWORD ACTIONS IF FIRE OCCURS
ACTIONS IF FIRE OCCURS

• Turn the starting switch to OFF position to stop the engine.
• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.
PC210LCI-11 00-41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 00 INDEX AND FOREWORD
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.
Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.
00-42 PC210LCI-11
00 INDEX AND FOREWORD ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

This machine conforms to either regulation of Tier4 Final (North America) or Stage IV (Europe).
This machine is equipped with the following two exhaust gas treatment systems:
• Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu-
rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
• Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas
into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction
between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen
oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea
as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertiliz-
er, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and
conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
• In Europe, use AdBlue®.
• In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).
The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification
Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).
PC210LCI-11 00-43
PRECAUTIONS FOR DEF 00 INDEX AND FOREWORD
PRECAUTIONS FOR DEF

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

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

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

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

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.
00-44 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

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

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.
Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.
PC210LCI-11 00-45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD
Preventing intrusion of foreign materials during refilling

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

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.
Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.
00-46 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.
PC210LCI-11 00-47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

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

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018
00-48 PC210LCI-11
00 INDEX AND FOREWORD INGS
Introduction of parts for the disconnection of the taper seal type hoses and
tubes
Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422
Introduction of parts for the disconnection of the split flange type hoses and
tubes
Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
PC210LCI-11 00-49
Nomi Bolt pitch (mm) Hose side Tube side

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

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
00-50 PC210LCI-11
Introduction of parts for the removal of taper pipe thread type joint
Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108
02 R1/4 07042-00211 07043-00211
03 R3/8 07042-00312 07043-00312
04 R1/2 07042-00415 07043-00415
06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222
14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026
Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.
PC210LCI-11 00-51
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.
NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
00-52 PC210LCI-11
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.
Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY
AND ASSEMBLY".
PC210LCI-11 00-53
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

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

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.
00-54 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.
Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.
PC210LCI-11 00-55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

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

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.
00-56 PC210LCI-11
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.
PC210LCI-11 00-57
PRACTICAL USE OF KOMTRAX 00 INDEX AND FOREWORD
PRACTICAL USE OF KOMTRAX

Various information which KOMTRAX system transmits by using the radio communication is useful for KOM-
TRAX operator to provide various services for the customers.
When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by
KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.
REMARK
(KOMTRAX may not be installed to the machine in some countries or areas.)
Merit of using KOMTRAX
• The location where the machine is working at can be checked on the map in a personal computer.
• Operation information such as service meter, operating hours, fuel consumption, and occurred caution as
well as failure code can be checked.
• The operator can check the hours used and replacement interval of consumable parts of the machine such
as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
• Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be
checked, and it is used to presume the machine operating condition.
• Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is
utilized as an advice tool for the user and operator.
• KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the
soundness of machine, in addition to KOMTRAX function described above. These data can be used on per-
sonal computer screens.
How to make a full use of KOMTRAX
Making use of KOMTRAX enables the following activities.
• Quick response to a request for immediate repair
1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair re-
quest from a user.
2. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
3. To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
• Proactive maintenance
1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure
code indicated by a red or yellow flag.
2. To check the condition of the machine with the customer and to make a plan to visit.
3. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
• Practice of periodic maintenance and periodic inspection service
1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits
for the consumable parts indicated by red flags are over.
2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replace-
ment work to the customer.
3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to operate KOMTRAX
For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.
00-58 PC210LCI-11
00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER
Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).
2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.
3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.
Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).
PC210LCI-11 00-59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD
2. After inserting the hose in the mating adapter perfectly, pull

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

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).
3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
00-60 PC210LCI-11
00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

COUPLER
Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.
2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.
3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.
PC210LCI-11 00-61
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.
00-62 PC210LCI-11
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

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

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.
Connecting connectors
1. Check the connector visually.
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
PC210LCI-11 00-63
NECTORS 00 INDEX AND FOREWORD
• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.
• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.
• If the connector clamp is removed, be sure to return it

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

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.
00-64 PC210LCI-11
00 INDEX AND FOREWORD NECTORS
1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.
2. Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.
Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.
PC210LCI-11 00-65
NECTORS 00 INDEX AND FOREWORD
NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).
Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.
00-66 PC210LCI-11
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
00 INDEX AND FOREWORD CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

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

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.
PC210LCI-11 00-67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

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

TOME-2)
Insert it straight until it clicks.
Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).
00-68 PC210LCI-11
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR
2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.
Method for connecting slide lock type connector (FRAMATOME-24)

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

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

Insert the connector securely until it "clicks".
00-70 PC210LCI-11
00 INDEX AND FOREWORD WITH LOCK TO PUSH

LOCK TO PUSH
Method for disconnecting connector with lock to push (BOSCH-3)
While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series
• 107 series
REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.
Method for connecting connector with lock to push (BOSCH-3)

PC210LCI-11 00-71
WITH LOCK TO PUSH 00 INDEX AND FOREWORD
Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
Method for connecting connector with lock to push (AMP-3)

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

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.
Method for connecting connector with lock to push (SUMITOMO-3)

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

While pressing lock (D), pull out connector (4) in the direction
of the arrow.
Method for connecting connector with lock to push (SUMITOMO-4)

00-72 PC210LCI-11
00 INDEX AND FOREWORD WITH HOUSING TO ROTATE

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

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.
PC210LCI-11 00-73
HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE

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

AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular com-
pressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.
AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material
of the coating.
(Table 1)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage For large current wiring
wire for auto- AV
mobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for auto- AVS
mobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1)
Annealed cop-
Thin-cover per for electric
low-voltage appliance For mid- to small-size excava-
wire for auto- CAVS tors
mobile (nominal No. 1.25 and lower)
(Type 2)
Heat-resistant General wiring for extremely

low-voltage Heat-resistant cross- cold weather specification
AEX -50 to +110
wire for auto- linked polyethylene Wiring at high-temperature
mobile place
00-74 PC210LCI-11
00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
20 7 30 11 50 16 37 26 58 41 65
strands
Diameter of
0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
( mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coating D
AV Standard - - - - - - - 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
50 84 41 70 85 108 127 169 217
strands
Diameter of
0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
strand
Conductor
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
( mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard - - - - - - - - -
Coating D
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Number of
- 7 - 11 - 16
strands
Diameter of round compres- round compres-
- - round compression
strand sion sion
Conductor
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
( mm2)
d (approx.) - 0.9 - 1.1 - 1.4
PC210LCI-11 00-75
HOW TO READ ELECTRICAL WIRE CODE 00 INDEX AND FOREWORD
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25

Coating D
CAVS Standard - 1.6 - 1.8 - 2.1
REMARK
“f” of nominal No. denotes "flexible".
Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White
REMARK
In a color code consisting of 2 colors, the first color is the color of the background and the second color is the
color of the marking.
Example) GW indicates that the background is "Green" and marking is "White".
00-76 PC210LCI-11
00 INDEX AND FOREWORD HOW TO READ ELECTRICAL WIRE CODE
Types of circuits and color codes

Type of wire AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -
PC210LCI-11 00-77
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called "tolerance".
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/
lower limit of tolerance)."
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0
00-78 PC210LCI-11
00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called "standard value", which is
indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.
Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called "interference".
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is "standard interference".
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
changes exceeding certain value, parts cannot be used any longer. This value is called "repair limit".
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called "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 judgment 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 "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 assem-
bled is called "allowable interference".
• The allowable interference shows the repair limit of the part of smaller tolerance.
PC210LCI-11 00-79
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD
• The parts whose interferences are out of the allowable interference must be replaced or repaired.
00-80 PC210LCI-11
00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE
STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for bolts and nuts
REMARK
Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.
Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10 to 12.5}
(*1, *2) 17
14 22 157 to 196 {16 to 20}
24
16 245 to 309 {25 to 31.5}
(*1) 22
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 1030 {84 to 105}
27 41 1180 to 1470 {120 to 150}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}
*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in
the table below.
PC210LCI-11 00-81
STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD
Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
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}
REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise
specified.
Type of bolt A B
Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC
5/ 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16-18UNC
3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC
7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC
1/ 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2-13UNC
9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC
5/ 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8-11UNC
3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4
7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC
00-82 PC210LCI-11
Type of bolt A B

1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}
11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}
11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}
11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}
REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise speci-
fied.
Type of bolt A B

1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF
5/ 34.3 to 39.2 {3.5 to 4} 37.3 {3.8} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF
3/ 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8-24UNF
7/ 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16-20UNF
1/ 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2-20UNF
9/ 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16-18UNF
5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF
3/ 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4-16UNF
7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF
1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}
11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}
11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}
11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}
PC210LCI-11 00-83
Table of tightening torque for O-ring boss piping joints

REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread di- Tightening torque ( Nm { kgm} )

Width across
Nominal No. ameter
flats ( mm) Range Target
( mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}
Table of tightening torque for O-ring boss plugs

REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.
Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( 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}
00-84 PC210LCI-11
Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
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}
Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
Width Tightening torque ( Nm { kgm} ) Taper seal Face seal

Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter( mm)
hose ( mm)
( mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
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/ 17.5
16-16UN
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/ -16UN 20.6
16
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 13/16-12UN 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 - -
PC210LCI-11 00-85
Table of tightening torque for face seal joints

REMARK
• The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated
low pressure piping which is used for engine.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
Outside di- Tightening torque ( Nm { kgm} ) Face seal

Width
ameter of Thread root diam-
across flats Nominal size -
adequate Range Target eter( mm) (refer-
( mm) threads per inch
pipe ( mm) ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

16
12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ 20.6

16-16UN
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} 13/16-12UN 30.2
Tightening torque table for bolts and nuts on 102,107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in
the following table unless otherwise specified.
Thread diameter ( mm) Tightening torque ( 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 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following
table unless otherwise specified.
00-86 PC210LCI-11
Thread diameter ( mm) Tightening torque ( 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
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16
1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

8
1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

4
3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

8
1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

2
3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}

4
PC210LCI-11 00-87
CONVERSION TABLE 00 INDEX AND FOREWORD
CONVERSION TABLE
Method of using the conversion table
The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit
from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in
(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 3.780 3.819 3.858 3.898
mm to in
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
00-88 PC210LCI-11
00 INDEX AND FOREWORD CONVERSION TABLE
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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
kg to lb
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.Gal
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
ℓ to U.K.Gal
1 ℓ = 0.21997 U.K.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
PC210LCI-11 00-89
1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
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 lbft
1 kgm = 7.233 lbft
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
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
00-90 PC210LCI-11
00 INDEX AND FOREWORD CONVERSION TABLE
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
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 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
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 in the center of 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 Fahren-
heit 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
PC210LCI-11 00-91
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-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
00-92 PC210LCI-11
01 SPECIFICATIONS
PC210LCI-11 01-1
CONTENTS 01 SPECIFICATIONS
CONTENTS
ABBREVIATION LIST .................................................................................................................................... 01-3
SPECIFICATIONS ......................................................................................................................................... 01-9
SPECIFICATION DRAWING................................................................................................................... 01-9
SPECIFICATION DRAWING: PC210LCI-11..................................................................................... 01-9
WORKING RANGE DRAWINGS ...........................................................................................................01-11
WORKING RANGE: PC210LCI-11..................................................................................................01-11
SPECIFICATIONS ................................................................................................................................ 01-12
SPECIFICATIONS: PC210LCI-11 .................................................................................................. 01-12
WEIGHT TABLE ................................................................................................................................... 01-15
WEIGHT TABLE: PC210LCI-11 ..................................................................................................... 01-15
TABLE OF FUEL, COOLANT, AND LUBRICANTS ............................................................................... 01-17
01-2 PC210LCI-11
01 SPECIFICATIONS ABBREVIATION LIST
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
System
AJSS
VERSE).
ARAC
braking force.
Automatic Retarder
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
PC210LCI-11 01-3
ABBREVIATION LIST 01 SPECIFICATIONS

Abbrevia-
tion
component/system)
(Same as ECU)
(Same as ECM)
tion
FOPS Cab and canopy
Structure
Forward-Neutral-Re-
verse
tem
Plus) earth.

lite System

HSS
and communication.
IMV)
01-4 PC210LCI-11

Abbrevia-
tion
component/system)
Unit
trol motions.
IMA)
case Ventilation

KCSF Engine
tion Catalyst
fler.
late Filter
KTCS
road.
LIN
sponding to load.
LVDS
as MAF sensor.
Service
ic system
PC210LCI-11 01-5

Abbrevia-
tion
component/system)
ic system
PCCS
and transmission.
Control
oil pressure.
Hydraulic system
(D, PC, etc)
PTP

Structure
ISO 12117-2.
duction
al unit system)
plied.
flow.
TOPS Cab and canopy
01-6 PC210LCI-11

Abbrevia-
tion
component/system)
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
PC210LCI-11 01-7

T/M Transmission
01-8 PC210LCI-11
01 SPECIFICATIONS SPECIFICATION DRAWING
SPECIFICATIONS
SPECIFICATION DRAWING
SPECIFICATION DRAWING: PC210LCI-11
Item Unit PC210LCI-11

Machine weight
For north america kg 21700
For european union 21900
Bucket capacity m3 0.8
Engine model - Komatsu SAA6D107E-3 diesel engine
Rated horsepower
• SAE J1995 (gross) 123 {165} /2000 {2000}
kW{ HP}/
• ISO 14396 123 {165} /2000 {2000}
min-1{ rpm}
• ISO 9249/SAE J1349 (net) 123 {165} /2000 {2000}
A Overall length mm 9700
B Overall height (including head guard) mm 2970
Overall width
C For north america mm 3080
Shoe width
D For north america mm 700
E Cab height mm 3045
F Tail swing radius mm 3020
G Overall length of the track mm 4465
H Distance between tumbler centers mm 3655
I Over handrsil height mm 3135
PC210LCI-11 01-9
SPECIFICATION DRAWING 01 SPECIFICATIONS

Min. ground clearance mm 440
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Continuous swing speed min-1{ rpm} 12.4 {12.4}
REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit. While, net denotes the value measured of an engine under the condition
essentially the same as that when it is installed on a machine.
01-10 PC210LCI-11
01 SPECIFICATIONS WORKING RANGE DRAWINGS
WORKING RANGE DRAWINGS

WORKING RANGE: PC210LCI-11

A Max. digging reach mm 9875
B Max. digging depth mm 6620
C Max. digging height mm 10000
D Max. vertical wall digging depth mm 5980
E Max. dumping height mm 7110
F Min. dumping height mm 2645
G Max. digging reach at ground level mm 9700
PC210LCI-11 01-11
SPECIFICATIONS 01 SPECIFICATIONS
SPECIFICATIONS
SPECIFICATIONS: PC210LCI-11
Machine model Unit PC210LCI-11
Bucket capacity m3 0.8
Machine weight kg 21700
Performance
Working ranges
Max. digging depth mm 6620
Max. vertical wall digging depth mm 5980
Max. digging reach mm 9875
Max. digging reach at ground level mm 9700
Max. digging height mm 10000
Max. dumping height mm 7110
Max. digging force
138.3{14100}
(When one-touch power maximizing function oper- kN{ kg}
(149.1{15200})
ates)
Continuous 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} 38.4{0.39}
Dimensions
Overall length mm 9625
Overall width mm 3080
Overall height (for transport) (*1) mm 3135
Cab height mm 3045
Ground clearance of upper structure mm 1085
Min. ground clearance mm 440
Tail swing radius mm 3020
Min. swing radius of work equipment mm 3040
Max. height of work equipment in min. swing radi-
mm 8005
us posture
Overall width of track mm 3080
Overall length of the track mm 4465
Track gauge mm 2380
Distance between tumbler centers mm 3655
Machine cab height mm 2250
Width of standard shoe
For north america mm 700
01-12 PC210LCI-11
01 SPECIFICATIONS SPECIFICATIONS

Engine
Model - SAA6D107E–3
4-cycle, water-cooled, in-line, vertical, direct in-
Type - jection, with turbocharger and air-cooled after-
cooler
No. of cylinders - bore x stroke mm 6-107 x 124
Total piston displacement ℓ{ cc} 6.69 {6690}
Performance
Rated horsepower
• SAE J1995 (gross) 123 {165}/ 2000 {2000}
kW{ HP}/
• ISO 14396 123 {165}/ 2000 {2000}
min-1{ rpm}
• ISO 9249/SAE J1349 (net) 123 {165}/ 2000 {2000}
Nm{ kgm}/
Max. torque 729 to 74.3 {1500 to 1500}
min-1{ rpm}
Max. speed with no load
• (when mounted on machine) 1850±50{1850±50}
min-1{ rpm}
• At basic engine 2060±50{2060±50}
Min. speed with no load min-1{ rpm} 1050±25{1050±25}
g/kWh{
Min. fuel consumption ratio 217.5{160}
g/HPh}
Starting motor - 24 V, 5.5 kW
Alternator - 24 V, 90 A
Battery (*2) - 12 V, 140Ah x 2 pcs.
Radiator type - CF90-4
*1: Including grouser height (26 mm)
*2: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit. While, net denotes the value measured of an engine under the condition essen-
tially the same as that when it is installed on a machine.
Undercarriage
Carrier roller - 2 on one side
Track roller - 9 on one side
Assembly type triple grouser shoe, 49 pieces on
Track shoe -
each side
Hydraulic system
Hydraulic pump
Variable displacement piston type (HPV125 +
Type x quantity -
125) x 2 pcs.
Discharged volume ℓ/min 245 x 2
Set pressure MPa{ kg/cm2} 37.2 {380}
Control valve
PC210LCI-11 01-13
SPECIFICATIONS 01 SPECIFICATIONS

Type x quantity - 7-spool type x 1 pc.
Operating method - Hydraulic
Variable displacement piston type (HMV120-2) x
Travel motor - 2 pcs.
(with brake valve and parking brake)
fixed displacement piston type (KMF125ABE-6)
Swing motor - x 1 piece
(with safety valve and parking brake)
Boom cylinder (*3)
Type - Double-acting piston type
Cylinder bore mm 130
Piston rod diameter mm 90
Stroke mm 1335
Max. distance between pins mm 3205
Min. distance between pins mm 1870
Arm cylinder (*4)
Stroke mm 1490
Bucket cylinder
Stroke mm 1120
Hydraulic tank: - Box-shaped sealed type
Hydraulic oil filter - Tank return side
Hydraulic oil cooler - Air-cooled type (thickness : 62)
*3: With cushion on head side.
*4: With cushions on head side and bottom side.
01-14 PC210LCI-11
01 SPECIFICATIONS WEIGHT TABLE
WEIGHT TABLE
WEIGHT TABLE: PC210LCI-11
k This weight table is provided for your reference for when handling the components or when trans-
porting.
k This weight table shows the dry weight.
Unit: kg
Machine model PC210LCI-11
Engine assembly 771
• Engine 575
• Damper 6
• Main pump 190
Radiator and oil cooler assembly 150
Hydraulic tank and filter assembly 120
Fuel tank assembly 165
Revolving frame 2232
Operator cab (including head guard and front half guard) 430
Operator's seat 35
Counterweight 3260
Swing machinery 169
Control valve 257
Swing motor 51.5
Travel motor 93 x 2
Center swivel joint 30
Track frame assembly (excluding piping) 4960
• Track frame 2660
• Swing circle 290
• Idler 101 x 2
• Idler cushion 119 x 2
• Carrier roller 13 x 4
• Track roller 36 x 18
• Final drive (including travel motor and sprocket) 344 x 2
Track shoe assembly
For north america
Triple grouser shoe (700 mm) 1530 x 2
For european union
Boom assembly 1523
Arm assembly 788
PC210LCI-11 01-15
WEIGHT TABLE 01 SPECIFICATIONS
Unit: kg
Bucket assembly 759
Boom cylinder assembly 192
Stroke sensing boom cylinder assembly 201
Stroke sensing arm cylinder assembly 241
Stroke and reset sensing bucket cylinder assembly 151
Bucket link (large) assembly 83
Bucket link (small) assembly 22 x 2
Boom foot pin 42
Boom cylinder bottom pin 8
Stroke sensing boom cylinder bottom pin 8
Stroke sensing boom cylinder head pin 28
Stroke sensing arm cylinder bottom pin 10
Stroke sensing arm cylinder head pin 12
Boom and arm connecting pin 26
Stroke sensing bucket cylinder bottom pin 8
Bucket pin 20 x 2
Bucket link pin 13 x 2
01-16 PC210LCI-11
01 SPECIFICATIONS TABLE OF FUEL, COOLANT, AND LUBRICANTS
TABLE OF FUEL, COOLANT, AND LUBRICANTS

For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.
Unit: ℓ
Specified capacity Refill capacity
Engine oil pan 25.4 24.6
Swing machinery case 7.1 6.5
Final drive case (each on right and left sides) 5.4 5.0
Damper case 0.65 0.65
Hydraulic oil system 234 132
Cooling system 32.7 30.7
Fuel tank 400 -
AdBlue/DEF tank 39.4 -
PC210LCI-11 01-17
10 STRUCTURE AND FUNCTION
PC210LCI-11 10-1
CONTENTS 10 STRUCTURE AND FUNCTION
CONTENTS
UREA SCR SYSTEM................................................................................................................................... 10-12
LAYOUT DRAWING OF UREA SCR SYSTEM ..................................................................................... 10-13
UREA SCR SYSTEM DIAGRAM .......................................................................................................... 10-18
FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-19
FUNCTION OF AdBlue/DEF SYSTEM........................................................................................... 10-19
INDUCEMENT STRATEGY ........................................................................................................... 10-21
COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-36
AdBlue/DEF MIXING TUBE ........................................................................................................... 10-36
SCR ASSEMBLY ........................................................................................................................... 10-37
AdBlue/DEF TANK ......................................................................................................................... 10-39
AdBlue/DEF PUMP ........................................................................................................................ 10-41
AdBlue/DEF INJECTOR................................................................................................................. 10-42
AdBlue/DEF HOSE ........................................................................................................................ 10-43
AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-44
BOOT-UP SYSTEM ..................................................................................................................................... 10-45
LAYOUT DRAWING OF BOOT-UP SYSTEM........................................................................................ 10-45
SYSTEM OPERATING LAMP SYSTEM ............................................................................................... 10-47
SYSTEM OPERATING LAMP SYSTEM DIAGRAM ....................................................................... 10-47
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM ............................................................... 10-47
BATTERY DISCONNECT SWITCH ...................................................................................................... 10-49
FUNCTION OF BATTERY DISCONNECT SWITCH ...................................................................... 10-49
ENGINE SYSTEM ....................................................................................................................................... 10-50
LAYOUT DRAWING OF ENGINE SYSTEM .......................................................................................... 10-50
SPECIFICATIONS OF ENGINE SYSTEM ..................................................................................... 10-51
FUNCTION OF ENGINE SYSTEM ................................................................................................ 10-51
ENGINE CONTROL SYSTEM .............................................................................................................. 10-52
ENGINE CONTROL SYSTEM DIAGRAM...................................................................................... 10-52
FUNCTION OF ENGINE CONTROL SYSTEM .............................................................................. 10-53
AUTO-DECELERATION SYSTEM ........................................................................................................ 10-55
AUTO-DECELERATION SYSTEM DIAGRAM ............................................................................... 10-55
FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................ 10-55
OPERATION OF AUTO-DECELERATION SYSTEM...................................................................... 10-56
ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................................................... 10-57
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM................................................................. 10-57
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................... 10-58
OVERHEAT PREVENTION SYSTEM ................................................................................................... 10-59
OVERHEAT PREVENTION SYSTEM DIAGRAM........................................................................... 10-59
FUNCTION OF OVERHEAT PREVENTION SYSTEM ................................................................... 10-60
TURBOCHARGER PROTECTION SYSTEM ........................................................................................ 10-62
TURBOCHARGER PROTECTION SYSTEM DIAGRAM ............................................................... 10-62
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM........................................................ 10-63
AUTOMATIC IDLE STOP SYSTEM ...................................................................................................... 10-64
AUTOMATIC IDLE STOP SYSTEM DIAGRAM.............................................................................. 10-64
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM ...................................................................... 10-64
COMPONENT PARTS OF ENGINE SYSTEM ...................................................................................... 10-67
VGT ............................................................................................................................................... 10-67
EGR SYSTEM ............................................................................................................................... 10-72
EGR VALVE ................................................................................................................................... 10-74
EGR COOLER ............................................................................................................................... 10-76
KCCV SYSTEM ............................................................................................................................. 10-78
KCCV VENTILATOR ...................................................................................................................... 10-80
KDPF ............................................................................................................................................. 10-82
COOLING SYSTEM..................................................................................................................................... 10-86
LAYOUT DRAWING OF COOLING SYSTEM ....................................................................................... 10-86
SPECIFICATIONS OF COOLING SYSTEM................................................................................... 10-87
10-2 PC210LCI-11
10 STRUCTURE AND FUNCTION CONTENTS
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH ........................................................................... 10-88

FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH................................................... 10-88
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH ........................................... 10-89
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH.................................................................. 10-90
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH ......................................... 10-90
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH.................................. 10-90
COMPONENT PARTS OF COOLING SYSTEM.................................................................................... 10-92
FAN CLUTCH ................................................................................................................................ 10-92
CONTROL SYSTEM.................................................................................................................................... 10-93
LAYOUT DRAWING OF CONTROL SYSTEM ...................................................................................... 10-93
MACHINE MONITOR SYSTEM ............................................................................................................ 10-96
MACHINE MONITOR SYSTEM DIAGRAM.................................................................................... 10-96
FUNCTION OF MACHINE MONITOR SYSTEM ............................................................................ 10-96
KomVision SYSTEM ............................................................................................................................. 10-98
LAYOUT DRAWING OF KOMVISION SYSTEM ............................................................................ 10-98
KomVision SYSTEM DIAGRAM..................................................................................................... 10-99
FUNCTION OF KomVision SYSTEM ............................................................................................10-100
KOMTRAX SYSTEM............................................................................................................................10-102
KOMTRAX SYSTEM DIAGRAM ...................................................................................................10-102
FUNCTION OF KOMTRAX SYSTEM ...........................................................................................10-102
COMPONENT PARTS OF CONTROL SYSTEM..................................................................................10-103
MACHINE MONITOR....................................................................................................................10-103
KomVision CONTROLLER............................................................................................................10-119
KomVision CAMERA.....................................................................................................................10-123
KOMTRAX TERMINAL .................................................................................................................10-124
PUMP CONTROLLER ..................................................................................................................10-126
RESISTOR FOR PC-EPC VALVE .................................................................................................10-131
CAN TERMINATING RESISTOR ..................................................................................................10-132
ENGINE CONTROLLER ...............................................................................................................10-133
FUEL CONTROL DIAL .................................................................................................................10-140
FUEL FEED PUMP .......................................................................................................................10-142
FUEL FEED PUMP SWITCH ........................................................................................................10-143
HYDRAULIC SYSTEM................................................................................................................................10-144
LAYOUT DRAWING OF HYDRAULIC SYSTEM ..................................................................................10-144
CLSS ...................................................................................................................................................10-150
STRUCTURE OF CLSS................................................................................................................10-150
OPERATION OF UNLOAD VALVE AND LS PRESSURE .............................................................10-152
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL ..............................................................10-153
PRESSURE COMPENSATION CONTROL...................................................................................10-166
ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................10-169
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM .............................................10-169
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................10-170
PUMP AND VALVE CONTROL SYSTEM ............................................................................................10-175
PUMP AND VALVE CONTROL SYSTEM DIAGRAM ....................................................................10-175
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM ............................................................10-176
COMPONENT PARTS OF HYDRAULIC SYSTEM ..............................................................................10-178
HYDRAULIC TANK .......................................................................................................................10-178
MAIN PUMP..................................................................................................................................10-180
CONTROL VALVE ........................................................................................................................10-207
WORK EQUIPMENT SYSTEM ...................................................................................................................10-266
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM .....................................................................10-266
STRUCTURE OF VALVE CONTROL...................................................................................................10-271
ONE-TOUCH POWER MAXIMIZING SYSTEM ...................................................................................10-273
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM ...........................................................10-273
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM ..................................................10-274
PPC LOCK SYSTEM ...........................................................................................................................10-275
PPC LOCK SYSTEM DIAGRAM...................................................................................................10-275
FUNCTION OF PPC LOCK SYSTEM ...........................................................................................10-275
PC210LCI-11 10-3
CONTENTS 10 STRUCTURE AND FUNCTION
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM .....................................................10-276

WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM.............................10-276
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM .....................10-276
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...................10-277
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT........................................................................10-278
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM........................................................10-278
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT .......................................10-279
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ..................................................................10-280
WORK EQUIPMENT AND SWING PPC VALVE ...........................................................................10-280
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) .........................................................10-286
2ND-LINE ATTACHMENT PPC VALVE.........................................................................................10-293
SOLENOID VALVE .......................................................................................................................10-295
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) ......................................10-299
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE).......................................10-301
PILOT CIRCUIT ACCUMULATOR ................................................................................................10-303
ATTACHMENT CIRCUIT ACCUMULATOR...................................................................................10-304
ICT SYSTEM ..............................................................................................................................................10-305
LAYOUT DRAWING OF ICT SYSTEM.................................................................................................10-305
ICT CONTROL SYSTEM DIAGRAM....................................................................................................10-309
BUCKET EDGE POSITION DETECTION SYSTEM.............................................................................10-310
BUCKET EDGE POSITION DETECTION SYSTEM DIAGRAM ....................................................10-310
FUNCTION OF BUCKET EDGE POSITION DETECTION SYSTEM ............................................10-310
OPERATION OF BUCKET EDGE POSITION DETECTION SYSTEM ..........................................10-310
THE INTELLIGENT MACHINE CONTROL SYSTEM...........................................................................10-312
FUNCTION OF THE INTELLIGENT MACHINE CONTROL SYSTEM...........................................10-312
AUTO GRADE ASSIST CONTROL ..............................................................................................10-312
AUTO STOP CONTROL ...............................................................................................................10-319
CUSHION SYSTEM FOR ARM IN END...............................................................................................10-333
CUSHION SYSTEM FOR ARM IN END DIAGRAM ......................................................................10-333
FUNCTION OF CUSHION SYSTEM FOR ARM IN END ..............................................................10-333
OPERATION OF CUSHION SYSTEM FOR ARM IN END ............................................................10-333
BOOM SECONDARY DRIVE SWITCH................................................................................................10-335
CONTROL FUNCTION WHEN BOOM SECONDARY DRIVE SWITCH IS TURNED TO ON POSITION.
..................................................................................................................................................10-335
COMPONENT PARTS OF ICT SYSTEM .............................................................................................10-336
ICT SENSOR CONTROLLER.......................................................................................................10-336
WORK EQUIPMENT CONTROLLER ...........................................................................................10-340
CONTROL BOX............................................................................................................................10-344
GNSS RECEIVER ........................................................................................................................10-348
GNSS ANTENNA..........................................................................................................................10-352
IMU SENSOR ...............................................................................................................................10-353
INTELLIGENT MACHINE CONTROL EPC VALVE .......................................................................10-354
STROKE SENSOR FOR BOOM CYLINDER ................................................................................10-357
STROKE SENSOR FOR ARM CYLINDER ...................................................................................10-359
STROKE AND RESET SENSOR FOR BUCKET CYLINDER .......................................................10-361
RESET SENSOR FOR BOOM CYLINDER...................................................................................10-364
RESET SENSOR FOR ARM CYLINDER......................................................................................10-365
BOOM SPOOL STROKE SENSOR ..............................................................................................10-366
ARM SPOOL STROKE SENSOR .................................................................................................10-368
SWING SYSTEM ........................................................................................................................................10-370
LAYOUT DRAWING OF SWING SYSTEM ..........................................................................................10-370
SWING CONTROL SYSTEM DIAGRAM .............................................................................................10-374
FUNCTION OF SWING CONTROL SYSTEM...............................................................................10-374
COMPONENT PARTS OF SWING SYSTEM.......................................................................................10-378
SWING MOTOR ...........................................................................................................................10-378
SWING MACHINERY ...................................................................................................................10-389
SWING CIRCLE............................................................................................................................10-391
TRAVEL SYSTEM.......................................................................................................................................10-392
10-4 PC210LCI-11
10 STRUCTURE AND FUNCTION CONTENTS
LAYOUT DRAWING OF TRAVEL SYSTEM .........................................................................................10-392

TRAVEL CONTROL SYSTEM DIAGRAM ............................................................................................10-396
FUNCTION OF TRAVEL CONTROL SYSTEM .............................................................................10-397
COMPONENT PARTS OF TRAVEL SYSTEM .....................................................................................10-398
TRAVEL MOTOR ..........................................................................................................................10-398
FINAL DRIVE................................................................................................................................10-411
TRAVEL PPC VALVE ....................................................................................................................10-413
CENTER SWIVEL JOINT..............................................................................................................10-417
UNDERCARRIAGE AND FRAME...............................................................................................................10-419
LAYOUT DRAWING OF UNDERCARRIAGE .......................................................................................10-419
SPECIFICATIONS OF UNDERCARRIAGE...................................................................................10-420
WORK EQUIPMENT...................................................................................................................................10-421
STRUCTURE OF WORK EQUIPMENT ...............................................................................................10-421
FUNCTION OF WORK EQUIPMENT ..................................................................................................10-422
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...................................................................10-423
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM ..................................10-423
BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................................................10-424
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................10-424
CAB AND ITS ATTACHMENTS ..................................................................................................................10-425
ROPS CAB ..........................................................................................................................................10-425
STRUCTURE OF ROPS CAB.......................................................................................................10-425
FUNCTION OF ROPS CAB ..........................................................................................................10-425
CAB MOUNT .......................................................................................................................................10-426
STRUCTURE OF CAB MOUNT....................................................................................................10-426
FUNCTION OF CAB MOUNT .......................................................................................................10-426
CAB TIPPING STOPPER ....................................................................................................................10-427
STRUCTURE OF CAB TIPPING STOPPER.................................................................................10-427
FUNCTION OF CAB TIPPING STOPPER ....................................................................................10-427
PC210LCI-11 10-5
ABBREVIATION LIST 10 STRUCTURE AND FUNCTION
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
System
AJSS
VERSE).
ARAC
braking force.
Automatic Retarder
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
10-6 PC210LCI-11
10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Abbrevia-
tion
component/system)
(Same as ECU)
(Same as ECM)
tion
FOPS Cab and canopy
Structure
Forward-Neutral-Re-
verse
tem
Plus) earth.

lite System

HSS
and communication.
IMV)
PC210LCI-11 10-7

Abbrevia-
tion
component/system)
Unit
trol motions.
IMA)
case Ventilation

KCSF Engine
tion Catalyst
fler.
late Filter
KTCS
road.
LIN
sponding to load.
LVDS
as MAF sensor.
Service
ic system
10-8 PC210LCI-11

Abbrevia-
tion
component/system)
ic system
PCCS
and transmission.
Control
oil pressure.
Hydraulic system
(D, PC, etc)
PTP

Structure
ISO 12117-2.
duction
al unit system)
plied.
flow.
TOPS Cab and canopy
PC210LCI-11 10-9

Abbrevia-
tion
component/system)
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
10-10 PC210LCI-11

T/M Transmission
PC210LCI-11 10-11
UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
UREA SCR SYSTEM

SCR
Abbreviation for Selective Catalytic Reduction
10-12 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
1: AdBlue/DEF filler port 3: AdBlue/DEF return hose

2: AdBlue/DEF tank coolant outlet hose 4: AdBlue/DEF tank
PC210LCI-11 10-13
LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
5: AdBlue/DEF tank pressure hose (low temperature 8: AdBlue/DEF tank coolant inlet hose
side) 9: AdBlue/DEF pressure hose (high-temperature side)
6: AdBlue/DEF pump 10: AdBlue/DEF tank heating valve
7: AdBlue/DEF suction hose
10-14 PC210LCI-11
11: KDPF 14: AdBlue/DEF injector coolant hose

12: AdBlue/DEF mixing tube 15: AdBlue/DEF injector
13: SCR assembly
16: Ambient temperature sensor 17: Engine room temperature sensor
PC210LCI-11 10-15
LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
Detailed drawing of SCR assembly
1: SCR outlet NOx sensor 4: Ammonia sensor

2. SCR outlet temperature sensor 5: SCR temperature sensor
3: Turbocharger outlet NOx sensor
10-16 PC210LCI-11
Detailed drawing of AdBlue/DEF tank
1: AdBlue/DEF tank sensor
PC210LCI-11 10-17
UREA SCR SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
UREA SCR SYSTEM DIAGRAM

1
4 7 8 17
2 5 6 15 18 19
9 16 25
3 A
11 12 13 B 20 22 23
10 26
14 21 24
27
28
29
34
36 31
A
B
35
38
39 37 32
33 30
A4P14891
A: Coolant inlet B: Coolant outlet

1: Mass air flow and temperature sensor 21: Ammonia sensor controller
2: Engine 22: SCR temperature sensor
3: Engine controller 23: SCR outlet temperature sensor
4: KDPF assembly 24: SCR temperature sensor controller
5: KDOC unit 25: SCR outlet NOx sensor
6: KCSF unit 26: SCR outlet NOx sensor controller
7: KDPF differential pressure sensor 27: Smart sensor
8: KDPF outlet pressure sensor 28: Ambient temperature sensor
9: Turbocharger outlet NOx sensor 29: Engine room temperature sensor
10: Turbocharger outlet NOx sensor controller 30: AdBlue/DEF system
11: KDOC inlet temperature sensor 31: AdBlue/DEF tank heating valve
12: KDOC outlet temperature sensor 32: AdBlue/DEF tank
13: KDPF outlet temperature sensor 33: AdBlue/DEF tank sensor
14: KDPF temperature sensor controller 34: AdBlue/DEF suction line
15: AdBlue/DEF mixing tube 35: AdBlue/DEF return line
16: AdBlue/DEF injector 36: AdBlue/DEF pressure line
17: SCR assembly 37: AdBlue/DEF pump
18: Upstream SCR catalyst 38: AdBlue/DEF line heater relay
19: Downstream SCR catalyst and ammonia oxidation 39: Machine monitor
catalyst (integrated type)
20: Ammonia sensor
10-18 PC210LCI-11
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM
FUNCTION OF UREA SCR SYSTEM

5
CO N2
1 NOx H2O
HC CO2
6 7 8
2
4
3
A4P14896
1: Engine 5: AdBlue/DEF injector

2: Engine controller 6: KDPF
3: AdBlue/DEF pump 7: SCR catalyst
4: AdBlue/DEF tank 8: Ammonia oxidation catalyst
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water.
• By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and
the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.
FUNCTION OF AdBlue/DEF SYSTEM

1: AdBlue/DEF tank 5
2: AdBlue/DEF suction hose
6
3: AdBlue/DEF pump
4
3A: Flow control valve
3B: Pump
3C: AdBlue/DEF filter
3D: Pressure sensor 2
4: AdBlue/DEF return hose
1
5: AdBlue/DEF pressure hose
6: AdBlue/DEF injector 3A 3D
P
• AdBlue/DEF system consists of AdBlue/DEF tank (1),
3C
AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3), and
AdBlue/DEF injector (6).
3B 3
• The AdBlue/DEF system is a part of the Komatsu Urea
SCR system and its function is to provide AdBlue/DEF into
the SCR Catalyst Assembly.
A4P14892
• However, the comprising devices, such as the AdBlue/DEF
pump, may not start functioning till certain conditions are
fulfilled.
• The AdBlue/DEF system has heating systems to thaw and prevent AdBlue/DEF from freezing because
AdBlue/DEF freezes at -11 °C.
PC210LCI-11 10-19
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
Function of AdBlue/DEF injection system

• The AdBlue/DEF pump pressurizes AdBlue/DEF and delivers it into the AdBlue/DEF mixing tube through
the AdBlue/DEF injector.
• The amount of AdBlue/DEF injection is controlled by the Engine Controller.
• The amount of AdBlue/DEF injection is calculated based on the information of the turbocharger outlet NOx
sensor, the SCR catalyst temperature sensor, the SCR outlet temperature sensor, the ammonia sensor, the
SCR outlet NOx sensor and the exhaust gas flow rate.
• AdBlue/DEF injection is also controlled by the system temperature because Urea SCR systems are not ef-
fective in low temperature. For the monitoring of the system temperature, the KDPF outlet temperature sen-
sor is used in addition to the SCR temperature sensors.
• If any abnormality is detected in any of the sensors that are used for the calculation of the amount of AdBl-
ue/DEF injection and the monitoring of the system temperature, the Engine Controller commands termina-
tion of AdBlue/DEF injection. When this occurs, alerts will be activated and failure codes will be registered.
• Some abnormalities may cause large amount of urea precipitation inside the AdBlue/DEF mixing tube and
result in deposit of urea on the inner surfaces. If it continues and urea deposit accumulates AdBlue/DEF
injection can be blocked at the AdBlue/DEF injector or the exhaust gas flow can be choked in the passag-
es.
Function of purge system
• The AdBlue/DEF purging is incorporated to purge remain- 5
ing AdBlue/DEF in the AdBlue/DEF injector, AdBlue/DEF
hoses and the AdBlue/DEF pump to prevent AdBlue/DEF 6
from solidifying inside by precipitation or freezing. 4
• The AdBlue/DEF purging is activated automatically when
the engine is shut down or the ambient temperature falls
so low that the heating systems is not capable of maintain-
ing fluidity of AdBlue/DEF.
2
• In the case of the AdBlue/DEF purging of the engine shut-
down, the purging operation continues several minutes af-
1
ter the engine stops. Once the purging operation com-
pletes, the Engine Controller shuts itself down automatical- 3A 3D
ly. P
NOTICE
3C
Do not turn the battery disconnect switch to the OFF posi-

3B 3
tion till the System Operating Lamp in the battery box goes
out. The System Operating Lamp will go out when the sys-
tem shuts itself down after the purging operation com-
pletes. A4P14893
Function of heating system

• The AdBlue/DEF heating system has two operation modes.
• One operation mode is “Thaw mode”.
• At engine start-up if the Engine Controller judges AdBlue/DEF is frozen, it automatically commands
heating the AdBlue/DEF injection system.
• The AdBlue/DEF pump and the AdBlue/DEF injector hold their operation till the Engine Controller judg-
es the completion of AdBlue/DEF thawing operation.
• The other operation mode is “Freeze Prevention mode”.
• While the machine is in operation if the Engine Controller judges AdBlue/DEF is likely to freeze, it auto-
matically commands heating the AdBlue/DEF system.
• While the heating is on during machine operation if the Engine Controller judges that cooling by the
ambient exceeds the heating capacity of the system, it automatically starts AdBlue/DEF purging and
10-20 PC210LCI-11
shuts down the operation of the AdBlue/DEF pump and the AdBlue/DEF injector. However, the heating
system is kept on as long as the machine is in operation.
• “Thaw mode” and “Freeze Prevention mode” are controlled by utilizing information by temperature sensors.
The temperature sensors used for the control of two modes are different and the temperature Freeze Pre-
vention modesensors utilized by the comprising devices are different. The following table shows which com-
prising device uses which heating system and which temperature sensors in relation to which operation
mode.
Heating system Thawing mode Freeze prevention mode
AdBlue/DEF suction and purge
hose Ambient temperature Ambient temperature
Heater around hose
AdBlue/DEF pressure hose (low- sensor sensor
temperature side)
AdBlue/DEF pressure hose (high- Engine room temperature Engine room temperature
Heater around hose
temperature side) sensor sensor
AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump Pump built-in heater
perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor
INDUCEMENT STRATEGY
• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine emis-
sions control system. It requires actions to limit engine performance and defines required indication such as
warning lamps and messages, as well as alarms while the control actions are imposed. The warning steps
of Inducement are different between for North America and for European Union.
• The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information”
screen of the machine monitor.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR NORTH AMERICA)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 5 levels from Warning, Escalated Warning, Mild Inducement, Se-
vere Inducement and Final Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement
if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine
speed to low idle and keeps it at low idle.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
PC210LCI-11 10-21
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)
5%
2: Without Red
(Within the CA3498
Escalated treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red
2.5%
Mild Induce- CA1673
ment (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)
Red
CA1673 Torque: over

Severe In- 0% 4: Engine 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: over
4) 40%
Red
Not remaining CA1673

Final Induce- in the tank CA3547
ment (*6) 5: Engine is Engine speed
5 running at low Continuously AS00ZK is fixed to low
(Inducement (All grada- idle. Red (AdBlue/DEF idle
3) tions lights level low error
off) 5)
*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
10-22 PC210LCI-11
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel
*6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR

SYSTEM DEVICES (FOR NORTH AMERICA)
• When any abnormality is found in the AdBlue/DEF quality or in the Urea SCR system tampering or fault,
AdBlue/DEF system caution lamp on the machine monitor lights up, the Audible alert sounds. If time has
elapsed after any abnormality is generated, not only the warning by AdBlue/DEF caution lamp on the ma-
chine monitor and Audible alert, but also an action level is displayed, Inducement strategy is activated and
then the engine output is reduced.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
Machine monitor
Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)
Yellow
1: Please
inspect and CA3571
1 Warning 1 hour maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.
Yellow
2: Without Triplet (*6) AS00R2

Escalated treatment,
2 Warning 2 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))
Red
AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA3571 (Inducement Torque: over
3 3 hours 1(SCR De-
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))
PC210LCI-11 10-23
Machine monitor

ment strategy
el) status (*4)
Red
4: Engine AS00R4 Torque: over

Severe In- 50%
ducement power is CA3571 (Inducement
Continu-
4 4 hours under 2 (SCR De- and
(Induce- Red ously CB3571
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%
Red
AS00R5
Final In- Engine
ducement 5: Engine is CA3571 (Inducement
Until repair- Continu- speed is
5 running at 3 (SCR De-
(Induce- ing Red ously CB3571 fixed to low
low idle. vice Abnor-
ment 3) idle
mality))
*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
the service mode.
the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
steps are the same and 5, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning”.
10-24 PC210LCI-11
Machine monitor

ment strategy
el) status (*4)
Red
1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 1 hour maintain No indication
Red mittently CB4151 25%
SCR sys-
tem.
Red
2: Without Yellow
Triplet (*6) AS00R2
Escalated treatment,
2 Warning 2 hours engine Short inter- CA4151 (Warning 2 Torque: over
power will mittently CB4151 (SCR Device 25%
(Warning 2)
Red
Red
Red AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA4151 (Inducement Torque: over
3 3 hours 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))
Red
PC210LCI-11 10-25
Machine monitor

ment strategy
el) status (*4)
Red
4: Engine Red AS00R4 Torque: over

Severe In- 50%
Continu-
4 4 hours under 2 (SCR De- and
(Induce- ously CB4151
heavy device Abnor- RPM: over
ment 2) ration. mality)) 40%
Red
Red
Red AS00R5
Final In- Engine
ducement 5: Engine CA4151 (Inducement
Until repair- Continu- speed is
5 is running 3 (SCR De-
(Induce- ing ously CB4151 fixed to low
at low idle. vice Abnor-
ment 3) idle
mality))
Red
ing” stage. Final Inducement is not cleared till abnormality is repaired.
the service mode.
the rated speed.
10-26 PC210LCI-11
FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR NORTH

AMERICA)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Mild Inducement” through
the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine pow-
er.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advan-
ces to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of
the Urea SCR system need to be corrected to regain another restoration capability.
• If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Induce-
ment”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine
speed will be fixed to low idle to disable practical machine operation.
• To activate Temporary Restoration, follow the procedures described below.
REMARK
For the operating procedure on this function, refer to "TEMPORARY RESTORATION FROM INDUCE-
MENT" on the OPERATION section in the Operation and Maintenance Manual.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR NORTH AMERICA)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.
• The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not
corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final In-
ducement” and engine speed will be fixed to low idle to disable practical machine operation.
INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR EUROPEAN UNION)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
PC210LCI-11 10-27
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)
5%
2: Without Red
(Within the CA3498
Continuous treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red
2.5%
Low-Level In- CA1673
ducement (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement Red tently level low error 25%
of the bottom der deration.
1) 3)
lights on)
Red
CA1673 Torque: over

Severe In- 0% 4: Engine 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de- Red
2) off) ration. level low error RPM: over
4) 40%
*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF

QUALITY OR IN THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• When any abnormality is found in the AdBlue/DEF quality or in the Urea SCR system tampering or fault,
AdBlue/DEF caution lamp on the machine monitor lights up, the Audible alert sounds. If time has elapsed
10-28 PC210LCI-11
after any abnormality is generated, not only the warning by AdBlue/DEF caution lamp on the machine moni-
tor and Audible alert, but also an action level is displayed, Inducement strategy is activated and then the
engine output is reduced.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)
Yellow
1: Please
inspect and CA3571
1 Warning 5 hours maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.
Yellow
2: Without Triplet (*6) AS00R2

Continuous treatment,
2 Warning 10 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
Red
AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA3571 (Inducement Torque: over
(Induce- under dera- Red mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))
PC210LCI-11 10-29
Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)
Red
4: Engine AS00R4 Torque: over

Severe In- 50%
Until repair- Continu-
4 under 2 (SCR De- and
(Induce- ing Red ously CB3571
ing” stage. Final Inducement is not cleared till abnormality is repaired.
the service mode.
the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
reduction) starts from that of “Warning ”.
10-30 PC210LCI-11
Machine monitor

ment strategy
el) status (*4)
Red
1: Please
inspect and CA4151
1 Warning 5 hours maintain No indication
SCR sys-
tem.
Red
2: Without Yellow
Triplet (*6) AS00R2
(Warning 2)
Red
Red
Red AS00R3
Low-Level 3: Engine
tion. vice Abnor-
ment 1)
mality))
Red
PC210LCI-11 10-31
Machine monitor

ment strategy
el) status (*4)
Red

Severe In- 50%
(Induce- ing ously CB4151
Red
the service mode.
the rated speed.
INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
• The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. Although the total
reduction) starts from that of “Warning”.
10-32 PC210LCI-11
Machine monitor

ment strategy
el) status (*4)
Red
1: Please
inspect and CA2271
1 Warning 5 hours maintain No indication
SCR sys-
tem.
Red
2: Without Yellow
Triplet (*6) AS00R2
(Warning 2)
Red
Red
Red AS00R3
Low-Level 3: Engine
tion. vice Abnor-
ment 1)
mality))
Red
PC210LCI-11 10-33
Machine monitor

ment strategy
el) status (*4)
Red

Severe In- 50%
(Induce- ing ously CB2271
Red
the service mode.
the rated speed.
FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EURO-

PEAN UNION)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Low-Level Inducement”
through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full en-
gine power.
• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another re-
storation capability.
• To activate Temporary Restoration, follow the procedures described below.
10-34 PC210LCI-11
REMARK
For the operating procedure on this function, refer to "TEMPORARY RESTORATION FROM INDUCE-
MENT" on the OPERATION section in the Operation and Maintenance Manual.
INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR EUROPEAN UNION)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated.
• Inducement in the recurrence resumes counting time at the time when the previous abnormalities were cor-
rected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The
alerts resume the previous Inducement.
• If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recur-
rence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2
hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnor-
malities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.
PC210LCI-11 10-35
COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF UREA SCR SYSTEM

SCR
AdBlue/DEF MIXING TUBE

STRUCTURE OF AdBlue/DEF MIXING TUBE
REMARK
The shape is subject to machine models.
A: Exhaust gas inlet (from KDPF) B: Exhaust gas outlet (to SCR)
1: Clamp 4: AdBlue/DEF mixing tube (connector)
2: AdBlue/DEF injector 5: AdBlue/DEF mixing tube (tube)
3: Gasket for AdBlue/DEF injector
FUNCTION OF AdBlue/DEF MIXING TUBE

It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which
is needed to purge NOx from SCR assembly.
10-36 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM
SCR ASSEMBLY
SCR
STRUCTURE OF SCR ASSEMBLY

REMARK
PC210LCI-11 10-37
A: From AdBlue/DEF mixing tube B: To exhaust pipe

1: SCR body 10: Sensor table
2: SCR temperature sensor 11: Sensor table band
3: SCR outlet NOx sensor 12: Catalyzer hold mat
4: SCR outlet temperature sensor 13: Water dam
5: Temperature sensor controller 14: Downstream SCR catalyst and ammonia oxidation
6: Ammonia sensor catalyst (integrated type)
7: Hanger plate 15: Upstream SCR catalyst
8: water baffle 16: Rectifier tube
9: Water drain port

• SCR assembly consists of rectifier tube (16) equalizing the distribution of flow speed by leading exhaust
gas, upstream SCR catalyst (15), downstream SCR catalyst, ammonia oxidation catalyst (14), and water
dam which prevents rain water from entering into downstream SCR catalyst and ammonia oxidation cata-
lyst (14) while exhausting gas.
• Ammonia oxidation catalyst (a part of 14) oxidizes ammonia to water and nitrogen with ammonia oxidation
catalyst (a part of 14) to prevent ammonia which is supplied to SCR assembly from being released out be-
cause SCR catalyst (a part of 14, 15)cannot completely consume it.
• Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (4), ammonia sensor (6), and
SCR outlet NOx sensor (3) are installed. These sensors are usable for various troubleshooting, such as
they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly
functions or not.
• Rectifying tube (16) equalizes the distribution of exhaust gas flow speed.
• SCR catalyst (15, a part of 14) uses the ceramic honeycomb.
• The catalyzer holding mat (12) is made of a specific fiber and protects the ceramic catalyst against vibra-
tions by the engine and the machine body. It also protects the outer periphery of SCR assembly against a
heat transfer of the ceramics during operation.
• Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit and ammonia oxidation catalyst (14).
• Water baffle (8) is located at the downstream side of the outlet and prevents rainwater at outlet from splash-
ing over the detection part of NOx sensor.
10-38 PC210LCI-11
AdBlue/DEF TANK
STRUCTURE OF AdBlue/DEF TANK
A: Coolant outlet D: To AdBlue/DEF pump

B: Coolant inlet E: To breather
C: From AdBlue/DEF pump
1: Sensor flange assembly 2: AdBlue/DEF filler cap
PC210LCI-11 10-39
3: Sight gauge 6: AdBlue/DEF tank filter

4: AdBlue/DEF tank 7: Drain plug
5: AdBlue/DEF tank sensor
AdBlue/DEF TANK SENSOR

STRUCTURE OF AdBlue/DEF TANK SENSOR
REMARK
1: Connector 3: Temperature sensing part

2: Concentration Sensing part 4: Level sensing part
FUNCTION OF AdBlue/DEF TANK SENSOR

• This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and
AdBlue/DEF temperature through CAN communication.
• AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.
10-40 PC210LCI-11
AdBlue/DEF PUMP
STRUCTURE OF AdBlue/DEF PUMP
A: Suction from AdBlue/DEF tank A B C
B: Return to AdBlue/DEF tank
2 3 4
C: Pressurized sending to AdBlue/DEF injector
1: AdBlue/DEF pump
2: AdBlue/DEF inlet connector
3: AdBlue/DEF backflow connector
4: AdBlue/DEF outlet connector
5: Electric connector
6: AdBlue/DEF filter cap
7: AdBlue/DEF filter (built-in)
5 1 6
7 A4P15768
• The followings are built-in: The filter to collect the dust in

AdBlue/DEF, the valve to switch the flow direction when
purging, and the heater to thaw AdBlue/DEF when it is fro-
zen.
• It purges AdBlue/DEF from AdBlue/DEF tank, pressurizes
it to 900 kPa {9.18 kg/cm2} , and sends it to AdBlue/DEF 2 3 4
injector.
• To prevent wrong connection of connectors, the backflow
connectors are white and can be distinguished from oth-
ers. The sizes of inlet connector and outlet connector are
different and they cannot be connected each other.
P
A4P14894
PC210LCI-11 10-41
AdBlue/DEF INJECTOR
STRUCTURE OF AdBlue/DEF INJECTOR
A: Pressurized sending from AdBlue/DEF pump
B: Coolant inlet
C: Coolant outlet
1: AdBlue/DEF injector
2: AdBlue/DEF inlet connector
3: Coolant inlet connector
4: Coolant outlet connector
5: Electric connector
FUNCTION OF AdBlue/DEF INJECTOR

• It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.
OPERATION OF AdBlue/DEF INJECTOR

Principle of injection of the injector is described. Following fig- 1 2 3
ure shows the state of injection. 4
1. Engine controller sends the electrical signal to control
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected. A4P15772
10-42 PC210LCI-11
AdBlue/DEF HOSE
STRUCTURE OF AdBlue/DEF HOSE
1: Connector 5: Insulation tape

2: Housing 6: Heating wire
3: Coupling 7: Nylon tube
4: Corrugated tube
• It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF
pump and AdBlue/DEF injector.
• The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injec-
tor pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one
touch.
• There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.
• There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one accord-
ing to the model and the part to use.
FUNCTION OF AdBlue/DEF HOSE

• In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It
heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube.
• It also keeps temperature constant to prevent AdBlue/DEF from freezing again while machine is operated.
PC210LCI-11 10-43
AdBlue/DEF TANK HEATING VALVE

STRUCTURE OF AdBlue/DEF TANK HEATING VALVE
A: Engine coolant inlet B: Engine coolant outlet

1: Solenoid 5: Plunger
2: Solenoid core 6: Diaphragm
3: Solenoid coil 7: Valve
4: Spring
FUNCTION OF AdBlue/DEF TANK HEATING VALVE

• AdBlue/DEF tank heating valve thaws AdBlue/DEF tank, and opening/closing of the valve (7) is done by
solenoid (1).
• The opening position of valve is fixed and the control is only for opening/closing. When the solenoid (1) is
de-energized, the valve is closed.
• Diaphragm (6) prevents entering of engine coolant into solenoid (1).
OPERATION OF AdBlue/DEF TANK HEATING VALVE

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7)
which is directly connected to plunger (5).
2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down
by spring (4) and valve (7) is closed.
10-44 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF BOOT-UP SYSTEM
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
PC210LCI-11 10-45
LAYOUT DRAWING OF BOOT-UP SYSTEM 10 STRUCTURE AND FUNCTION
1: Fuse box 4: Battery

2: Pump controller 5: KOMTRAX terminal
3: Engine controller 6: Machine monitor
7: Fusible link 9: Battery disconnect switch

8: System operating lamp
10-46 PC210LCI-11
10 STRUCTURE AND FUNCTION SYSTEM OPERATING LAMP SYSTEM
SYSTEM OPERATING LAMP SYSTEM

SYSTEM OPERATING LAMP SYSTEM DIAGRAM
1: Battery disconnect switch 7: Engine controller

2: Battery 8: Pump controller
3: Fusible link 9: KOMTRAX terminal
4: Fuse box 10: ICT sensor controller
5: System operating lamp 11: Work equipment controller
6: Machine monitor 12: KomVision controller (*1)
*1: Machine with KomVision.
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM

System operating lamp is lit while any of controllers are in operation. To prevent the abnormal end of the discon-
nection of the battery power supply circuit while the controllers are in operation, check the operation state with
this lamp.
REMARK
• Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and check that
the system operating lamp goes off, then turn the battery disconnect switch to “OFF” position.
• If the battery disconnect switch is turned to “OFF” position (the battery power supply circuit is OFF) while the
system operating lamp is lit, data loss error of controller may occur. Never operate the battery disconnect
switch while the system operating lamp is lit.
• The system operating lamp goes off in 5 minutes after the starting switch is turned to “OFF” position.
• The system operating lamp may sometimes light up while the starting switch is in “OFF” position, because
KOMTRAX terminal may maintain its communication under this condition.
ON and OFF of system operating lamp
• Voltage of 24 V is constantly applied to one side of system operating lamp (LED (Light Emitting Diode)).
• When any controller is in operation, the controller side outputs Low (0 V), and a current flows through the
diode and the system operating lamp lights up.
• When all controllers are stopped, the controller side outputs High (24 V), and no current flows through the
diode and the system operating lamp goes off.
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.
• When the starting switch is in “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 state and machine stop time. So the lamp can be lit as long as approximately 1 hour.
When you want to cut off the battery circuit for maintenance but the system operating lamp is kept lit, turn
the starting switch to “ON” position once and then turn it to “OFF” position. Lamp goes off in a maximum of.
PC210LCI-11 10-47
SYSTEM OPERATING LAMP SYSTEM 10 STRUCTURE AND FUNCTION
5 minutes. After system operating lamp goes off, turn the battery disconnect switch immediately to “OFF”
position.
10-48 PC210LCI-11
10 STRUCTURE AND FUNCTION BATTERY DISCONNECT SWITCH
BATTERY DISCONNECT SWITCH

FUNCTION OF BATTERY DISCONNECT SWITCH
(O): OFF position
(I): ON position
• Usually, battery disconnect switch (1) is used instead of
disconnecting the cable from the negative terminal of the
battery in the following cases.
• When storing the machine for a long period (1 month
or longer)
• When servicing or repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
• When battery disconnect switch (1) is turned to OFF position (the contact is opened), all the continuous
power supplies for the components, including the starting switch B terminal and controllers, are all cut out,
and the condition is the same as the condition when the battery is not connected. Accordingly, all of the
electrical system of the machine does not operate.
NOTICE
• Do not turn battery disconnect switch (1) to OFF position while the system operating lamp is lit.
If battery disconnect switch (1) is turned to OFF position while the system operating lamp is lit, the
data in the controller may be lost and the controller may be damaged seriously.
• Do not turn battery disconnect switch (1) to OFF position while the engine is running or immediately
after the engine is stopped.
If battery disconnect switch (1) is turned to OFF position while the alternator is generating power, the
generated current has nowhere to go, leading to overvoltage in the electrical system of the machine,
which may cause serious damage to the electrical system, including the electric devices and control-
lers.
REMARK
• The system operating lamp lights up while the controller is in operation or AdBlue/DEF pump is in operation.
It lights up when KOMTRAX is performing communication, even if the starting switch is set to OFF position.
• If battery disconnect switch (1) has been at OFF position for a long period, the machine monitor and the
clock of the radio may be initialized. In this case, re-setting is required.
PC210LCI-11 10-49
LAYOUT DRAWING OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
1: EGR cooler 4: SCR assembly

2: VGT 5: KDPF
3: Engine oil filter 6: KCCV ventilator
10-50 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF ENGINE SYSTEM
7: Vibration damper 12: Damper

8: Auto-tensioner 13: Rear engine mount
9: Air cleaner 14: Front engine mount
10: Alternator 15: Engine controller
11: Starting motor
SPECIFICATIONS OF ENGINE SYSTEM

Type of damper: Wet type
Damper oil: TO30
Quantity of damper oil: 0.65 ℓ
FUNCTION OF ENGINE SYSTEM

• VGT (2) is a turbocharger which can change the cross-sectional area of the exhaust passage.
• EGR cooler (1) cools the exhaust gas with the coolant.
• KDPF (5) has KDOC (catalyst) and KCSF (soot collecting filter) in it and purifies the exhaust gas.
• KCCV ventilator (6) separates and returns oil to the intake side to burn the blowby gas again. It mainly con-
sists of filters.
PC210LCI-11 10-51
ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM DIAGRAM
1: Battery disconnect switch 11: Starting motor cut-off relay (for PPC lock)
2: Battery 12: Starting motor cut-off relay (for personal code)
3: Battery relay 13: Fuel control dial
4: Fusible link 14: Safety relay
5: Fuse box 15: Starting motor
6: Starting switch 16: Fuel supply pump
7: Engine shutdown secondary switch 17: Various sensors
8: Engine controller 18: Machine monitor
9: Lock lever 19: KOMTRAX terminal
10: PPC lock switch 20: Pump controller
10-52 PC210LCI-11
10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
FUNCTION OF ENGINE CONTROL SYSTEM

Mechanism and function of engine starting system
• When starting switch (6) is turned to ON position, engine controller (8) sends a command current to fuel
supply pump (16).
Accordingly, a fail-safe mechanism is provided, that is, the engine stops when the electrical system has
trouble.
• When starting switch (6) is turned to START position while lock lever (9) is in LOCK position, the starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in FREE position, starting motor cut-off relay (11) operates to cut off the starting current to
starting motor (15) and the engine does not start, that is, a 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) operates starting motor cut-off relay (12) to cut off the starting current to starting mo-
tor (15), thus the engine does not start.
Mechanism and function of engine speed control system
PC210LCI-11 10-53
ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8) se-
lects the lower throttle signal and sends the command current to fuel supply pump (16). Fuel supply pump (16)
adjust the fuel injection rate to control the engine speed.
Mechanism and function of engine stopping system
When starting switch (6) is turned to OFF position, the current from terminal ACC of starting switch (6) to engine
controller (8) is cut off, and the command current to fuel supply pump (16) is also cut off. Fuel supply pump (16)
stops supplying fuel, the engine speed decreases, and the engine stops.
Mechanism and function of engine stopping system with engine shutdown sec-
ondary switch
When engine shutdown secondary switch (7) is set to the engine stop position, the current from terminal ACC of
starting switch (6) to engine controller (8) is cut off forcibly. The condition becomes the same as when starting
switch (6) is turned to OFF position, and the engine stops.
10-54 PC210LCI-11
10 STRUCTURE AND FUNCTION AUTO-DECELERATION SYSTEM
AUTO-DECELERATION SYSTEM
AUTO-DECELERATION SYSTEM DIAGRAM
a: CAN signal d: 1st throttle signal

b: Oil pressure sensor signal e: Fuel supply pump control signal
c: Oil pressure switch signal f: Various sensor signals
1: Pump controller 8: Oil pressure sensor
2: Engine controller 9: Main pump
3: Machine monitor 10: Control valve
4: Fuel control dial 10a: Self-pressure reducing valve
5: Fuel supply pump 10b: Merge-divider valve
6: Various sensors 10c: Travel junction valve
7: Oil pressure switch 11: PPC lock solenoid valve
FUNCTION OF AUTO-DECELERATION SYSTEM

• When all the control levers are set to NEUTRAL positions while waiting for a dump truck or next work, the
engine speed decreases to the control speed automatically to improve the fuel economy and reduce the
noise.
• If any control lever is operated, the engine speed returns immediately to the speed set with the fuel control
dial.
PC210LCI-11 10-55
AUTO-DECELERATION SYSTEM 10 STRUCTURE AND FUNCTION
OPERATION OF AUTO-DECELERATION SYSTEM

A: All work equipment control levers in NEUTRAL
B: Work equipment control lever operated
C: Fuel control dial at set speed
D: Engine control speed (approximately 1050 rpm)
E: 4 sec.
F: Max. 2 sec.
G: Max. 1 sec.
When control lever is in NEUTRAL

While the engine is running at approximately 1050 rpm or higher speed, when all the control levers are kept in
NEUTRAL for 4 seconds or more, engine speed is decreased to approximately 1050 rpm and kept to the engine
control speed (approximately 1050 rpm) until any control lever is operated.
When control lever is operated
While the engine speed is kept at the engine control speed (approximately 1050 rpm), when any control lever is
operated, the engine speed increases immediately to the fuel control dial set speed.
10-56 PC210LCI-11
10 STRUCTURE AND FUNCTION ENGINE AUTOMATIC WARM-UP SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM

ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM
a: Front pump PC-EPC valve drive signal e: Hydraulic oil temperature signal
b: Rear pump PC-EPC valve drive signal f: 1st throttle signal
c: Solenoid valve GND g: Fuel supply pump control signal
d: CAN signal h: Various sensor signals
1: Battery disconnect switch 16: Front pump
2: Battery 16a: Servo
3: Battery relay 16b: LS valve
4: Fusible link 16c: PC valve
5: Fuse box 17: Rear pump
6: Resistor for PC-EPC valve 17a: Servo
7: Pump controller 17b: LS valve
8: Engine controller 17c: PC valve
10: Air conditioner unit 18a: Self-pressure reducing valve
11: Pump drive secondary switch 18b: Merge-divider valve
12: Fuel control dial 18c: Travel junction valve
13: Fuel supply pump 19: Front pump PC-EPC valve
14: Various sensors 20: Rear pump PC-EPC valve
15: Hydraulic oil temperature sensor
PC210LCI-11 10-57
ENGINE AUTOMATIC WARM-UP SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM

• When the coolant temperature is low after the engine is started, the engine speed is increased automatical-
ly to warm up the engine.
• The engine automatic warm-up function has 2 kinds; “Heater warm-up” and “Normal warm-up”, either of
which is used according to the purpose.
The purpose of the heater warm-up is to increase the coolant temperature to improve the effect of the heat.
The purpose of the normal warm-up is to heat the engine to prevent damage on the engine caused by low
temperature.
Operating conditions 1
Machine specification: Air conditioner specification
Air conditioner: Blower “ON”
Coolant temperature: Below 55 °C
Ambient temperature: Below 5 °C
Manual stationary regeneration: OFF
Soot accumulation: Max. 2 g/ ℓ
↓ ↓
When any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up disabled (normal warm-up) Heater warm-up enabled
Operating conditions 2
(Operates when all of the following conditions are sat- ↓
isfied)
Coolant temperature: Below 30 °C
↓
Engine speed: Max. 1200 rpm
↓ ↓
Operation Operation
Engine speed: 1200 rpm Engine speed: Min. 1300 rpm
↓ ↓
Condition to cancel Condition to cancel
(Canceled when any of the following conditions is sat- (Canceled when any of the following conditions is sat-
isfied) isfied)
Automat- Coolant temperature: Min. 30 °C

ic Warm-up operation time: Min. 10 minutes Coolant temperature: Min. 60 °C
Fuel control dial: Held at 70 % or more of Ambient temperature: Min. 10 °C
Manual
High idle (MAX) for 3 seconds and longer.
↓ ↓
Cancellation
Engine speed: Any
10-58 PC210LCI-11
10 STRUCTURE AND FUNCTION OVERHEAT PREVENTION SYSTEM
OVERHEAT PREVENTION SYSTEM

OVERHEAT PREVENTION SYSTEM DIAGRAM
PC210LCI-11 10-59
OVERHEAT PREVENTION SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF OVERHEAT PREVENTION SYSTEM

When the coolant temperature or the hydraulic oil temperature increases too high during operation, the pump
load is reduced and the engine speed is lowered to prevent overheat and protect the engine and hydraulic com-
ponents.
Operating condition Operation and remedy Condition to cancel

Hydraulic oil temperatureBelow
93 °C
Working mode: Travel → Engine speed: Kept as it is → • When above condition is
Hydraulic oil temperatureMin. Pump discharged volume: Throt-
satisfied, state before op-
95 °C tled
eration is restored (auto-
matic restoration).

Coolant temperatureBelow
Working mode: P, E, ATT-P, Engine speed: Kept as it is
100 °C
or ATT-E mode Pump discharged volume: Throt-
Coolant temperatureMin. → tled → 100 °C
100 °C
• Pump absorption torque is
or • When above condition is
lowered and engine load is
Hydraulic oil temperatureMin. reduced according to the
100 °C torque control signal.
matic restoration).

Working mode: P, E, ATT-P, Engine speed: Kept as it is
102 °C
or ATT-E mode Pump discharged volume: Throt-
Coolant temperatureMin. → tled → 102 °C
102 °C
• Pump absorption torque is
or • When above condition is
lowered and engine load is
Hydraulic oil temperatureMin. reduced according to the
102 °C torque control signal.
matic restoration).

Working mode: B mode 102 °C
Coolant temperatureMin. Engine speed: Kept as it is Hydraulic oil temperatureBelow
102 °C → Pump discharged volume: Throt- → 102 °C
or tled • When above condition is
Hydraulic oil temperatureMin. Alarm monitor: Lights up satisfied, state before op-
102 °C eration is restored (auto-
matic restoration).
10-60 PC210LCI-11
10 STRUCTURE AND FUNCTION OVERHEAT PREVENTION SYSTEM

105 °C
Working mode: All modes Hydraulic oil temperatureBelow
Coolant temperatureMin. 105 °C
Engine speed: Low idle
105 °C → → Fuel control dial: Return to Low
Alarm monitor: Lights up
or idle (MIN) position.
Alarm buzzer: Sounds
Hydraulic oil temperatureMin. • When above condition is
105 °C satisfied, state before op-
eration is restored (man-
ual restoration).
PC210LCI-11 10-61
TURBOCHARGER PROTECTION SYSTEM 10 STRUCTURE AND FUNCTION
TURBOCHARGER PROTECTION SYSTEM

TURBOCHARGER PROTECTION SYSTEM DIAGRAM
10-62 PC210LCI-11
10 STRUCTURE AND FUNCTION TURBOCHARGER PROTECTION SYSTEM
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM

This function limits the engine speed to prevent seizure of the turbocharger when the engine speed is increased
suddenly just after the engine is started.
Operating condition Operation

→
Engine oil pressure: Below 50 kPa {0.51 kg/cm2} Protection of turbocharger (see following figure)
A: Starting of engine
B: Turbocharger protection time (approximately 0 to 20 sec-
onds)
C: Modulation time (approximately 1 second)
D: 500 rpm
E: Approximately 1050 rpm
F: 1650 rpm (*1)
(*1) Working mode: P mode
Fuel control dial: High idle (MAX) position
Travel lever: Fine control
PC210LCI-11 10-63
AUTOMATIC IDLE STOP SYSTEM 10 STRUCTURE AND FUNCTION
AUTOMATIC IDLE STOP SYSTEM

AUTOMATIC IDLE STOP SYSTEM DIAGRAM
a: CAN signal c: Lock lever signal

b: BR signal d: Various sensor signals
1: Battery disconnect switch 9: PPC lock switch
2: Battery 10: Pump controller
3: Battery relay 11: Machine monitor
4: Fusible link 12: Engine controller
5: Fuse box 13: KOMTRAX terminal
6: Starting switch 14: Engine
7: Relay 15: Hydraulic oil temperature sensor
8: Lock lever 16: Coolant temperature sensor
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM

• When the auto idle stop function is enabled and the conditions for operation are satisfied, the engine is
stopped after the set time.
• Engine stops by auto idle stop function when engine controller judges the applicable condition and stops
the engine.
• When the engine is stopped by the auto idle stop function while it is running at high speed, a message to
turn ON the auto-deceleration function is displayed on the machine monitor, and the auto-deceleration func-
tion is set to ON.
• The operating time of the auto idle stop function can be set by user menu or service menu on the machine
monitor.
Operating condition of automatic idle stop system
The auto idle stop function starts when all of the following conditions are satisfied at the same time.
• Engine is running.
• Lock lever is in LOCK position.
• Working mode is “P”, “E”, “ATT/P”, “ATT/E”, or “B”. (Disabled when working mode is “L” or “Arm crane”).
• Engine automatic warm-up function of "Normal warm-up" mode is not being operated.
• Engine coolant is not overheating (below 102 °C).
10-64 PC210LCI-11
10 STRUCTURE AND FUNCTION AUTOMATIC IDLE STOP SYSTEM
• Hydraulic oil is not overheating (below 102 °C)

• Auto idle stop time on machine monitor has not been reset.
• Machine monitor is not set in service mode. (*1)
• None of following failure codes is occurring.
*1: See "Setting time".
Corresponding failure codes are as follows.
Failure code Failure (displayed on screen)
B@BCNS Eng Water Overheat
B@HANS Hydraulic Oil Overheat
CA144 Coolant Temperature Sensor High Error
CA145 Coolant Temperature Sensor Low Error
D8AQKR CAN 2 Defective Communication (KOMTRAX)
DA2RKR Controller Area Network 1 Defective Communication (Pump Controller)
DA2QKR Controller Area Network 2 Defective Communication (Pump Controller)
DAFQKR CAN 2 Defective Communication (Monitor)
DB2RKR CAN 1 Defective Communication (Engine Controller)
DB2QKR CAN 2 Defective Communication (Engine Controller)
DGH2KA Hydraulic Oil Temperature Sensor Open Circuit
DGH2KB Hydraulic Oil Temperature Sensor Ground Fault
Setting time
The set time for the auto idle stop function is set in the following menus.
For setting of each menu, see "Testing and adjusting".
Fixing auto idle stop time (service menu)

Setting Contents of setting
In auto idle stop time setting menu, operator can select OFF or minimum set time in auto idle stop
Variable
setting to maximum time of 60 minutes. (Default)
The auto idle stop function does not operate, and the auto idle stop time setting menu is not dis-
OFF
played.
In auto idle stop time setting menu, operator can select set time in auto idle stop setting to X mi-
Fix to X min.
nutes (set time at left). (Cannot select OFF)
Fixing auto idle stop time (user menu)

Setting Contents of setting
OFF Auto idle stop function does not operate. (Default)
Y min. Stop the engine at Y minutes (set time at left) after setting the lock lever to LOCK position.
NOTICE
When "Fix X min." is selected in the Auto idle stop time fixing menu, the screen changes to the operator
screen automatically and the auto idle stop function operates 60 minutes after the lock lever is set to
LOCK position, even if the Service menu is being used.
Before performing work with the Service menu, check the set value of the auto idle stop function.
PC210LCI-11 10-65
AUTOMATIC IDLE STOP SYSTEM 10 STRUCTURE AND FUNCTION
Sensing abrupt engine stop

• When the engine is stopped by the auto idle stop function, if the auto-deceleration function is OFF and the
fuel control dial is at a position above MIN., abrupt engine stop is sensed and the failure code is sent.
• The failure code is recorded in the mechanical system abnormality record.
• If abrupt engine stop is sensed, the auto-deceleration function is turned ON automatically.
• The failure code displayed at abrupt engine stop varies with the number of occurrence, and the message
displayed on the machine monitor varies according to the failure code.
Action level Failure code Failure (displayed on screen)
L00 A900N6 Abrupt Engine Stop by Auto Idle Stop 1
L01 A900NY Abrupt Engine Stop by Auto Idle Stop 2
L03 A900FR Abrupt Engine Stop by Auto Idle Stop 3
• When failure code “A900FR” of action level “L03” is sent, the turbocharger assembly must be replaced
since the durability of the engine may decrease.
• After replacing the turbocharger assembly, reset the number of occurrence by using “Reset number of
abrupt stops by auto idle stop” in “Inspection” on the service menu.
REMARK
If the number of occurrence is not reset by using “Reset number of abrupt stops by auto idle stop”, failure code
“A900FR” is sent again next time and after. Accordingly, be sure to reset after replacing the turbocharger as-
sembly.
10-66 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM

VGT
VGT
Abbreviation for Variable Geometry Turbocharger
STRUCTURE OF VGT
REMARK
General view, sectional view
A: Intake air inlet B: Intake air outlet
PC210LCI-11 10-67
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION
C: Exhaust inlet D: Exhaust outlet

1: Blower housing 7: Nozzle ring
2: VGT speed sensor 8: Push rod
3: Hydraulic actuator 9: Shaft
4: Turbine housing 10: Blower impeller
5: Plate 11: Turbine impeller
6: Vane 12: Piston
FUNCTION OF VGT
C: Blower impeller T: Turbine impeller

1: Air cleaner 5: SCR assembly(*1)
2: VGT 6: EGR cooler
3: KDPF 7: EGR valve
4: AdBlue/DEF mixing tube(*1)
*1: This may not be installed on some machine models and specifications.
• The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well
as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount
of fresh suction air)
• To attain high EGR ratio, turbine inlet pressure (P3) must be set higher than boost pressure (P2) (P3 > P2).
For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on
turbine impeller (T) is adjustable.
Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen
during low-speed operation (rotation) is reduced.
• The shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for
combustion.
If VGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased.
In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel in-
jection rate can be increased and the engine output is increased.
NOTICE
Adequate amount of clean high quality oil is required to maintain VGT performance. Be sure to use Ko-
matsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
REMARK
It sounds like air is leaking from VGT or a boost pipe, but it is not abnormal.
10-68 PC210LCI-11
OPERATION OF VGT
REMARK
Six cylinder engine is shown in this item.
1. The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is
surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6).
The area of its passage is changed by sliding push rod (8) to the right or left.
2. Hydraulic actuator (3) moves piston in the actuator up and down with the hydraulic pressure controlled by
EPC valve installed to the front cover, and slides push rod (8) to the right and left.
3. The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine
impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through
(A) is compressed and discharge through (B).
4. When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range),
push rod (8) slides to the right and narrows portion (P).
5. The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air
(oxygen) is taken in.
VGT speed sensor (2) detects the rotation of the turbocharger.
PC210LCI-11 10-69
When nozzle ring is "closed"

1. During low speed operation (rotation), exhaust gas inlet
passage (P) is narrow (L1). (It is not fully closed, however.)
2. If the turbine inlet pressure increases while the nozzle ring
is closed, the turbine inflow speed increases, and accord-
ingly the turbocharger speed increases.
When nozzle ring is "open"

1. During high speed operation (rotation), exhaust gas inlet
passage (P) is wide (L2).
2. As the engine speed increases and the turbine inlet pres-
sure (exhaust gas pressure) increases exhaust gas inlet
passage (P) is widened (L2) so that the exhaust gas acts
on turbine impeller (11) efficiently.
REMARK
• Nozzle ring (7), vanes (6), and push rod (8) are made in
one unit, and it slides only and does not rotate.
• Hydraulic actuator (3) is equipped with VGT position sen-
sor. VGT position sensor is calibrated together with the vari-
able mechanism of VGT and the result is written in the
memory in VGT position sensor. Accordingly, if any of hy-
draulic actuator (3), VGT position sensor, and VGT unit
fails, whole VGT must be replaced.
Operation of hydraulic actuator
10-70 PC210LCI-11
1. Hydraulic actuator (1) is controlled by EPC valve (3) instal-

led to EGR valve (2) and driven hydraulically.
2. The hydraulic pressure supplied by boost oil pump (4) is
used for this purpose.
3. The position of hydraulic actuator (1) is fed back to engine
controller by the signals from VGT position sensor.
PC210LCI-11 10-71
EGR SYSTEM
EGR
Abbreviation for Exhaust Gas Recirculation
LAYOUT DRAWING OF EGR SYSTEM

REMARK
• Six cylinder engine is shown in this item.
• The shape is subject to machine models.
1: VGT 4: Intake connector

2: EGR valve 5: Exhaust manifold
3: Intake pipe 6: EGR cooler
FUNCTION OF EGR SYSTEM

• EGR valve (hydraulically driven type) (2) controls the gas flowing from the exhaust section to the intake
section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake side.
• EGR cooler (6) cools down the exhaust gas.
Engine coolant is used for cooling.
10-72 PC210LCI-11
• It controls EGR circuit on the basis of the information from the sensors installed to various parts so that
clean exhaust gas is always discharged to obtain EGR ratio corresponding to the operating condition. (EGR
ratio means the ratio of EGR gas contained in the intake gas.)
• It monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure
from occurring.
CIRCUIT DIAGRAM OF EGR SYSTEM
C: Blower impeller T: Turbine impeller

1: Air Cleaner 10: EGR valve lift sensor
2: KDPF 11: EPC valve (for VGT)
3: SCR assembly 12: Exhaust manifold
4: Ambient pressure sensor 13: Engine boost oil pump
5: Aftercooler 14: Intake manifold
6: EGR cooler 15: Charge (boost) pressure and temperature sensor
7: EGR valve 16: Engine controller
8: Hydraulic actuator (power piston) 17: Mass air flow and temperature sensor
9: EPC valve (for EGR valve)
OPERATION OF EGR SYSTEM

1. The engine controller outputs signals in order to open EGR valve (7) most properly in accordance with the
engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (12) into
EGR cooler (6) through the EGR piping.
3. The exhaust gas cooled by EGR cooler (6) flows through EGR valve (7) and mixes with the intake air in the
intake connector, and then flows in intake manifold (14).
PC210LCI-11 10-73
EGR VALVE
EGR
STRUCTURE OF EGR VALVE

REMARK
Sectional view
A: EGR gas inlet (from EGR cooler) D: Servo drive oil outlet
B: EGR gas outlet (to intake manifold) E: VGT control hydraulic outlet
C: Servo drive oil inlet F: VGT drive pressure outlet
1: Valve 5: Spring
2: Spring 6: EGR valve lift sensor
3: Power piston 7: EPC valve (for EGR)
4: Spool 8: EPC valve (for VGT)
Structure
• EGR valve consists of the EGR gas flow control mechanism and EPC valve.
• There are 2 EPC valves, one for the EGR control and one for the VGT control.
10-74 PC210LCI-11
OPERATION OF EGR VALVE

1. The oil from engine boost oil pump enters through port (C)
of EGR valve. The control pressure from EPC valve is
transmitted to port (E).
2. Spool (4) is moved to the right by the reaction force of
spring (5), and EGR valve (1) is closed by the reaction
force of spring (2). Accordingly, the exhaust gas from EGR
cooler does not flow to the intake side.
3. To open EGR valve (1), the control pressure from EPC
valve is transmitted to port (E) first. The position of spool
(4) is determined by the balance of the control pressure
and spring (5).
4. Since the hydraulic circuit of power piston (3) opens, the
oil from the engine boost oil pump flows through port (C) and pushes power piston (3) to the left.
5. The oil from the engine boost oil pump acts on power piston (3) and generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the ex-
haust gas flows to the intake side.
7. Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) is stop-
ped at a position determined by spool (4).
8. The engine controller controls the valve position by controlling the spool position with the control pressure
of EPC valve.
9. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is
in contact with power piston (3).
10. EGR valve lift sensor senses the displacement of spool (4).
PC210LCI-11 10-75
EGR COOLER
EGR
STRUCTURE OF EGR COOLER

REMARK
General view and sectional view
A: EGR gas inlet D: EGR gas outlet (to EGR valve)

B: Air vent E: Coolant inlet
C: Coolant outlet
1: Flat tube
Detailed drawing of flat tube
1: Flat tube
2: Inner fin
OPERATION OF EGR COOLER

1. EGR gas enters through (A) and flows through flat tubes (1) (11 pieces).
10-76 PC210LCI-11
2. Coolant enters through (E), flows outside of flat tubes (1) in the case, and goes out through (C).
3. Flat tube (1) has inner fins (2), thus EGR gas is cooled efficiently and discharged through EGR gas outlet
(D).
PC210LCI-11 10-77
KCCV SYSTEM
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
LAYOUT DRAWING OF KCCV SYSTEM

REMARK
General view
A: Blowby gas (from flywheel housing) C: Engine oil segregated at the filter (to oil pan)
B: Blowby gas from which engine oil is removed (to
VGT)
1: KCCV ventilator 5: Check valve
2: VGT 6: CDR valve
3: Blowby duct 7: Crankcase pressure sensor
4: Flywheel housing
10-78 PC210LCI-11
FUNCTION OF KCCV SYSTEM

• In the past, blowby gas (A) was allowed to be released into the atmosphere in the past, but now it is re-
stricted by emission regulations.
• Blowby gas (A) contains ingredients of the engine oil. A filter is installed to KCCV ventilator (1) to remove
the engine oil to prevent the following possible problems if it is recirculated to VGT (2) as it is.
• Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
• Abnormal combustion in engine
• Malfunction of each sensor caused by sticking engine oil
OPERATION OF KCCV SYSTEM

Drawing on the left shows the conventional flow of blowby gas. Drawing on the right shows the flow of blowby
gas which is sucked in KCCV ventilator and recirculated.
A: Blowby gas C: Engine oil

B: Clean gas
1: Air cleaner 5: Breather
2: VGT 6: KCCV ventilator
3: Aftercooler 7: Engine oil pan
4: Cylinder block (crankcase)
1. This system removes engine oil (C) from blowby gas (A) in cylinder block (4) by using the filter in KCCV
ventilator (6), and recirculate clean gas (B) to the air intake side of VGT (2).
2. Separated engine oil (C) is drained to engine oil pan (7) through the check valve.
PC210LCI-11 10-79
KCCV VENTILATOR
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
STRUCTURE OF KCCV VENTILATOR

REMARK
A: Blowby gas inlet (from flywheel housing) C: Oil drain port (to engine oil pan)
B: Blowby gas outlet (to VGT intake side)
1: Case 4: Relief valve
2: CDR valve 5: Impactor
3: Crankcase pressure sensor 6: Filter
Structure
• Filter is classified by the working direction for filter replacement into the top load type (removed upward)
and bottom load type (removed downward).
• Crankcase pressure sensor is installed to blowby gas inlet piping if it is top load type, and installed to upper
part of KCCV ventilator body if it is bottom load type.
FUNCTION OF KCCV VENTILATOR

• If the blowby gas is returned to the intake side of VGT and crank case pressure becomes negative, the dust
may be sucked in through crank seal.
The pressure inside the crankcase is controlled by CDR valve (2) to prevent this to occur.
• Crankcase pressure may increases and oil leakage may occur if filter (6) of KCCV ventilator is clogged.
Thus, crankcase pressure sensor detects the clogging of filter (6).
10-80 PC210LCI-11
• Keep KCCV ventilator warm with warmed-up engine coolant, to prevent the blowby gas passage from being
clogged due to freeze.
• Relief valve (4) is inside case (1) and it protect both KCCV ventilator and the engine when filter (6) is
blocked.
OPERATION OF KCCV VENTILATOR

1. When blowby gas enters blowby gas inlet (A) and passes through the hole of impactor (5) in filter (6), large
particles in the oil mist are separated.
2. Small particles in the oil mist are separated by filter (6).
3. The separated oil oozes out from the bottom of the filter (6), and flows to oil drain port (C), and then flows to
the engine oil pan.
4. The crankcase pressure sensor (3) senses the crankcase pressure (blowby gas pressure).
If the engine controller detects filter clogging by detected value of crankcase pressure sensor (3), it displays
failure code CA555. If the pressure increases further, it displays failure code CA556.
5. Relief valve (4) is installed in case (1) and operates when filter (6) is blocked.
6. When the crankcase pressure becomes negative, CDR valve (2) operates for it not to become excessively
negative.
CDR VALVE
CDR
Abbreviation for Crankcase Depression Regulator
OPERATION OF CDR VALVE

1. Spring (2) normally pushes up diaphragm (1), and the
blowby gas flows from crankcase side (A) into turbocharg-
er side (air intake side) (B).
2. As the intake air at turbochaeger side (air intake side) (B)
increases, pressure on crankcase side (P1) decreases.
3. The reaction force of spring (2) is overwhelmed by ambient
pressure (P2). Diaphragm (1) shuts the passage and tem-
porarily blocks the flow.
4. When the blowby gas accumulates in the crankcase, pres-
sure (P1) on the crankcase side increases, and it pushes
up diaphragm (1) again and blowby gas starts to flow.
PC210LCI-11 10-81
KDPF
KDPF
Abbreviation for KOMATSU Diesel Particulate Filter
STRUCTURE OF KDPF
REMARK
General view
A: From VGT B: To AdBlue/DEF mixing connector

1: Inlet unit 8: Temperature sensor controller
2: Hanger bracket 9: KDOC outlet temperature sensor
3: Outlet unit 10: KDOC inlet temperature sensor
4: Sensor bracket band 11: KDPF differential pressure sensor port
5: KCSF unit 12: KDPF differential pressure sensor
6: Sensor bracket 13: KDPF differential pressure sensor port
7: KDPF outlet temperature sensor
Structure
• KDPF has a function to introduce the exhaust gas, and it consists of inlet unit (1) to store the oxidation cata-
lyst (KDOC), KCSF unit (5) to store the soot collecting filter with catalyst, and outlet unit (3) to discharge the
exhaust gas.
• Inlet unit (1) stores KDOC consisting of ceramic honeycomb with the oxidation catalyst.
• The ceramic honeycomb contributes to properly perform two following processes, which are to oxidize NO
(nitrogen monoxide) contained in the exhaust gas into NO2 (nitrogen dioxide), and to burn the fuel injected
10-82 PC210LCI-11
during automatic regeneration and manual stationary regeneration. (Automatic regeneration means the
method to purify (oxidize) the soot accumulated on soot collecting filter (KCSF) in KDPF.)
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics
under the vibration condition of the engine and machine body This mat also thermally insulates the periph-
ery of KDPF from the ceramics which becomes high temperature during operation.
• KCSF unit (5) consists of ceramic honeycomb with the oxidation catalyst as well as KDOC does.
This ceramic honeycomb collects soot.
The inside of KCSF unit (5) consists of many cells partitioned by ceramic walls. The cells blocked on the
inlet side and those blocked on the outlet side are arranged alternately.
• KDPF is equipped with KDPF temperature sensor (assembly of KDOC inlet temperature sensor, KDOC out-
let temperature sensor, and KDPF outlet temperature sensor) and the differential pressure sensor (assem-
bly of KDPF differential pressure sensor and KDPF outlet pressure sensor).
The system monitors the combinations of temperatures measured by 3 temperature sensors to see if KCSF
unit (5) and KDOC function normally , and to troubleshoot various components.
The differential pressure sensor detects the pressure difference between before and after the KCSF unit (5)
to monitor the accumulation of soot in KCSF unit (5), and to troubleshoot various components.
FUNCTION OF KDPF
A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
• KDPF purifies the exhaust gas by catching large amount of
chainlike soot or PM (Particulate Matter such as soot)
which is contained in the engine exhaust gas.
• KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen mon-
oxide) contained in the exhaust gas into NO 2 (nitrogen di-
oxide), and regenerates (*1) KCSF.
• KCSF (2) captures soot.
• Accumulated soot in KCSF (2) in operation range where
the temperature of exhaust gas is relatively high state is
naturally oxidized and burnt away by the effect of KDOC
(oxidation catalyst) (1). (This is called “passive regenera-
tion”)
REMARK
“Passive regeneration” cannot be performed if the light
load operation and low temperature state of the exhaust
gas continue. Accumulated soot is gradually increased.
• Engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot
accumulation based on the engine operating conditions, and the other is the calculated soot accumulation
based on the signal from the differential pressure sensor which is attached to KCSF (2).
• If the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level,
engine controller performs “automatic regeneration” to burn (oxydize) the soot.
While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at
KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust
gas. (This is called “exhaust gas temperature raise control”)
The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the fuel
doser installed at the turbocharger outlet part,and exhaust gas volume is controlled by VGT.
The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the
injector, and exhaust gas volume is controlled by VGT.
PC210LCI-11 10-83
The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine ex-
haust gas automatically, and improves combustion efficiency of soot captured in KCSF (2).
REMARK
When regeneration function on the machine monitor is disabled, or outside air temperature is extremely
low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such
case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.
• If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2),
perform “manual stationary regeneration” to burn (oxydize) the soot and reduce the amount of soot inside
KCSF (2).
REMARK
Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine
combustion state. It may lead to other failures.
If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This
will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Op-
eration and Maintenance Manual when performing “manual stationary regeneration”.
*1: Soot purification (oxidation) treatment
TYPES OF REGENERATION FUNCTIONS

Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or
maintain the urea SCR system normal.
Passive regeneration
When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas
components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally.
Active regeneration (engine exhaust temperature rise control + fuel dosing)
• Automatic regeneration
• When soot is accumulated more than a certain level or the urea SCR system makes a request to main-
tain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel
dosing (*2) and starts regeneration automatically.
The automatic regeneration is also performed by the direction from the engine controller at a set time
after the previous regeneration, regardless of soot accumulation in KCSF.
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT.
*2: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.
• Manual stationary regeneration
• When the exhaust temperature does not reach a certain level, depending on the operating condition of
the machine, or when the operator disables regeneration, the automatic regeneration is not performed
and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon
receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level,
depending on the operating condition of the machine. In these cases, a request for the manual station-
ary regeneration request is displayed on the machine monitor, and the operator must perform regener-
ation by the operation on the machine monitor screen.
In addition, when the engine controller is replaced or ash in KCSF is washed, a serviceman performs
regeneration by the operation on the machine monitor screen (“active regeneration for service”).
10-84 PC210LCI-11
NOTICE
• For the procedure to start and stop the regeneration of KDPF, see the Operation and Maintenance
Manual for each machine.
• Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a
failure in KDPF.
• Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the speci-
fied one is used, it can clog KDPF quickly, and that can increase fuel consumption and cause a fail-
ure in KDPF.
• Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally
and may have trouble.
• Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceram-
ic parts in it, and they may be broken by a strong impact.
• Even when soot is not accumulated much, the engine controller may start “automatic regeneration”.
This is automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is
not an abnormal operation. Automatic regeneration to maintain the function of urea SCR system nor-
mal or manual stationary regeneration takes approximately 1 hour.
• During the “automatic regeneration” and the “manual stationary regeneration”, VGT operates auto-
matically and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and ac-
cordingly the exhaust sound changes. These phenomena are not abnormal.
• During the “automatic regeneration” and the “manual stationary regeneration”, especially at low
temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This
phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since car-
bon monoxide may be generated.
• During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe
may smell different from usual. This is not abnormal phenomenon.
• During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of
the exhaust gas discharged from the exhaust pipe may increase above 650 °C. To prevent a fire,
check that there is no combustible around the exhaust pipe. Also, check that there is no person in
the blow-out direction of the exhaust gas and confirm the safety around the machine.
• KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF
when operation is continued at relatively low temperature for long hours.
• This is a function that the engine controller increases the engine exhaust temperature automatically
and performs dry operation of KCSF when the set condition is satisfied. When the automatic dry op-
eration is insufficient for the treatment, manual stationary regeneration may be required.
• The standard temperature of KDPF is shown below.
KDOC Out (KDOC out- KDPF Out (KDPF out-
KDOC In (KDOC inlet
let temperature sen- let temperature sen-
temperature sensor)
sor) sor)
While regeneration is not per-
100 to 250 °C
formed (idling state)
While regeneration is performed
100 to 250 °C 400 to 550 °C
(thermal mode: 1000 rpm)
PC210LCI-11 10-85
LAYOUT DRAWING OF COOLING SYSTEM 10 STRUCTURE AND FUNCTION
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
1: Aftercooler 4: Fuel cooler outlet

2: Fuel cooler inlet 5: Condenser
3: Fuel cooler 6: Air conditioner condenser opening and closing
bracket
10-86 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF COOLING SYSTEM
7: Oil cooler inlet 14: Oil cooler

8: Reservoir tank 15: Oil cooler outlet
9: Aftercooler outlet hose 16: Aftercooler inlet hose
10: Fan guard 17: Shroud
11: Radiator inlet hose 18: Fan clutch assembly
12: Radiator 19: Radiator outlet hose
13: Radiator cap 20: Radiator drain valve
SPECIFICATIONS OF COOLING SYSTEM

Radiator
Core type: CF90-4
Fin pitch: 3.5/2 mm
Total heat dissipation area: 60.87 m2
Cracking pressure of pressure valve: 0.05 MPa {0.5 kg/cm2}
Cracking pressure of vacuum valve: -0.005 MPa {-0.05 kg/cm2}
Oil cooler
Core type: Thickness 62
Fin pitch: 3.5/2 mm
Aftercooler
Core type: Aluminum wave
Fin pitch: 4.0/2 mm
Fuel cooler
Core type: Drawn cup
Fin pitch: 4.0/2 mm
PC210LCI-11 10-87
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 10 STRUCTURE AND FUNCTION
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH

FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH
*1: Only when air conditioner is used

*2: Control line corresponding to the control state of air conditioner is selected.
a: Hydraulic oil temperature sensor signal d: Solenoid signal
b: CAN signal (coolant temperature sensor signal, en- e: CAN signal (air conditioner fresh air temperature
gine speed sensor signal) sensor signal, air conditioner compressor signal)
c: Cooling fan speed sensor signal
1: Engine controller 3: Engine speed sensor
2: Coolant temperature sensor 4: Hydraulic oil temperature sensor
10-88 PC210LCI-11
10 STRUCTURE AND FUNCTION FAN SPEED CONTROL SYSTEM OF FAN CLUTCH
5: Air conditioner compressor 8: Machine monitor

6: Air conditioner fresh air temperature sensor 9: Pump controller
7: Air conditioner controller 10: Fan clutch
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH

• Fan speed is controlled by engine speed, hydraulic oil temperature, and coolant temperature.
• Fan speed is controlled also by outside air temperature and information of air conditioner control (air condi-
tioner compressor signal) while air conditioner is operated.
• Excess noise and fuel consumption are reduced by decreasing the fan speed when these temperatures are
low.
PC210LCI-11 10-89
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 10 STRUCTURE AND FUNCTION
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH

ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH
a: Hydraulic oil temperature sensor signal d: Solenoid signal

b: CAN signal (coolant temperature sensor signal, en- e: CAN signal (air conditioner fresh air temperature
gine speed sensor signal) sensor signal, air conditioner compressor signal)
c: Cooling fan speed sensor signal
1: Engine controller 6: Air conditioner fresh air temperature sensor
2: Coolant temperature sensor 7: Air conditioner controller
3: Engine speed sensor 8: Machine monitor
4: Hydraulic oil temperature sensor 9: Pump controller
5: Air conditioner compressor 10: Fan clutch
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH

At normal operation
The pump controller calculates the horsepower consumed by the fan, and controls engine output curves (A1)
and (B2) with the fan speed to reduce unnecessary fuel consumption.
10-90 PC210LCI-11
10 STRUCTURE AND FUNCTION ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH
Image of engine output (when fan speed varies)
At one-touch power maximizing function operation
The engine output curves (A2) and (B2) are kept constant regardless of the fan speed.
Accordingly, the horsepower consumed by the main pump varies with the fan speed.
Image of engine output (when fan speed varies)
PC210LCI-11 10-91
COMPONENT PARTS OF COOLING SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF COOLING SYSTEM

FAN CLUTCH
STRUCTURE OF FAN CLUTCH
General view
1: Connector 3: Clutch body

2: Fan 4: Shaft (engine mounted portion)
SPECIFICATIONS OF FAN CLUTCH

Type: Fluid coupling
FUNCTION OF FAN CLUTCH

Fan speed which is transmitted from the engine to the shaft is decreased by built-in fluid coupling to achieve the
target speed.
10-92 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF CONTROL SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM
Chassis part
1: Camera
PC210LCI-11 10-93
LAYOUT DRAWING OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
2: CAN terminating resistor 3: Engine controller
10-94 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF CONTROL SYSTEM
Around cab and floor
1: Machine monitor 6: Pump controller

2: Control box 7: Resistor for PC-EPC valve
3: GNSS receiver 8: KOMTRAX terminal
4: KOMTRAX communication antenna 9: Work equipment controller
5: KOMTRAX GPS antenna 10: ICT sensor controller
PC210LCI-11 10-95
MACHINE MONITOR SYSTEM 10 STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEM DIAGRAM
a: Power supply d: Drive signal

b: CAN signal e: Camera signal
c: Sensor signal and switch signal f: Image signal
1: Machine monitor 8: Wiper motor and window washer motor
2: Battery 9: Rearview camera (*1)
3: Pump controller 10: KomVision controller (*2)
4: Engine controller 11: KomVision camera (*2)
5: Air conditioner controller 12: Work equipment controller
6: KOMTRAX terminal 13: ICT sensor controller
7: Sensors and switches
*1: Machine without KomVision.
*2: Machine with KomVision.
FUNCTION OF MACHINE MONITOR SYSTEM

• The monitor system keeps the operator informed of all the machine conditions, by monitoring them by using
the sensors and switches installed in various parts of the machine and processing them instantly to display
on the machine monitor.
10-96 PC210LCI-11
10 STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
The information displayed on the machine monitor falls into the following types:
• Alarm when the machine has trouble
• Machine state display (coolant temperature, power train oil temperature, hydraulic oil temperature, fuel
level, etc.)
• Display of camera image (machine with camera)
• The switches on the machine monitor also have the functions to control the machine.
PC210LCI-11 10-97
KomVision SYSTEM 10 STRUCTURE AND FUNCTION
KomVision SYSTEM
LAYOUT DRAWING OF KOMVISION SYSTEM
Chassis part
1: R.H. front camera 3: Rear camera

2: R.H. camera 4: L.H. camera
10-98 PC210LCI-11
10 STRUCTURE AND FUNCTION KomVision SYSTEM
1: Machine monitor 2: KomVision controller
KomVision SYSTEM DIAGRAM
PC210LCI-11 10-99
KomVision SYSTEM 10 STRUCTURE AND FUNCTION
1: Machine monitor 4: Rear camera

2: KomVision controller 5: R.H. camera
3: L.H. camera 6: R.H. front camera (*1)
*1: When four cameras are installed
FUNCTION OF KomVision SYSTEM

• KomVision system is the system that captures the vision around the machine by cameras attached to the
various positions of the machine, and reflects the vision on the machine monitor.
• The machine monitor shows the bird's eye view and the camera view.
• The bird's eye view displayed on the machine monitor is an image which is electrically composed with im-
ages captured by cameras attached to the machine.
• The camera image displayed on the machine monitor is an image which is captured by camera installed to
the machine. The images to be displayed can be selected freely.
k The image displayed on the machine monitor does not reflect all around the machine. Perform the
visual check always when operating the machine.
k Do not rely only on the image displayed on the machine monitor for the safety.
k The cameras do not capture the objects which are located higher than the cameras. Be careful about
the objects which are located higher than the cameras such as a work equipment of the large ma-
chine, a branch of the tree, etc.
REMARK
• The upper part of the monitor screen does not always mean the front of the machine when the machine is
with swing function.
• The upper part of the monitor screen recognizes the work equipment side of the upper structure as the front
side, and the longitudinal and lateral directions are determined with that. The direction of the undercarriage
is not recognized.
• For the function and the method of operation of KomVision system, see “Operation and Maintenance Man-
ual”.
• Resetting of the items will be required when the blade is replaced or the track length is changed by referring
to TESTING AND ADJUSTING, "SETTING OF KomVision (MAIN SETTING)".
The area KomVision cameras can capture
The area KomVision cameras can capture for the bird's eye view varies as shown below, it depends on how
many cameras are installed to the machine.
When three cameras are installed
1: L.H. camera
2: Rear camera
3: R.H. camera
10-100 PC210LCI-11
10 STRUCTURE AND FUNCTION KomVision SYSTEM
When four cameras are installed

1: L.H. camera
2: Rear camera
3: R.H. camera
4: R.H. front camera
PC210LCI-11 10-101
KOMTRAX SYSTEM 10 STRUCTURE AND FUNCTION
KOMTRAX SYSTEM
KOMTRAX SYSTEM DIAGRAM
KOMTRAX system consists of KOMTRAX terminal, communication antenna, and GPS antenna
FUNCTION OF KOMTRAX SYSTEM

• KOMTRAX system transmits various types of information on the machine. KOMTRAX administrator sees
the information in the office and supplies various services to the customers.
• KOMTRAX system can transmits the following information.
• Positional information
• Working information
• Alarm and failure information
• Fuel consumption information
• Maintenance information
• Machine working condition information
REMARK
To provide the services, you need to establish radio station for KOMTRAX separately.
10-102 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM

MACHINE MONITOR
FUNCTION OF MACHINE MONITOR
• The machine monitor has the monitor display function, mode selection function, and switch function of the
electrical components, etc. It also has the built-in warning buzzer.
• CPU (Central Processing Unit) is mounted inside, and it processes, displays, and outputs information.
• The monitor system monitors the machine state by obtaining the information with the sensors and switches
installed in various parts of the machine, processes the information instantly to display on the machine
monitor, and informs the operator of the machine condition.
The information displayed on the machine monitor falls into the following types.
• Alarm when the machine has trouble
• Machine state display (engine coolant temperature, hydraulic oil temperature, fuel level, etc.)
• Display of camera image
• The switches on the machine monitor have functions to control the machine.
PC210LCI-11 10-103
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
REMARK
• The machine monitor consists of the display and switch section. The display is LCD (Liquid Crystal Display),
and the switch section consists of flat sheet switches.
• If there is abnormality in the machine monitor, controller, or wiring between the machine monitor and control-
ler, the machine monitor does not display normally.
• The battery voltage may drop sharply when the engine is started depending on the ambient temperature and
battery condition. In this case, the display may disappear for a while, but it is not an abnormal phenomenon.
• If environmental temperature of the machine monitor is high, brightness may be automatically reduced to
protect the liquid crystal.
• Intensity or color of the objects may change because of the automatic adjustment function of the camera.
• See “Operation and Maintenance Manual” for the following items.
• Display (screen display)
• Switches
• Guidance icons and function switches
INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR

070-18P “CM01”
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
3 GND (continuous power supply) -
4 GND (continuous power supply) -
5 External starting 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 terminal R) Input
17 (*1) -
18 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.

070-12P “CM02”
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
10-104 PC210LCI-11

4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 (*1) -
7 CAN (C) terminating resistor terminal -
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal -
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output

070-20P “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) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -

070-8P “CM04”
1 Power supply for camera (8 V) Output
2 Camera NTSC signal 1 Input
PC210LCI-11 10-105

5 GND (power supply for camera) -
6 Camera 2 normal image/mirror image selection Output
7 Camera 3 normal image/mirror image selection Output
8 GND (shield) -
10-106 PC210LCI-11
TYPES OF GAUGES AND METERS DISPLAYED ON MACHINE MONITOR

*1: The gauge pointer disappears if the gauge signal is not available due to an open circuit in the CAN commu-
nication line.
*2: Display can be switched by selecting another item in ECO Guidance → Configurations on user menu.
Gauge Item displayed Description Remarks
Monitor • Indicates corresponding tempera-
Tempera-
Range back- ture range.
ture
ground
• Alarm buzzer sounds at 105 °C
(*1) W1 105 °C Red or higher.
Engine coolant W2 102 °C Red • If monitor background color is

temperature white, warm up the engine.
W3 100 °C Blue
gauge
W4 85 °C Blue
W5 60 °C Blue
W6 30 °C White
Monitor • Indicates corresponding tempera-
Tempera-
Range back- ture range.
ture
ground
• Alarm buzzer sounds at 105 °C
(*1) H1 105 °C Red or higher.
Hydraulic oil H2 102 °C Red • If monitor background color is

temperature white, warm up the hydraulic
H3 100 °C Blue components.
gauge
H4 85 °C Blue
H5 40 °C Blue
H6 20 °C White
Monitor Indicates corresponding level range.
Range Quantity back-
ground
F1 304 ℓ Blue
(*1)
F2 245 ℓ Blue
Fuel level
gauge F3 200 ℓ Blue
F4 100 ℓ Blue
F5 60 ℓ Blue
F6 41 ℓ Red
Segment Load level Indicates instantaneous fuel consump-
tion (average of fuel consumption by 3
Light to
Green 1 to 8 seconds) in 10 steps.
(*2) medium
(Displays when ECO Guidance → Con-
ECO gauge figurations → ECO Gauge on user
Orange 9, 10 Heavy menu is set to ON.)
PC210LCI-11 10-107
Gauge Item displayed Description Remarks

Gauge Indicates corresponding level range.
Range Quantity
range
A1 100 % Green
A2 75 % Green
AdBlue/DEF A3 50 % Green
level gauge
A4 25 % Green
A5 10 % Green
A6 2.5 % Red
A7 0 % Red
Indicates accumulated engine operating
hours (alternator is generating).
Service meter 00000.0 h to 99999.9 h
(Press F4 switch to change to clock dis-
play.)
• 12-hour system display Displays time.

Clock (AM/PM) (Press F4 switch to change to service
meter display.)
• 24-hour system display
Displays average fuel consumption.

(*2) • 1 Day
(Display can be switched by selecting
Fuel consump- • Split time another item in ECO Guidance → Con-
tion gauge • None figurations → Average Fuel Consump-
tion Display on user menu.)
10-108 PC210LCI-11
TYPES OF CAUTION LAMPS DISPLAYED ON MACHINE MONITOR

Range and method for display
Item to be dis- Caution

Symbol lamp display Action level Remarks
played Range
(background display
color)
102 °C or higher Lit (red) L02 • Monitor background color
changes depending on the
30 °C or higher,
and lower than Lit (blue) - temperature detected.
102 °C • Alarm buzzer sounds when
Coolant tem-
the temperature exceeds
perature (*1)
105 °C.
Below 30 °C Lit (white) - • If monitor background color
is white, warm up the en-
gine.
102 °C or higher Lit (red) L02 • Monitor background color
changes depending on the
20 °C or higher,
and lower than Lit (blue) - temperature detected.
Hydraulic oil 102 °C • Alarm buzzer sounds when
temperature the temperature exceeds
(*1) 105 °C.
Below 20 °C Lit (white) - • If monitor background color
is white, warm up the hy-
draulic components.
Below 56 ℓ Lit (red) - Background color of monitor
changes according to fuel level.
Fuel level (*1)
56 ℓ or higher Lit (blue) -
When it is abnor- Caution lamp lights up if an ab-

Radiator cool- mal normality is detected when en-
Lit (yellow) L01 (*3) gine stops.
ant level (*1) (below specified
level)
When charging Caution lamp lights up and alarm
is faulty buzzer sounds when an abnor-
Battery charge mality is detected while engine is
(charge voltage Lit (red) L03
(*1) running.
< battery volt-
age)
When it is abnor- Caution lamp lights up and alarm
Engine oil mal buzzer sounds when an abnor-
Lit (red) L03 mality is detected while engine is
pressure (*1) (Below specified
pressure) running.

Engine oil lev- mal normality is detected when en-
Lit (yellow) L01 (*3) gine stops.
el (*1) (below specified
level)
mal normality is detected while engine
Air cleaner is is running.
(Above the Lit (yellow) L01 (*3)
clogged (*1)
specified pres-
sure)
PC210LCI-11 10-109

played Range
(background display
color)
When mainte- • The display changes de-
nance due time Lit (red) - pending on how long it has
is over passed since the mainte-
nance due time was over.
Maintenance
due time warn- • After starting switch is
ing When mainte- turned to ON position, cau-
nance notice Lit (yellow) - tion lamp lights up if condi-
time is over (*2) tion for lighting it up is sat-
isfied, and then goes out in
30 seconds.
When action lev- • Caution lamp lights up
el L04 or L03 is Lit (red) L04, L03 when an abnormality is de-
State of sys- detected tected in machine system.
tem When action lev- • When the background color
el L01 is detect- Lit (yellow) L01 (*3) of caution lamp is red, the
ed warning buzzer sounds.
el L04 or L03 is Lit (red) L04, L03 when an abnormality in en-
State of en- detected gine system is detected.
gine system When action lev- • When the background color
State of hy- detected tected in hydraulic system.
draulic system When action lev- • When the background color
el L04 or L03 is Lit (red) L04, L03 when an abnormality in
State of KDPF detected KDPF system is detected.
system When action lev- • When the background color
el L04 or L03 is Lit (red) L03 when soot is accumulated
detected inside the KDPF or clean-
Accumulation ing function is abnormally
of soot in degraded.
KDPF When action lev-
el L01 is detect- Lit (yellow) L01 (*3) • When the background color
ed of caution lamp is red, the
warning buzzer sounds.
Caution lamp lights up and warn-
Engine over- When engine ing buzzer sounds when engine
Lit (red) L02
run overruns overrun is detected.
10-110 PC210LCI-11

played Range
(background display
color)
Caution lamp lights up when an
When air condi-
State of air abnormality is detected in air con-
tioner is abnor- Lit (yellow) L01 (*3)
conditioner ditioner system.
mal
0.09 % or low Lit (red) L04 • The background color of

caution lamp changes cor-
AdBlue/DEF 2.5 % or low Lit (red) L03
responding to the fuel level.
level 10 % or low Lit (red) - • Alarm buzzer sounds at
Exceeds 10 % Lit (blue) - 2.5 % or lower.
State of AdBl- detected tected in AdBlue/DEF sys-
ue/DEF system.
tem When action lev-
• Alarm buzzer sounds when
el L01 is detect- Lit (yellow) L01 (*3)
the monitor background is
ed
red.
Engine stops High tempera- When the engine is stopped with
while the tem- ture is detected high temperature of AdBlue/DEF
perature of in AdBlue/DEF Lit (yellow) L01 (*3) being detected more than 150
AdBlue/DEF system 150 times, the caution lamp lights up.
system is high. times or more
Engine abruptly
stops 2000 times Lit (red) L03
or more
Engine abrupt- Engine abruptly
ly stops by AIS stops 1000 times
or more, and Lit (yellow) L01 (*3)
less than 2000
times
el L04 is detect- Lit (red) L04 when abnormality is detect-
ed ed in the machine.
When action lev- • When the background color
el L03 is detect- Lit (red) L03 of caution lamp is red, the
Action level
When action lev-
el L02 is detect- Lit (red) L02
ed
When action lev-
el L01 is detect- Lit (yellow) L01 (*3)
ed
abnormality caused by open cir-
When action lev-
Camera sys- cuit of cables, looseness of con-
el L01 is detect- Lit (yellow) L01
tem (*4) nectors, or abnormality of camera
ed
signals caused by disconnection
is detected.
PC210LCI-11 10-111

played Range
(background display
color)
When action lev-
Camera sys- abnormality is detected in KomVi-
tem (*4) sion system.
ed
Monitor dis- • Monitor lights up when ab-

play (back- Action level normality is detected in ICT
Range
ground col- monitor component.
or)
When action lev- the background color is
el L04 is detect- Lit (red) L04 red.
ed
ICT compo-
When action lev-
nent abnor-
mality
ed
When action lev-
ed
When action lev-
ed
Monitor dis- • Monitor lights up when ab-
play (back- Action level normality is detected in ICT
Range
ground col- monitor system.
or)
When action lev- the background color is
el L04 is detect- Lit (red) L04 red.
ed
ICT System When action lev-
Abnormality el L03 is detect- Lit (red) L03
ed
When action lev-
ed
When action lev-
ed
• Monitor lights up when cali-
ICT calibration When action lev-
bration is detected as not
has not been el L01 is detect- Lit (yellow) L01
performed yet. ed having been performed yet.
• Monitor lights up when in-

IMU initial When action lev-
ternal sensor output error is
process ab- el L00b is detect- Lit (yellow) -
normality ed detected in IMU.
10-112 PC210LCI-11

played Range
(background display
color)
Lit when none of the cylinder re-
State of cylin- Cylinder has not set for arm, boom, or bucket has
Lit (yellow) -
der function been reset. been performed after turning the
starting switch to ON position.
*1: These are included in the Check before starting items. these symbols are lit for 2 seconds after the starting
switch is turned to ON position, and returns to the standard state if no failure is found.
*2: Maintenance notice time can be changed on Maintenance Mode Display Setting of service mode.
*3: These items are lit for 2 seconds, and then go out.
*4: For machine with KomVision.
PC210LCI-11 10-113
TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR

Symbol Item displayed Description Remarks
• Operates automatically Displays the operation state of
at low temperature. preheating.
Automatic (Be lit for approx.30
preheating sec. at maximum.)
• Goes out after engine
is started.
Elapsed time
after turning
starting Monitor dis-
Preheating switch to play
HEAT (pre-
heat)
Manual pre-
heating 0 to 30 sec-
Lights up
onds
30 to 40 sec-
Flashes
onds
40 seconds
Lights off
or longer
One-touch Indicates operation state of one-
power maxi- Monitor display touch power maximizing func-
mizing switch tion.
One-touch pow- Lights up
er maximizing
ON (Goes out approx. 8.5 sec-
onds after, if held down)
OFF Lights off
Swing park- Displays operation state of swing
Swing lock Monitor dis-
ing brake lock.
switch play
cancel switch
OFF OFF Lights off
Swing lock
ON OFF Lights up
OFF ON Flashes
ON ON Flashes
INT: Intermittent operation Displays the operation state of

front window wiper.
Wiper ON: Continuous operation
Goes off: Stopped
Indicates the operation state of

Lights up: ON air conditioner and blower.
Air conditioner
Lights off: OFF
Indicates whether seat belt is

Lights up: Not fastened fastened.
Seat belt
Lights off: Fastened
Indicates the operation state of

Lights up: When engine is stopped engine.
Stopping engine
Lights off: When engine is running
10-114 PC210LCI-11
Symbol Item displayed Description Remarks

Lights up: Aftertreatment devices regenera- Indicates regeneration state of
Aftertreatment tion in progress aftertreatment devices.
devices regen-
eration Lights off: Aftertreatment devices regenera-
tion completed
• Indicates regeneration
state of aftertreatment de-
Lights up: Aftertreatment devices regenera-
Aftertreatment vices.
tion disabled
devices regen- • When manual stationary
eration disable Lights off: When aftertreatment devices re-
generation disable is canceled
regeneration is necessary,
KDPF soot accumulation
caution lamp lights up.
Displays the state of message.
Message Lights up: There is unread message.
(Unread) Lights off: No message.
Message Displays the state of message.

Lights up: There is already-read message
(No return mes- but return message for it is not sent yet.
sage, already-
Lights off: No message.
read message)
Displays operation state of auto-
Auto-decelera- Lights up: ON deceleration function.
tion Lights off: OFF
P: Heavy-duty operation Displays the set working mode.

E: Low-fuel consumption operation
L: Fine control operation
Working mode B: Breaker operation
ATT/P: 2-way attachment operation
ATT/E: 2-way attachment operation with low
fuel consumption
Lo: Low-speed travel Displays the set mode of travel

speed.
Travel speed Mi: Middle-speed travel
Hi: High-speed travel
Displays position state of lock

Lights up: Lock position lever.
Lock lever
Lights off: FREE position
• Idle stop guidance Displays the guidance to support

operation of the machine.
• Deterrence guidance of hydraulic re-
lief
• Economy mode recommended guid-
ECO guidance
ance
• Travel at reduced engine speed rec-
ommended guidance
• Low fuel level guidance
PC210LCI-11 10-115
OPERATOR MODE FUNCTION OF MACHINE MONITOR

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.
Items available in the operator mode are as follows:
*1: The operator mode items are classified as follows.
A: Display from the time when the starting switch is turned to “ON” position to the time when display changes to
the standard screen, and display after starting switch is turned to “OFF” position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches
*2: Display sequence from the time when the starting switch is turned to ON position to the time when the stand-
ard screen appears varies depending on the settings and conditions of the machine as follows:
V: When engine start lock is enabled
W: When engine start lock is disabled
X: When working mode at start is set to “Breaker mode (B)”
Y: When any abnormality is detected by the check before starting
Z: When any item is detected as the maintenance due time is over
REMARK
• For how to operate the operator mode functions, see the Operation and Maintenance Manual.
• For the operating method of the engine start lock function, see "Password setting and canceling manual".
Category Display order (*2)
Item
(*1) V W X Y Z
Display of KOMATSU logo 1 1 1 1 1
Display of password input 2 - - - -
Display of technician identification status 3 - 2 - -
Display of operator ID input screen 4 - 3 - -
Display to check breaker mode - - 4 - -
Display of check before starting 5 2 5 2 2
A
Display of warning after check before starting - - - 3 -
Display of maintenance due time over - - - - 3
Display to check working mode and travel speed 6 3 6 4 4
Display of standard screen 7 4 7 5 5
Display of engine shutdown secondary switch screen
Display of end screen
10-116 PC210LCI-11
Category Display order (*2)

Item
(*1) V W X Y Z
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Stop operation of alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner
Operation to display camera mode
B Operation to display clock and service meter
Check of maintenance information
Setting and display of user menu
• ECO Guidance
• Machine Setting
• Aftertreatment Devices Regeneration
• SCR Information
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Display of ECO guidance
Display of caution monitor
C
Display of KDPF regeneration
Display of action level and failure code
Checking function by LCD (Liquid Crystal Display)
D Function to check service meter
Function of usage limitation setting/change password
PC210LCI-11 10-117
SERVICE MODE FUNCTION OF MACHINE MONITOR

These functions are not displayed normally. A technician can display and set them special operation of
switches. These functions are used for special settings, testing, adjusting, or troubleshooting.
Items available in the service mode are as follows:
REMARK
For operating method of the service mode functions, see TESTING AND ADJISTING, “SERVICE MODE”.
Pre-defined Monitoring
Self-define Monitoring
Mechanical System Abnormality Record
Abnormality Record
Electrical System Abnormality Record
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Key-on Mode
Unit setting
Default With/Without Attachment
Camera
Auto Idle Stop Time Fixing
Cylinder Cutout Mode Operation
Active Regeneration for Service
KDPF Memory Reset
SCR Service Test
Diagnostic Tests
Engine Stop at AdBlue/DEF Inj Overheat Count Reset
Engine Controller Active Fault Clear
Ash in Soot Accumulation Correction
Reset Number of Abrupt Engine Stop by AIS
Pump Absorption Torque (F)
Pump Absorption Torque (R)
Travel Low speed
Adjustment Att Flow Adjust in Combined Ope
Calibrate F Pump Swash Plate Sensor
Calibrate R Pump Swash Plate Sensor
Fan Speed Mode Select
No-Injection Cranking
Terminal Status
KOMTRAX Settings GPS & Communication State
Modem Information
Service Message
10-118 PC210LCI-11
KomVision CONTROLLER
STRUCTURE OF KomVision CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF KOMVISION CONTROLLER

AMP-81P“CA01”
Input and output
Pin No. Signal name
signals
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
PC210LCI-11 10-119
Input and output

Pin No. Signal name
signals
14 (*1) -
15 (*1) -
16 Shield -
17 Shield -
18 Shield -
19 Shield -
20 (*1) -
21 NTSC signal output 3ch Input
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
32 (*1) -
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 Image signal system GND 3ch Input
45 (*1) -
46 (*1) -
47 (*1) -
48 (*1) -
49 (*1) -
50 (*1) -
51 (*1) -
10-120 PC210LCI-11
Input and output

Pin No. Signal name
signals
52 (*1) -
53 (*1) -
54 (*1) -
55 (*1) -
56 (*1) -
57 (*1) -
58 (*1) -
59 (*1) -
60 (*1) -
61 (*1) -
62 (*1) -
64 (*1) -
65 (*1) -
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
73 (*1) -
74 (*1) -
75 (*1) -
76 (*1) -
77 (*1) -
78 (*1) -
79 (*1) -
80 (*1) -
81 (*1) -
*1: Never connect these pins, otherwise it may cause malfunction or failures.
AMP-40P“CA02”
Input and output
Pin No. Signal name
signals
82 (*1) -
83 (*1) -
84 (*1) -
85 (*1) -
PC210LCI-11 10-121
Input and output

Pin No. Signal name
signals
86 (*1) -
87 System operating lamp output Output
88 (*1) -
89 WAKE Input
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 ACC (key input) Input
97 ACC (key input) Input
98 NTSC output GND Output
99 (*1) -
100 (*1) -
101 (*1) -
102 Shield -
103 Shield -
104 Power supply GND Input
105 Power supply GND Input
106 NTSC signal output Output
107 (*1) -
108 (*1) -
109 (*1) -
110 CAN signal + Input and output
111 CAN0 signal - Input and output
112 Continuous power supply Input
114 (*1) -
115 (*1) -
116 (*1) -
117 (*1) -
118 (*1) -
119 (*1) -
120 (*1) -
121 (*1) -
10-122 PC210LCI-11
KomVision CAMERA
STRUCTURE OF KomVision CAMERA
General view
INPUT AND OUTPUT SIGNALS OF KomVision CAMERA

DT-4P
Input and output
Pin No. Signal name
signals
1 Camera power supply Input
2 Video output Output
3 (*1) -
4 GND -
*1: Never connect these pins. It may cause malfunction or failure.
PC210LCI-11 10-123
KOMTRAX TERMINAL
STRUCTURE OF KOMTRAX TERMINAL
General view
Model: TC630/TC635
1: GPS antenna connection 4: Communication antenna connection

2: Machine harness connection (070-18P) 5: LED lamp display
3: Machine harness connection (070-12P)
FUNCTION OF KOMTRAX TERMINAL

• This terminal uses the communication technology of cell phone.
• This terminal is the wireless communication equipment which enables to transmit GPS locational informa-
tion and various machine information which is received from network signal or input signal. It can transmit
the information via communication antenna.
• The condition of KOMTRAX terminal can be checked on the “KOMTRAX Setting” screen in the service
mode of the machine monitor.
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• The terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its dis-
play section.
REMARK
• When commencing the operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice to Komatsu Ltd.
• When operating the system in Japan, it is required to install a terminal for exclusive use in Japan.
INPUT AND OUTPUT SIGNALS OF KOMTRAX TERMINAL

070-18P“CK01”
Pin No. Signal name Input and output signals
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
10-124 PC210LCI-11

9 (*1) -
10 CAN (C)_H Input and output
11 CAN (C)_L Input and output
12 (*1) -
13 (*1) -
14 External starting signal Input and output
15 System operating lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
070-12P“CK02”
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
PC210LCI-11 10-125
PUMP CONTROLLER
STRUCTURE OF PUMP CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF PUMP CONTROLLER

AMP-81P “CP01”
Pin No. Signal name Input and output
2 Continuous power supply return Input
3 Window washer Output
5 Continuous power supply return Input
6 Potentiometer power supply (5 V) Output
7 CAN(R)_H Input and output
8 Service oil pressure sensor Input
9 (*1) -
10 Boom bottom pressure sensor/R.H. lever potentiometer Sub (*2) Input
10-126 PC210LCI-11

11 Front pump oil pressure sensor Input
12 ATT1: R pressure sensor Input
13 (*1) -
14 (*1) -
15 Left travel REVERSE PPC oil pressure sensor Input
16 (*1) -
17 (*1) -
18 GND (analog signal) -
19 (*1) -
20 Swing lock switch Input
21 Model selection 3 Input
22 PPC lock solenoid valve emergency activation switch monitor signal Input
23 Breaker switch Input
24 Starting switch ACC signal Input
25 Fan speed sensor -
26 CAN(R)_L Input and output
27 (*1) -
28 Hydraulic oil temperature sensor Input
29 Boom head pressure sensor/L.H. lever potentiometer Sub (*2) Input
30 Rear pump oil pressure sensor Input
31 ATT1 L pressure sensor Input
32 (*1) -
33 (*1) -
34 Left travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) -
37 (*1) -
38 Fan clutch speed Input
39 Swing parking brake cancel switch Input
41 PPC lock solenoid valve monitor signal Input
42 One-touch power maximizing switch Input
44 Pulse signal return -
45 CAN(C)_H Input and output
46 GND (analog signal) Input
47 (*1) -
48 R.H. lever potentiometer Main (*2) Input
49 Front pump swash plate sensor Input
PC210LCI-11 10-127

50 (*1) -
51 (*1) -
52 Counterweight remover pressure sensor (*3) Input
53 Right 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
64 CAN(C)_L Input and output
65 (*1) -
66 (*1) -
67 L.H. lever potentiometer Main (*2) Input
68 Rear pump swash plate sensor Input
69 (*1) -
70 (*1) -
71 (*1) -
72 Right 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 PPC lock switch (solenoid side) Input
79 PPC lock switch (starting motor side) Input
81 (*1) -
*2: Machine with proportional lever
*3: Machine with counterweight remover only
AMP-40P“CP02”
82 (*1) -
10-128 PC210LCI-11

83 (*1) -
84 PPC lock relay Output
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 2nd service EPC-L (*2) Output
88 LS-EPC valve Output
89 Merge-divider EPC valve (LS) Output
90 (*1) -
91 BR cut-off relay -
92 (*1) -
93 Travel speed increase solenoid valve Output
94 2-stage swing relief solenoid valve Output
95 2nd service EPC-R (*2) Output
96 Front pump PC-EPC valve Output
97 Attachment flow adjustment EPC valve Output
98 Fan reverse solenoid valve Output
99 Fan clutch PWM solenoid valve Output
100 System-in-use signal Output
101 Swing parking brake solenoid valve Output
102 1st service EPC-L (*2) Output
103 Fan pump EPC -
104 Rear pump PC-EPC valve Output
105 (*1) -
106 Driving relay for arm crane (revolving lamp) Output
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 1st service EPC-R (*2) Output
111 (*1) -
112 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
PC210LCI-11 10-129
*2: Machine with proportional lever
10-130 PC210LCI-11
RESISTOR FOR PC-EPC VALVE

PC
Abbreviation for Pressure Compensation
EPC
Abbreviation for Electromagnetic Proportional Control
STRUCTURE OF REGISTER FOR PC-EPC VALVE

General view
1: Resistor 2: Connector
SPECIFICATIONS OF RESISTOR FOR PC-EPC VALVE

Resistance: 20 Ω
FUNCTION OF RESISTOR FOR PC-EPC VALVE

It allows a proper current to flow to EPC valve, according to the condition, when the pump drive secondary
switch s turned to “ON” position.
REMARK
No current flows normally.
PC210LCI-11 10-131
CAN TERMINATING RESISTOR

CAN
Abbreviation for Controller Area Network
STRUCTURE OF CAN TERMINATING RESISTOR

General view
1: Connector (with built-in resistor)
SPECIFICATIONS OF CAN TERMINATING RESISTOR

Resistance: 120 Ω
FUNCTION OF CAN TERMINATING RESISTOR

This function is used to suppress reflection of the high-frequency signals at the CAN communication line termi-
nal so that noises are not mixed in the CAN communication signals sent and received between each terminals.
REMARK
If the CAN terminating resistor is not installed, CAN communication errors occur and the operator cannot oper-
ate the machine.
10-132 PC210LCI-11
ENGINE CONTROLLER
STRUCTURE OF ENGINE CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER

Delphi96Pin “ECM J1”
Ground/Shield/
1 Injector #1 (-)
Return
Ground/Shield/
2 Injector #2 (-)
Return
Ground/Shield/
3 Injector #3 (-)
Return
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 Sensor power supply relay Output
Ground/Shield/
10 IMV (-)
Return
11 IMV (+) Output
PC210LCI-11 10-133

12 (*1) -
13 EGR valve solenoid (+) Output
14 (*1) -
15 (*1) -
Ground/Shield/
16 Turbocharger speed (-)
Return
17 Turbocharger speed (+) Input
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 (*1) -
24 (*1) -
25 Injector #1 (+) Output
28 (*1) -
29 (*1) -
30 (*1) -
31 Engine NE speed sensor Input
32 Mass air flow (MAF) sensor Input
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
41 (*1) -
42 Common rail pressure sensor Input
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 (*1) -
47 (*1) -
48 (*1) -
10-134 PC210LCI-11

52 Engine oil pressure switch Input
53 (*1) -
Ground/Shield/
54 GND
Return
Ground/Shield/
55 GND
Return
Ground/Shield/
56 GND
Return
Ground/Shield/
57 GND
Return
Ground/Shield/
58 GND
Return
59 (*1) -
60 (*1) -
61 Mass air flow and temperature sensor Input
62 Charge temperature sensor Input
63 Crank case pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 VGT position sensor Input
68 (*1) -
69 CAN_C (+) Communication
70 Datalink3 (+) (KOMNET/r) Communication
71 (*1) -
72 (*1) -
Ground/Shield/
73 Injector #4 (-)
Return
Ground/Shield/
74 Injector #5 (-)
Return
Ground/Shield/
75 Injector #6 (-)
Return
Ground/Shield/
76 EGR valve solenoid (-)
Return
77 (*1) -
78 Sensor 5V power supply Power supply
PC210LCI-11 10-135

83 Coolant temperature sensor Input
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
88 EGR valve lift sensor Input
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 CAN_C (-) Communication
94 Datalink3 (-) (KOMNET/r) Communication
95 (*1) -
96 (*1) -

Delphi96Pin “CE02/ECM J2”
1 Power supply (+24 V, continuous) Power supply
Ground/Shield/
2 VGT solenoid (-)
Return
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/ AdBlue/DEF pump driver Input/ Output
7 AdBlue/DEF line heater relay 2 Output
8 Sensor 5 V power supply Power supply
9 Sensor 5 V power supply Power supply
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 Water-in-fuel sensor Input
14 (*1) -
15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
10-136 PC210LCI-11

21 Datalink4 (+) (sensor controller) Communication
22 Datalink4 (+) (KOMNET/c) Communication
23 (*1) -
24 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
Ground/Shield/
32 GND
Return
Ground/Shield/
33 GND
Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater Diag1 Input
39 AdBlue/DEF line heater Diag2 Input
40 (*1) -
41 KDPF differential pressure sensor Input
42 KDPF outlet pressure sensor Input
(*1): Machine equipped with fuel control dial
43 -
Idle validation switch 2: Machine with accelerator pedal
(*1): Machine equipped with fuel control dial
44 -
Idle validation switch 1: Machine with accelerator pedal
45 Datalink4 (-) (Sensor controller) Communication
46 Datalink4 (-) (KOMNET/c) Communication
47 (*1) -
Ground/Shield/
49 Power GND
Return
Ground/Shield/
50 Power GND
Return
Ground/Shield/
51 Power GND
Return
Ground/Shield/
52 Power GND
Return
PC210LCI-11 10-137

Ground/Shield/
53 AdBlue/DEF injector (-)
Return
Ground/Shield/
54 GND
Return
55 (*1) -
56 Ambient temperature sensor Input
Ground/Shield/
57 GND
Return
58 (*1) -
59 (*1) -
60 (*1) -
Ground/Shield/
61 GND
Return
62 (*1) -
63 (*1) -
64 (*1) -
65 Engine room temperature sensor Input
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
Ground/Shield/
73 Power GND
Return
74 (*1) -
75 Intake air heater relay (+) Output
76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
79 AdBlue/DEF pump voltage Output
80 VGT solenoid (+) Output
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -
87 (*1) -
10-138 PC210LCI-11

88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -
PC210LCI-11 10-139
FUEL CONTROL DIAL

STRUCTURE OF FUEL CONTROL DIAL
The fuel control dial is installed to R.H. console box.
1: Potentiometer 3: Knob
2: Spring
FUNCTION OF FUEL CONTROL DIAL
When knob (3) is turned, the shaft of potentiometer (1) rotates. The resistance of variable resistor in potentiome-
ter (1) varies according to this rotation, and throttle signals are sent to the controller.
10-140 PC210LCI-11
REMARK
The hatched area in the following graph is the abnormality de-
tection area. When the throttle voltage is in this area, the en-
gine speed is set to low idle.
PC210LCI-11 10-141
FUEL FEED PUMP

STRUCTURE OF FUEL FEED PUMP
General view
A: Fuel inlet B: Fuel outlet

1: Body 3: Bracket
2: Rubber 4: Connector
FUNCTION OF FUEL FEED PUMP

The fuel feed pump is controlled and driven by the engine controller or fuel feed pump switch in the following
cases.
• Increase the fuel pressure during fuel dosing process. (Controlled by engine controller)
• Bleed air from the fuel line (on engine side). (Controlled by fuel feed pump switch)
10-142 PC210LCI-11
FUEL FEED PUMP SWITCH

STRUCTURE OF FUEL FEED PUMP SWITCH
General view
1: Body 3: LED lamp

2: Toggle switch 4: Connector
FUNCTION OF FUEL FEED PUMP SWITCH

• This switch receives signals from the engine controller and drives the fuel feed pump.
• The fuel feed pump is driven to bleed air from the fuel line by operating the toggle switch, when the fuel
filter is replaced, etc.
Air in the fuel line is bled by driving the fuel feed pump for the set time of the built-in timer.
• When the starting switch is at OFF position, the fuel feed pump is driven in the following pattern; Pump is
driven (30 seconds) → Pump is stopped (10 seconds). After 10 cycles of this pattern, the pump is stopped
automatically.
PC210LCI-11 10-143
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
10-144 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYDRAULIC SYSTEM
1: Hydraulic tank 7: Front pump oil pressure sensor

2: Fuel supply pump 8: Variable back pressure solenoid valve
3: Engine controller 9: Travel junction solenoid valve
4: Control valve 10: Solenoid valve
5: Merge-divider EPC valve (for main spool) 11: 2-stage relief solenoid valve
6: Merge-divider EPC valve (for LS spool) 12: Rear pump oil pressure sensor
PC210LCI-11 10-145
13: Main pump 16: Rear pump PC-EPC valve

14: Front pump swash plate sensor 17: LS-EPC valve
15: Rear pump swash plate sensor 18: Front pump PC-EPC valve
10-146 PC210LCI-11
19: Bucket CURL sensor 23: Bucket DUMP sensor

20: Boom LOWER sensor 24: Boom RAISE sensor
21: Swing RIGHT sensor 25: Swing LEFT sensor
22: Arm IN sensor 26: Arm OUT sensor
PC210LCI-11 10-147
1: Machine monitor 2: Fuel control dial
10-148 PC210LCI-11
3: Pump controller 7: L.H. travel FORWARD pressure sensor

4: Resistor for PC-EPC valve 8: L.H. travel REVERSE pressure sensor
5: One-touch power maximizing switch 9: R.H. travel REVERSE pressure sensor
6: R.H. travel FORWARD pressure sensor 10: Service pressure switch
11: Pump drive secondary switch
PC210LCI-11 10-149
CLSS 10 STRUCTURE AND FUNCTION
CLSS
CLSS
Abbreviation for Closed-center Load Sensing System
STRUCTURE OF CLSS
• CLSS consists of main pump, control valves, and respective actuators.
• The main pump consists of a pump body, PC valve, and LS valve.
1. Variable displacement piston pump
It is 2 pump type with front and rear, and controls the flow rate by changing the swash plate angle.
2. Servo piston
Piston actuates in accordance with the inlet pressure to change the pump swash plate angle.
3. Valve for control of swash plate angle
1) PC valve (Power Constant)
It prevents the engine from stopping by the large load on the engine.
2) LS Valve (Load Sensing)
It controls the pump flow rate in accordance with the travel of control lever.
10-150 PC210LCI-11
10 STRUCTURE AND FUNCTION CLSS
4 4
5 5
6 6
7 7
10
9 9
8 8
A4P15701
1: Actuator 6: PC valve
2: Control valve 7: LS valve
3: Merge-divider valve 8: Servo piston
4: Main relief valve 9: Pump
5: Unload valve 10: Engine
Unload valve
It returns the minimum discharged volume from the pump to the tank (although the flow amount is little, there is
no place for this oil to go) at neutral.
PC210LCI-11 10-151
OPERATION OF UNLOAD VALVE AND LS PRESSURE

Operation of unload valve and LS pressure
• When lever is in NEUTRAL
When lever is in NEUTRAL, spool is closed and the oil in
pump circuit has no where to go, so it opens unload valve
(2) and drain to the tank (unload pressure). LS pressure
(PLS) transmitted to the spring chamber is drained to the
tank through LS bypass valve (3), and it become to 0 MPa.
Note) The pressure is for PC200-10
1 2
PP
3.9MPa
F + PLS
3.9Mpa 0Mpa
A4P15702
• When lever is operated (before relief)

When lever is operated, spool opens and cylinder is acti-
vated. LS pressure (PLS) is transmitted to the spring
chamber of unload valve (2), and it is closed by LS pres- PLS
sure + set pressure {spring force (F)}. 13Mpa
1 2
PP
15MPa
F + PLS
3.9Mpa 13Mpa
A4P15703
10-152 PC210LCI-11
• At relief
When cylinder comes to the stroke end, pump pressure
(PP) and LS pressure (PLS) increases to the main relief
pressure. Unload valve stays closed.
1 2
PP
34.8MPa
F + PLS
3.9Mpa 34.8Mpa
A4P15704
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL

FUNCTION OF PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL
• The pump swash plate angle (pump discharged volume) is so controlled that LS differential pressure
(ΔPLS), which is the differential pressure between pump discharged pressure (PP) and control valve outlet
LS pressure (actuator load pressure), is constant.
“LS differential pressure (ΔPLS) = Pump discharged pressure (PP) - LS pressure (PLS)” = Constant
• The pump swash plate shifts toward the maximum angle position when LS differential pressure (ΔPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• The pump swash plate shifts toward the minimum angle position when LS differential pressure is higher
than the set pressure (when the actuator load pressure is low).
PC210LCI-11 10-153
OPERATION OF PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL

When lever is in NEUTRAL
2
4
1
5 6
7
8 Min.
Max.
A
Max. Min.
10
(Large ¢PLS) (Small ¢PLS)
16 13
Balanced
11
(Large PP) (Small PP)
15 12
Balanced
14
A4P15706
1: PPC valve 2: Hydraulic cylinder
10-154 PC210LCI-11
3: Control valve 10: LS valve

4: Spool 11: PC valve
5: 2-stage relief valve 12: PC-EPC valve
6: Unload valve 13: LS-EPC valve
7: LS bypass valve 14: Controller
8: Main pump 15: Self-pressure reducing valve
9: Seavo piston 16: 2-stage relief solenoid valve
PC210LCI-11 10-155
When balanced
2
4
1
5 6 7
8 Min.
Max.
A
Max. Min.
Balanc ed 10
16 13
11
15 12
Balanced
14
4AP15707
10-156 PC210LCI-11
When lever is returned to fine control state

2
4
1
5 6 7
8 Min.
Max.
A
Max. Min.
10
16 13
Balanced
11
15 12
Balanced
14
4AP15708
PC210LCI-11 10-157
When lever is pulled at a stroke

2
4
1
5 6 7
8 Min.
Max.
A
Max. Min.
10
16 13
Balanced
11
15 12
Balanced
14
4AP15709
10-158 PC210LCI-11
When lever is in stroke end

2
4
1
5 6 7
8 Min.
Max.
A
Max. Min.
10
16 13
Balanced
Balanc ed 11
15 12
14
4AP15710
PC210LCI-11 10-159
FUNCTION OF LS VALVE
• LS valve controls the pump flow rate so that the LS differ- PP Decrease Increase
ential pressure (ΔPLS = PP - PLS) is constant. Pump Flow Pump Flow
PLS
• As ΔPLS lowers, it increases the pump flow rate, and as
ΔPLS rises, it decrease the pump flow rate. The spring
force regulates the set pressure of LS differential pressure. LS-EPC Pressure
Balanced
• When the command current from the controller increases,
the LS-EPC valve lowers the set pressure of LS differential A4P15711
pressure by increasing the LS-EPC output pressure, and
decreases the pump discharged volume.
• LS-EPC command current is o mA at the normal operation, however it increases when the control lever is
in NEUTRAL or when travel Lo or Mi is selected or when L mode is setting.
• When the lever is in NEUTRAL, LS pressure is 0 mA. Accordingly, the LS valve is fixed at left position and
the swash plate angle of pump becomes minimum. (pump pressure > spring force)
Relation between travel of lever and differential pressure
• Flow (Q) is in proportion to "(A) x Pressure difference (ΔP)". Accordingly, if the flow rate is constant;
(1) Area is small → Pressure difference is large
(2) Area is large → Pressure difference is small
• LS valve increases and decreases the flow rate until the differential pressure becomes to the set pressure,
and returns to the balanced position.
• LS valve controls the pump discharged volume to keep the LS differential pressure at constant.
• Pump discharged volume is controlled so be in proportion to travel of lever.
Differential pressure is large
Differential pressure is small
¢P
¢P
A A
Small Lever Stroke Large Lever Stroke
Decrease Increase
Pump Flow Pump Flow
A4P15712
10-160 PC210LCI-11
LS valve principle (ΔPLS is canstant)
Harf stroke
Balanced at ΔPLS set pressure Return to fine control quickly Incline to full quickly
ΔPLS Large ΔPLS Small
ΔPLS
open or close
control
Pump LS
Spool
pressure pressure
Flow rate decreases Flow rate increases

and balanced and balanced
Min ΔPLS ΔPLS
Max
LS valve
+ + Spring = ΔPLS
A4P15713
FUNCTION OF PC VALVE
• It controls the engine output horsepower and pump absorbing horsepower to be constant to prevent the en-
gine from stopping.
• When pump pressure (PP) increases, PC valve moves to the right against springs 1 and 2, and decreases
the pump discharged volume.
• PC-EPC command current increases PC-EPC output pressure, and the PC-EPC output pressure pushes
PC valve to the right against spring. This function enables the pump absorbs 100 % of engine horsepower.
• Pump controller controls the PC-EPC current to keep the engine speed at constant by the signal of engine
speed sensor.
PC210LCI-11 10-161
Spring 1 + Spring 2
P
Engine stall
Spring 1
Engine horse power

PC valve
PP
Decrease Q
Pump Flow
Spring 2
Spring 1
PC-EPC
Pressure
A4P15714
P-Q DIAGRAM AND PC VALVE

1. When pump pressure is low
Pump (1) swash plate angle becomes maximum and flow rate becomes maximum.
1
Max
2 P
3 A
4
5 6
Q
A4P15744
2. Range A in P-Q diagram

Service piston (2) and follow up link (3) are mechanically connected.
As the swash plate angle decreases, follow up link (3) pushes back PC valve spool (4) to the center.
10-162 PC210LCI-11
PC valve spool (4) is balanced.
2 A
P
3
4
5 6
Q
A4P15745
3. Range A in P-Q diagram

The pump pressure increases further, and springs (6) are compressed.
PC valve spool (4) moves to the right, and pump pressure is transmitted to the large diameter side of piston
(2).
2 A
P
3
4
5 6
Q
A4P15746
4. Range B in P-Q diagram

As the pump pressure increases further and compressed spring (6) reaches to the stroke end, only spring
(5) is applied.
PC210LCI-11 10-163
The swash plate angle decreases slowly.
2 P
3
4
5 6
Q
A4P15747
5. Electronic control by PC-EPC valve

In addition to the mechanical control by springs (5), (6) electronic control by PC-EPC valve (8) is prepared
in order to match to the engine horsepower setting.
If PC valve (4) fails, the engine stops due to the excessive pump absorption horsepower.
Controller (7) changes the command current in order to shift the working mode to P, E, B or L.
Engine horsepower
Q
7
4
5 6
9
A4P15748
10-164 PC210LCI-11
FUNCTION OF PC-EPC VALVE AND LS-EPC VALVE

Engine pump control (working mode)
• P,ATT mode hyperbola shows the setting to use maximum Cut-OFF
output of engine for hydraulic system, and indicates “Pres- P,ATT
sure (P) x Discharged volume (Q) = Constant = Engine
E
Pump discharged pressure P

output”.
• Command current from the controller to the PC-EPC valve B
PC-EPC
and LS-EPC valve decreases the pump absorbing horse- Current
power and maximum pump discharged volume. The com-
mand current increases and the discharged volume de- L
creases.
• When E, B or L is selected for the working mode, the set-
tings of engine speed and pump absorbing horsepower
are decreased simultaneously by the controller. LS-EPC
Current
• When the command current is increased and L mode is
selected, LS-EPC valve controls to decrease the maximum Pump discharge amount Q
discharged volume.
• When the pressure sensor detects the high pressure close
to the max. set pressure, it is cut off by PC-EPC valve. A4P15716
Travel control
• As travel speed selector switch is switched to Hi, Mi or Lo, ( /min)
command current from controller changes, and the output
Pump discharge amount Q
Lo (800mA)
pressure from LS-EPC valve to LS valve changes, and
Mi (460mA)
pump discharged volume change point “LS differential
pressure (PLS)” in the LS valve changes. Hi (0mA)
• The start-up time of the pump discharged volume is opti-

mized and the combined operation and fine control per-
formance are improved.
(MPa {kg/cm2})
LS differential pressure ΔPLS A4P15717
Cut-off function
• This function increases PC-EPC current to reduce the flow rate in the relief state and improve the fuel econ-
omy.
• Operating condition 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.
It does not operate when machine is traveling or swing lock switch is “ON”.
PC210LCI-11 10-165
PRESSURE COMPENSATION CONTROL

FUNCTION OF PRESSURE COMPENSATION CONTROL
• Pressure compensation valves (2) (2 pieces) are installed A B
at outlet of the downstream and return side of main spool W W
(4) by each actuator (1).
1 1
• The highest LS pressure is transmitted to the back of all
pressure compensation valves (2), and light load side is C
throttled. 2 2
• When it is throttled until all pressure compensation valves 3 3
(2) are balanced, the differential pressures before and after
main spool (4) become the same. Δ P 4 Δ P
S1 S2
• As a result, the flow rate control in proportion to the travel 5 4
of levers (3) in the combined operation becomes available
without influenced by the load.
A: Heavy load
B: Light load 6
C: LS circuit
7
1: Actuator
2: Pressure compensation valves A4P15718
3: Levers
4: Main spool
5: LS shuttle valve
6: Main pump
7: Servo piston
• If the pressure compensation valve is not installed, ••• A B
CLSS is a parallel circuit, so light load side (B) actuates W W
earlier than heavy load side (A). As a result, performance 1 1
of the simultaneous operation becomes worse.
3 3
4
Δ P 4 Δ P
S1 S2
A4P15719
10-166 PC210LCI-11
LS SELECT VALVE
LS
Abbreviation for Load Sensing
FUNCTION OF LS SELECT VALVE

The illustration shows the state of simultaneous operation of swing and travel RIGHT. (It shows the state when
pilot pressure (BP) is supplied)
1: Valve 4 3 2 1
2: Spring
B A
3: Piston BP
ࠕONࠖ 5
4: Piston
Swing
5: Swing valve spool
P1
6: R.H. travel valve spool
7: Arm valve spool
8: LS shuttle valve 6
9: LS circuit P2
8
• It prevents entry of the high LS pressure from the swing
circuit into the LS circuit of the work equipment valve at the
combined operation of swing and travel RIGHT.
7
• It prevents high pressure which is generated when the ma- P3
chine swings, and improves operability of the work equip-
ment.
9
A4P15729
PC210LCI-11 10-167
OPERATION OF LS SELECT VALVE

When pilot pressure (BP) is cut off (OFF)
1. Since pilot pressure (BP) is cut off, piston (3) is pressed to 4 3 2 B 1 A
the left by the reaction force of spring (2).
2. When the swing operation is performed, swing LS pres-
sure (P1) passes through swing spool (5) and enters port
(A).
3. Swing LS pressure (P1) pushes valve (1) to the left, and P1
port (A) is connected to port (B).
4. Swing LS pressure (P1) flows from port (A) through port
(B) to LS shuttle valve.
When pilot pressure (BP) is supplied (ON)
1. When pilot pressure (BP) is supplied, it moves piston (3) to To Shuttle valve
the right against the reaction force of spring (2).
2. When piston (3) moves to the right, valve (1) disconnect
port (A) from port (B).
4 3 2 B 1 A
3. Since port (A) is disconnected from port (B), swing LS
pressure (P1) does not flow to LS shuttle valve.
4. Even swing LS pressure (P1) increases, it does not affect
other LS circuits.
P1
To Shuttle valve
A4P15730
10-168 PC210LCI-11
10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM
ENGINE AND PUMP COMBINED CONTROL SYSTEM

ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM
a: Front pump PC-EPC valve drive signal g: Oil pressure sensor signal
b: Rear pump PC-EPC valve drive signal h: One-touch power maximizing switch signal
c: Solenoid valve GND i: Oil pressure switch signal
d: CAN signal j: 1st throttle signal
e: LS-EPC valve drive signal k: Fuel supply pump control signal
f: Swash plate sensor signal l: Various sensor signals
1: Battery disconnect switch 11: Pump drive secondary switch
2: Battery 12: Fuel control dial
3: Battery relay 13: Fuel supply pump
4: Fusible link 14: Various sensors
5: Fuse box 15: Front pump swash plate sensor
6: Resistor for PC-EPC valve 16: Rear pump swash plate sensor
7: Pump controller 17: One-touch power maximizing switch
8: Pump controller 18: Front pump oil pressure sensor
9: Engine controller 19: Rear pump oil pressure sensor
10: Machine monitor 20: Oil pressure sensor
PC210LCI-11 10-169
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
21: Oil pressure switch 23c: PC valve

22: Front pump 24: Control valve
22a: Servo 24a: Self-pressure reducing valve
22b: LS valve 24b: Merge-divider valve
22c: PC valve 24c: Travel junction valve
23: Rear pump 25: Front pump PC-EPC valve
23a: Servo 26: Rear pump PC-EPC valve
23b: LS valve 27: LS-EPC valve
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM

Working mode selection function
• This function allows the operator to select one from the 6
working modes of P, E, L, ATT-P, ATT-E, and B by using
the working mode selector switch on the machine monitor.
The operator can select the optimum engine torque (T)
and pump absorption torque according to the contents of
work. When Without Attachment is selected at the initial
setting of service mode, 4 modes of P, E, L and B are
available.
• The pump controller calculates the pump absorption upper
limit torque corresponding to the engine speed set with the
working mode and the fuel control dial and the actual en-
gine speed, and controls the pump so that the engine
speed is kept around the matching point set in each mode
even when heavy load is applied.
• When the engine speed decreases, it reduces the pump
absorption torque to prevent the engine from stalling.
10-170 PC210LCI-11
Control method in mode P, E, ATT-P, and ATT-E

Working mode Matching point
P, ATT-P (at opera-
99.7 kW/1700 rpm {134 HP/1700 rpm}
tion)
E, ATT-E (at opera-
85.2 kW/1680 rpm {114 HP/1680 rpm}
tion)
• In mode P, E, ATT-P, or ATT-E, the engine speed is kept

around the matching point set in each mode.
• When the load is light, the engine operates in high speed
range. As the load increases, the engine speed is de-
creased and the torque is increased to a matching point
where the torque is balanced with the pump absorption up-
per limit torque (PT). [(1) in graph]
• If the load increases further, the engine speed decreases
further as well. [(2) in graph]
• The controller decreases pump absorption upper limit tor-
que (PT) to reduce the load applied to the engine. [(3) in
the graph]
• As the load on the engine decreases, the engine speed in-
creases. [(4) in the graph]
• The controller increases pump absorption upper limit tor-
que (PT) to keep the engine speed at around the matching
point. [(5) in the graph]
• The controller controls the engine so that the engine
matching speed (Nm) is decreased when the load is light
(low flow rate and low torque) to improve the fuel economy.
[(6) in graph]
PC210LCI-11 10-171
Control method in mode B and L

Working mode Partial output
B 75 %
L 70 %
Working mode Matching point

B 77.2 kW/1655 rpm {104 HP/1655 rpm}
L 73.55 kW/1650 rpm {98.6 HP/1650 rpm}
• In B mode or L mode, engine output is kept constant.

• The controller controls pump absorption upper limit torque
(PT) so that the engine torque is kept constant along the
equal engine horsepower curve.
10-172 PC210LCI-11
Control function when traveling

• When the machine travels in P mode or ATT-P mode, en-
gine speed (N) increases.
• When the machine travels in mode E, ATT-E, or B, the
working mode is kept as it is, and the pump absorption tor-
que and engine speed (N) increase as in traveling in mode
P.
• When the machine travels in mode L, the working mode
and engine speed (N) are kept as they are, and the pump
absorption torque increases.
Control function when pump drive secondary switch is ON

If abnormality should occur in the controller, etc., and the main pump does not operate normally and machine
does not work, the operator can temporarily work with absorption torque equivalent to mode E by operating
pump drive secondary switch (1). At this time, since a constant current flows from the battery to PC-EPC valve,
control is performed by only sensing the oil pressure by PC-EPC valve.
REMARK
Pump drive secondary switch (1) is alternative type. If the operator operates the machine with this switch at the
Emergency (a) position while the machine is normal, action level L03 appears on the display.
PC210LCI-11 10-173
a: Emergency (when abnormal) b: Normal (when normal)
10-174 PC210LCI-11
10 STRUCTURE AND FUNCTION PUMP AND VALVE CONTROL SYSTEM
PUMP AND VALVE CONTROL SYSTEM

PUMP AND VALVE CONTROL SYSTEM DIAGRAM
a: Front pump PC-EPC valve drive signal h: Merge-divider EPC valve (for LS spool) drive signal
b: Rear pump PC-EPC valve drive signal i: Travel junction solenoid valve drive signal
c: Solenoid valve GND j: 2-stage relief solenoid valve drive signal
d: CAN signal k: Variable back pressure solenoid valve drive signal
e: LS-EPC valve drive signal l: 1st throttle signal
f: Swash plate sensor signal m: Fuel supply pump control signal
g: Merge-divider EPC valve (for main spool) drive sig- n: Various sensor signals
nal
1: Battery disconnect switch 9: Machine monitor
2: Battery 10: Pump drive secondary switch
3: Battery relay 11: Fuel control dial
4: Fusible link 12: Fuel supply pump
5: Fuse box 13: Various sensors
6: Resistor for PC-EPC valve 14: Front pump swash plate sensor
7: Pump controller 15: Rear pump swash plate sensor
8: Engine controller 16: Front pump
PC210LCI-11 10-175
PUMP AND VALVE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
16a: Servo 18d: Main relief valve

16b: LS valve 18e: Variable back pressure valve
16c: PC valve 19: Front pump PC-EPC valve
17: Rear pump 20: Rear pump PC-EPC valve
17a: Servo 21: LS-EPC valve
17b: LS valve 22: Merge-divider EPC valve (for main spool)
17c: PC valve 23: Merge-divider EPC valve (for LS spool)
18: Control valve 24: Travel junction solenoid valve
18a: Self-pressure reducing valve 25: 2-stage relief solenoid valve
18b: Merge-divider valve 26: Variable back pressure solenoid valve
18c: Travel junction valve
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM

LS control function
• The output pressure from LS-EPC valve to LS valve is changed and the switching point of pump discharged
volume in LS valve [LS set differential pressure (DLS)] is changed, according to the operation method of the
actuator.
• The start-up time of the pump discharged volume is optimized and the combined operation and fine control
performance are improved.
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 in the relief state and improve the fuel econo-
my.
The cut-off function operates when the one-touch power maximizing function is OFF and the average value of
the oil pressure sensors of the front pump and rear pump is 27.9 MPa {285 kg/cm2} and above. However, it
does not operate when the swing lock switch is ON during travel in P mode.
A: PC-EPC power supply when cut-off function operates
2-stage relief function

When the operating conditions of 2-stage relief function are satisfied, the relief pressure during work increases.
10-176 PC210LCI-11
10 STRUCTURE AND FUNCTION PUMP AND VALVE CONTROL SYSTEM
Operating conditions of 2-stage relief function Relief pressure

• During travel
• When swing lock switch is ON 34.8 MPa {355 kg/cm2}
• When boom is lowered ↓
• When one-touch power maximizing function operates 37.2 MPa {380 kg/cm2}
• In L mode
Variable back pressure function

The set pressure of the back pressure valve varies depending on the operating conditions of the machine.
Operating condition Setting of back pressure valve
During swinging or travel High-pressure set
During state other than swinging or travel Low-pressure set
PC210LCI-11 10-177
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM

HYDRAULIC TANK
STRUCTURE OF HYDRAULIC TANK
1: Main pump 6: Breather

2: Hydraulic tank 7: Bypass valve
3: Oil filler cap 8: Strainer
4: Sight gauge 9: Filter element
5: Drain plug 10: Suction strainer
SPECIFICATIONS OF HYDRAULIC TANK

Hydraulic tank capacity: 190 ℓ
Hydraulic tank refill capacity: 132 ℓ
Bypass valve set pressure: 0.25 ± 0.05 MPa {2.5 ± 0.5 kg/cm2}
HYDRAULIC TANK OIL FILLER CAP

STRUCTURE OF HYDRAULIC TANK OIL FILLER CAP
Sectional view
1: Bottom plate
2: Gasket
10-178 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM
FUNCTION OF HYDRAULIC TANK OIL FILLER CAP

Prevention of pressure rise in hydraulic tank
While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and the
temperature in the hydraulic tank rise corresponding to the operation of the hydraulic cylinders. When the pres-
sure in the tank exceeds the set pressure, bottom plate (1) is pushed up to release the pressure in the tank and
prevent pressure rise.
(Set pressure of exhaust valve: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2} )
HYDRAULIC TANK BREATHER

STRUCTURE OF HYDRAULIC TANK BREATHER
Sectional view
1: Nut
2: Cover
3: Filter element
4: Case
5: Valve assembly
6: Body
FUNCTION OF HYDRAULIC TANK BREATHER

Prevention of negative pressure in hydraulic tank
Since the hydraulic tank is pressurized and sealed, if the oil level in it decreases, negative pressure is generated
in it. At this time, valve assembly (5) is opened by the differential pressure from the ambient pressure, and ambi-
ent pressure is transmitted into the tank to prevent generation of negative pressure in the tank
(Set pressure of intake valve: 2 ± 0.3 kPa {0.02 ± 0.003 kg/cm2} )
PC210LCI-11 10-179
MAIN PUMP
STRUCTURE OF MAIN PUMP
Model: HPV125 + 125
10-180 PC210LCI-11
General view
IMF: Front pump PC mode selector current ISIG: LS set pressure selector current
IMR: Rear pump PC mode selector current PAF: Front pump discharge port
PC210LCI-11 10-181
PAR: Rear pump discharge port PLSF: Front pump load pressure input port
PBF: Front pump pressure input port PLSFC: Front pump load pressure pickup port
PD3R: Air bleeder PLSR: Rear pump load pressure input port
PD1R: Case drain port PLSRC: Rear pump load pressure pickup port
PD2F: Drain plug PMF: Front pump PC mode selector pressure pickup
PD2R: Drain plug port
PENF: Front pump control pressure pickup port PMR: Rear pump PC mode selector pressure pickup
port
PENR: Rear pump control pressure pickup port
PRC: Rear pump discharged pressure pickup port
PEPC: EPC source pressure input port
PS: Pump suction port
PEPB: EPC source pressure pickup port
PSIG: LS set selector pressure pickup port
PFC: Front pump discharged pressure pickup port
1: Front pump 7: Rear pump swash plate sensor
2: Rear pump 8: Front pump LS valve
3: LS-EPC valve 9: Rear pump LS valve
4: Front pump PC-EPC valve 10: Front pump swash plate sensor
5: Rear pump PC-EPC valve 11: Front pump PC valve
6: Rear pump PC valve
10-182 PC210LCI-11
Sectional view
a: Spline
1: Front shaft 9: End cap
2: Cradle 10: Rear shaft
3: Front case 11: Rear case
4: Rocker cam 12: PC valve
5: Shoe 13: Servo piston
6: Piston 14: Slider
7: Cylinder block 15: Bearing
8: Valve plate 16: LS valve
PC210LCI-11 10-183
Structure
• Cylinder block (7) is supported on front shaft (1) by spline (a).

• Front shaft (1) is supported on the front and rear bearings (15).
• The end of piston (6) is a concave sphere, and it is made in one with crimped shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Shoe (5) is kept pressed against surface (A) of rocker cam (4) and slides in a circular pattern.
• Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to the case. High-pressure oil is supplied
between them to form a static pressure bearing.
• Piston (6) moves relatively in the axial direction in each cylinder chamber of cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
The oil pressure is balanced properly on this surface.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
10-184 PC210LCI-11
FUNCTION OF MAIN PUMP
It converts the engine speed and torque transmitted to pump front shaft (1) into hydraulic pressure and dis-
charges pressurized oil, according to the load. The discharged volume can be changed by changing the swash
plate angle.
PC210LCI-11 10-185
OPERATION OF MAIN PUMP

Discharged volume selection (swash plate angle selection)
1. Cylinder block (7) rotates together with shaft (1) and shoe
(5) slides on plane (A).
2. Rocker cam (4) pivots on cylindrical surface of cradle (2),
and accordingly swash plate angle (a) between center line
(X) of rocker cam (4) and the axis of cylinder block (7)
changes.
Suction and discharge of pressurized oil

1. While angle (a) is made between center line (X) of rocker
cam (4) and the axis of cylinder block (7), plane (A) works
as a cam for shoe (5).
2. Piston (6) slides inside cylinder block (7) and a difference
is made between volumes (E) and (F) in cylinder block (7).
3. Amount of (F) minus (E) per piston (6) is suctioned and
discharged.
4. Pressurized is discharged while cylinder block (7) rotates
and the volume of chamber (E) decreases.
5. Oil is suctioned as the volume of chamber (F) increases.
Condition where no pressurized oil is suctioned or discharged (swash plate an-

gle = 0)
1. When center line (X) of rocker cam (4) matches the axis of
cylinder block (7) (the swash plate angle is zero), the dif-
ference between volumes (E) and (F) inside cylinder block
(7) is zero.
2. Suction and discharge of pressurized oil are not performed
in this stage. Namely pumping action is not performed.
(Angle of swash plate never become zero.)
10-186 PC210LCI-11
Control of discharged volume

1. The swash plate angle (a) increases, the difference be-
tween volumes (E) and (F) increases, and also pump dis-
charged volume (Q) increases.
2. Swash plate angle (a) is changed by servo piston (13).
3. Servo piston (13) moves in a linear reciprocating motion
corresponding to the signal pressure from the PC valve
and LS valve.
This linear reciprocating motion is transmitted to rocker
cam (4) through slider (14).
4. Rocker cam (4) supported on the cylindrical surface of cra-
dle (2) slides and pivots on that surface.
5. Output pressure (PEN) of LS valve is supplied to the pres-
sure chamber on large diameter piston side.
6. The pressure receiving areas on the right and left sides of
servo piston (13) are different, and discharged pressure
(self pressure) (PP) of the main pump is constantly sup-
plied to the pressure chamber on the small diameter piston
side.
7. The movement of servo piston (13) is controlled by the dif-
ference between pressure (PP) on the small diameter pis-
ton side and pressure (PEN) on the large diameter piston
side and the ratio of the pressure receiving area between
the small diameter piston and large diameter piston.
PC210LCI-11 10-187
MAIN PUMP LS VALVE

LS
STRUCTURE OF MAIN PUMP LS VALVE

Sectional view
PA: Pump port PP: Pump port

PDP: Drain port PPL: Control pressure input port
PLP: LS control pressure output port PSIG: LS mode selector pilot port
PLS: LS pressure input port
1: Sleeve 5: Seat
2: Piston 6: Sleeve
3: Spool 7: Plug
4: Spring 8: Lock nut
FUNCTION OF MAIN PUMP LS VALVE

• The LS (load sensing) valve detects the load of the actuator and controls the pump discharged volume.
• This valve controls pump discharged volume (Q) according to differential pressure (∆PLS) = “(PP) - (PLS)”
(called LS differential pressure) between pump discharged pressure (PP) and control valve outlet port pres-
sure (PLS).
• This valve receives main pump pressure (PP), pressure (PLS) (called LS pressure) from the control valve
output, and pressure (PSIG) (called LS set selector pressure) from the proportional solenoid valve.
• The relationship between differential pressure (∆PLS) =
“(PP) - (PLS)”, the difference between main pump pres-
sure (PP) and LS pressure (PLS), and discharged volume
(Q) varies with LS set pressure selector current (ISIG) of
LS-EPC valve as shown in the figure.
• When (ISIG) varies from 0A to 1A, the set pressure of the
spring changes, and the selector point for pump dis-
charged volume changes as shown in the figure below.
10-188 PC210LCI-11
OPERATION OF MAIN PUMP LS VALVE

When control valve is in neutral position
1. LS valve is a 3-way selector valve, and LS pressure (PLS) at the control valve outlet (actuator load pres-
sure) is supplied to spring chamber (B), and pump discharged pressure (PP) is supplied to port (H) of
sleeve (8).
The position of spool (6) is decided by the difference between the force caused by LS pressure (PLS), the
force of spring (4), and the force caused by pump discharged pressure (self-pressure) (PP).
However, the position of spool (6) also varies with the level of output pressure (OSIG) (called the LS set
select pressure) of EPC valve for LS valve which enters port (G). (The set force of the spring changes.)
2. Before the engine is started, servo piston (12) is pushed to
the left. (See the figure below.)
3. When the engine is started, if the control lever is in neutral,
LS (PLS) is 0 MPa {0 kg/cm2} . (It is connected to the drain
circuit through the control valve spool.)
4. Spool (6) is pushed to the right and port (C) and port (D)
are connected.
5. Pump discharged pressure (PP) enters the large diameter
piston side from port (K).
6. The same pump discharged pressure (PP) also enters port
(J) on small diameter piston side.
PC210LCI-11 10-189
7. Servo piston (12) moves in the direction to minimize the swash plate angle (rightward direction), depending
on the area difference in servo piston (12). (See the previous figure.)
When pump discharged volume is increased
1. When the difference between pump discharged pressure (PP) and LS pressure (PLS), or LS differential
pressure (∆PLS), decreases (for example, when the open area of the control valve increases and pump dis-
charged pressure (PP) decreases), the combined force of LS pressure (PLS) and force of spring (4) pushes
spool (6) to the left.
2. As spool (6) moves, port (D) is connected to port (E) and connected to PC valve.
3. PC valve is connected to the drain port, and the line between ports (D) and (K) is set to drain pressure (PT).
(The operation of PC valve is explained later.)
4. Since the pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT) and
pump pressure (PP) is constantly supplied to port (J) on the small diameter piston side, servo piston (12) is
pushed to the left and moves the swash plate in the direction to increase the discharged volume.
5. If the output pressure of EPC valve for LS valve enters port (G) at this time, a force occurs on the right side
of piston (7).
6. If piston (7) is pushed to the right, the set force of spring (4) is reduced, and LS differential pressure (∆PLS)
“difference between oil pressures (PLS) and (PP)” changes when ports (D) and (E) of spool (6) are con-
nected.
10-190 PC210LCI-11
When pump discharged volume is decreased
1. When servo piston (12) moves to the right (in the direction to reduce the discharged volume) and LS differ-
ential pressure (∆PLS) increases (for example, when the open area of the control valve decreases and
pump discharged pressure (PP) increases), the force caused by pump discharged pressure (PP) pushes
spool (6) to the right.
2. As spool (6) moves, pump discharged pressure (PP) flows through port (C) to port (D), and then through
port (K) to the large diameter piston side.
3. Pump discharged pressure (PO) also enters port (J) on small diameter piston side, but servo piston (12) is
pushed to the right because of the area difference between large diameter piston side and small diameter
piston side of servo piston (12). As a result, the swash plate angle is decreased further.
4. When LS set select pressure (PSIG) enters port (G), the set force of spring (4) is decreased.
PC210LCI-11 10-191
When servo piston is balanced

The pressure receiving area on the large diameter piston side is set as (A1), that on the small diameter piston
side as (A0), and the pressure entering the large diameter piston side as (PEN).
1. When main pump pressure (PP) of LS valve is balanced with the combined force of LS pressure (PLS) and
spring (4) and (A0) x (PP) = (A1) x (PEN), servo piston (12) stops at that position.
2. The pump swash plate is held at an intermediate position. “It stops at a position where the open area be-
tween port (D) and port (E) of spool (6) is almost equal to that between port (C) and port (D).”
3. The relationship between the pressure receiving areas at both ends of servo piston (12) is (A0):(A1) = 3:5.
Under the balanced state, the ratio of the pressures applied to both ends is (PP) : (PEN)C 5 : 3.
4. The force of spring (4) is so adjusted that the balanced and stopped position of spool (6) is decided when
(PP) - (PLS) = 1.7 MPa {17.75 kg/cm2} at the standard center.
5. When (PSIG) “output pressure of LS-EPC valve, 0 to 2.9 MPa {30 kg/cm2} ” is applied to port (G), the bal-
anced position changes in the range of (PP) - (PLS) = 1.7 MPa {17.75 kg/cm2} to 0.27 MPa {2.78 kg/cm2} ,
in proportion to pressure (PSIG).
10-192 PC210LCI-11
MAIN PUMP PC VALVE

PC
STRUCTURE OF MAIN PUMP PC VALVE

Sectional view
PA: Pump port PM: Mode selector pressure pilot port

PA2: Pump pressure pilot port PPL: Control pressure output port (to LS valve)
PDP: Drain port
1: Plug 5: Retainer
2: Servo piston assembly 6: Seat
3: Pin 7: Cover
4: Spool 8: Wire ring
FUNCTION OF MAIN PUMP PC VALVE

• The PC valve limits the oil flow to a certain level depending on the discharged pressure, even if the travel of
the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed the
engine horsepower, when pump discharged pressures (PP1) (self pressure) and (PP2) (the other pump
pressure) are high.
• When the load increases and the pump discharged pressure (PP) also increases during work, the pump
discharged volume is reduced.
• When the pump discharged pressure decreases, the pump discharged volume is increased.
The relation between the average of front and rear pump
discharged pressures “(PP1) + (PP2)”/2 and pump dis-
charged volume (Q) in this case is shown in the figure be-
low by using current values (X) given to PC-EPC valve sol-
enoid as parameters.
• When the load increases and the rotation speed decreas-
es, the pump discharged volume is decreased to recover
the rotation speed.
• When the load increases and the engine speed drops be-
low the set value, the command current from the controller
PC210LCI-11 10-193
to PC-EPC valve solenoid increases according to the decrease of the engine speed, and the pump inclina-
tion angle decreases.
• The controller counts the actual engine r.p.m.
OPERATION OF MAIN PUMP PC VALVE

Function of PC-EPC valve solenoid (1) when pump controller is normal and ac-
tuator load is low and pump pressures (PP1) and (PP2) are low
• Command current (X) flows from the pump controller into PC-EPC valve solenoid (1).
Command current (X) acts on PC-EPC valve and outputs signal pressure to change the force to push pis-
ton (2).
• Spool (3) stops at a position where the spring set force of springs (4) and (6) is balanced with the combined
force of pump pressures (PP1) (self pressure) and (PP2) (pressure of the other pump) which pushes spool
(3).
The pressure output from PC valve “Pressure in port (C)” varies, depending on the above position.
• The level of command current (X) depends on the contents of work (lever operation), selected working
mode, and set value and actual value of the engine speed.
REMARK
The other pump pressure means the pressure of the pump on the opposite side.
The other pump pressure for the front pump is the rear pump pressure, and that for the rear pump is the front
pump pressure.
10-194 PC210LCI-11
Function of spring when pump controller is normal and actuator load is low and
pump pressures (PP1) and (PP2) are low
• The spring load of springs (4) and (6) in the PC valve is determined by the angle of the swash plate.
• When servo piston (9) moves to the right, spring (6) is compressed.
When the servo piston moves to the right further, it touches seat (5) and spring (6) is fixed.
After this, only spring (4) operates.
• Servo piston (9) expands or compress springs (4) and (6) to change the spring loads.
• When command current (X) input to PC-EPC valve solenoid (1) changes, the force pressing piston(2)
changes.
• The spring loads of springs (4) and (6) also varies with command current (X) of PC-EPC valve solenoid.
• Port (C) of PC valve is connected to port (E) of LS valve.
• Self-pressure (PP1) enters the small diameter piston side of servo piston (9) and port (B), and other pump
pressure (PP2) enters port (A).
• When pump pressures (PP1) and (PP2) are low, spool (3) is at the left position.
• Port (C) is connected to port (D), and the pressure entering LS valve becomes drain pressure (PT).
• When port (E) and port (G) of LS valve are connected, the pressure entering from port (J) to large diameter
piston side becomes drain pressure (PT), and servo piston (9) moves to the left.
The pump discharged volume increases.
• As servo piston (9) moves, springs (4) and (6) expand, and their reaction forces decrease.
PC210LCI-11 10-195
When the reaction forces of the springs decrease, spool (3) moves to the right, port (C) is disconnected
from port (D), and pump discharged pressure port (B) is connected to port (C).
Since the pressure in port (C) increases and the pressure on the large diameter piston side increases, ser-
vo piston (9) stops moving to the left.
The stop position (= pump discharged volume) of servo piston (9) is determined by the position where the
thrust caused by pressures (PP1) and (PP2) applied to spool (3) is balanced with the thrust of PC-EPC
valve solenoid and forces of springs (4) and (6).
When pump controller is normal and actuator load is high and pump pressures
(PP1) and (PP2) are high
• When the load is high and pump discharged pressures (PP1) and (PP2) are high, the force pushing spool
(3) to the right increases and spool (3) is positioned as shown in the previous figure.
• Part of the pressure from port (B) flows through LS valve and port (C) to port (D) as shown in the previous
figure, and the pressure flowing from port (C) to LS valve becomes approximately half of pump pressure
(PP2).
• When spool (3) moves to the left, the openings of port (C) and port (D) increase further.
• The pressure (= J) in port (C) decreases and servo piston (9) stops moving to the right.
At this time, servo piston (9) stops at a position on the right side of the position when pump pressures (PP1)
and (PP2) are low.
• When port (E) of LS valve and port (G) are connected, this pressure enters from port (J) to the large diame-
ter piston side of servo piston, and servo piston (9) stops.
10-196 PC210LCI-11
• When pump pressure (PP2) increases further and spool (3) moves to the right further, pump pressure
(PP1) flows to port (C) to minimize the discharged volume.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3).
• The positional relationship between average of pump pressures (PP1 + PP2)/2 and servo piston (9) is an-
gled since springs (4) and (6) are 2-stage springs.
• The relationship between average of pump pressures
(PP1 + PP2)/2 and average of pump discharged volume
(Q) is shown in the figure below.
• When command current (X) sent to PC-EPC valve sole-
noid (1) increases, the relationship between average of
pump pressures (PP1 + PP2)/2 and pump discharged vol-
ume (Q) is translated in proportion to the thrust of PC-EPC
valve solenoid.
• Since the thrust of PC-EPC valve solenoid (1) is added to

the rightward thrust caused by the pump pressure applied
to spool (3), the relationship between average of pump
pressures (PP1 + PP2)/2 and pump discharged volume
(Q) is translated from (A) to (B) as command current (X) in-
creases.
PC210LCI-11 10-197
When secondary pump drive switch is turned ON due to failure in pump control-
ler and main pump load is low
1. If the pump controller fails, turn the secondary pump drive switch ON and switch to the resistor side.
At this time, the power is supplied directly from the battery. Since the current is too high, the resistor is in-
serted to control the current flowing to PC-EPC valve solenoid (1).
Since the current is stabilized, the force pressing piston (2) is stabilized.
2. When main pump pressures (PP1) and (PP2) are low, the combined force of the force of PC-EPC valve
solenoid (1) and pump pressure is lower than the spring set force, and accordingly spool (3) is balanced at
the left side.
3. Port (C) is connect to the drain pressure in port (D). The large diameter piston side of servo piston (9) is
also set to the drain pressure (PT) through LS valve.
4. Since the pressure on the small diameter piston side is high, servo piston (9) moves in the direction to in-
crease the discharged volume.
10-198 PC210LCI-11
When secondary pump drive switch is turned ON due to failure in pump control-
ler and main pump load is high
1. Similarly to the above explanation, when the secondary pump drive switch is ON, command current (X)
sent to PC-EPC valve solenoid (1) is constant.
Accordingly, the piston (2) pushes spool (3) with a constant force.
2. When main pump pressures (PP1) and (PP2) increase, spool (3) moves right more, compared with when
the main pump load is low, and is balanced at the position shown in the previous figure.
3. Since the pressure from port (B) flows in port (C), servo piston (9) moves to the right (small discharged vol-
ume) and the pump stops on a more right position than when the pump load is low.
4. When secondary pump drive switch is ON, the curve of pump discharged pressure (PP) and discharged
volume (Q) is decided for the current supplied to PC-EPC valve solenoid through the resistor, as shown in
the figure.
PC210LCI-11 10-199
The curve when the secondary pump drive switch is ON

(B) is on the left side of the curve when the pump control-
ler is normal (A).
10-200 PC210LCI-11
MAIN PUMP LS-EPC VALVE

LS
EPC
STRUCTURE OF MAIN PUMP LS-EPC VALVE

C: To LS valve T: To hydraulic tank

P: From self-pressure reducing valve
1: Connector 5: Spool
2: Coil 6: Rod
3: Body 7: Plunger
4: Spring
PC210LCI-11 10-201
FUNCTION OF MAIN PUMP LS-EPC VALVE

Upon receiving signal current (i) from the pump controller, this
valve generates EPC output pressure in proportion to that sig-
nal current and outputs it to LS valve.
OPERATION OF MAIN PUMP LS-EPC VALVE

When signal current from pump controller is zero (coil de-energized)
1. When the signal current from the controller is not flowing
through coil (2), coil (2) is de-energized.
2. Spool (5) is pushed to the left by spring (4).
3. Port (P) is closed, and the pressurized oil from the self-
pressure reducing valve does not flow to LS valve.
4. The pressurized oil from LS valve is drained to the tank
through port (C) and port (T).
10-202 PC210LCI-11
When signal current from pump controller is low (coil energized)

1. When low signal current flows through coil (2), coil (2) is
energized and generates thrust to push plunger (7) to the
right.
2. Rod (6) pushes spool (5) to the right, and the pressurized
oil from port (P) flows to port (C).
3. When the pressure in port (C) increases, the total of the
force acting on the surface of spool (5) and the reaction
force of spring (4) becomes larger than the thrust of plung-
er (7).
4. Spool (5) is pushed to the left, and port (P) is disconnected
from port (C).
5. Port (C) is connected to port (T).
6. Spool (5) so moves that the thrust of plunger (7) is bal-
anced with the total of the pressure in port (C) and the re-
action force of spring (4).
7. The circuit pressure between the EPC valve and the LS
valve is controlled in proportion to the amperage of the sig-
nal current.
When signal current from pump controller is maximum (coil energized)

1. When signal current flows through coil (2), coil (2) is ener-
gized.
Since the signal current is maximum at this time, the thrust
of plunger (7) is also maximum.
2. Spool (5) is pushed to the right by spring (6).
3. The pressurized oil flows from port (P) to port (C) at the
maximum rate, and the circuit pressure between the EPC
valve and LS valve is maximized.
4. Since port (T) closes, the pressurized oil does not flow into
the tank.
PC210LCI-11 10-203
MAIN PUMP PC-EPC VALVE

PC
EPC
STRUCTURE OF MAIN PUMP PC-EPC VALVE

C: To PC valve T: To hydraulic tank

1: Connector 5: Spool
2: Coil 6: Rod
3: Body 7: Plunger
4: Spring
10-204 PC210LCI-11
FUNCTION OF MAIN PUMP PC-EPC VALVE

Upon receiving signal current (i) from the pump controller, it
generates EPC output pressure in proportion to that signal cur-
rent and outputs it to the PC valve.
OPERATION OF MAIN PUMP PC-EPC VALVE

When signal current from pump controller is zero (coil de-energized)
1. When the signal current from the pump controller does not
flow through coil (2), coil (2) is de-energized.
2. Spool (5) is pushed to the left by spring (4).
3. Port (P) is closed, and the pressurized oil from the self-
pressure reducing valve does not flow to PC valve.
4. The pressurized oil from PC valve is drained to the tank
through port (C) and port (T).
PC210LCI-11 10-205
When signal current from pump controller is low (coil energized)

1. When low signal current flows through coil (2), coil (2) is
energized and generates thrust to push plunger (7) to the
right.
2. Rod (6) pushes spool (5) to the right, and the pressurized
oil from port (P) flows to port (C).
3. When the pressure in port (C) increases, the total of the
force acting on the surface of spool (5) and the reaction
force of spring (4) becomes larger than the thrust of plung-
er (7).
4. Spool (5) is pushed to the left, and port (P) is disconnected
from port (C).
5. Port (C) is connected to port (T).
6. Spool (5) so moves that the thrust of plunger (7) is bal-
anced with the total of the pressure in port (C) and the re-
action force of spring (4).
7. The circuit pressure between the EPC valve and the PC
valve is controlled in proportion to the amperage of the sig-
nal current.
When signal current from pump controller is maximum (coil energized)

1. When signal current flows through coil (2), coil (2) is ener-
gized.
Since the signal current is maximum at this time, the thrust
of plunger (7) also becomes maximum.
2. Spool (5) is pushed to the right by spring (6).
3. The pressurized oil flows from port (P) to port (C) at the
maximum rate, and the circuit pressure between the EPC
valve and PC valve is maximized.
4. Since port (T) closes, the pressurized oil does not flow into
the tank.
10-206 PC210LCI-11
CONTROL VALVE
STRUCTURE OF CONTROL VALVE
• The control valves of the following types are available.
6-spool valve (without service valve)
7-spool valve (6-spool valve + service valve)
• The control valve consists of a 6-spool valve (integrated) and a service valve, and the merge-divider valve,
variable back pressure valve, and boom hydraulic drift prevention valve are installed to it.
• Since these valves are formed in one unit with connecting bolts and the passages are connected inside, the
control valve is compact and serviced very easily.
• Since this control valve is of actuator-to-spool type, its structure is simple.
The structure of the 7-spool valve (6-spool valve + service valve) is explained below.
PC210LCI-11 10-207
General view
A1: To bucket cylinder head A2: To L.H. travel motor
10-208 PC210LCI-11
A3: To boom cylinder bottom P9: From travel PPC valve (right travel REVERSE)
A4: To swing motor P10: From travel PPC valve (right travel FORWARD)
A5: To R.H. travel motor P11: From L.H. work equipment PPC valve (arm OUT)
A6: To arm cylinder head P12: From L.H. work equipment PPC valve (arm IN)
A-1: To attachment P-1: From R.H. attachment PPC valve
ATT: From attachment P-2: From R.H. attachment PPC valve
B1: To bucket cylinder bottom PLS1: To rear pump LS valve
B2: To L.H. travel motor PLS2: To front pump LS valve
B3: To boom cylinder head PLSC: LS pressure pickup port
B4: To swing motor PP1: From rear pump
B5: To R.H. travel motor PP2: From front pump
B6: To arm cylinder bottom PP1S: Front pump pressure sensor mounting port
B-1: To attachment PPC: Pilot source pressure pickup port
BP1: From LS select solenoid valve PP2S: Rear pump pressure sensor mounting port
BP5: From attachment selector solenoid valve PPS2: To front pump LS valve
C: To oil cooler PR: To solenoid valve, PPC valve, and EPC valve
P1: From R.H. work equipment PPC valve (bucket PST: From travel junction solenoid valve
DUMP) PX1: From 2-stage relief solenoid valve
P2: From R.H. work equipment PPC valve (bucket PX2: From 2-stage relief solenoid valve
CURL)
T: To hydraulic tank
P3: From travel PPC valve (L.H. travel REVERSE)
T1: To hydraulic tank
P4: From travel PPC valve (L.H. travel FORWARD)
TS: To hydraulic tank
P5: From R.H. work equipment PPC valve (boom
RAISE) TSW: From swing motor
P6: From R.H. work equipment PPC valve (boom IS1: Signal for driving merge-divider EPC valve (main
LOWER) spool)
P7: From L.H. work equipment PPC valve (swing IS2: Signal for driving merge-divider EPC valve (LS
RIGHT) spool)
P8: From L.H. work equipment PPC valve (swing IS3: Signal for driving variable back pressure solenoid
LEFT) valve
1: Variable back pressure valve 7: Service valve

2: Variable back pressure solenoid valve 8: Cover A
3: Merge-divider EPC valve (for LS spool) 9: 7-spool valve
4: Merge-divider EPC valve (for main spool) 10: Arm quick return valve
5: Arm hydraulic drift prevention valve 11: Cover B
6: Boom hydraulic drift prevention valve 12: Merge-divider valve
PC210LCI-11 10-209
Sectional views (A-A, B-B)
1: Pressure compensation valve (arm OUT) 2: Pressure compensation valve (right travel RE-
VERSE)
10-210 PC210LCI-11
3: Pressure compensation valve (swing RIGHT) 13: Pressure compensation valve (arm IN)
4: Pressure compensation valve (boom RAISE) 14: Main relief valve
5: Pressure compensation valve (left travel RE- 15: Unload valve
VERSE) 16: Main relief valve
6: Pressure compensation valve (bucket DUMP) 17: Spool (service)
7: Pressure compensation valve (service) 18: Spool (bucket)
8: Pressure compensation valve (bucket CURL) 19: Spool (left travel)
9: Pressure compensation valve (left travel FOR- 20. Spool (boom)
WARD)
21: Spool (swing)
10: Pressure compensation valve (boom LOWER)
22: Spool (right travel)
11: Pressure compensation valve (swing LEFT)
23: Spool (arm)
12: Pressure compensation valve (right travel FOR-
WARD)
PC210LCI-11 10-211
Sectional views (C-C, D-D)
1: Suction valve (arm OUT) 6: Suction safety valve (service)

2: Suction valve (right travel REVERSE) 7: 2-stage suction safety valve (service)
3: Suction valve (boom RAISE) 8: Suction safety valve (bucket CURL)
4: Suction valve (left travel REVERSE) 9: Suction valve (left travel FORWARD)
5: Suction safety valve (bucket DUMP) 10: Suction safety valve (boom LOWER)
10-212 PC210LCI-11
11: Suction valve (right travel FORWARD) 16: LS shuttle valve (boom)
12: Suction safety valve (arm IN) 17: LS shuttle valve (left travel)
13: LS shuttle valve (arm) 18: LS shuttle valve (bucket)
14: LS shuttle valve (right travel) 19: LS shuttle valve (service)
15: LS selector valve 20: LS check valve
Sectional views (E-E, F-F, G-G, H-H, AM-AM)
PC210LCI-11 10-213
1: Unload valve
2: Suction safety valve for hydraulic drift prevention valve (boom RAISE and arm OUT)
3: Main relief valve
4: Variable back pressure valve
Arm valve
5: Arm hydraulic drift prevention valve
6: LS shuttle valve
7: Arm quick return valve
8: Pressure compensation valve (arm IN)
9: Spool
10: Suction safety valve (arm IN)
11: Cooler check valve
12: Check valve for regeneration circuit
13: Suction valve (arm OUT)
14: Pressure compensation valve (arm 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
21: LS selector valve
22: Pressure compensation valve (left)
23: Spool
24: Pressure compensation valve (right)
10-214 PC210LCI-11
Sectional views (J-J, K-K, L-L, M-M)
1: Return spring
2: Merge-divider valve (for LS)
3: Valve (sequence valve)
4: Spring (sequence valve)
5: Merge-divider valve (main)
PC210LCI-11 10-215
6: Return spring
Boom valve
7: Boom hydraulic drift prevention valve
8: LS shuttle valve
9: Pressure compensation valve (LOWER)
10: Spool
11: Suction safety valve (LOWER)
12: Check valve for regeneration circuit
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 (bucket CURL)
25: Spool
26: Suction safety valve (bucket CURL)
27: Suction safety valve (bucket DUMP)
28: Pressure compensation valve (bucket DUMP)
10-216 PC210LCI-11
Sectional views (N-N, AB-AB, AC-AC, AE-AE)
1: LS shuttle valve 5: Suction safety valve

2: Pressure compensation valve 6: Unload valve
3: Spool 7: Main relief valve
4: 2-stage suction safety valve 8: LS bypass plug
PC210LCI-11 10-217
HYDRAULIC CIRCUIT DIAGRAMS OF CONTROL VALVE AND NAMES OF

VALVES
1: Arm valve 3: Swing valve

2: R.H. travel valve 4: Boom valve
10-218 PC210LCI-11
5: L.H. travel valve 33: Main relief valve (boom, L.H. travel, bucket, and
6: Bucket valve attachment)
7: Service valve Set pressure: 35.4 ± 0.5 MPa {360.5 ± 5 kg/cm2}

8: Arm valve spool When digging force is increased: 37.5 ± 0.5 MPa {382
± 5 kg/cm2}
9: R.H. travel valve spool
34: Main relief valve (arm, R.H. travel, and swing)
10: Swing valve spool
Set pressure: 35.4 ± 0.5 MPa {360.5 ± 5 kg/cm2}
11: Boom valve spool
When digging force is increased: 37.5 ± 0.5 MPa {382
12: L.H. travel valve spool ± 5 kg/cm2}
13: Bucket valve spool 35: Unload valve (boom, L.H. travel, bucket, and at-
14: Service spool tachment)
15: Pressure compensation valve Cracking pressure2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
16: Suction valve 36: Unload valve (arm, R.H. travel, and swing)
17: Check valve (for boom regeneration circuit) Cracking pressure2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
18: Check valve (for arm regeneration circuit) 37: Suction safety valve
19: Merge-divider EPC valve (for LS spool) Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
20: Merge-divider EPC valve (for main spool) 38: Suction safety valve
21: LS shuttle valve Set pressure: 38.9 ± 0.5 MPa {397 ± 5 kg/cm2}
22: LS bypass plug 39: Suction safety valve
23: LS selector valve Set pressure: 31.4 ± 0.5 MPa {320 ± 5 kg/cm2}
24: Merge-divider valve 40: 2-stage suction safety valve
25: Arm quick return valve 1st-stage set pressure: 29.9 ± 0.5 MPa {305 ±
26: Arm hydraulic drift prevention valve 5 kg/cm2}
27: Self-pressure reducing valve 2nd-stage set pressure: 24.5 ± 0.5 MPa {250 ±
5 kg/cm2}
28: Travel junction valve
41: Suction safety valve for hydraulic drift prevention
29: Variable back pressure valve
valve
30: Variable back pressure solenoid valve
Set pressure: 38.9 ± 0.5 MPa {397 ± 5 kg/cm2}
31: Cooler check valve
32: Boom hydraulic drift prevention valve
PC210LCI-11 10-219
PRESSURE COMPENSATION VALVE OF CONTROL VALVE

FUNCTION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE
The bucket valve (cylinder bottom), arm Hi valve (cylinder bottom), and service valve in this machine have re-
spective built-in pressure compensation valves.
When load pressure is higher than other actuator in combined operation, in sin-
gle operation, or at maximum load pressure
1: Main pump 4: Piston

2: Valve 5: Spring
3: Shuttle valve 6: LS shuttle valve
• The pressure compensation valve works as a load check valve.
• When pump pressure (LS pressure) is lower than the load on port (c), shuttle valve (3) in pressure compen-
sation valve piston (4) connects spring chamber (E) and port (c).
• Piston (4) and valve (2) are moved in the closing direction by the force of spring (5).
• When high peak pressure occurs in the actuator circuit or when continuous repeated pressure occurs (ex-
ample: when the breaker is used), valve (2) collides with valve chamber seat (C), and high pressure can
occur.
10-220 PC210LCI-11
To prevent this, the pressure compensation valve having

valve (2) and piston (4) as one unit in it is used.
When load pressure is lower than other actuators during combined operation,
or when compensated

2: Valve 5: Spring
3: Shuttle valve 6: LS shuttle valve
• The pressure compensation valve is closed by LS pressure in port (D), and the spool meter-in downstream
pressure at port (B) becomes equal to the maximum pressure in the other actuator.
• Since the spool meter-in upstream pressure at port (A) is the pump pressure, the spool meter-in differential
pressure “Upstream pressure (Port (A) pressure) - Downstream pressure (Port (B))” is the same in all the
spools in operation.
• The pump discharged volume is divided at the meter-in opening area ratio.
PC210LCI-11 10-221
OPERATION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE

When load pressure is lower than it of other work equipments during combined
operation, or when compensated
1. Spring chamber (E) is interconnected with port (D).

2. Piston (4) and valve (2) move in the closing direction (right side) with the LS circuit pressure from other
work equipment of port (F).
3. The valve upstream pressure (= spool meter-in downstream pressure) at port (B) is controlled by LS pres-
sure.
10-222 PC210LCI-11
SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE OF CONTROL

VALVE
FUNCTION OF SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE
OF CONTROL VALVE
• The oil flow division state varies according to the surface area ratio of portion (A1) and portion (A2) of the
pressure compensation valve. Surface area ratio = (A2)/(A1)
• When the surface area ratio is 1, the spool meter-in downstream pressure is equal to the maximum load
pressure, and the oil flow is divided according to the surface area ratio.
• When the surface area ratio is larger than 1, the spool meter-in downstream pressure is higher than the
maximum load pressure, and the oil flow is divided less than the surface area ratio.
• When the surface area ratio is smaller than 1, the spool meter-in downstream pressure is lower than the
maximum load pressure, and the oil flow is divided more than the surface area ratio.
PC210LCI-11 10-223
SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF CONTROL VALVE

STRUCTURE OF SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF
CONTROL VALVE
During travel
1: Main pump 5: Pressure compensation valve

Since no holding pressure occurs in port (A) of the travel circuit, pressure compensation valve (5) having no
shuttle valve is employed.
10-224 PC210LCI-11
OPERATION OF SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF

CONTROL VALVE
When holding pressure in port (A) exceeds LS pressure in spring chamber (B)

2: Valve 5: Pressure compensation valve
3: Shuttle valve
1. Shuttle valve (3) is pressed to the right by port (A) pressure and disconnects ports (A) and (C).
2. The holding pressure in port (A) is supplied to spring chamber (B) and presses piston (4) to the left so that
piston (4) and valve (2) do not separate from each other.
PC210LCI-11 10-225
INTRODUCTION OF LS PRESSURE IN CONTROL VALVE

LS
FUNCTION OF INTRODUCTION OF LS PRESSURE IN CONTROL VALVE
1: Main pump 5: Check valve

2: Main spool 6: LS circuit
3: Pressure compensation valve 7: LS shuttle valve
4: Valve
• The upstream pressure of pressure compensation valve (3) (spool meter-in downstream pressure) is intro-
duced as LS pressure into LS shuttle valve (7).
• Then, this pressure is connected to port (B) of the actuator through valve (4), and LS pressure ≒ Actuator
load pressure.
• Introduction hole (a) in main spool (2) is small in diameter and used as an orifice.
• LS pressure is used as source pressure for closing the unload valve and as operating pressure when the
pressure compensation valve is compensated.
10-226 PC210LCI-11
OPERATION OF INTRODUCTION OF LS PRESSURE IN CONTROL VALVE
1. When main spool (2) is operated, the pump pressure enters port (c) through introduction hole (a), and is
introduced into LS circuit.
2. When the pump pressure increases up to the load pressure on port (B), check valve (5) opens and the
pressurized oil flows.
PC210LCI-11 10-227
LS BYPASS PLUG OF CONTROL VALVE

LS
STRUCTURE OF LS BYPASS PLUG OF CONTROL VALVE
1: Main pump 4: LS shuttle valve

2: Main spool 5: LS bypass plug
3: Pressure compensation valve 6: LS circuit
10-228 PC210LCI-11
FUNCTION OF LS BYPASS PLUG OF CONTROL VALVE
• It releases the remaining pressure in LS pressure circuit (6) through orifices (a) and (b).
• It reduces the LS pressure rising speed and prevents sudden change of the hydraulic pressure.
• When oil bypasses through LS bypass plug (5), pressure loss is generated due to the resistance in the cir-
cuit from orifice (c) of main spool (2) to LS shuttle valve (4).
• The effective LS differential pressure decreases, and the dynamic stability of the actuator is improved.
PC210LCI-11 10-229
BOOM REGENERATION CIRCUIT OF CONTROL VALVE

FUNCTION OF BOOM REGENERATION CIRCUIT OF CONTROL VALVE
When the cylinder head pressure is lower than the bottom pressure (when
boom lowers by its own weight, etc.)
1: Main pump 5: Suction valve

2: Boom valve spool 6: Check valve
4: Suction safety valve
When the boom is lowered, a regeneration circuit is formed from the cylinder bottom to the cylinder head to in-
crease the oil flow to the cylinder head.
10-230 PC210LCI-11
When cylinder head pressure is higher than the bottom pressure (when digging,
etc.)
Check valve (6) installed to regeneration circuit (C) closes to stop the oil flow from the cylinder bottom to the
cylinder head.
PC210LCI-11 10-231
OPERATION OF BOOM REGENERATION CIRCUIT OF CONTROL VALVE

When the cylinder head pressure is lower than the bottom pressure (when
boom lowers by its own weight, etc.)
When the cylinder head pressure is lower than the bottom pressure, part of pressurized oil (A) from the cylinder
bottom flows to drain circuit (B) through the notch of boom valve spool (2).
Other part flows to regeneration circuit (C), opens valve (6), and flows to the cylinder head through circuit (D).
The flows from regeneration circuit (C) and main pump (1) merge in circuit (E).
10-232 PC210LCI-11
ARM REGENERATION CIRCUIT OF CONTROL VALVE

FUNCTION OF ARM REGENERATION CIRCUIT OF CONTROL VALVE
When cylinder head pressure is higher than bottom pressure
1: Main pump 5: Suction valve

2: Arm valve spool 6: Check valve
4: Suction safety valve
When the arm is moved IN, both of the pump discharged volume and regeneration volume flow through the re-
generation circuit from the cylinder head to the cylinder bottom and increase the cylinder speed.
PC210LCI-11 10-233
When cylinder head pressure is lower than bottom pressure
Check valve (6) installed to regeneration circuit (C) closes and stops the flow from the cylinder head to the bot-
tom.
10-234 PC210LCI-11
OPERATION OF ARM REGENERATION CIRCUIT OF CONTROL VALVE

When cylinder head pressure is higher than bottom pressure
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 valve spool (2).
Other part flows to regeneration circuit (C), opens valve (6), and flows to the cylinder bottom through circuit (D).
The flows from regeneration circuit (C) and main pump (1) merge in circuit (E).
PC210LCI-11 10-235
MERGE-DIVIDER VALVE OF CONTROL VALVE

FUNCTION OF MERGE-DIVIDER VALVE OF CONTROL VALVE
When pumps are merged “when merge-divider valve selector signals (IS1) and
(IS2) are OFF”
Connected
IS2 OFF IS1 OFF

Connected
Arm side Bucket side
(Front Pump) (Rear Pump)
5 8 A B C D 3 4 7 6
PC200-8
2 x EPC valve
10 9
E F
To control valve
To control valve
P1 P2
A4P15736
1: Main spool 6: LS circuit (bucket side)

2: Spring 7: LS circuit (bucket side)
3: LS spool 8: LS circuit (arm side)
4: Spring 9: Merge-divider EPC valve (for selecting main spool)
5: LS circuit (arm side) 10: Merge-divider EPC valve (for selecting LS spool)
• This valve merges pressurized oils (P1) and (P2) discharged from the 2 pumps, or divides them (supply
them to their respective control valve spools).
• This valve merges or divides the LS circuit pressure.
10-236 PC210LCI-11
OPERATION OF MERGE-DIVIDER VALVE OF CONTROL VALVE

When pumps are merged “when merge-divider valve selector signals (IS1) and
(IS2) are OFF”
Connected
IS2 OFF IS1 OFF

Connected
5 8 A B C D 3 4 7 6
PC200-8
2 x EPC valve
10 9
E F
To control valve
To control valve
P1 P2
A4P15736
1. Since EPC valve drive signal (IS1) to the main spool is OFF, the output pressure of merge-divider EPC
valve is 0 MPa {0 kg/cm2} .
2. Main spool (1) is pressed to the right by spring (2), and ports (E) and (F) are connected.
3. Pressurized oils (P1) and (P2) discharged from the 2 pumps are merged in ports (E) and (F) and sent to the
control valve that requires them.
4. EPC valve drive signal (IS2) to LS spool (3) is also OFF, LS spool (3) is pressed to the right, and ports (A)
and (D), and ports (B) and (C) are connected respectively.
5. LS pressures supplied from each control valve spool to LS circuits (5), (6), (7), and (8) are transmitted to all
of the pressure compensation valve.
PC210LCI-11 10-237
When pumps are divided “when merge-divider valve selector signals (IS1) and
(IS2) are ON”
IS2 ON IS1 ON
Connected
5 8 A B C D 3 4 7 6
10 9
E F
To control valve
To control valve
P1 P2
A4P15737
1. Since EPC valve drive signal (IS1) to the main spool is ON, the output pressure from merge-divider EPC
valve moves main spool (1) to the left, and ports (E) and (F) are disconnected.
2. The pressurized oils discharged from the 2 pumps are sent to the respective control valve groups.
Pressure P1: To bucket, L.H. travel, and boom
Pressure P2: To swing, R.H. travel, and arm
3. When EPC valve drive signal (IS2) to LS spool (3) is turned ON, the output pressure from merge-divider
EPC valve moves the LS spool to the left, ports (A) and (C) are connected, and other ports are disconnect-
ed.
4. LS pressures supplied from each control valve spool to LS circuits (5), (6), (7), and (8) are transmitted to
the respective control valves.
10-238 PC210LCI-11
SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE

FUNCTION OF SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE
This valve reduces the discharged pressure of the main pump and supplies it as control pressure to the solenoid
valves, EPC valves, etc.
PC210LCI-11 10-239
OPERATION OF SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE

When engine is stopped
1. Since poppet (11) is pressed to the seat by spring (12), the
circuit between ports (PR) and (TS) is closed.
2. Since valve (14) is pressed to the left by spring (13), the
circuit between ports (P2) and (TS) is closed.
3. Since valve (7) is pressed to the left by spring (8), the cir-
cuit between ports (P2) and (A2) is closed.
10-240 PC210LCI-11
When load pressure (A2) is lower than self-pressure reducing valve output pres-
sure (PR) and control valve is in neutral or when load pressure (P2) is low
1. Spring (8) and pressure (PR) (0 MPa {0 kg/cm2} when the
engine is stopped) apply force to valve (7) in the direction
to close the circuit between ports (P2) and (A2).
2. When pressurized oil flows in from port (P2), “(Area of di-
ameter d x Pressure P2) = Force of spring (8) + (Area of
diameter d x Pressure PR)”, and the valve is balanced.
3. The opening of valve (7) is so adjusted that pressure (P2)
is kept higher than pressure (PR).
4. When pressure (PR) exceeds the set pressure, poppet
(11) opens.
5. The pressurized oil flows from port (PR) to orifice (a) in
spool (14), and then flows to seal drain port (TS) through
the opening of poppet (11).
6. Differential pressure occurs between the upstream side
downstream side of orifice (a) in spool (14), and spool (14)
moves in the direction to close the opening between ports
(P2) and (PR).
Pressure (P2) is reduced and adjusted to a constant pres-
sure (set pressure) by the opening at this time, and it is
supplied as pressure (PR).
When load pressure (P2) is high

1. Load pressure (A2) is increased by the operation of dig-
ging, etc., and the pump discharged volume increases.
2. Pressure (P2) increases and “(Area of diameter d x Pres-
sure P2) > Force of spring (8) + (Area of diameter d x
Pressure PR)”, and valve (7) moves to the right stroke
end.
3. The opening between ports (P2) and (A2) increases and
the passage resistance decreases, and the engine horse-
power loss reduces.
4. When pressure (PR) exceeds the set pressure, poppet
(11) opens.
5. The pressurized oil flows from port (PR) to orifice (a) in
spool (14), and then flows to seal drain port (TS) through
the opening of poppet (11).
6. Differential pressure occurs between the upstream side
downstream side of orifice (a) in spool (14), and spool (14)
moves in the direction to close the opening between ports
(P2) and (PR).
Pressure (P2) is reduced and adjusted to a constant pres-
sure (set pressure) by the opening at this time, and it is
supplied as pressure (PR).
PC210LCI-11 10-241
When abnormally high pressure occurs

1. When pressure (PR) of the self-pressure reducing valve in-
creases abnormally, ball (16) compresses spring (15) and
leaves the seat.
2. The pressurized oil flows from port (PR) to port (TS), and
pressure (PR) decreases.
3. The devices such as PPC valves, solenoid valves, etc. are
protected from abnormal pressure.
10-242 PC210LCI-11
TRAVEL JUNCTION VALVE OF CONTROL VALVE

FUNCTION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE
• When the travel lever is operated for straight travel, the travel junction valve does not receive pilot pressure
(PST) from the travel junction solenoid valve, and accordingly R.H. and L.H. travel circuits are connected,
and oil is supplied evenly to R.H. and L.H. travel motors to keep the straight travel performance.
• When the travel lever is operated for steering, the travel junction valve receives pilot pressure (PST) from
the travel junction solenoid valve, and accordingly R.H. and L.H. travel circuits are disconnected, and inde-
pendent oils are supplied individually to R.H. and L.H. travel motors to keep the steering performance.
PC210LCI-11 10-243
OPERATION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE

When pilot pressure (PST) is cut off (travel circuits are connected to each other)
1. When pilot pressure (PST) from the travel junction solenoid valve is cut off, travel junction spool (2) is push-
ed back to the left by the reaction force of spring (1), and port (PTL) and port (PTR) are connected.
2. When there is difference between the inflow rates to R.H. and L.H. travel motors, oil is supplied from the
port on the high pressure side through the opening of travel junction spool (2) to the port on the low pres-
sure side to compensate for the differential pressure, and oil is supplied to R.H. and L.H. motors evenly.
10-244 PC210LCI-11
When pilot pressure (PST) is supplied (travel circuits independent from each
other)
1. When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2) com-
presses spring (1) and moves to the right, and port (PTL) and port (PTR) are disconnected.
2. Independent oil flows are supplied to R.H. and L.H. travel motors.
PC210LCI-11 10-245
TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE

PPC
Abbreviation for Proportional Pressure Control
FUNCTION OF TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE

• While traveling on the steep uphill, if operation of boom RAISE or arm IN or arm OUT or bucket CURL or
bucket DUMP is performed, the pilot pressure of travel PPC valve controls the stroke of each spool of boom
or arm or bucket, and limit the flow to each cylinder.
• When the stroke of boom or arm or bucket is restricted, the pilot pressure of the travel PPC valve acts
through the internal circuit of the control valve.
OPERATION OF TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE

When travel lever is in NEUTRAL
1. The oil in stroke limit signal chamber (a) flows through orifices (5) and (6) of pistons (3) and (4) in the travel
spring case, and flows through travel PPC valve and then drained.
10-246 PC210LCI-11
2. By performing boom RAISE (or arm IN, OUT or bucket CURL, DUMP) operation, spool (1) moves to the left
side until it hits the end surface of spring case (2) (st0).
When travel lever is operated
1. By performing right travel REVERSE (or FORWARD) operation, the pilot pressure from travel PPC valve
pushes spool (7) to the left side (or right side).
2. Spool (7) pushes piston (3), and orifice (5) closes and cuts off the drain circuit of stroke control signal cham-
ber (a) and travel PPC valve.
3. By performing right travel REVERSE (or FORWARD) operation, the pilot pressure from travel PPC valve is
transmitted through orifice (6) of piston (4) to the left end surface of piston (8) to push piston (8) to the right
side.
4. By performing boom RAISE (or arm IN, OUT or bucket CURL, DUMP) operation, spool (1) moves to the left
side.
5. Maximum stroke of spool is reduced by the moving amount of piston (8) to the right side (st2), and be-
comes (st1).
PC210LCI-11 10-247
BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE

FUNCTION OF BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL
VALVE
When the boom is not operated with the R.H. work equipment control lever, this function is used to prevent the
pressurized oil in the boom cylinder bottom from leaking through spool (1) and causing boom hydraulic drift.
10-248 PC210LCI-11
OPERATION OF BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL

VALVE
When boom “RAISE” operation is performed
1. When boom “RAISE” operation is performed, the pressurized oil from the control valve acts leftward on the
right side of area (S) of the ring of poppet (5) having outside diameter (d1) and inside diameter (d2).
2. The force acting leftward on area (S) compresses spring (4) and moves poppet (5) to the left.
3. The pressurized oil from the control valve flows through the opening of poppet (5) to the bottom side of the
boom cylinder.
PC210LCI-11 10-249
When boom is in “NEUTRAL”
1. When the boom control lever is returned to “NEUTRAL” position, the pressurized oil flowing through orifice
(a) of poppet (5) into poppet (5) is stopped by pilot piston (2).
2. The holding pressure of the boom cylinder bottom acts rightward on the left side of area (S) of the ring
formed by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2).
3. The combined force of the force acting rightward on area (S) and the reaction force of spring (4) moves
poppet (5) to the right.
4. The circuit from the control valve to the boom cylinder bottom is blocked and the hydraulic pressure on the
boom cylinder bottom side is held.
10-250 PC210LCI-11
When boom “LOWER” operation is performed
1. When boom “LOWER” operation is performed, the pilot pressure from PPC valve pushes pilot piston (2).
2. The pressurized oil in the boom cylinder bottom flows to drain port (T) through orifice (a), chamber (b), and
orifice (c).
3. Chamber (b) in the poppet is connected to drain port (T), and the pressure in chamber (b) decreases.
4. When the pressure in chamber (b) decreases below the pressure in port (B), poppet (5) opens.
5. When poppet (5) opens, the pressurized oil from port (B) flows to port (A), and then flows to the control
valve.
PC210LCI-11 10-251
ARM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE

FUNCTION OF ARM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL
VALVE
(if equipped)
When the arm is not operated with the L.H. work equipment control lever, this function is used to prevent the
pressurized oil in the arm cylinder head from leaking through spool (1) and causing arm hydraulic drift.
10-252 PC210LCI-11
OPERATION OF ARM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL

VALVE
When arm is moved “OUT”
1. When arm “OUT” operation is performed, the pressurized oil from the control valve acts leftward on the
right side of area (S) of the ring of poppet (5) having outside diameter (d1) and inside diameter (d2).
2. The force acting leftward on area (S) compresses spring (4) and moves poppet (5) to the left.
3. The pressurized oil from the control valve flows through the opening of poppet (5) to the arm cylinder head.
PC210LCI-11 10-253
When arm control lever is in “NEUTRAL”
1. When the arm control lever is returned to “NEUTRAL” position, the pressurized oil flowing through orifice
(a) of poppet (5) into poppet (5) is stopped by pilot piston (2).
2. The holding pressure of the arm cylinder head acts rightward on the left side of area (S) of the ring formed
by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2).
3. The combined force of the force acting rightward on area (S) and the reaction force of spring (4) moves
poppet (5) to the right.
4. The circuit from the control valve to the arm cylinder head is blocked and the hydraulic pressure on the arm
cylinder head side is held.
10-254 PC210LCI-11
When arm is moved “IN”
1. When arm “IN” operation is performed, the pilot pressure from PPC valve pushes pilot piston (2).
2. The pressurized oil in the arm cylinder head flows to drain port (T) through orifice (a), chamber (b), and
orifice (c).
3. Chamber (b) in the poppet is connected to drain port (T), and the pressure in chamber (b) decreases.
4. When the pressure in chamber (b) decreases below the pressure in port (B), poppet (5) opens.
5. When poppet (5) opens, the pressurized oil from port (B) flows to port (A), and then flows to the control
valve.
PC210LCI-11 10-255
SUCTION SAFETY VALVE FOR HYDRAULIC DRIFT PREVENTION VALVE OF

CONTROL VALVE
OPERATION OF SUCTION SAFETY VALVE FOR HYDRAULIC DRIFT PREVEN-
TION VALVE OF CONTROL VALVE
When abnormally high pressure occurs
If abnormally high pressure occurs in the boom cylinder bottom circuit, the pressurized oil in port (B) pushes
open check valve (6), and suction safety valve (3) operates.
10-256 PC210LCI-11
By arm hydraulic drift prevention valve installed to the arm cylinder head circuit, the higher one of the boom cyl-
inder bottom circuit pressure and the arm cylinder head circuit pressure does push open check valve (6) or (6A),
and suction safety valve (3) operates.
PC210LCI-11 10-257
ARM QUICK RETURN VALVE OF CONTROL VALVE

FUNCTION OF ARM QUICK RETURN VALVE OF CONTROL VALVE
When the arm is moved OUT, much oil returns from the cylinder bottom. This function is used to decrease the
pressure loss in this process.
OPERATION OF ARM QUICK RETURN VALVE OF CONTROL VALVE

When arm is moved OUT
1. When arm OUT operation is performed, the pilot pressure from PPC valve pushes pilot piston (1).
2. The pressurized oil in chamber (B) is drained through orifice (c).
3. The pressurized oil in the arm cylinder bottom flows to drain port (T) through orifice (a), chamber (b), and
orifice (c).
4. Chamber (b) is connected to drain port (T), and the pressure in chamber (b) decreases.
5. When pressure in chamber (b) decreases below that in port (A), the pressure applied to the pressure re-
ceiving portion on port (A) side “area (S2) of diameter d2 (area of seat diameter)” becomes larger than the
combined force of the pressure applied to the pressure receiving portion on chamber (b) side of valve (2)
“area (S1) of diameter d1” and reaction force of the spring.
6. As a result, the pressure applied to diameter d2 > the pressure applied to diameter + the reaction force of
the spring.
7. Valve (2) moves to the left, and pressurized oil flows from port (A) to port (B).
8. The pressurized oil on the arm cylinder bottom side is drained from port (B) directly to the tank.
10-258 PC210LCI-11
When arm is in NEUTRAL
1. When the arm OUT control lever is returned to the neutral position, the pilot pressure from PPC valve is
stopped.
2. The pressurized oil sent and drained from orifice (a) of valve (2) is held by pilot piston (1).
3. The holding pressure of the arm cylinder bottom side acts rightward on the left side of the area of the ring
formed by the difference between area (S2) of valve (2) and area (S1).
4. The combined force of the force acting rightward on the area of the ring and the reaction force of spring (3)
moves valve (2) to the right, and port (A) and port (B) are disconnected.
PC210LCI-11 10-259
VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE

FUNCTION OF VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE
• This valve applies back pressure to the drain circuit to prevent cavitation which is caused by negative pres-
sure of each actuator (motor, cylinder, etc.)
• Lower the back pressure of the drain circuit except for travel and swing operations in order to reduce output
loss.
OPERATION OF VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE

When engine is stopped
1. No pressurized oil is supplied from the main pump to self-
pressure reducing valve (1).
2. No hydraulic pressure is supplied from variable back pres-
sure solenoid valve (3) to spring chamber (C), and valve
(6) is pressed to the right by the reaction force of spring
(5).
3. Drain circuit (A) of the control valve is interconnected with
port (T) through orifice (b) of valve (6).
10-260 PC210LCI-11
When engine is in operation (swing or travel operation)

1. Pressurized oil (PR) output from self-pressure reducing
valve (1) flows to variable back pressure solenoid valve
(3).
2. Since drive signal (IS3) to variable back pressure solenoid
valve (3) is “OFF”, pressurized oil (PR) flows to spring
chamber (C) of variable back pressure valve.
3. Pressurized oil (PR) flowing to spring chamber (C) acts on
the left end surface (area of diameter d) of valve (6) and
pushes valve (6) to the right together with the reaction
force of spring (5).
4. Pressure (PA) in drain circuit (A) of the control valve acts
on the right end surface (area of diameter d1) of valve (6)
and pushes valve (6) to the left.
5. Valve (6) keeps balance so that the back pressure be-
comes (PA) in the following equation. PA = (Area of diame-
ter d x Pressure (PR) + Reaction force of spring (5) ) /
Area of diameter d1
6. The oil flow from drain circuit (A) of the control valve to
port (T) is adjusted to the set pressure of variable back
pressure valve (4).
When engine is in operation (other than swing and travel operations)

1. Pressurized oil (PR) output from self-pressure reducing
valve (1) flows to variable back pressure solenoid valve
(3).
2. Since drive signal (IS3) to variable back pressure solenoid
valve (3) is turned “ON”, pressurized oil (PR) from self-
pressure reducing valve (1) that is flowing into spring
chamber (C) of variable back pressure valve (4) is drained
through variable back pressure solenoid valve (3).
3. Only the reaction force of spring (5) acts on valve (6), and
pushes valve (6) to the right.
4. Pressure (PA) in drain circuit (A) of the control valve acts
on the right end surface (area of diameter d1) of valve (6)
and pushes valve (6) to the left.
5. Valve (6) keeps balance so that the back pressure be-
comes (PA) in the following equation. PA = Reaction force
of spring (5) / Area of diameter d1
6. The oil flow from drain circuit (A) of the control valve to
port (T) is adjusted to the set pressure of variable back
pressure valve (4).
PC210LCI-11 10-261
MAIN RELIEF VALVE OF CONTROL VALVE

STRUCTURE OF MAIN RELIEF VALVE OF CONTROL VALVE
Sectional view
1: Spring 2: Poppet
FUNCTION OF MAIN RELIEF VALVE OF CONTROL VALVE
• The set pressure is changed to 2 stages.

• When power is required, high pressure is set by receiving pilot pressure (P) from the 2-stage relief solenoid
valve.
• The set pressure of the relief valve depends on the installed load of spring (1). (1st stage)
• When the 1st stage is normal, the 2nd stage does not need setting.
When the 1st stage is set, the 2nd stage is set as well.
10-262 PC210LCI-11
OPERATION OF MAIN RELIEF VALVE OF CONTROL VALVE

When pilot pressure (P) is cut off (low pressure setting)
The set pressure is determined by the installed load of spring (1).

When pilot pressure (P) is supplied (high pressure setting)
Pilot pressure (P) is applied to diameter (d1) of poppet (2) and added to the installed load of spring (1), and the
set pressure becomes high.
PC210LCI-11 10-263
2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE

STRUCTURE OF 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE
Sectional view
[Port (B) of service valve]
1: Spring 3: Spring
2: Piston 4: Holder
FUNCTION OF 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE

[Port (B) of service valve]
• Pressure is set to 2 stages.

• Low-pressure set is obtained by receiving pilot pressure from the attachment selector solenoid valve.
• The set pressure can be changed by turning ON/OFF the pilot pressure, corresponding to the types of the
attachments (for examples, breaker and crusher).
• The set pressure depends on the load at installed height of spring (1). (High-pressure side)
• The set pressure on the low-pressure side depends on the moving distance of the piston (2).
10-264 PC210LCI-11
OPERATION OF 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE

When pilot pressure (P) is cut off (high pressure setting)
1. Since pilot pressure (P) is cut off, piston (2) is pressed to
the left by the reaction force of spring (3). “Installed load of
spring (1) < Installed load of spring (3)”
2. The installed load of spring (1) becomes maximum and the
set pressure increases.
3. Passage (B) is connected through passages (C) and (D) to
the drain circuit.
When pilot pressure (P) is supplied (low pressure setting)

1. When pilot pressure (P) is supplied, it flows through pas-
sage (B) to portion (A).
2. The pilot pressure acts on the pressure receiving diameter
“(d1) - (d2)” of portion (A) of piston (2).
3. Upon receiving the pilot pressure, piston (2) compresses
spring and moves to the right until it touches holder (4).
4. Since spring (1) expands and its installed load decreases,
the set pressure decreases.
5. The pressurized oil for the stroke of piston (2) is drained
from passage (C) through chamber (D).
PC210LCI-11 10-265
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM

LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
Chassis part
1: Bucket cylinder 6: Fuel supply pump

2: Arm cylinder 7: Engine controller
3: Boom cylinder 8: Attachment circuit accumulator (for high pressure
4: Attachment selector valve circuit)
5: Attachment circuit accumulator (for low pressure cir-
cuit)
10-266 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
9: Main pump 11: Front pump PC-EPC valve

10: Rear pump PC-EPC valve
PC210LCI-11 10-267
12: Front pump oil pressure sensor 17: Attachment selector signal solenoid valve
13: Control valve 18: Pilot circuit accumulator
14: Rear pump oil pressure sensor 19: Solenoid valve
15: Travel speed increase solenoid valve 20: PPC lock solenoid valve
16: Travel junction solenoid valve 21: 2-stage relief solenoid valve
10-268 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
1: Machine monitor 2: R.H. work equipment PPC valve
PC210LCI-11 10-269
3: Fuel control dial 10: 1st-line attachment PPC valve

4: PPC lock switch 11: R.H. travel FORWARD pressure sensor
5: Lock lever 12: Travel PPC valve
6: L.H. work equipment PPC valve 13: L.H. travel FORWARD pressure sensor
7: One-touch power maximizing switch 14: L.H. travel REVERSE pressure sensor
8: Service pressure switch 15: R.H. travel REVERSE pressure sensor
9: Attachment flow adjustment EPC valve
16: Pump controller 18: Resistor for PC-EPC valve

17: Pump drive secondary switch
10-270 PC210LCI-11
10 STRUCTURE AND FUNCTION STRUCTURE OF VALVE CONTROL
STRUCTURE OF VALVE CONTROL
1: 1st-line attachment control pedal (*1) 9: Solenoid valve

2: L.H. travel lever 10: L.H. work equipment control lever (for operation of
3: R.H. travel lever arm and swing)
4: R.H. PPC valve for work equipment 11: L.H. PPC valve for work equipment
5: R.H. work equipment control lever (for operation of 12: Lock lever
boom and bucket) 13: 2nd-line attachment control pedal (*1)
6: Control valve 14: 2nd-line attachment PPC valve (*1)
7: Junction block 15: Travel PPC valve
8: Pilot circuit accumulator 16: Travel pedal
PC210LCI-11 10-271
STRUCTURE OF VALVE CONTROL 10 STRUCTURE AND FUNCTION
17: 1st-line attachment PPC valve (*1) 18: Lock pin (*1)
*1: Machines ready for installation of attachment
10-272 PC210LCI-11
10 STRUCTURE AND FUNCTION ONE-TOUCH POWER MAXIMIZING SYSTEM
ONE-TOUCH POWER MAXIMIZING SYSTEM

ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM
a: Front pump PC-EPC valve drive signal f: Pump oil pressure sensor signal
b: Rear pump PC-EPC valve drive signal g: One-touch power maximizing switch signal
c: Solenoid valve GND h: 1st throttle signal
d: CAN signal i: Fuel supply pump control signal
e: 2-stage relief solenoid valve drive signal j: Various sensor signals
10: Pump drive secondary switch 19a: Self-pressure reducing valve
11: Fuel control dial 19b: Merge-divider valve
12: Fuel supply pump 19c: Travel junction valve
13: Various sensors 19d: Main relief valve
14: One-touch power maximizing switch 20: Front pump PC-EPC valve
15: Front pump oil pressure sensor 21: Rear pump PC-EPC valve
16: Rear pump oil pressure sensor 22: 2-stage relief solenoid valve
PC210LCI-11 10-273
ONE-TOUCH POWER MAXIMIZING SYSTEM 10 STRUCTURE AND FUNCTION
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM

• The power is increased for a certain time by operating the one-touch power maximizing switch installed to
the knob of L.H. work equipment control lever.
• This function is used to increase the digging force for a certain time for digging out rocks, etc. during exca-
vation work.
• If the one-touch power maximizing switch is pressed when the load pressure in mode P, E, ATT/P, or ATT/E,
the hydraulic force increases approximately 7 %, and the digging force increases.
Each function is set automatically as follows;
Function Setting
Engine and pump combined control Matching at rated horsepower point
34.8 MPa {355 kg/cm2}
2-stage relief function ↓
37.2 MPa {380 kg/cm2}
Cutoff function Cancel
The one-touch power maximizing system keeps increasing the

power while one-touch power maximizing switch (1) is pressed.
Even if the switch is kept pressed, this function is canceled au-
tomatically in approximately 8.5 seconds.
10-274 PC210LCI-11
10 STRUCTURE AND FUNCTION PPC LOCK SYSTEM
PPC LOCK SYSTEM

PPC
PPC LOCK SYSTEM DIAGRAM
a: PPC lock signal g: Breaker operating switch signal

b: PPC lock signal h: Oil pressure sensor signal
c: Lock lever automatic lock cancel switch signal i: Oil pressure switch signal
d: Lock lever automatic lock relay drive signal j: 1st-line attachment flow adjustment EPC valve sig-
e: PPC lock solenoid valve drive signal nal
f: Switch potentiometer signal
1: Battery disconnect switch 11: 1st-line attachment proportional switch
2: Battery 12: Breaker operating switch
3: Battery relay 13: PPC lock solenoid valve
4: Fusible link 14: Control valve
5: Fuse box 14a: Merge-divider valve
6: Starting switch 14b: Self-pressure reducing valve
7: Lock lever 15: Main pump
8: PPC lock switch 16: Lock lever automatic lock cancel switch
9: Pump controller 17: 1st-line attachment flow adjustment EPC valve
10: Work equipment automatic lock relay
FUNCTION OF PPC LOCK SYSTEM

• PPC lock switch is interlocked with the lock lever. When the lock lever is set to LOCK position, PPC lock
switch is turned “OFF”.
• When PPC lock switch is turned OFF, the current flowing into PPC lock solenoid valve is cut out, and the
work equipment and machine body do not move even if any control lever or pedal is operated.
PC210LCI-11 10-275
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10 STRUCTURE AND FUNCTION
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM
a: PPC lock signal g: Breaker operating switch signal

b: PPC lock signal h: Oil pressure sensor signal
c: Lock lever automatic lock cancel switch signal i: Oil pressure switch signal
d: Lock lever automatic lock relay drive signal j: 1st-line attachment flow adjustment EPC valve sig-
e: PPC lock solenoid valve drive signal nal
f: Switch potentiometer signal
1: Battery disconnect switch 11: 1st-line attachment proportional switch
2: Battery 12: Breaker operating switch
3: Battery relay 13: PPC lock solenoid valve
4: Fusible link 14: Control valve
5: Fuse box 14a: Merge-divider valve
6: Starting switch 14b: Self-pressure reducing valve
7: Lock lever 15: Main pump
8: PPC lock switch 16: Lock lever automatic lock cancel switch
9: Pump controller 17: 1st-line attachment flow adjustment EPC valve
10: Work equipment automatic lock relay
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

This function automatically sets the lock lever in the same state as when it is locked to prevent the work equip-
ment or the machine continues its operation when the lock lever is unlocked while the work equipment control
lever or the travel lever is operated.
10-276 PC210LCI-11
10 STRUCTURE AND FUNCTION WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

When an oil pressure switch or a sensor detects pressure high-
er than specified pressure (D) and it is kept for longer than
specified time (E) or an attachment drive signal is input within
certain time (C) after the lock lever is unlocked (A), this function
judges that the operation is abnormal and the pump controller
outputs the lock lever automatic lock relay drive signal to shut
off the current to PPC lock solenoid to lock the machine (B).
A: PPC lock lever is unlocked
B: Lock lever automatic lock operates
C: Within 0.2 sec.
D: 5 kPa
E: 0.1 sec. or longer
REMARK
When the hydraulic oil temperature is low or high-viscosity hydraulic oil is used, the pressure does not increase
within time (C), and the lock lever automatic lock control may not operate.
Control when lock lever automatic lock cancel switch is “ON”
If PPC solenoid valve does not operate and the operator cannot work because of abnormality in the controller,
the operator can operate the machine by operating lock lever automatic lock cancel switch (1).
At this time, the lock lever automatic lock control function does not work.
a: Emergency (when abnormal)

b: Normal (when normal)
REMARK
Lock lever automatic lock cancel switch (1) is an alternate type switch. If it is set to “Emergency” position (a)
while PPC lock lever is in the free state, the lock lever automatic lock cancel pilot lamp lights up on the display.
The following failure codes are recorded when this switch is “ON”.
Action level Failure code Failure (displayed on screen)
L00 DDNS00 Lock Lever Auto Lock Release SW On
PC210LCI-11 10-277
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10 STRUCTURE AND FUNCTION
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT

ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM
(Machines ready for installation of attachment)
a: Front pump PC-EPC valve drive signal f: Attachment flow adjustment EPC valve drive signal
b: Rear pump PC-EPC valve drive signal g: Oil pressure switch signal
c: Solenoid valve GND h: 1st throttle signal
d: CAN signal i: Fuel supply pump control signal
e: Attachment selector solenoid valve drive signal j: Various sensor signals
1: Battery disconnect switch 15a: Servo
2: Battery 15b: LS valve
3: Battery relay 15c: PC valve
4: Fusible link 16: Rear pump
5: Fuse box 16a: Servo
6: Resistor for PC-EPC valve 16b: LS valve
7: Pump controller 16c: PC valve
8: Engine controller 17: Control valve
9: Machine monitor 17a: Self-pressure reducing valve
12: Fuel supply pump 18: Attachment selector solenoid valve
13: Various sensors 19: PPC lock solenoid valve
14: Oil pressure switch 20: Attachment flow adjustment EPC valve
15: Front pump 21: Front pump PC-EPC valve
10-278 PC210LCI-11
10 STRUCTURE AND FUNCTION OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT
22: Rear pump PC-EPC valve 25: Attachment

23: Attachment circuit selector valve (for high pressure 26: Attachment circuit accumulator (for high pressure
side) circuit)
24: Attachment circuit selector valve (for low pressure 27: Attachment circuit accumulator (for low pressure
side) circuit)
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT

When the attachment control pedal is depressed fully, the oil flow to the attachment is controlled by setting the
working mode and oil flow with the machine monitor.
The operation of the attachment changes as shown in the table below, depending on the working mode.
Working mode Operation of attachment
ATT/P, ATT/E Double-acting
B Single-acting
PC210LCI-11 10-279
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

WORK EQUIPMENT AND SWING PPC VALVE
PPC
STRUCTURE OF WORK EQUIPMENT AND SWING PPC VALVE

General view
10-280 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
L.H. work equipment control lever

P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
P3: To control valve (swing LEFT port)
P4: To control valve (swing RIGHT 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)
PC210LCI-11 10-281
Sectional view
1: Spool 3: Disc
2: Piston 4: Nut (for connecting lever)
10-282 PC210LCI-11
5: Joint 8: Body
6: Plate 9: Filter
7: Retainer
OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE

When in NEUTRAL
Ports (A) and (B) of the control valve and ports (P1) and P2) of
PPC valve are connected to drain chamber (D) through fine
control hole (f) of spool (1).
PC210LCI-11 10-283
In fine control (when fine control is started from neutral state)

1. When piston (4) is pushed by disc (5), retainer (9) is push-
ed and spool (1) is also pushed and moved down through
metering spring (2).
2. Almost at the same time when fine control hole (f) is dis-
connected from drain chamber (D), it is connected to pump
pressure chamber (PP).
3. The pilot pressure oil of the main pump flows to port (A)
through fine control hole (f) and port (P1).
4. When the pressure in port (P1) increases, spool (1) is
pushed back. Almost at the same time when fine control
hole (f) is disconnected from pump pressure chamber
(PP), it is connected to drain chamber (D), and the pres-
sure in port (P1) is released.
5. Spool (1) moves up and down so that the force of metering
spring (2) is balanced with the pressure in port (P1).
6. The positional relationship between spool (1) and body
(10) “fine control hole (f) is in an intermediate position be-
tween drain chamber (D) and pump pressure chamber
(PP)” does not change until retainer (9) touches spool (1).
7. Metering spring (2) is compressed in proportion to the trav-
el of control lever.
8. The pressure in port (P1) also increases in proportion to
the travel of control lever.
9. The control valve spool moves to a position where the pressure in port (A) “which is the same as the pres-
sure in port (P1)” is balanced with the reaction force of the control valve spool return spring.
In fine control (when control lever is returned)
1. When disc (5) starts being returned, spool (1) is pushed up
by the force of centering spring (3) and the pressure in port
(P1).
2. Fine control hole (f) is connected to drain chamber (D),
and the pressurized oil in port (P1) is released.
3. If the pressure in port (P1) decreases too much, spool (1)
is pushed down by metering spring (2).
5. The pump pressure is supplied until the pressure in port
(P1) recovers to the pressure corresponding to the lever
position.
6. When the control valve spool returns, the pressurized oil in
drain chamber (D) flows in through fine control hole (f) of
the valve on the stationary side, and then it flows through
port (P2) to port (B).
10-284 PC210LCI-11
When control lever is fully operated

1. Disc (5) pushes down piston (4), and retainer (9) pushes
down spool (1).
2. Fine control hole (f) is disconnected from drain chamber
(D) and connected to pump pressure chamber (PP).
3. The pilot pressure oil from the self-pressure reducing valve
flows to port (A) through fine control hole (f) and port (P1),
and pushes the control valve spool.
4. The return oil from port (B) flows to drain chamber (D)
through port (P2) and fine control hole (f).
PC210LCI-11 10-285
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)

PPC
EPC
STRUCTURE OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)

10-286 PC210LCI-11
P: From self-pressure reducing valve P2: To control valve (service valve 1 port)
P1: To control valve (service valve 1 port) T: To hydraulic tank
PC210LCI-11 10-287
1: Spool 5: Retainer
2: Piston 6: Body
3: Lever 7: EPC valve
4: Plate
OPERATION OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)

REMARK
For explanation of operation of PPC valve, see “Operation of work equipment and swing PPC valve”.
10-288 PC210LCI-11
EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE

PPC
EPC
STRUCTURE OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE

P: From self-pressure reducing valve T: To hydraulic tank

C: To PPC valve (R.H. attachment)
1: Body 4: Coil
2: Spool 5: Plunger
3: Spring 6: Push pin
PC210LCI-11 10-289
7: Connector
FUNCTION OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE

Upon receiving signal current (i) from the pump controller, this
valve generates EPC output pressure in proportion to that sig-
nal current and outputs it to the control valve.
OPERATION OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE

When signal current is zero (coil is de-energized)
10-290 PC210LCI-11
1. When the signal current from the controller does not flow through coil (4), coil (5) is de-energized.
2. Spool (2) is pressed to the right by spring (3).
3. Port (P) is closed and no pressurized oil from the self-pressure reducing valve flows to the control valve.
4. The oil from the control valve is drained into the tank from port (C) through port (T).
When signal current is minute (coil is energized)
1. When minute signal current flows through coil (4), coil (4) is energized to generate thrust in rightward direc-
tion of plunger (5).
2. Push pin (6) pushes spool (2) to the left, and the pressurized oil from port (P) flows to port (C).
3. When the pressure at port (C) increases, combined force on surface (a) of spool (2) and the reaction force
of spring (3) becomes larger than the thrust of plunger (5).
4. Spool (2) is pushed to the right and port (P) and port (C) are disconnected, and port (C) and port (T) are
connected.
5. Spool (2) moves up and down so that the thrust of plunger (5) is balanced with the total of the pressure in
port (C) and load of spring (3).
6. The circuit pressure between EPC valve and control valve is controlled in proportion to the signal current.
PC210LCI-11 10-291
When signal current is maximum (coil is energized)
1. When the signal current flows to coil (4), coil (4) is energized.
Since the signal current is maximum at this time, the thrust of plunger (5) is also maximum.
2. Spool (2) is pressed to the left by push pin (6).
3. The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
EPC valve and control valve becomes maximum.
4. Port (T) closes and no pressurized oil flows to the hydraulic tank.
10-292 PC210LCI-11
2ND-LINE ATTACHMENT PPC VALVE

PPC
STRUCTURE OF 2ND-LINE ATTACHMENT PPC VALVE

P: From self-pressure reducing valve P2: To control valve (service valve 2 port)
P1: To control valve (service valve 2 port) T: To hydraulic tank
PC210LCI-11 10-293
1: Spool 4: Plate
2: Piston 5: Retainer
3: Lever 6: Body
OPERATION OF 2ND-LINE ATTACHMENT PPC VALVE

REMARK
For explanation of operation of PPC valve, see “Operation of work equipment and swing PPC valve”.
10-294 PC210LCI-11
SOLENOID VALVE
STRUCTURE OF SOLENOID VALVE
REMARK
The figure shows the solenoid valve for the machine ready for installation of attachment.
PC210LCI-11 10-295
P1: From self-pressure reducing valve

A1: To PPC valve
10-296 PC210LCI-11
A2: To control valve (port (PST))

A3: To swing motor (port (B))
A4: To travel motor (port (P))
A5: To control valve (port (PX1), (PX2))
A6: To 2-stage relief valve for swing motor
A7: To attachment circuit selector valve
ACC: To accumulator (for PPC circuit)
1: PPC lock solenoid valve

2: Travel junction solenoid valve
3: Swing parking brake solenoid valve
4: Travel speed increase solenoid valve
5: 2-stage relief solenoid valve
6: 2-stage swing relief solenoid valve
7: Attachment selector solenoid valve (for the 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 OF SOLENOID VALVE AND CHECK VALVE

When the solenoid valve is “de-energized” (the circuit is blocked).
1. Coil (1) is de-energized when the signal current does not
flow to coil (1).
2. Spool (2) is pushed back to the left with the reaction force
of spring (3).
3. The circuit between port (P) and port (A) closes and pilot
pressure does not flow from port (A) to the actuator. At the
same time, port (T) opens and oil from the actuator is
drained to the hydraulic tank.
PC210LCI-11 10-297
When the solenoid valve is “energized” (the circuit is connected).

1. Coil (1) is energized when the signal current flows to coil
(1).
2. Accordinglys, spool (2) is pushed to the right by push pin
(4).
3. The circuit between port (P) and port (A) opens and pilot
pressure flows from port (A) to the actuator. At the same
time, port (T) closes and oil from the actuator does not flow
to the hydraulic tank.
Check valve (with engine stopped)

The check valve is installed between port (P) and PPC sole-
noid valve. When the engine is stopped, the reaction force of
spring (2) pushes plunger (1) to the left, and port (ACC) and
port (P) are disconnected, thus the accumulated pressure in
the accumulator is held.
Check valve (with engine running)

When the engine is running, the pilot pressure in port (P) pushes plunger (1) to the right, and port (P) and port
(ACC) are interconnected.
10-298 PC210LCI-11
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)

STRUCTURE OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRES-
SURE)
Sectional view
PI: From attachment selector solenoid valve ATT: To attachment

ACC: To accumulator TS: To hydraulic tank
1: Spool
FUNCTION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRES-

SURE)
• When the breaker is installed, main circuit from the control valve to the breaker and accumulator are inter-
connected with this valve.
• When the other attachment (crusher etc.) is installed, main circuit and accumulator are blocked with this
valve.
PC210LCI-11 10-299
OPERATION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRES-

SURE)
When attachment other than breaker is installed
1. Spool (1) is pressed to the left by the force of spring (2).
2. Since port (ATT) and port (ACC) are disconnected, no oil
flows into the accumulator.
When breaker is installed

1. Pilot pressure (PI) from the attachment circuit selector sol-
enoid valve compresses spring (2), and spool (1) moves
rightward to the stroke end.
2. Since port (ATT) and port (ACC) are interconnected, oil
flows into the accumulator and absorbs the oil pulsation.
10-300 PC210LCI-11
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)

STRUCTURE OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRES-
SURE)
P1: From attachment selector solenoid valve ATT: to attachment

V: To control valve attachment 1 port T: To hydraulic tank
ACC: To accumulator TS: To hydraulic tank
1: Spool
FUNCTION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRES-

SURE)
When the breaker is installed, this function is used to connect the main circuit between the control valve and
breaker to the accumulator. When another attachment (crusher, etc.) is installed, this function is used to discon-
nect the main circuit from the accumulator.
PC210LCI-11 10-301
OPERATION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRES-

SURE)
When attachment other than breaker is installed
1. Spool (1) is pressed to the left by the force of spring (2).
2. Port (ATT) is connected to port (V), and port (ATT) is dis-
connected from port (T), and the attachment is connected
to the control valve.
When breaker is installed

1. Pilot pressure (PI) from the attachment circuit selector sol-
enoid valve compresses spring (2), and spool (1) moves
rightward to the stroke end.
2. Port (ATT) is disconnected from port (V), and port (ATT) is
connected to port (T).
3. The pressurized oil returning from the breaker returns di-
rectly to the hydraulic tank through port (T) without passing
through the control valve.
10-302 PC210LCI-11
PILOT CIRCUIT ACCUMULATOR

STRUCTURE OF PILOT CIRCUIT ACCUMULATOR
1: Gas plug
2: Shell
3: Poppet
4: Holder
5: Bladder
6: Oil port
SPECIFICATIONS OF PILOT CIRCUIT ACCUMULATOR

Gas used: Nitrogen gas
Volume of gas: 300 cc
Charged gas pressure: 1.18 MPa {12 kg/cm2} (at 80 °C)
Max. using pressure: 4.91 MPa {50 kg/cm2}
FUNCTION OF PILOT CIRCUIT ACCUMULATOR

This accumulator (for Pilot circuit) is installed to the solenoid valve. Even if the engine is stopped while the work
equipment is raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of
the compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its own
weight.
PC210LCI-11 10-303
ATTACHMENT CIRCUIT ACCUMULATOR

STRUCTURE OF ATTACHMENT CIRCUIT ACCUMULATOR
Sectional view
1: Cap
2: Core
3: Gas port
4: Bladder
5: Shell
6: Valve
7: Oil port
SPECIFICATIONS OF ATTACHMENT CIRCUIT ACCUMULATOR

Gas used: Nitrogen gas
Volume of gas: 1000 cc
Charged gas pressure (for low pressure circuit): 0.10 MPa {1 kg/cm2} (at 20 °C)
Charged gas pressure (for high pressure circuit): 8.83 MPa {90 kg/cm2} (at 20 °C)
Max. using pressure: 29.4 MPa {300 kg/cm2}
FUNCTION OF ATTACHMENT CIRCUIT ACCUMULATOR

This accumulator is installed to the attachment piping to absorb the oil pulsation generated by the breaker oper-
ation into the compressed nitrogen gas in it for protection of the hydraulic component and piping.
10-304 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF ICT SYSTEM
ICT SYSTEM
ICT
Abbreviation for Information and Communication Technology
LAYOUT DRAWING OF ICT SYSTEM

Chassis part
PC210LCI-11 10-305
LAYOUT DRAWING OF ICT SYSTEM 10 STRUCTURE AND FUNCTION
1: Stroke sensing bucket cylinder 8: GNSS receiver

2: Reset sensor for arm cylinder 9: Work equipment controller
3: Stroke sensing arm cylinder 10: ICT sensor controller
4: Reset sensor for boom cylinder 11: IMU sensor
5: GNSS antenna 12: Control box
6: Control valve 13: Stroke sensing boom cylinder
7: Solenoid valve block
10-306 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF ICT SYSTEM
(Machines with auto tilt bucket)

Chassis part
1: Stroke sensing bucket cylinder 5: GNSS antenna

2: Reset sensor for arm cylinder 6: Control valve
3: Stroke sensing arm cylinder 7: Solenoid valve block
4: Reset sensor for boom cylinder 8: Pump controller
PC210LCI-11 10-307
LAYOUT DRAWING OF ICT SYSTEM 10 STRUCTURE AND FUNCTION
9: GNSS receiver 13: Control box

10: Work equipment controller 14: Stroke sensing boom cylinder
11: ICT sensor controller 15: Auto tilt bucket cylinder
12: IMU sensor 16: Stroke sensing auto tilt bucket cylinder
1: Proportional lever 2: Auto/manual switch
10-308 PC210LCI-11
10 STRUCTURE AND FUNCTION ICT CONTROL SYSTEM DIAGRAM
ICT CONTROL SYSTEM DIAGRAM
Input and output signals

a: Controller Area Network signal 1 (komnet/c) f: GNSS signal (MAIN antenna)
b: CAN signal 1 (Komnet/r) g: GNSS signal (AUX antenna)
c: Cylinder stroke signal h: PPC pressure (lever side) signal
d: Cylinder reset signal i: PPC pressure reduce pressure EPC drive signal
e: Ethernet signal j: PPC pressure (control valve side) signal
1: ICT sensor controller 13: Reset sensor for bucket cylinder
2: Work equipment controller 14: IMU sensor
3: Pump controller 15: PPC valve
4: Control box 16: PPC pressure sensor (lever side)
5: Machine monitor 17: EPC valve for intelligent Machine Control
6: Auto/manual switch 18: PPC pressure sensor (control valve side)
7: Stroke sensor for bucket cylinder 19: Spool stroke sensor
8: Stroke sensor for boom cylinder 20: Control valve
9: Stroke sensor for arm cylinder 21: GNSS receiver
10: Stroke sensor for bucket cylinder 22: GNSS antenna (MAIN)
11: Reset sensor for boom cylinder 23: GNSS antenna (AUX)
12: Reset sensor for arm cylinder
PC210LCI-11 10-309
BUCKET EDGE POSITION DETECTION SYSTEM 10 STRUCTURE AND FUNCTION
BUCKET EDGE POSITION DETECTION SYSTEM

BUCKET EDGE POSITION DETECTION SYSTEM DIAGRAM
A: Figuring out of work equipment posture

a: Cylinder length information d: Satellite acquisition information
b: GNSS antenna positioning information e: Current coordinates information of bucket blade
c: Machine posture and work equipment posture infor- edge
mation f: Target coordinates information of bucket blade edge
1: ICT sensor controller 5: Control box
2: Stroke sensor for cylinder 6: GNSS antenna
3: Reset sensor for cylinder 7: IMU sensor
4: GNSS receiver
FUNCTION OF BUCKET EDGE POSITION DETECTION SYSTEM

The bucket edge position detection system figures out the blade tip coordinates to display the blade tip position
on the control box.
OPERATION OF BUCKET EDGE POSITION DETECTION SYSTEM

Operation of GNSS receiver
The GNSS receiver measures the position of each antenna, and transmits the data of the information to the
control box.
Operation of ICT sensor controller
1. The ICT sensor controller figures out the work equipment posture by calculating the length of each work
equipment cylinder.
2. The ICT sensor controller figures out the machine pitch angle and machine roll angle by calculating the an-
gle information detected by IMU sensor.
10-310 PC210LCI-11
10 STRUCTURE AND FUNCTION BUCKET EDGE POSITION DETECTION SYSTEM
3. The ICT sensor controller transmits the data of the work equipment posture, machine pitch angle, and ma-
chine roll angle to the control box.
Operation of control box

1. The control box figures out the position and direction of machine by calculating the positional relationship of
each antenna.
2. The control box figures out the coordinates of current bucket blade edge by calculating the machine posi-
tion, machine direction, work equipment posture, machine pitch angle, and machine roll angle.
3. The control box figures out the deflection by calculating the target bucket blade edge coordinates.
PC210LCI-11 10-311
THE INTELLIGENT MACHINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION
THE INTELLIGENT MACHINE CONTROL SYSTEM

FUNCTION OF THE INTELLIGENT MACHINE CONTROL SYSTEM
• The intelligent Machine Control has the auto grade assist control and the auto stop control.
• The intelligent Machine Control is a system that controls the work equipment to move or stop automatically
in order not to damage the design surface.
Auto grade assist control: Raises the boom automatically when operating the arm
Auto stop control: Stops the boom automatically when operating the boom
Auto stop control: Stops the bucket automatically when operating the bucket
Auto stop control: Stops the tilt bucket automatically when operating the tilt bucket (*1)
• EPC valves are installed to each shaft (boom RAISE and LOWER, arm IN and OUT, bucket CURL and
DUMP) in order to reduce PPC circuit pressure.
• EPC valve which intervenes in PPC circuit is installed only to boom RAISE PPC circuit.
(*1): Machines with auto tilt bucket.
Structure of EPC
EPC valve circuit Function Actuated
Boom RAISE Intervention Raises boom automatically.
Boom RAISE Reduction of the pressure Slows down boom RAISE operation or stops it.
Boom LOWER Reduction of the pressure Slows down boom LOWER operation or stops it.
Arm IN Reduction of the pressure Slows down arm IN operation or stops it.
Arm OUT Reduction of the pressure Slows down arm OUT operation or stops it.
Bucket CURL Reduction of the pressure Slows down bucket CURL operation or stops it.
Bucket DUMP Reduction of the pressure Slows down bucket DUMP operation or stops it.
Service flow rate adjustment Reduction of the pressure Slows down tilt bucket operation or stops it.
EPC 1
Service flow rate adjustment Reduction of the pressure Slows down tilt bucket operation or stops it.
EPC 2
REMARK
• Pressure reducing EPC valve cannot move the work equipment by itself alone.
• When the work equipment controller to control EPC valve is abnormal, or when EPC line has an open cir-
cuit, the pressure reducing EPC valve is fully closed, and consequently it cannot move the work equipment.
AUTO GRADE ASSIST CONTROL

FUNCTION OF AUTO GRADE ASSIST CONTROL
• The auto grade assist control is a control that automatically raises the boom in order not to damage the
design surface during the arm operation.
10-312 PC210LCI-11
10 STRUCTURE AND FUNCTION THE INTELLIGENT MACHINE CONTROL SYSTEM
The blade edge moves along dashed line (L) and draws an arc when the arm is moved IN singly without
this function. The boom is raised automatically so that the blade edge moves along the design surface with
this function.
• EPC valve reduces the pressure in the PPC circuit when the Auto/manual switch is set to semi-auto mode,
and the movement of tilt bucket slows down or stops.
• The command current flows from the pump controller to the EPC valve corresponding to the proportional
control lever opening position when shifting the auto/manual switch to the manual mode on the machines
with auto tilt bucket. Oil flows from the control valve to the tilt bucket cylinder corresponding to the com-
mand current from the EPC valve, and it moves the tilt bucket.
OPERATION OF AUTO GRADE ASSIST CONTROL

When arm IN is operated(boom lever is not operated)
Boom control circuit
A: Boom RAISE PPC circuit B: Boom LOWER PPC circuit

1: Work equipment controller 5: Boom cylinder
2: PPC pressure reducing EPC valve 6: Work equipment control lever
3: PPC pressure sensor 7: Boom RAISE EPC valve
4: Boom spool (control valve)
1. When arm IN is operated, the bucket blade edge heads to the design surface as the arm moves. (Bucket
blade edge speed (S1))
2. The work equipment controller decomposes this bucket blade edge speed (S1) into the components, one
which is in parallel with the design surface and the other which is in perpendicular to the design surface.
PC210LCI-11 10-313
3. The work equipment controller compares the bucket blade edge speed (component perpendicular to the
design surface) with the speed limit value which is obtained from the following parameter map, and figures
out target blade edge speed (S2).
When the bucket blade edge speed is larger than the map value: Limit value is set as the target speed.
When the bucket blade edge speed is smaller than the map value: No limit value is set and current value is
left as it is.
(The figure below shows a case that the value is figured out where the current blade edge speed is larger
than the map value.)
REMARK
The value in this map are specific value for the machine
model, and they are not applicable to calibration.
4. The work equipment controller figures out the target speed
of boom RAISE by geometric computation from target
speed blade edge (S2).
5. The cylinder speed, spool stroke, PPC pressure, and EPC
valve opening (current) which is the final command are fig-
ured out in order after the target speed of boom RAISE is
figured out.
REMARK
These control maps which are used for the calculation can
be calibrated in the “Adjustment” in service mode on the
machine monitor. (For the calibration procedure, see
TESTING AND ADJUSTING, “SPECIAL FUNCTIONS OF
MACHINE MONITOR”.)
10-314 PC210LCI-11
1: Bucket blade edge speed 3: Target speed of boom cylinder

2: Target speed of bucket blade edge 4: EPC current value
6. The work equipment controller outputs calculated EPC current (A1). When EPC valve opens, PPC circuit
pressure (P1) is applied and the boom is raised automatically.
7. If the arm speed limit is set in the machine monitor, arm OUT PPC pressure reducing EPC valve operates
to reduce the arm OUT speed.
(For the arm speed limit, see “Operation and Maintenance Manual”, “MACHINE MONITOR”.)
Arm control circuit
A: Arm IN PPC circuit B: Arm OUT PPC circuit

1: Work equipment controller 4: Arm spool (control valve)
2: PPC pressure reducing EPC valve 5: Arm cylinder
3: PPC pressure sensor 6: Work equipment control lever
1. The work equipment controller figures out the arm limit speed, cylinder speed, spool stroke, PPC pressure,
and arm IN PPC pressure reducing EPC valve opening (current) which is the final command.
PC210LCI-11 10-315
REMARK
These control maps which are used for the calculation can be calibrated in the “Adjustment” in service
mode on the machine monitor. (For the calibration procedure, see TESTING AND ADJUSTING, “SPECIAL
FUNCTIONS OF MACHINE MONITOR”.)
1: Target speed of arm cylinder 2: EPC current value

pressure (P1) is applied and the arm IN speed decreases.
When arm OUT is operated

10-316 PC210LCI-11
1. When arm OUT is operated, the bucket blade edge heads to the design surface as the arm moves. (Bucket
2. The work equipment controller decomposes this bucket blade edge speed (S1) into the components, one
which is in parallel with the design surface and the other which is in perpendicular to the design surface.
3. The work equipment controller compares the bucket blade edge speed (component perpendicular to the
design surface) with the speed limit value which is obtained from the following parameter map, and figures
out target blade edge speed (S2).
left as it is.
REMARK
4. The work equipment controller figures out the target speed
of boom RAISE by geometric computation from target
speed blade edge (S2).
5. The cylinder speed, spool stroke, PPC pressure, and EPC
valve opening (current) which is the final command are fig-
ured out in order after the target speed of boom RAISE is
figured out.
REMARK
PC210LCI-11 10-317

pressure (P1) is applied and the boom is raised automatically.
7. If the arm speed limit is set in the machine monitor, arm IN PPC pressure reducing EPC valve operates to
reduce the arm IN speed.
(For the arm speed limit, see “Operation and Maintenance Manual”, “MACHINE MONITOR”.)
Arm control circuit
A: Arm IN PPC circuit B: Arm OUT PPC circuit

1: Work equipment controller 4. Arm spool (control valve)
2: PPC pressure reducing EPC valve 5: Arm cylinder
1. The work equipment controller figures out the arm limit speed, cylinder speed, spool stroke, PPC pressure,
and arm OUT PPC pressure reducing EPC valve opening (current) which is the final command.
10-318 PC210LCI-11
REMARK
These control maps which are used for the calculation can be calibrated in the “Adjustment” in service
mode on the machine monitor. (For the calibration procedure, see TESTING AND ADJUSTING, “SPECIAL
FUNCTIONS OF MACHINE MONITOR”.)
1: Target speed of arm cylinder 2: EPC current value

2. The work equipment controller outputs EPC current (A1) figured out. When EPC valve opens, PPC circuit
pressure (P1) is applied and the arm OUT speed decreases.
AUTO STOP CONTROL

FUNCTION OF AUTO STOP CONTROL
The auto stop control is the control that automatically stops the
work equipment in order not to damage the design surface.
PC210LCI-11 10-319
OPERATION OF AUTO STOP CONTROL

When the boom LOWER operation is performed

1. Boom is lowered and the bucket blade edge heads to the
design surface by operating the boom LOWER. (Bucket
2. The work equipment controller compares the bucket blade edge speed (S1) with the speed limit value
which is figured out from the following parameter map, and figures out target blade edge speed (S2).
left as it is.
10-320 PC210LCI-11
(The figure below shows a case that the value is figured

out where the current blade edge speed is larger than the
map value.)
REMARK
3. The work equipment controller figures out the spool stroke,
PPC pressure, EPC valve opening position (current value)
as a final command in order to set the boom LOWER
speed to the value which has been calculated.
REMARK

4. The work equipment controller outputs the command of EPC current (A1) figured out, and the boom LOW-
ER speed decreases when the EPC valve is throttled (closed finally) (P1). (The boom LOWER is stopped
finally.)
PC210LCI-11 10-321
When bucket CURL is operated

Bucket control circuit
A: Bucket CURL PPC circuit B: Bucket DUMP PPC circuit

1: Work equipment controller 4: Bucket spool (control valve)
2: PPC pressure reducing EPC valve 5: Bucket cylinder
1. The bucket blade edge heads to the design surface by op-
erating the bucket CURL. (Bucket blade edge speed (S1))
left as it is.
10-322 PC210LCI-11

map value.)
REMARK
3. The work equipment controller figures out the PPC pres-
sure, EPC valve opening position (current value) as a final
command in order to set the bucket CURL speed to the
value which has been calculated.
REMARK
• These control maps which are used for the calculation
can be calibrated in the “Adjustment” in service mode
on the machine monitor. (For the calibration procedure,
see TESTING AND ADJUSTING, “SPECIAL FUNC-
TIONS OF MACHINE MONITOR”.)
• Bucket PPC circuit does not have a spool stroke sen-
sor.
1: Bucket blade edge speed 3: Target speed of bucket cylinder

4. The work equipment controller outputs the command of EPC current (A1) figured out, and the bucket CURL
speed decreases when the EPC valve is throttled (closed finally) (P1). (The bucket CURL is stopped final-
ly.)
PC210LCI-11 10-323
When bucket DUMP is operated


2: PPC pressure reducing EPC valve 5: Bucket cylinder
1. The bucket blade edge heads to the design surface by op-
erating the bucket DUMP. (Bucket blade edge speed (S1))
left as it is.
10-324 PC210LCI-11

map value.)
REMARK
command in order to set the bucket DUMP speed to the
value which has been calculated.
REMARK
can be calibrated in the “Adjustment” in service mode
on the machine monitor. (For the calibration procedure,
see TESTING AND ADJUSTING, “SPECIAL FUNC-
TIONS OF MACHINE MONITOR”.)
• Bucket PPC circuit does not have a spool stroke sen-
sor.
1: Bucket blade edge speed 3: Target speed of bucket cylinder

4. The work equipment controller outputs the command of EPC current (A1) figured out, and the bucket
DUMP speed decreases when the EPC valve is throttled (closed finally) (P1). (The bucket DUMP is stop-
ped finally.)
PC210LCI-11 10-325
When operating the bucket tilting operation clockwise with auto tilt bucket
equipped machine.
A: Figures out the current work equipment posture B: Figures out EPC valve drive signal
Input signal
a: Control Area Network signal 1 (Komnet/r) d: Lever input signal
b: Control Area Network signal 2 (Komnet/c) e: Cylinder stroke signal
c: EPC valve drive signal f: Pressure sensor signal
1: Work equipment controller 6: Service flow rate adjustment EPC 2
2: ICT sensor controller 7: Service flow rate adjustment EPC 1
3: Pump controller 8: Control valve
4: ATT1 left pressure sensor 9: Stroke sensing bucket tilt cylinder
5: ATT1 right pressure sensor
10-326 PC210LCI-11
1. The bucket blade edge heads to the design surface by operating the bucket tilt operation clockwise. (Buck-
et blade edge speed (S1))
2. The work equipment controller compares the tilt bucket blade edge speed (S1) with the speed limit value
When the tilt bucket blade edge speed is larger than the map value: Limit value is set as the target speed.
When the tilt bucket blade edge speed is smaller than the map value: No limit value is set and current value
is left as it is.
REMARK
command in order to set the bucket TILT speed to the val-
ue which has been calculated.
REMARK
can be calibrated in the “Auto-Tilt Bucket Control Ad-
justment” in “MC Setting” in service mode on the ma-
chine monitor. (For the calibration procedure, see “Au-
to-Tilt Bucket Control Adjustment”, “MC Setting”, “MA-
CHINE MONITOR”, “SETTING”, in Operation and
Maintenance Manual.)
• Tilt bucket PPC circuit does not have a spool stroke
sensor.
PC210LCI-11 10-327
1: Tilt bucket blade edge speed 3: Target speed of tilt bucket cylinder
2: Target speed of tilt bucket blade edge 4: EPC current value
4. The work equipment controller outputs the command of EPC current (A1) figured out, and the bucket TILT
speed decreases when the EPC valve is throttled (closed finally) (P1). (The bucket TILT is stopped finally.)
When operating the bucket tilting operation counterclockwise with auto tilt
bucket equipped machine.
Input signal
1: Work equipment controller 4: ATT1 left pressure sensor
2: ICT sensor controller 5: ATT1 right pressure sensor
3: Pump controller 6: Service flow rate adjustment EPC 2
10-328 PC210LCI-11
7: Service flow rate adjustment EPC 1 9: Stroke sensing bucket tilt cylinder
8: Control valve
1. The bucket blade edge heads to the design surface by operating the bucket CURL counterclockwise.
(Bucket blade edge speed (S1))
2. The work equipment controller compares the tilt bucket blade edge speed (S1) with the speed limit value
When the tilt bucket blade edge speed is larger than the map value: Limit value is set as the target speed.
When the tilt bucket blade edge speed is smaller than the map value: No limit value is set and current value
is left as it is.
REMARK
command in order to set the bucket TILT speed to the val-
ue which has been calculated.
REMARK
can be calibrated in the “Auto-Tilt Bucket Control Ad-
justment” in “MC Setting” in service mode on the ma-
chine monitor. (For the calibration procedure, see “Au-
to-Tilt Bucket Control Adjustment”, “MC Setting”, “MA-
CHINE MONITOR”, “SETTING”, in Operation and
Maintenance Manual.)
• Tilt bucket PPC circuit does not have a spool stroke
sensor.
PC210LCI-11 10-329
1: Tilt bucket blade edge speed 3: Target speed of tilt bucket cylinder
2: Target speed of tilt bucket blade edge 4: EPC current value
4. The work equipment controller outputs the command of EPC current (A1) figured out, and the bucket TILT
speed decreases when the EPC valve is throttled (closed finally) (P1). (The bucket TILT is stopped finally.)
When normal manual operation is performed
Pressure reducing EPC valve of each shaft inserted in PPC circuit is fully opened by the work equipment con-
troller. Accordingly, the work equipment operates according to the lever operation performed by the operator
during manual operation.
The intervening EPC valve for boom RAISE is not controlled at all (it is fully closed).
The work equipment may become inoperable if the work equipment controller failed. In that case, the boom sec-
ondary drive switch enables the emergency escape.
(For how to use the boom secondary drive switch, see Operation and Maintenance Manual, "HANDLING", "EX-
PLANATION OF COMPONENTS".

2: PPC pressure reducing EPC valve (fully open) 6: Work equipment control lever
3: PPC pressure sensor 7: Boom RAISE EPC valve (fully closed)
10-330 PC210LCI-11
Arm control circuit
A: Arm OUT PPC circuit B: Arm IN PPC circuit

1: Work equipment controller 4: Arm spool (control valve)
2: PPC pressure reducing EPC valve (fully open) 5: Arm cylinder

2: PPC pressure reducing EPC valve (fully open) 5: Bucket cylinder
PC210LCI-11 10-331
Auto tilt bucket control circuit

(Machines with auto tilt bucket)
Input signal
1: Work equipment controller 6: Service flow rate adjustment EPC 2
2: ICT sensor controller 7: Service flow rate adjustment EPC 1
3: Pump controller 8: Control valve
4: ATT1 left pressure sensor 9: Stroke sensing bucket tilt cylinder
5: ATT1 right pressure sensor
10-332 PC210LCI-11
10 STRUCTURE AND FUNCTION CUSHION SYSTEM FOR ARM IN END
CUSHION SYSTEM FOR ARM IN END

CUSHION SYSTEM FOR ARM IN END DIAGRAM
Input and output signals d: Stroke and reset sensor signal for cylinder
a: Control Area Network signal 1 (Komnet/r) e: PPC Pressure signal (lever side)
b: Control Area Network signal 2 (Komnet/c) f. PPC pressure reduce pressure EPC drive signal
c. Cylinder stroke signal g. PPC pressure signal (control valve side)
1: ICT sensor controller 6. PPC valve
2: Work equipment controller 7. PPC pressure sensor (lever side)
3: Machine monitor 8. PPC pressure sensor (control valve side)
4: Stroke sensor for cylinder 9. EPC valve for intelligent Machine Control
5: Reset sensor for cylinder 10: Control valve
REMARK
Devices and systems used in the cushion system for arm IN end are common to those described in the ICT
control function.
FUNCTION OF CUSHION SYSTEM FOR ARM IN END

• The cushion system for arm IN end operates when the arm IN operation is performed.
• The cushion system for arm IN end reduces the impact caused when it reaches the stroke end of arm IN
operation by decreasing the speed of the arm cylinder around the stroke end.
• The arm IN PPC pressure is set not to be 0 MPa so that the warm-up operation can be operated even after
the arm cylinder reaches to the arm IN end.
OPERATION OF CUSHION SYSTEM FOR ARM IN END

1. The ICT controller (1) figures out the distance to the current arm IN end by calculating the information from
the cylinder stroke sensor (4) and the cylinder reset sensor (5), and transmits the data to the work equip-
ment controller (2).
2. The work equipment controller figures out the target speed for the arm cylinder by calculating the distance
information to the arm IN end.
3. The work equipment controller (2) outputs the EPC drive signal (PPC reducing pressure) corresponding to
the cylinder target speed which is figured out.
4. The arm IN reducing pressure EPC is operated by the EPC drive signal.
PC210LCI-11 10-333
CUSHION SYSTEM FOR ARM IN END 10 STRUCTURE AND FUNCTION
5. The arm IN PPC pressure which flows into the main valve is decreased so that it will not be higher than the
value obtained by the controller. Accordingly, the speed of the arm cylinder is decreased, and the impact
caused when the arm cylinder reaches the stroke end of arm IN operation is reduced.
10-334 PC210LCI-11
10 STRUCTURE AND FUNCTION BOOM SECONDARY DRIVE SWITCH
BOOM SECONDARY DRIVE SWITCH

CONTROL FUNCTION WHEN BOOM SECONDARY DRIVE SWITCH IS TURNED
TO ON POSITION
The boom secondary drive switch (1) is a switch used to ena-
ble the boom RAISE and LOWER operation by energizing the
intelligent Machine Control EPC valve for boom RAISE and
LOWER operation in case that abnormality occurs in the con-
troller, etc., and the work equipment cannot be operated.
a: Drive (when abnormal)
b: Normal (when normal)
REMARK
• Turning the boom secondary drive switch (1) to “a position
(Drive)” does not enable the boom RAISE and LOWER op-
eration when the PPC lock lever is locked.
• Operation should be performed with manual operation since
the intelligent Machine Control is not enabled when the
boom secondary drive switch (1) is in “a position (Drive)”.
• The boom secondary drive switch (1) is an alternative type.
An error message may appear on the machine monitor
when this switch is turned to “a position (Drive)”.
PC210LCI-11 10-335
COMPONENT PARTS OF ICT SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF ICT SYSTEM

ICT SENSOR CONTROLLER
STRUCTURE OF ICT SENSOR CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF ICT SENSOR CONTROLLER

DRC26-24P“CS01”
Input and output sig-
Pin No. Signal name
nals
1 Stroke and reset sensor for bucket cylinder Input
2 Stroke sensor B for boom cylinder Input
3 Stroke sensor A for arm cylinder Input
4 (*1) -
5 Model selection signal 4 Input
6 (*1) -
7 Stroke sensor B for bucket cylinder Input
8 Stroke sensor A for boom cylinder Input
9 Stroke sensor A for tilt bucket cylinder (*2) Input
10 (*1) -
12 (*1) -
13 Stroke sensor A for bucket cylinder Input
10-336 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ICT SYSTEM

Pin No. Signal name
nals
14 Stroke sensor B for tilt bucket cylinder (*2) Input
15 (*1) -
16 (*1) -
18 Design surface offset DOWN -
19 (*1) -
20 Stroke sensor B for arm cylinder Input
21 Analog signal GND 0 Input
24 Design surface offset UP -
DRC26-40P(A)“CS02”
Pin No. Signal name
nals
1 Potentiometer power supply 1 Output
2 Stroke and reset encoder Z for arm cylinder Input
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 Stroke and reset encoder B for arm cylinder Input
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 Stroke and reset encoder A for arm cylinder Input
18 (*1) -
19 TPS accessory signal Output
20 (*1) -
21 (*1) -
22 CAN0_L(KOMNET/c) Input and output
23 CAN1_L(KOMNET/r) Input and output
PC210LCI-11 10-337

Pin No. Signal name
nals
25 (*1) -
26 (*1) -
27 Stroke and reset encoder B for boom cylinder Input
28 (*1) -
29 Encoder pulse GND Input
30 (*1) -
31 (*1) -
32 CAN0_H(KOMNET/c) Input and output
33 CAN1_H(KOMNET/r) Input and output
34 (*1) -
35 (*1) -
36 (*1) -
37 Stroke and reset encoder A for boom cylinder Input
38 Stroke and reset encoder Z for boom cylinder Input
39 Encoder pulse GND Input
40 (*1) -
DRC26-40P(B)“CN03”
Pin No. Signal name
nals
2 Solenoid power supply (24 V) Input
3 (*1) -
4 Battery relay signal Output
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 TSP power supply (24 V) Input
13 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
10-338 PC210LCI-11

Pin No. Signal name
nals
18 (*1) -
19 (*1) -
21 Controller GND Input
23 (*1) -
25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
PC210LCI-11 10-339
WORK EQUIPMENT CONTROLLER

STRUCTURE OF WORK EQUIPMENT CONTROLLER
General view
INPUT AND OUTPUT SIGNALS OF WORK EQUIPMENT CONTROLLER

DRC26-24P“CW01”
Pin No. Signal name
nals
1 Arm IN PPC pressure sensor (lever side) Input
2 (*1) -
3 Arm spool stroke sensor (OUTPUT1) Input
5 (*1) -
6 (*1) -
7 Arm OUT PPC pressure sensor (lever side) Input
8 (*1) -
9 Boom spool stroke sensor (OUTPUT1) Input
10 (*1) -
11 EPC secondary switch signal Input
12 PPC source pressure sensor Input
13 Boom LOWER PPC pressure sensor (lever side) Input
14 Arm spool stroke sensor (OUTPUT2) Input
10-340 PC210LCI-11

Pin No. Signal name
nals
15 (*1) -
16 (*1) -
17 Region limitation control (hold) Input
18 Bucket CURL PPC pressure sensor (lever side) Input
19 Boom RAISE PPC pressure sensor (lever side) Input
20 Boom spool stroke sensor (OUTPUT2) Input
23 Region limitation control (change over) Input
24 Bucket DUMP PPC pressure sensor (lever side) Input

DRC26-40P(A)“CW02”
Pin No. Signal name
nals
1 Potentiometer power supply 1 Output
2 (*1) -
3 (*1) -
4 (*1) -
5 Arm IN PPC pressure sensor (valve side) Input
6 Swing RIGHT PPC pressure sensor Input
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
14 (*1) -
15 Arm OUT PPC pressure sensor (valve side) Input
16 Swing LEFT PPC pressure sensor Input
18 (*1) -
19 (*1) -
20 (*1) -
21 (*1) -
22 CAN0_L(KOMNET/c) Input and output
23 CAN1_L(KOMNET/r) Input and output
PC210LCI-11 10-341

Pin No. Signal name
nals
25 Boom LOWER PPC pressure sensor (valve side) Input
26 Bucket CURL PPC pressure sensor (valve side) Input
28 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
32 CAN0_H(KOMNET/c) Input and output
33 CAN1_H(KOMNET/r) Input and output
34 (*1) -
35 Boom RAISE PPC pressure sensor (valve side) Input
36 Bucket DUMP PPC pressure sensor (valve side) Input
38 (*1) -
39 (*1) -
40 (*1) -

DRC26-40P(B)“CW03”
Pin No. Signal name
nals
3 Solenoid GND Input
4 (*1) -
5 (*1) -
6 (*1) -
7 Bucket DUMP PPC pressure reducing EPC Output
8 Boom Raise PPC pressure reducing EPC Output
9 (*1) -
10 PPC lock lever signal Input
15 (*1) -
16 (*1) -
17 Bucket CURL PPC pressure reducing EPC Output
18 Boom LOWER PPC pressure reducing EPC Output
10-342 PC210LCI-11

Pin No. Signal name
nals
19 (*1) -
25 (*1) -
26 (*1) -
27 Boom RAISE PPC pressure intervening EPC Output
28 Arm OUT PPC pressure reducing EPC Output
29 (*1) -
30 Starting switch C signal Input
34 Busy signal Output
35 (*1) -
36 (*1) -
37 Boom RAISE intervening EPC cut relay Output
38 Arm IN PPC pressure reducing EPC Output
39 (*1) -
40 (*1) -
PC210LCI-11 10-343
CONTROL BOX
STRUCTURE OF CONTROL BOX
General view
1: Touch panel 6: Auto/manual switch

2: Connector: CN5-4P (USB port) 7: Connector: CN4-4P (USB port)
3: Connector: CN2-26P 8: Reset button
4: Connector: CN1-26P 9: Power supply button
5: Connector: CN3-8P (LAN port)
Structure
This monitor employs the touch panel type monitor.
Precautions on the control box display
• An LCD panel sometimes shows black spots (spots that remain unlit) and bright spots (spots that do not go
off) as one of the characteristics, but it is not a failure.
• The battery voltage may suddenly drop when starting the engine depending on the temperature and the
battery condition. The screen may disappear temporarily in this case, but it is not a failure.
FUCTION OF CONTROL BOX

• The control box has the monitor display function, mode selection function, and the switch function of GNSS
antenna, etc. It also has the built-in warning buzzer.
10-344 PC210LCI-11
• CPU (Central Processing Unit) is mounted inside the control box, and it processes, displays, and outputs
information.
• The control box consists of the display and switch section. The display is LCD (Liquid Crystal Display), and
the switch section consists of flat sheet switches.
• The control box does not display correctly if there is any abnormality in the machine monitor, controller, or
wiring between the machine monitor and controller.
• The control box processes, displays, and outputs the location information of global positioning system.
• The control box displays the design surface, set it and adjust it.
INPUT AND OUTPUT SIGNALS OF CONTROL BOX

CN1–26P“CX01”
Pin No. Signal name
nals
1 Power supply -
3 GND -
4 (*1) -
5 L.H. headphone Output
6 (*1) -
7 GND -
8 J1939 Hi Input and output
9 J1939 Lo Input and output
10 CAN2 Hi Input and output
11 CAN2 Lo Input and output
12 (*1) -
13 GND -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
25 (*1) -
26 (*1) -
PC210LCI-11 10-345
CN2-26P“CX02”
Pin No. Signal name
nals
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 Lighting switch signal Input and output
20 (*1) -
21 (*1) -
22 (*1) -
23 (*1) -
24 TPS power supply signal Output
25 GND (speaker) -
26 (*1) -

CN3-8P“CX03”
Pin No. Signal name
nals
1 ENET 0TX+ Output
2 ENET 0TX- Input
3 ENET 0RX+ Output
4 (*1) -
5 (*1) -
6 ENET 0RX- Input
7 (*1) -
10-346 PC210LCI-11

Pin No. Signal name
nals
8 (*1) -

CN4-8P“S55”
Pin No. Signal name
nals
NO1 (*1) -
NC2 Auto/manual signal (hold) Input
NC1 Auto/manual signal (change over) Input
NO2 (*1) -
L(-) GND Output
L(+) Lighting switch signal Input
CAN1 GND Output
CAN2 GND Output
PC210LCI-11 10-347
GNSS RECEIVER
GNSS
Abbreviation for Global Navigation Satellite System
STRUCTURE OF GNSS RECEIVER

General view
1: External GPS antenna connection port 4: Machine wiring harness connection port
2: GNSS antenna connection port (DRC26-40P(B))
3: Machine wiring harness connection port 5: Radio antenna connection port

(DRC26-40P(A))
FUNCTION OF GNSS RECEIVER

• The GNSS receiver receives the GNSS positioning information from GNSS satellite through GNSS anten-
na, and processes them.
• The GNSS receiver receives the corrected GNSS positioning information from base station through a radio
antenna, and processes them.
• The GNSS receiver receives the information from network signals or input signals inside the machine, and
processes them.
• The GNSS receiver figures out the GNSS antenna coordinates information, and outputs them.
INPUT AND OUTPUT SIGNALS OF GNSS RECEIVER

DRC26-40P(A)“CG01”
Pin No. Signal name
nals
1 (*1) -
2 GND -
10-348 PC210LCI-11

Pin No. Signal name
nals
3 ENET 0RX+ Input
4 (*1) -
5 RS232C (A) RXD Input
6 TX CTRL RS232C 1 Output
7 RX CTRL RS233C 1 Input
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 ENET 0RX- Input
14 (*1) -
15 Power supply (Control box) Input
16 GND (Control box) -
17 RS232C (D) RXD Input
18 (*1) -
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 ENET 0TX+ Input
24 Switch signal (control box) Input
26 GND -
27 RS232C (D) TXD Input
28 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
32 Power supply 12 V (external radio device) -
33 ENET 0TX- Output
34 RS232C (A) TXD Input
35 Power supply -
36 GND -
37 (*1) -
38 (*1) -
39 (*1) -
40 (*1) -
PC210LCI-11 10-349

DRC26-40P(B)“CG02”
Pin No. Signal name
nals
1 (*1) -
2 (*1) -
3 (*1) -
4 RS232C (C) TXD Input
5 (*1) -
6 ENET 1RX+ Input
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 RS232C (C) RXD Input
15 (*1) -
16 ENET 1RX- Output
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 (*1) -
24 (*1) -
25 (*1) -
26 ENET 1TX+ Input
27 (*1) -
28 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
32 (*1) -
33 (*1) -
34 (*1) -
35 (*1) -
36 ENET 1TX- Output
10-350 PC210LCI-11

Pin No. Signal name
nals
37 VSUPPLY Output
38 GND -
39 (*1) -
40 (*1) -
PC210LCI-11 10-351
GNSS ANTENNA
GNSS
Abbreviation for Global Navigation Satellite System
STRUCTURE OF GNSS ANTENNA

General view
1: Connector
FUNCTION OF GNSS ANTENNA

This antenna is installed to the handrail and receives radio waves of GNSS positioning data from a satellite.
10-352 PC210LCI-11
IMU SENSOR
IMU
Abbreviation for Inertial Measurement Unit
STRUCTURE OF IMU SENSOR

General view
1: Connector
FUNCTION OF IMU SENSOR

• The IMU sensor is installed to the inside of the machine. It detects the machine posture state, and outputs
the information.
• The IMU sensor detects angular velocities and acceleration of three axes of the longitudinal, the lateral, and
the vertical directions of the machine as the machine posture information.
NOTICE
If the IMU sensor fails to function properly, it reduces the finishing accuracy of the earthmoving opera-
tion design surface.
PC210LCI-11 10-353
INTELLIGENT MACHINE CONTROL EPC VALVE

STRUCTURE OF INTELLIGENT MACHINE CONTROL EPC VALVE
General view
C: To control valve (angle port) T: To hydraulic tank

P: From pump
1: Body 5: Push pin
2: Plug 6: Coil
3: Spool 7: Plunger
4: Spring 8: Connector
FUNCTION OF INTELLIGENT MACHINE CONTROL EPC VALVE

• The intelligent Machine Control EPC valve consists of the proportional solenoid part and the hydraulic valve
part.
10-354 PC210LCI-11
• The intelligent Machine Control EPC valve receives the

signal currentfrom the work equipment controller, and out-
puts the EPC output pressure in proportion to the signal
current to the control valve.
OPERATION OF INTELLIGENT MACHINE CONTROL EPC VALVE

When signal current is zero (coil is de-energized)
1. When the signal current from the controller does not flow
into coil (1), coil (1) is de-energized.
2. Spool (2) is pressed to the right by spring (3).
3. The port (P) is closed and no pressurized oil from the
pump flows into the control valve.
4. The pressurized oil from the control valve flows through
port (C) and port (T), and drained into the tank.
PC210LCI-11 10-355
When signal current is minute (coil is energized)

1. When minute signal current flows through coil (1), coil (1)
is energized to generate thrust in leftward direction of
plunger (4).
2. The push-pin (5) pushes spool (2) to the left, and the pres-
surized oil from port (P) flows into port (C).
3. The pressure at port (C) increases and the total of the
force applied to surface (a) of spool (2) and the force of
spring (3) becomes larger than thrust of plunger (4).
4. The spool (2) is pushed to the right and port (P) and port
(C) are disconnected, and port (C) and port (T) are con-
nected.
5. The spool (2) moves so that the thrust of plunger (4) is bal-
anced with the total of the pressure in port (C) and load of
spring (3).
6. The circuit pressure between the intelligent Machine Con-
trol EPC valve and the control valve is controlled in propor-
tion to the signal current.
When signal current is maximum (coil is energized)

1. When the signal current flows into coil (1), coil (1) is ener-
gized.
2. Since the signal current is maximum at this time, the thrust
of plunger (4) also becomes the maximum.
3. The spool (2) is pushed to the left by push-pin (5).
4. The maximum rate of the pressurized oil flows from port
(P) to port (C), and the circuit pressure between the intelli-
gent Machine Control EPC valve and the control valve be-
comes the maximum.
5. The port (T) closes and no pressurized oil flows into the
hydraulic tank.
10-356 PC210LCI-11
STROKE SENSOR FOR BOOM CYLINDER

STRUCTURE OF STROKE SENSOR FOR BOOM CYLINDER
NOTICE
Do not disassemble. It will require an adjustment to obtain an optimal performance.
General view
1: Stroke sensor 3: Connector

2: Tube
FUNCTION OF STROKE SENSOR FOR BOOM CYLINDER
PC210LCI-11 10-357
• The stroke sensor part of this sensor detects the stroke amount, and outputs the variable voltage.
• This sensor detects the stroke amount of cylinder rod (1) by the rotation of stroke sensor roller (2) which is
pressed onto the surface of cylinder rod (1).
Output characteristics
• The relationship between the stroke and the output voltage
is shown in the following graph.
10-358 PC210LCI-11
STROKE SENSOR FOR ARM CYLINDER

STRUCTURE OF STROKE SENSOR FOR ARM CYLINDER
NOTICE
General view
1: Stroke sensor 3: Connector

2: Tube
FUNCTION OF STROKE SENSOR FOR ARM CYLINDER
PC210LCI-11 10-359
10-360 PC210LCI-11
STROKE AND RESET SENSOR FOR BUCKET CYLINDER

STRUCTURE OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER
NOTICE
General view
1: Stroke sensor 3: Reset sensor

2: Tube 4: Connector
FUNCTION OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER

• The reset sensor part (3) of this sensor corrects a difference from the actual stroke amount.
PC210LCI-11 10-361
FUNCTION OF STROKE SENSOR FOR BUCKET CYLINDER
FUNCTION OF RESET SENSOR FOR BUCKET CYLINDER
10-362 PC210LCI-11
• The reset sensor part (2) of this sensor detects the magnetic force of magnet (1) installed to piston (3).
PC210LCI-11 10-363
RESET SENSOR FOR BOOM CYLINDER

STRUCTURE OF RESET SENSOR FOR BOOM CYLINDER
NOTICE
General view
1: Shaft 3: Connector
2: Housing
FUNCTION OF RESET SENSOR FOR BOOM CYLINDER

• This sensor is installed to the boom foot portion. This sensor detects the resetting position of the boom.
• This sensor outputs the three types of pulse signals corresponding to the resetting position of the boom.
10-364 PC210LCI-11
RESET SENSOR FOR ARM CYLINDER

STRUCTURE OF RESET SENSOR FOR ARM CYLINDER
NOTICE
General view
1: Shaft 3: Connector
2: Housing
FUNCTION OF RESET SENSOR FOR ARM CYLINDER

• This sensor is installed to the arm foot portion. This sensor detects the resetting position of the arm.
• This sensor outputs the three types of pulse signals corresponding to the resetting position of the arm.
PC210LCI-11 10-365
BOOM SPOOL STROKE SENSOR

STRUCTURE OF BOOM SPOOL STROKE SENSOR
NOTICE
General view
1: Connector 2: Stroke sensor
FUNCTION OF BOOM SPOOL STROKE SENSOR

• This sensor is installed to the spring case of boom spool of control valve. This sensor is pushed by the ter-
minal of spool. This sensor detects the movement of boom spool stroke.
10-366 PC210LCI-11
• The relationship between the stroke and the output voltage is shown in the following graph.
PC210LCI-11 10-367
ARM SPOOL STROKE SENSOR

STRUCTURE OF ARM SPOOL STROKE SENSOR
NOTICE
General view
1: Connector 3: Stroke sensor
FUNCTION OF ARM SPOOL STROKE SENSOR

• This sensor is installed to the spring case of arm spool of control valve. This sensor is pushed by the termi-
nal of spool. This sensor detects the movement of arm spool stroke.
10-368 PC210LCI-11
• The relationship between the stroke and the output voltage is shown in the following graph.
PC210LCI-11 10-369
LAYOUT DRAWING OF SWING SYSTEM 10 STRUCTURE AND FUNCTION
SWING SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
Chassis part
1: Swing circle 4: Swing motor

2: Center swivel joint 5: Control valve
3: Swing machinery 6: Main pump
10-370 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM
7: Swing RIGHT oil pressure switch 8: Swing LEFT oil pressure switch
PC210LCI-11 10-371
LAYOUT DRAWING OF SWING SYSTEM 10 STRUCTURE AND FUNCTION
9: 2-stage swing relief solenoid valve 10: Swing parking brake solenoid valve
10-372 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM
1: Machine monitor 4: Swing parking brake cancel switch

2: Swing lock switch 5: Work equipment controller
3: Pump controller
PC210LCI-11 10-373
SWING CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
SWING CONTROL SYSTEM DIAGRAM
Input and output signals e: 2-stage swing relief solenoid valve drive signal
a: Swing parking brake cancel switch signal f: Oil pressure sensor signal
b: Swing parking brake solenoid valve drive signal g: Oil pressure switch signal
c: CAN signal h: CAN signal
d: Swing lock switch signal
1: Battery disconnect switch 12: Oil pressure sensor
2: Battery 13: Main pump
3: Battery relay 14: Control valve
4: Fusible link 14a: Self-pressure reducing valve
5: Fuse box 14b: Merge-divider valve
6: Swing parking brake cancel switch 14c: Travel junction valve
7: Swing lock switch 15: Swing motor
8: Pump controller 15a: 2-stage relief valve
9: Work equipment controller 16: Swing parking brake solenoid valve
10: Machine monitor 17: 2-stage swing relief solenoid valve
11: Oil pressure switch
FUNCTION OF SWING CONTROL SYSTEM

Swing lock and swing parking brake function
• The operator can lock the swing operation at any position
by turning ON swing lock switch (1) of the swing lock sys-
tem (manual type).
• The swing parking brake (automatic) is interlocked with the
swing operation and prevents hydraulic drift after swing is
stopped.
• To reduce the load on the swing device during digging
work, the swing parking brake is released simultaneously
with operations of R.H. and L.H. work equipment control
levers and attachment control pedal.
10-374 PC210LCI-11
10 STRUCTURE AND FUNCTION SWING CONTROL SYSTEM DIAGRAM
Swing lock
OFF ON
switch
Swing lock moni-
Lights off Lights up
tor
Function Swing parking brake Swing lock
• When the R.H. and L.H. work equipment
control levers and attachment control
pedal are set to NEUTRAL, the swing • The swing parking brake operates to lock
parking brake operates approximately 5 the swing operation.
seconds later. • Even if the L.H. work equipment control
Operation
• When R.H. or L.H. work equipment con- lever is operated to swing, the swing
trol lever or the attachment control pedal parking brake is not released and the up-
is operated, the swing parking brake is per structure does not swing.
released and the upper structure can
swing freely.
A: Work equipment control lever or attachment control pedal is

operated (swing parking brake is released)
B: Work equipment control lever and attachment control pedal
are in NEUTRAL
C: Swing parking brake operates
D: Approximately 5 seconds
Swing parking brake cancel function

k While the swing parking brake is released, only the hydraulic brake is applied by the relief valve. If
swing is stopped on a slope, the hydraulic drift may occur. Take care.
If the swing parking brake does not operate normally and the upper structure cannot swing because of trouble in
the controller, etc., the operator can swing by releasing the swing parking brake with swing parking brake cancel
switch (2).
Swing parking
brake cancel Cancel (when controller is abnormal) Normal (when controller is normal)
switch
Swing lock
ON OFF ON OFF
switch
Swing lock is canceled Swing parking brake
Swing brake Swing lock is applied Swing lock is applied
(*) operates
*: Operation of hydraulic brake by relief valve

REMARK
• Even if swing parking brake cancel switch (2) is set to CANCEL position (a), the swing parking brake is not
released while the swing lock switch is ON.
• Swing parking brake cancel switch (2) is alternate type. When it is set to RELEASE (a) position, the swing
lock monitor on the machine monitor flashes.
PC210LCI-11 10-375
SWING CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
a: Release (when abnormal) b: Normal (when normal)

Quick warm-up function
When swing lock switch (1) is turned ON, the pump cut-off
function is canceled and the main relief pressure increases. If
the work equipment is relieved while the main relief pressure is
high, the hydraulic oil temperature increases quickly, and the
warm-up time is shortened.
Operating condition Main relief pressure
34.8 MPa {355 kg/cm2}
Swing lock switch: ON ↓
37.2 MPa {380 kg/cm2}
2-stage swing relief function

During swing acceleration, the set pressure of 2-stage swing relief valve is changed to reduce the relief flow and
improve the fuel consumption.
Operating condition Relief flow rate
180 ℓ/min
During swing acceleration
↓
(except abrupt swing back operation)
70 ℓ/min
Relation between set pressure and flow rate
10-376 PC210LCI-11
10 STRUCTURE AND FUNCTION SWING CONTROL SYSTEM DIAGRAM
A: When pilot pressure is blocked (low-pressure setting)

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

B: Flow at high-pressure setting
C: Flow rate necessary to swing
Z: Loss reducing (improving fuel consumption) area at relief
PC210LCI-11 10-377
COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF SWING SYSTEM

SWING MOTOR
STRUCTURE OF SWING MOTOR
General view
MA: From control valve (swing LEFT port) S: From control valve (variable back pressure valve)
MB: From control valve (swing RIGHT port) T: To hydraulic tank
B: From swing parking brake solenoid valve P1: From 2-stage relief solenoid valve
1: Reverse prevention valve 2: 2-stage swing relief valve
10-378 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM
Sectional view
1: Brake spring 8: Housing

2: Drive shaft 9: Piston
3: Spacer 10: Cylinder block
4: Case 11: Valve plate
5: Disc 12: Center shaft
6: Plate 13: Center spring
7: Brake piston 14: Check valve
PC210LCI-11 10-379
15: Shuttle valve
SPECIFICATIONS OF SWING MOTOR

Model: KMF125ABE-6
Theoretical discharged volume: 125 cm3/rev
2-stage swing relief pressure: 28.4 MPa {290 kg/cm2}
2-stage swing relief flow rate (low-pressure setting): 180 ℓ/min
2-stage swing relief flow rate (high-pressure setting): 70 ℓ/min
Rated speed: 1694 rpm
Brake releasing pressure: 1.6 ± 0.4 MPa {16 ± 4 kg/cm2}
FUNCTION OF SWING MOTOR

The swing motor converts the fluid energy of hydraulic oil into rotational mechanical energy and swings the up-
per structure.
SWING PARKING BRAKE OF SWING MOTOR

OPERATION OF SWING PARKING BRAKE OF SWING MOTOR
When solenoid valve is de-energized (swing parking brake operates)
1. When the swing parking brake solenoid valve is de-ener-
gized, the pressurized oil from the self-pressure reducing
valve is stopped.
2. Port (B) is connected to tank circuit (T).
3. Brake piston (7) is pushed down by brake spring (1).
4. Discs (5) and plates (6) are pressed and the brake oper-
ates.
10-380 PC210LCI-11
When solenoid valve is energized (swing parking brake is canceled)

1. When the swing parking brake solenoid valve is energized,
the valve is changed.
2. The pressurized oil from the self-pressure reducing valve
flows into brake chamber (a) through port (B).
3. The pressurized oil in chamber (a) compresses brake
spring (1) and moves up brake piston (7).
4. Discs (5) and plates (6) separate and the brake is re-
leased.
CHECK VALVE, SHUTTLE VALVE, AND 2-STAGE SWING RELIEF VALVE OF

SWING MOTOR
FUNCTION OF CHECK VALVE, SHUTTLE VALVE, AND 2-STAGE SWING RELIEF
VALVE OF SWING MOTOR
• When the upper structure stops swinging, the motor outlet
circuit is closed by control valve (6), but the motor is turned
by the inertial force.
• If the motor outlet circuit pressure increases abnormally,
the motor may be damaged.
• Abnormally high pressure is released from the motor outlet
(high-pressure side) to port (S) to prevent damage to the
motor.
PC210LCI-11 10-381
OPERATION OF CHECK VALVE, SHUTTLE VALVE, AND 2-STAGE SWING RE-

LIEF VALVE OF SWING MOTOR
When starting swing
1. When swing RIGHT operation is performed, the pressur-
ized oil from the pump flows through control valve (6) into
port (MA).
2. The pressure in port (MA) increases, and starting torque
occurs and rotates the motor.
3. During swing acceleration, the pilot pressure from the 2-
stage swing relief solenoid valve is added to port (P1), and
the relief rate is limited.
4. The pressurized oil from the motor outlet returns to the
tank through port (MB) and control valve (6).
When stopping swing

1. When the swing control lever is returned from swing
RIGHT position to NEUTRAL position, the pressurized oil
from the pump is not supplied to port (MA).
2. Since the return circuit of the pressurized oil from the mo-
tor output to the tank is closed by control valve (6), the
pressure in port (MB) increases.
3. When the pressure in port (MB) becomes high, the oil re-
turns to the hydraulic tank through 2-stage swing relief
valve (1) and port (S).
4. Rotational resistance occurs in the motor, and the brake
starts working.
5. When the pressure in port (MA) exceeds that in port (MA),
it pushes shuttle valve (4).
6. The pressure in chamber (C) becomes the same with port
(MB) and increases to the set pressure of relief valve.
7. High braking torque acts on the motor, and the motor
stops.
8. While relief valve (1) is in operation, the relieved pressur-
ized oil and the pressurized oil from port (S) are supplied
to port (MA) through check valve (3).
9. Cavitation in port (MA) is prevented.
10-382 PC210LCI-11
2-STAGE SWING RELIEF VALVE OF SWING MOTOR

STRUCTURE OF 2-STAGE SWING RELIEF VALVE OF SWING MOTOR
Sectional view
1: Valve seat 4: Spring

2: Valve 5: Spring
3: Poppet 6: Piston
FUNCTION OF 2-STAGE SWING RELIEF VALVE OF SWING MOTOR
• The set pressure can be changed to 2 stages.

• The set pressure depends on the load at installed height of spring (4).
• During swing acceleration, the relief rate (drain rate) is reduced by receiving pilot pressure (P1) from the 2-
stage swing relief solenoid valve.
• When pressure (P) is constant, energy loss can be suppressed by reducing flow (Q), or relief rate (drain
rate), according to the formula of [Energy loss = Pressure (P) x Flow (Q)]. Fuel efficiency can be improved
by suppressing the energy loss.
PC210LCI-11 10-383
Relation between set pressure and flow rate
A: When pilot pressure is blocked (low-pressure set- P: 28.4 MPa {290 kg/cm2}

ting) Q1: 180 ℓ/min
B: When pilot pressure is supplied (high-pressure set- Q2: 70 ℓ/min
ting)
OPERATION OF 2-STAGE SWING RELIEF VALVE OF SWING MOTOR

When pilot pressure (PU) is cut off (low pressure setting)
The set pressure depends on the installed load of spring (4).
10-384 PC210LCI-11
When pilot pressure (PU) is supplied (high pressure setting)
1. During swing acceleration, pilot pressure (P1) from the 2-stage swing relief solenoid valve acts on pressure
receiving area (d2 - d1).
2. Spring (4) is compressed and its installed load increases, and the pump discharged volume is reduced by
the controller and the passage between valve (2) and valve seat (1) is choked.
By the above operation, the relief rate is reduced when the relief pressure is constant.
PC210LCI-11 10-385
SWING MOTOR REVERSE PREVENTION VALVE

STRUCTURE OF SWING MOTOR REVERSE PREVENTION VALVE
10-386 PC210LCI-11
MA: From control valve (swing LEFT port) T1: To hydraulic tank
MB: From control valve (swing RIGHT port) T2: To hydraulic tank
1: Valve body 5: Spool (MB side)
2: Spool (MA side) 6: Spring (MB side)
3: Spring (MA side) 7: Plug (MB side)
4: Plug (MA side)
Figure to explain effect
FUNCTION OF SWING MOTOR REVERSE PREVENTION VALVE

• When the swing operation is stopped, the upper structure may swing back. This is due to inertia of the
weight of the upper structure, the backlash and rigidity of the swing machinery system, or compression of
the hydraulic oil. This valve can reduce such movement.
• The valve contributes in preventing spill of load when the swing is stopped and also contributes in reducing
cycle time (enhances the positioning performance, and enables to proceed to the next work quicker).
PC210LCI-11 10-387
OPERATION OF SWING MOTOR REVERSE PREVENTION VALVE

When brake pressure occurs in port (MB)
1. Pressure (MB) flows to chamber (d) through notch (g).
2. The circle area difference of spool (5) (diameter D1 > di-
ameter D2) compresses spring (6) and moves spool (5) to
the left.
3. Port (MB) and chamber (e) are connected.
4. Spool (2) does not move since pressure (MA) is the set
pressure of spring (3) or lower. The pressurized oil is
closed and the braking force is secured.
When motor reverse pressure occurs in port (MA)

1. The motor rotates in reverse by the closed pressure gener-
ated in port (MB). (First reverse rotation)
2. The reverse pressure occurs in port (MA) side. Pressure
(MA) flows to chamber (a).
3. The circle area difference of spool (2) (diameter D3 > di-
ameter D4) compresses spring (3) and moves spool (2) to
the right.
4. Port (MA) and chamber (b) are connected.
5. The oil flows through drilled hole (h) of spool (5) and port
(b) and port (f) are connected. The reverse pressure of
port (MA) is bypassed to port (T) to prevent the second re-
verse rotation.
10-388 PC210LCI-11
SWING MACHINERY
STRUCTURE OF SWING MACHINERY
1: Swing pinion (number of teeth: 13) 2: No. 2 planetary carrier
PC210LCI-11 10-389
3: No. 2 sun gear (number of teeth: 18) 9: Dipstic/oil filler port cap
4: No.2 planetary gear (number of teeth: 19) 10: No. 1 sun gear (number of teeth: 17)
5: No. 1 planetary carrier 11: Ring gear (number of teeth: 58)
6: No.1 planetary gear (number of teeth: 20) 12: Swing machinery case
7: Swing motor 13: Drain plug
8: Breather
SPECIFICATIONS OF SWING MACHINERY

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
FUNCTION OF SWING MACHINERY

The swing machinery reduces the swing motor speed, increases the swing force, and reduces the swing speed
to proper speed.
10-390 PC210LCI-11
SWING CIRCLE
STRUCTURE OF SWING CIRCLE
a: Stamping position of inner race soft zone b: Position of outer race soft zone
1: Grease fitting of swing circle bearing 4: Ball
2: Greasing port of swing circle pinion 5: Outer race
3: Inner race (number of teeth: 96) 6: Seal
SPECIFICATIONS OF SWING CIRCLE

Reduction ratio: -96/13 = -7.385
Grease: G2-LI
Quantity of grease: 14.6 ℓ
FUNCTION OF SWING CIRCLE

The swing circle connects the upper structure and carrier unit.
PC210LCI-11 10-391
LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
10-392 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF TRAVEL SYSTEM
1: Control valve 4: Fuel supply pump

2: Main pump 5: Engine controller
3: LS-EPC valve 6: Travel alarm
7: Travel control lever 10: Pump controller

8: Machine monitor 11: R.H. travel REVERSE pressure sensor
9: Fuel control dial 12: R.H. travel FORWARD pressure sensor
PC210LCI-11 10-393
LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION
13: Travel PPC valve 15: L.H. travel REVERSE pressure sensor
14: L.H. travel FORWARD pressure sensor
16: Front pump oil pressure sensor 19: Travel junction solenoid valve
17: Control valve 20: Travel speed increase solenoid valve
18: Rear pump oil pressure sensor
10-394 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF TRAVEL SYSTEM
21: Center swivel joint 22: Travel motor
PC210LCI-11 10-395
TRAVEL CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION
TRAVEL CONTROL SYSTEM DIAGRAM
a: Oil pressure sensor signal g: Oil pressure sensor signal

b: CAN signal h: Travel alarm operation signal
c: LS-EPC valve drive signal i: 1st throttle signal
d: Solenoid valve GND j: Fuel supply pump control signal
e: Travel junction solenoid valve drive signal k: Various sensor signals
f: Travel speed increase solenoid valve drive signal
1: Pump controller 11c: PC valve
2: Engine controller 12: Rear pump
3: Machine monitor 12a: Servo
4: Fuel control dial 12b: LS valve
5: Fuel supply pump 12c: PC valve
6: Various sensors 13: Control valve
7: Front pump oil pressure sensor 13a: Self-pressure reducing valve
8: Rear pump oil pressure sensor 13b: Merge-divider valve
9: Oil pressure sensor 13c: Travel junction valve
10: Travel alarm 14: Travel motor
11: Front pump 15: Travel speed increase solenoid valve
11a: Servo 16: Travel junction solenoid valve
11b: LS valve 17: LS-EPC valve
10-396 PC210LCI-11
10 STRUCTURE AND FUNCTION TRAVEL CONTROL SYSTEM DIAGRAM
FUNCTION OF TRAVEL CONTROL SYSTEM

Travel speed selector function
Manual change of travel speed
The operator can change the travel speed by setting the travel speed selector switch to Hi, Mi, or Lo position to
change the motor capacity.
Travel speed selector switch Lo (Low speed) Mi (Middle speed) Hi (High speed)
Motor flow 75 % 70 % 100 %
Motor capacity Max. Min. Min.
Travel speed 3.0 km/h 4.1 km/h 5.5 km/h
Automatic change of travel speed

• Automatic change in accordance with engine speed
When the engine speed is decreased to 1500 rpm or below by using the fuel control dial, the travel speed
does not change to "Hi" if the current speed is Mi, but changes to Mi automatically if the current speed is Hi.
• Automatic change in accordance with pump discharged pressure
• While traveling with the travel speed selector switch at Hi position, if the load increases on uphill slope,
etc., and the travel pressure is 30.4 MPa {310 kg/cm2} or higher for 0.5 seconds or more, the motor
capacity is changed automatically and the travel speed is changed to a middle speed (a speed equiva-
lent to Mi) (however, travel speed selector switch is kept at Hi position).
• While traveling at low speed set by the automatic travel speed change with load, when the load de-
creases on a flat or downhill slope and the travel pressure is 16.7 MPa {170 kg/cm2} or less for 0.5
seconds or more, the motor capacity is changed automatically and the travel speed is returned to the
set speed of Hi.
A: 16.7 MPa {170 kg/cm2}
B: 30.4 MPa {310 kg/cm2}
C: 0.5 seconds or more
D: 0.5 seconds or more
Pump control function when traveling

For details, see “Engine and pump combined control function”.
Travel junction function
• When the travel lever is operated, the control system detects the pilot pressure and judges if the operation
is straight travel or steering.
• In the straight travel operation, signals are sent to the travel junction solenoid valve to set the flow rates to
the right and left travel motors to almost the same level to prevent travel deviation and improve the straight
travel performance.
• In the steering operation, signals to the travel junction solenoid valve are blocked to set the flow rates to the
right and left travel motors independently to improve the travel performance during steering.
PC210LCI-11 10-397
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF TRAVEL SYSTEM

TRAVEL MOTOR
STRUCTURE OF TRAVEL MOTOR
General view
L.H. travel motor

PA: From control valve (left travel FORWARD port)
PB: From control valve (left travel REVERSE port)
10-398 PC210LCI-11
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM
R.H. travel motor

PA: From control valve (right travel REVERSE port)
PB: From control valve (right travel FORWARD port)
Common to R.H. and L.H. travel motors
P: From travel speed increase solenoid valve
B: Plug (break release pressure port)
MA: Port (MA) pressure pickup port
MB: Port (MB) pressure pickup port
PC210LCI-11 10-399
Sectional view
1: Regulator piston 6: Rocker cam

2: Motor case 7: Retainer guide
3: Regulator valve 8: Output shaft
4: Suction safety valve 9: Pin
5: Check valve 10: Retainer
10-400 PC210LCI-11
11: Piston 16: Brake piston

12: Cylinder block 17: Plate
13: Valve plate 18: Disc
14: Counterbalance valve spool 19: Ball retainer
15: Ring
SPECIFICATIONS OF TRAVEL MOTOR

Model: HMV120-2
Theoretical discharged volume (Min.): 82 cm3/rev
Theoretical discharged volume (Max.): 120 cm3/rev
Rated pressure: 37.3 MPa {380 kg/cm2}
Rated speed (at max. discharged volume): 2565 rpm
Rated speed (at min. discharged volume): 1595 rpm
Brake releasing pressure: 1.18 MPa {12 kg/cm2}
Travel speed selector pressure: 0.78 MPa {8.0 kg/cm2}
FUNCTION OF TRAVEL MOTOR

The travel motor converts the fluid energy of hydraulic oil into rotational mechanical energy, and travels the ma-
chine.
PC210LCI-11 10-401
MOTOR PORTION OF TRAVEL MOTOR

OPERATION OF MOTOR PART OF TRAVEL MOTOR
During low-speed travel (motor swash plate angle is maximum)
1. When the solenoid valve is de-energized, no pilot pressure oil flows from the self-pressure reducing valve
to port (P).
2. Regulator valve (9) is pressed right by spring (10).
3. The pressurized oil is transmitted to end cover (8) from control valve by pushing check valve (22), but it is
blocked by regulator valve (9).
4. Fulcrum (a) of rocker cam (4) is decentering against application point (b) of a resultant force of piston thrust
of cylinder (6).
5. Resultant force of piston thrust acts as a moment to tilt rocker cam (4) to the direction of maximum swash
plate angle.
6. The pressurized oil in regulator piston (15) is drained to motor case through orifice (c) of regulator valve (9).
10-402 PC210LCI-11
7. Rocker cam (4) tilts to the direction of maximum swash plate angle, and motor capacity becomes maximum
and machine travels at low speed.
During high-speed travel (motor swash plate angle is minimum)
1. When the solenoid valve is energized, the pressurized pilot oil from the self-pressure reducing valve flows
into port (P).
2. It pushes regulator valve (9) to the left.
3. The pressurized oil from the control valve flows to regulator piston (15) through passage (d) of regulator
valve (9).
4. It pushes regulator piston (15) to the right.
5. Rocker cam (4) tilts to the direction of minimum swash plate angle, and motor capacity becomes minimum
and machine travels at high speed.
PC210LCI-11 10-403
PARKING BRAKE OF TRAVEL MOTOR

OPERATION OF PARKING BRAKE OF TRAVEL MOTOR
When machine starts traveling (parking brake is canceled)
1. When the travel lever is operated, the pressurized oil from the pump operates counterbalance valve spool
(19) and opens the parking brake circuit.
2. The oil flows into chamber (e) of brake piston (12) and shortens spring (11) to push piston (12) to the left.
3. Press force to plate (13) and disc (14) is lost, and plate (13) and disc (14) apart each other to release the
brake.
10-404 PC210LCI-11
When machine stops traveling (parking brake is applied)
1. When the travel lever is set in NEUTRAL position, counter balance valve spool (19) returns to neutral posi-
tion to close the parking brake circuit.
2. The pressurized oil in chamber (e) of brake piston (12) is drained to case through orifice (f) of brake piston
(12).
3. Brake piston (12) is pushed down to the right by spring (11).
4. Plate (13) is pressed to disc (14) and brake is applied.
5. When brake piston (12) returns, pressurized oil flow is throttled by slow return valve (22).
6. Time delay is set so that the brake is applied after the machine stops.
PC210LCI-11 10-405
COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL MOTOR

FUNCTION OF COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL
MOTOR
1: Counterbalance valve
2: Check valve
• When the machine travels downhill, it tends to travel faster
than the motor (engine) rotation because of its gravity.
• If the machine travels downhill with the engine at low
speed, the motor runs idle and the machine runs away.
This is very dangerous.
• This valve prevents the motor from running away and
makes it travel in accordance with the engine speed (pump
discharged volume).
10-406 PC210LCI-11
OPERATION OF COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL

MOTOR
During normal travel (flat ground and uphill ground)
1. When travel lever is operated, the pressurized oil from the
control valve is supplied to port (PA).
2. It pushes open suction safety valve (18a), and flows from
motor inlet port (MA) to motor outlet port (MB).
3. Since the motor outlet side is closed by suction safety
valve (18B) and spool (19), the pressure on the supply
side increases.
4. The pressurized oil on the supply side flows to chamber

(S1) through orifice (E1) of spool (19) and orifice (E2).
5. When the pressure in chamber (S1) increases higher than
the reaction force of the spool selector pressure, spool
(19) is pushed to the right.
6. Motor outlet port (MB) and port (PB) are connected to the
outlet passage, and the motor outlet side opens and the
motor turns.
PC210LCI-11 10-407
During downhill travel

1. If the machine runs away on a downhill, the motor runs idle
and the pressure on the motor inlet side decreases.
2. The pressure in chamber (S1) decreases through orifices
(E1) and (E2).
3. When the pressure in chamber (S1) decreases lower than
the spool selector pressure, spool (19) is pushed back to
the left by the reaction force of spring (20), and port (MB)
on the outlet side is throttled.
4. The pressure on the motor outlet side increases and rotat-
ing resistance is generated in the motor, thus the machine
is prevented from running away.
5. Spool (19) moves to a position where the force caused by
the machine weight and the hydraulic force on the motor
inlet side are balanced with the pressure of motor outlet
port (MB).
6. The motor outlet circuit is throttled and the machine travels
at speed corresponding to the pump discharged volume.
SPECIFICATIONS OF SAFETY VALVE OF TRAVEL MOTOR

Set pressure: 27.5 MPa {280 kg/cm2}
SUCTION SAFETY VALVE OF TRAVEL MOTOR

FUNCTION OF SUCTION SAFETY VALVE OF TRAVEL MOTOR
When the machine stops travel (or travels downhill), the outlet and inlet circuits of the motor are closed. Since
the motor is turned by inertial force, the pressure on the motor outlet side increases abnormally, and the motor
or piping may be damaged. The safety valve releases this abnormal pressure into the motor inlet side to protect
the devices from damage.
10-408 PC210LCI-11
OPERATION OF SUCTION SAFETY VALVE OF TRAVEL MOTOR

When machine stops traveling (or traveling downhill)
1. When the travel lever is set in NEUTRAL, the pressure
(PA) at motor inlet side decreases and the pressure in
chamber (S1) decreases as well.
2. When the pressure in chamber (S1) drops below the spool
switching pressure, spool (19) is pushed to the left by re-
action force of springs (20), and outlet passage (B1) is
throttled.
3. Since the motor continues rotation because of inertial
force, the pressure on the outlet (MB) side increases.
When machine stops traveling (motor turns clockwise)

1. The pressurized oil pushes open check valve (17) and
flows through notch (A1) of spool (19) to inlet side circuit
on the opposite side.
2. When the pressure exceeds the set pressure of suction
safety valve (18A), poppet (1) opens.
3. When the motor turns anticlockwise, the operation is re-
verse to the case when motor turns clockwise.
PC210LCI-11 10-409
When machine starts traveling (or normal travel)

1. When the travel lever is operated, the pressurized oil from
the pump moves spool (19) to the right.
2. The pass to suction safety valve (18B) will be the circuit
through check valve (16) to orifice (A2).
3. Since the pressurized oil in the circuit is throttled at orifice
(A2), the differential pressure between inlet side and suc-
tion safety valve (18B) side increases.
4. The pump pressure rises and large drawbar pull is ob-
tained.
10-410 PC210LCI-11
FINAL DRIVE
STRUCTURE OF FINAL DRIVE
PC210LCI-11 10-411
1: Level plug 9: No. 2 planetary carrier

2: No.1 planetary gear (number of teeth: 42) 10: Ring nut
3: Drain plug 11: Hub
4: No. 1 sun gear (number of teeth: 10) 12: Sprocket
5: No. 2 sun gear (number of teeth: 21) 13: Floating seal
6: No. 1 planetary carrier 14: Travel motor
7: Cover 15: No.2 planetary gear (number of teeth: 36)
8: Ring gear (number of teeth: 95)
SPECIFICATIONS OF FINAL DRIVE

Reduction ratio: -((10 + 95) / 10 x (21 + 95) / 21) + 1 = -57.000
FUNCTION OF FINAL DRIVE

The travel motor is high in speed but low in torque. Accordingly, the final drive reduces the speed, increases the
driving force, and transmits it to the sprocket.
10-412 PC210LCI-11
TRAVEL PPC VALVE

PPC
STRUCTURE OF TRAVEL PPC VALVE

General view
P: From self-pressure reducing valve T: To hydraulic tank

P1: To control valve (left REVERSE port) P1S: Pressure sensor port
P2: To control valve (left FORWARD port) P2S: Pressure sensor port
P3: To control valve (right REVERSE port) P3S: Pressure sensor port
P4: To control valve (right FORWARD port) P4S: Pressure sensor port
PC210LCI-11 10-413
Sectional view
1: Plate 4: Seal
2: Case 5: Spool
3: Piston 6: Damper
10-414 PC210LCI-11
OPERATION OF TRAVEL PPC VALVE

When in NEUTRAL
Ports (A) and (B) of the control valve and ports (P1) and P2) of
PPC valve are connected to drain chamber (D) through fine
control hole (f) of spool (1).
In fine control (when fine control is started from neutral state)

1. When piston (4) is pushed by lever (5), retainer (9) is
pushed and spool (1) is also pushed and moved down
through metering spring (2).
3. The pilot pressure oil of the control pump flows to port (A)
through fine control hole (f) and port (P1).
4. When the pressure in port (P1) increases, spool (1) is
pushed back. Almost at the same time when fine control
hole (f) is disconnected from pump pressure chamber
(PP), it is connected to drain chamber (D), and the pres-
sure in port (P1) is released.
5. Spool (1) moves up and down so that the force of metering
spring (2) is balanced with the pressure in port (P1).
6. The positional relationship between spool (1) and body
(10) “fine control hole (f) is in an intermediate position be-
tween drain chamber (D) and pump pressure chamber
(PP)” does not change until retainer (9) touches spool (1).
7. Metering spring (2) is compressed in proportion to the trav-
el of control lever.
8. The pressure in port (P1) also increases in proportion to
the travel of control lever.
9. The control valve spool moves to a position where the pressure in port (A) “which is the same as the pres-
sure in port (P1)” is balanced with the reaction force of the control valve spool return spring.
PC210LCI-11 10-415
In fine control (when control lever is returned)

1. When lever (5) starts being returned, spool (1) is pushed
up by the force of centering spring (3) and the pressure in
port (P1).
2. Fine control hole (f) is connected to drain chamber (D),
and the pressurized oil in port (P1) is released.
3. If the pressure in port (P1) decreases too much, spool (1)
is pushed down by metering spring (2).
5. The pump pressure is supplied until the pressure in port
(P1) recovers to the pressure corresponding to the lever
position.
6. When the control valve spool returns, the pressurized oil in
drain chamber (D) flows in through fine control hole (f) of
the valve on the stationary side, and then it flows through
port (P2) to port (B).
When control lever is fully operated

1. Lever (5) pushes down piston (4), and retainer (9) pushes
down spool (1).
2. Fine control hole (f) is disconnected from drain chamber
(D) and connected to pump pressure chamber (PP).
3. The pilot pressure oil from the self-pressure reducing valve
flows to port (A) through fine control hole (f) and port (P1),
and pushes the control valve spool.
4. The return oil from port (B) flows to drain chamber (D)
through port (P2) and fine control hole (f).
10-416 PC210LCI-11
CENTER SWIVEL JOINT

STRUCTURE OF CENTER SWIVEL JOINT
Outline drawing, sectional view
A1: To L.H. travel motor [port (PB)] D1: To right travel motor [port (PB)]
A2: From control valve (left travel FORWARD port) D2: From control valve (right travel REVERSE port)
B1: To left travel motor [port (PA)] E1: To R.H. and L.H. travel motors [port (P)]
B2: From control valve (left travel REVERSE port) E2: From travel speed increase solenoid valve
C1: To right travel motor [port (PA)] DR1: From R.H. and L.H travel motors (port (T)]
C2: From control valve (right travel FORWARD port) DR2: To hydraulic tank
1: Cover 5: Oil seal
2: Slipper seal 6: Cover
3: Rotor 7: Shaft
4: Dust seal 8: O-ring
PC210LCI-11 10-417
FUNCTION OF CENTER SWIVEL JOINT

Center swivel joint sends the oil from main pump installed to the the upper structure to travel motor installed to
the lower structure while rotating. Center swivel joint would not be twisted unlike hoses or tubes which would be
twisted if they are installed, for the upper structure rotating relative to the lower structure.
10-418 PC210LCI-11
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UNDERCARRIAGE
UNDERCARRIAGE AND FRAME

LAYOUT DRAWING OF UNDERCARRIAGE
1: Idler 5: Track roller

2: Track frame 6: Track shoe
3: Carrier roller 7: Center guard
4: Final drive 8: Front guard
PC210LCI-11 10-419
LAYOUT DRAWING OF UNDERCARRIAGE 10 STRUCTURE AND FUNCTION
Front idler detailed drawing
9: Idler cushion
SPECIFICATIONS OF UNDERCARRIAGE
Number of track rollers (each side)
9 pieces
Standard shoe
Shoe width: 700 mm
Link pitch: 190.3 mm
Number of shoes (each side) 49 pieces
10-420 PC210LCI-11
10 STRUCTURE AND FUNCTION STRUCTURE OF WORK EQUIPMENT
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
General view
1: Bucket 5: Stroke sensing arm cylinder

2: Bucket link 6: Boom
3: Stroke sensing boom cylinder 7: Stroke sensing boom cylinder
4: Arm 8: Boom cylinder
PC210LCI-11 10-421
FUNCTION OF WORK EQUIPMENT 10 STRUCTURE AND FUNCTION
FUNCTION OF WORK EQUIPMENT

• The boom is operated by the boom cylinder, and moves the whole work equipment up and down.
• The arm is operated by the arm cylinder, and pulls in or pushes out the bucket.
• The bucket is operated by the bucket cylinder.
• The bucket link increases the moving range of the bucket.
10-422 PC210LCI-11
10 STRUCTURE AND FUNCTION WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM

FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
There are 2 types of the work equipment clearance adjustment shim; the steel shim and plastic shim. The fol-
lowing is the explanation of the function of each type of the work equipment clearance adjustment shim.
Steel shim
• Mainly inserted in the parts which are greased every 100
hours.
• The purpose of the steel shim is to reduce the clearance in
the right and left direction. Depending on the size of clear-
ance, it may be required to insert the shim into either of the
right and left sides and insert no shim on the other side.
Plastic shim
The lubrication interval of 500 hours is attained by combining the long-lubrication-interval bushings, dust seals,
and plastic shims.
• Mainly inserted in the parts which are greased every 500
hours.
• The purpose of the plastic shim is to reduce the clearance
in the right and left direction of the work equipment and to
prevent a creak and scuffing caused by rubbing of the end
faces of steel parts of a joint.
• A creak caused by drying of grease is prevented and the
lubrication interval is lengthened by combining with long-
lubrication-interval bushings.
• The plastic shims are inserted between every pair of con-
tact faces so that the steel end surfaces of the joint do not
touch each other.
PC210LCI-11 10-423
BUCKET CLEARANCE ADJUSTMENT SHIM 10 STRUCTURE AND FUNCTION
BUCKET CLEARANCE ADJUSTMENT SHIM

FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM
Split-type iron shims are used for the joint of the arm and buck-
et.
You can adjust the clearance in the joint by changing the num-
ber of the shims. When the clearance increases, you can re-
duce it by reducing the shims.
10-424 PC210LCI-11
10 STRUCTURE AND FUNCTION ROPS CAB
CAB AND ITS ATTACHMENTS

ROPS CAB
ROPS
Abbreviation for Roll-Over Protective Structure
STRUCTURE OF ROPS CAB

General view
1: Front window 5: Radio antenna

2: Windshield wiper 6: KOMTRAX communication antenna
3: Ceiling window 7: Door
4: KOMTRAX GPS antenna 8: Mirror
FUNCTION OF ROPS CAB

ROPS cab is to protect the operator wearing seat belt from being crushed when the machine tips over.
PC210LCI-11 10-425
CAB MOUNT 10 STRUCTURE AND FUNCTION
CAB MOUNT
STRUCTURE OF CAB MOUNT
1: Front damper 2: Rear damper

Structure
• The dampers are installed at 2 places in front of the cab and 2 places at the rear of the cab, and they are
fixing the cab and frame to the revolving frame.
• The type of each damper depends on the location as shown in the identification table below.
Location of damper Bent claw Identification seal color
Front left None Yellow
Front right Made Blue
Rear left None Yellow
Rear right None Yellow
FUNCTION OF CAB MOUNT

Sealed and lubricated type damper absorbs vibration of machine in order to reduce the vibration transmitted to
an operator.
10-426 PC210LCI-11
10 STRUCTURE AND FUNCTION CAB TIPPING STOPPER
CAB TIPPING STOPPER

STRUCTURE OF CAB TIPPING STOPPER
1: Bolt 3: Lock plate for fixing

2: Lock plate bolt for fixing
FUNCTION OF CAB TIPPING STOPPER

Cab tipping stopper is installed at 1 place in the rear part to secure the cab when the machine tips over.
PC210LCI-11 10-427
20 STANDARD VALUE TABLE
PC210LCI-11 20-1
CONTENTS 20 STANDARD VALUE TABLE
CONTENTS
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11 ...................................................................... 20-9
STANDARD VALUE TABLE FOR MACHINE................................................................................................ 20-13
STANDARD VALUE TABLE FOR MACHINE: PC210LCI-11 ................................................................. 20-13
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ................................ 20-36
STANDARD VALUE TABLE FOR ELECTRICAL .......................................................................................... 20-40
STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-40
20-2 PC210LCI-11
20 STANDARD VALUE TABLE ABBREVIATION LIST
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
System
AJSS
VERSE).
ARAC
braking force.
Automatic Retarder
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
PC210LCI-11 20-3
ABBREVIATION LIST 20 STANDARD VALUE TABLE

Abbrevia-
tion
component/system)
(Same as ECU)
(Same as ECM)
tion
FOPS Cab and canopy
Structure
Forward-Neutral-Re-
verse
tem
Plus) earth.

lite System

HSS
and communication.
IMV)
20-4 PC210LCI-11

Abbrevia-
tion
component/system)
Unit
trol motions.
IMA)
case Ventilation

KCSF Engine
tion Catalyst
fler.
late Filter
KTCS
road.
LIN
sponding to load.
LVDS
as MAF sensor.
Service
ic system
PC210LCI-11 20-5

Abbrevia-
tion
component/system)
ic system
PCCS
and transmission.
Control
oil pressure.
Hydraulic system
(D, PC, etc)
PTP

Structure
ISO 12117-2.
duction
al unit system)
plied.
flow.
TOPS Cab and canopy
20-6 PC210LCI-11

Abbrevia-
tion
component/system)
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
PC210LCI-11 20-7

T/M Transmission
20-8 PC210LCI-11
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11
STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11
Performance
Engine SAA6D107E–3
Standard val-
Item Measurement condition Unit ue for new ma- Repair limit
chine
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine • Working mode: P (Power Mode)

speed at • Fuel control dial: MAX (High idle) position rpm 1850±70 1850±70
high idle • Each control lever and control pedal: NEUTRAL
• Auto-deceleration switch: OFF
• Swing lock switch: ON
Engine • Hydraulic oil temperature: 45 to 55 °C

speed at low • Working mode: P (Power Mode) rpm 1050±50 1050±50
idle • Fuel control dial: MIN (Low idle) position
• Each control lever and control pedal: NEUTRAL
Air intake and exhaust system

Standard val-
chine
• Engine coolant temperature: 60 to Gauge pres- 80 60
100 °C sure {600} {450}
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power Mode)
• Fuel control dial: MAX (High idle) po-
sition
Boost pres- kPa
sure • Arm IN relief + One-touch power {mmHg}
Absolute 181.3 161.3
maximizing ON
pressure {1360} {1210}
REMARK
• The gauge pressure does not include
the atmospheric pressure.
• The absolute pressure is obtained by
adding atmosphere
101.3 kPa{760 mmHg} at 0 m above
sea level to the gauge pressure.
PC210LCI-11 20-9
STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11 20 STANDARD VALUE TABLE

Standard val-
chine
• Engine coolant temperature: 60 to Engine outlet
100 °C (between
- Max. 2.2
VGT and
Exhaust gas KDPF) Bosch
sition
color SCR outlet index
• At arm IN relief
(exhaust pipe - Max. 0.5
• After keeping it at normal condition outlet)
for 5 seconds
Intake valve 0.25 0.152 to 0.381
Valve clear- Engine coolant temperature: Normal tem-
Exhaust mm
ance perature 0.51 0.381 to 0.762
valve
EGR valve • Engine coolant temperature: 60 to 100 °C
oil pressure MPa Min. 1.2 Min. 1.2
and VGT oil { kg/cm2} {Min. 12.0} {Min. 12.0}
pressure • Fuel control dial: MIN (Low idle) position
Main body
Standard val-
chine
Compres- • Engine coolant temperature: 40 to 60 °C

MPa Min. 2.41 Min. 1.69
sion pres- • At cranking (engine speed): 250 to 280 rpm (refer-
sure { kg/cm2} {Min. 24.6} {Min. 17.2}
ence)
Blowby pres- • Working mode: P (Power Mode) kPa Max. 0.98 Max. 1.96
sure • Fuel control dial: MAX (High idle) position { mmH2O} {Max. 100} {Max. 200}
• Arm IN relief + One-touch power maximizing ON
20-10 PC210LCI-11
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11

Standard val-
chine
Fuel control
dial: MAX 207 to 650 207 to 650
(High idle) {2.11 to 6.63} {2.11 to 6.63}
Pressure in Low-pressure circuit (fuel main
position
filter inlet side)
207 to 500 207 to 500
At cranking
{2.11 to 5.1} {2.11 to 5.1}
Fuel control
dial: MAX Max. 81 Max. 81
(High idle) kPa {Max. 0.83} {Max. 0.83}
Pressure difference between main filter in-
position
let side and outlet side { kg/cm2}
Fuel pres- Max. 81 Max. 81
At cranking
sure {Max. 0.83} {Max. 0.83}
Fuel control
dial: MAX Max. 18.6 Max. 18.6
(High idle) {Max. 0.19} {Max. 0.19}
Return circuit pressure position
Max. 18.6 Max. 18.6
At cranking
{Max. 0.19} {Max. 0.19}
Fuel control
dial: MAX
Pressure in negative pressure circuit mmHg Max. -305 Max. -305
(High idle)
position
Supply pump discharged volume At cranking Min. 70 Min. 70
Fuel control
dial: MIN
Max. 575 Max. 575
(Low idle)
Return rate from supply pump position
At cranking mℓ
(Min. Max. 575 Max. 575
150 rpm)
Fuel dis- Fuel control
charged vol- dial: MIN
Max. 8 Max. 8
ume, return (Low idle)
amount and Leakage from pressure limiter position
leakage
At cranking
amount
(Min. - Max. 5 drops Max. 5 drops
150 rpm)
Fuel control
dial: MIN
Max. 150 Max. 150
(Low idle)
Return rate from injector position mℓ
At cranking
(Min. Max. 45 Max. 45
150 rpm)
PC210LCI-11 20-11
STANDARD VALUE TABLE FOR ENGINE: PC210LCI-11 20 STANDARD VALUE TABLE
Lubrication system
Standard val-
chine
• Engine coolant temperature: 60 to Fuel control
100 °C dial: MAX Min. 0.29 Min. 0.25
(High idle) {Min. 3.0} {Min. 2.5}
position
Engine oil • Engine oil (*1) MPa
pressure EO10W30-LA Fuel control { kg/cm2}
EO15W40-LA dial: MIN Min. 0.10 Min. 0.07
EOS5W30-LA (Low idle) {Min. 1.0} {Min. 0.7}
position
EOS5W40-LA
Engine oil
Whole speed range (inside oil pan) °C 80 to 110 Max. 120
temperature
*1: KES diesel engine oil
Cooling system
Standard val-
chine
Air condi- • Between compressor pulley and fan pulley
tioner com-
• Deflection when pressed with finger at approxi- mm 6 to 9 6 to 9
pressor belt
tension mately 60 N{6.1 kg}
Cooling fan
Standard val-
chine
• Set the fan speed mode to 100 % Fuel control
(See “SET AND OPERATE MA- dial: MAX
1345±50 1345±50
CHINE MONITOR”) (High idle)
position
• Auto-deceleration switch: OFF Engine
Cooling fan
speed: rpm 945±100 945±100
speed
1300rpm
Fuel control
dial: MIN
762±100 762±100
(Low idle)
position
20-12 PC210LCI-11
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: PC210LCI-11
STANDARD VALUE TABLE FOR MACHINE

STANDARD VALUE TABLE FOR MACHINE: PC210LCI-11
Engine speed
Engine SAA6D107E-3
Standard value
Item Measurement condition Unit for new ma- Repair limit
chine
Engine • Fuel control dial: MAX (High idle) position
speed at 2- rpm 1700±100 1700±100
pump relief • Working mode: P (Power Mode)
• Arm IN relief
Engine
speed when • Engine coolant temperature: 60 to 100 °C
oil pressure • Hydraulic oil temperature: 45 to 55 °C
of 2 pumps
• Fuel control dial: MAX (High idle) position
are relieved rpm 1950±100 1950±100
+ One-touch • Working mode: P (Power Mode)
power maxi- • Pressure when arm IN is relieved and one-touch
mizing is ac- power maximizing is turned on
tuated
Speed when
auto decel- • Fuel control dial: MAX (High idle) position
rpm 1050±100 1050±100
eration is ac- • Auto-deceleration switch: ON
tuated
SCR related items

Engine SAA6D107E-3
Standard value
chine
AdBlue/DEF
Within approximately 200 seconds after starting
Pump Pres- kPa 800 or more 800 or more
AdBlue/DEF Pump Pressure Up Test
sure Up Test
AdBlue/DEF
Injection Injection quantity after the AdBlue/DEF Injection Quantity
mℓ 100(+7/-26) 100(+7/-26)
Quantity Test is completed
Test
AdBlue/DEF
Within 900 seconds after starting AdBlue/DEF Line Heater
Line Heater V 24.5±1.5 24.5±1.5
Relay 1 Test
Relay 1 Test
AdBlue/DEF
Within 900 seconds after starting AdBlue/DEF Line Heater
Line Heater V 24.5±1.5 24.5±1.5
Relay 2 Test
Relay 2 Test
PC210LCI-11 20-13
STANDARD VALUE TABLE FOR MACHINE: PC210LCI-11 20 STANDARD VALUE TABLE

Engine SAA6D107E-3
Standard value
chine
AdBlue/DEF
Pump Heat- Within 900 seconds after starting AdBlue/DEF Pump
V 24.5±1.5 24.5±1.5
er Relay Heater Relay Test
Test
AdBlue/DEF
Within 900 seconds after starting AdBlue/DEF Tank Heat-
Tank Heater V 24.5±1.5 24.5±1.5
er Valve Test
Valve Test
AdBlue/DEF
Injection 1 (Normal) 1 (Normal)
SCR Deni-
Machine monitor display after SCR Denitra- Test Result
tration Effi- -
tion Efficiency Test is completed SCR Effi-
ciency Test
ciency Test 1 (Normal) 1 (Normal)
Result
Control valve spool stroke

Engine SAA6D107E-3
Standard value
chine
Boom con- RAISE 11.5±0.5 11.5±0.5

mm
trol valve LOWER 9.5±0.5 9.5±0.5
Arm control CURL 11.5±0.5 11.5±0.5

mm
valve DUMP 9.5±0.5 9.5±0.5
• Stop the engine.
Bucket con- • Measuring point: See “MACHINE CURL 9.5±0.5 9.5±0.5
mm
trol valve POSTURE AND PROCEDURE FOR DUMP 9.5±0.5 9.5±0.5
MEASURING PERFORMANCE”,
Swing LEFT 9.5±0.5 9.5±0.5
Swing con- “Control valve”.
Swing mm
trol valve 9.5±0.5 9.5±0.5
RIGHT
Travel con- Forward 9.5±0.5 9.5±0.5

mm
trol valve Reverse 9.5±0.5 9.5±0.5
20-14 PC210LCI-11
Travel of control lever

Engine SAA6D107E-3
Standard value
chine
Boom con-
mm 85±10 85±10
trol lever
Arm control
mm 85±10 85±10
lever
Bucket con-
mm 85±10 85±10
trol lever • Stop the engine.
Swing con- • Center of lever knob mm
85±10 85±10
trol lever • Read the maximum value when the lever is operat-
Travel con- ed to the stroke end (Exclude play in NEUTRAL
position) mm 115±12 115±12
trol lever
Play of work mm
equipment 15 or less 20 or less
control lever
Play of con-
mm 20 or less 20 or less
trol lever
Operating effort of control lever and pedal

Engine SAA6D107E-3
Standard value
chine
Boom con- N 15.7±3.9 24.5 or less

trol lever { kg} {1.6±0.4} {2.5 or less}
Arm control N 15.7±3.9 24.5 or less

lever { kg} {1.6±0.4} {2.5 or less}
Bucket con- • Fuel control dial: MAX (High idle) position N 12.7±2.9 21.6 or less
• Control lever: At center of grip
Swing con- • Pedal: At tip of pedal N 12.7±2.9 21.6 or less
trol lever • Read the maximum value when the lever is operat- { kg} {1.3±0.3} {2.2 or less}
ed to the stroke end N 24.5±5.9 39.2 or less
Travel con-
Travel con- N 74.5±18.6 107.6 or less

trol pedal { kg} {7.6±1.9} {11 or less}
PC210LCI-11 20-15
Work equipment, Swing, and Travel oil pressure

Engine SAA6D107E-3
Standard value
chine
Unload pres- • Fuel control dial: MAX (High idle) position
MPa 3.9 (+0.8/-1.2) 3.9 (+0.8/-1.2)
sure • Working mode: P (Power Mode)
{ kg/cm2} 40 (+8/-12) 40 (+8/-12)
(PFC, PRC) • Auto-deceleration switch: OFF
34.8
At normal re- 33.1 to 37.2
(+1.5/-1.2)
Boom relief lief {338 to 380}
MPa 355 (+15/-12)
pressure
{ kg/cm2} 37.3
(PFC, PRC) At power 36.1 to 39.7
(+1.5/-1.2)
maximizing {368 to 405}
380 (+15/-12)
• Hydraulic oil temperature: 45 to 34.8
55 °C (+1.5/-1.2)
Arm relief lief {338 to 380}
• Fuel control dial: MAX (High idle) po- MPa 355 (+15/-12)
pressure
sition { kg/cm2} 37.3
• Working mode: P (Power Mode) (+1.5/-1.2)
• Swing lock switch: OFF 380 (+15/-12)
34.8
(+1.5/-1.2)
Bucket relief lief {338 to 380}
MPa 355 (+15/-12)
pressure
{ kg/cm2} 37.3
(+1.5/-1.2)
380 (+15/-12)
Swing relief
• Fuel control dial: MAX (High idle) position MPa 29.3±1.5 27.4 to 31.3
pressure
• Working mode: P (Power Mode) { kg/cm2} {300±15} {280 to 320}
(PFC, PRC)
Travel relief • Hydraulic oil temperature: 45 to 55 °C 38.7

MPa 36.2 to 40.2
pressure • Fuel control dial: MAX (High idle) position (+1.0/-2.0)
{ kg/cm2} {370 to 410}
(PFC, PRC) • Working mode: P (Power Mode) 395 (+10/-20)
Control cir- • Fuel control dial: MAX (High idle) position 3.23
MPa 2.75 to 3.43
cuit source • Working mode: P (Power Mode) (+0.2/-0.3)
pressure { kg/cm2} {28 to 35}
• Auto-deceleration switch: OFF 33 (+2/-3)
20-16 PC210LCI-11

Engine SAA6D107E-3
Standard value
chine
Front pump 37.3

36.1 to 39.7
discharged (+1.5/-1.2)
pressure {368 to 405}
• Hydraulic oil temperature: 45 to 380 (+15/-12)
PC valve 55 °C
Servo piston
outlet pres- • Fuel control dial: MAX (High idle) po- inlet pres- Above value x Above value x
sure (servo approx. 0.6 approx. 0.6
sition sure MPa
piston inlet
pressure) • Working mode: P (Power Mode) Rear pump { kg/cm2} 37.3
36.1 to 39.7
(PFC-PENF, • Swing lock switch: ON discharged (+1.5/-1.2)
pressure {368 to 405}
PRC-PENR) • Work equipment control: Arm IN re- 380 (+15/-12)
lief Servo piston
Above value x Above value x
inlet pres-
approx. 0.6 approx. 0.6
sure
Fuel control
• Hydraulic oil temperature: 45 to dial: MIN Approx. 2.6 Approx. 2.6
PC-EPC 55 °C (Low idle) {Approx. 26} {Approx. 26}
valve outlet position MPa
pressure • Working mode: P (Power Mode)
Fuel control { kg/cm2}
(PMF, PMR) • Each control lever and control pedal: dial: MAX Approx. 1.0 Approx. 1.0
NEUTRAL (High idle) {Approx. 10} {Approx. 10}
position
• Hydraulic oil temperature: 45 to Each control
55 °C lever and 3.9 (+0.8/-1.2) 3.9 (+0.8/-1.2)
control ped-
• Fuel control dial: MAX (High idle) po- 40 (+8/-12) 40 (+8/-12)
al: NEU-
LS differen- sition
TRAL
tial pressure • Working mode: P (Power Mode) MPa
(PFC-PLSF, • Travel speed: Hi { kg/cm2}
PRC-PLSR) Travel con- 1.8 1.8
• Travel operation: One-side track idle
trol lever: (+0.05/-0.1) (+0.05/-0.1)
off the ground
Half stroke 18 (+0.5/-1.0) 18 (+0.5/-1.0)
• LS differential pressure = Pump
pressure - LS pressure
• Hydraulic oil temperature: 45 to Each control
LS valve Almost the Almost the
55 °C lever and
outlet pres- same as pump same as pump
control ped-
sure (servo • Fuel control dial: MAX (High idle) po- discharged discharged
al: NEU- MPa
piston inlet sition pressure pressure
TRAL
pressure) { kg/cm2}
(PFC-PENF, Travel con-
• Travel operation: One-side track idle Above value x Above value x
PRC-PENR) trol lever:
off the ground approx. 0.6 approx. 0.6
Half stroke
• Travel Approx. 2.45 Approx. 2.45

Hydraulic oil temperature: 45 to
55 °C speed: Lo {Approx. 25} {Approx. 25}
Outlet pres-
sure of LS- • Fuel control dial: MAX (High idle) po- Travel MPa Approx. 1.79 Approx. 1.79
EPC valve sition speed: Mi { kg/cm2} {Approx. 18.2} {Approx. 18.2}
(PSIG) • Working mode: P (Power Mode)
Travel 0 0
• Travel control lever: Fine control speed: Hi {0} {0}
PC210LCI-11 20-17

Engine SAA6D107E-3
Standard value
chine
• Hydraulic oil temperature45 to 55 °C OFF (de- 0 0
• Fuel control dial: MAX (High idle) po- energized) {0} {0}
sition
Solenoid MPa
valve outlet • For energized/De-energized condi-
pressure tions of solenoid, see “TESTING ON (ener- { kg/cm2} 2.9 2.9
AND ADJUSTING, TEST OUTLET gized) {30} {30}
PRESSURE OF SOLENOID
VALVE”.
Each control
lever and 0 0
• Hydraulic oil temperature: 45 to control ped-
al: NEU- {0} {0}
PPC valve 55 °C
TRAL MPa
outlet pres- • Fuel control dial: MAX (High idle) po-
sure sition Each control { kg/cm2} Almost same Almost same
lever and pressure as pressure as
• Working mode: P (Power Mode) control ped- source pres- source pres-
al: Full sure of control sure of control
stroke circuit circuit
Swing
Engine SAA6D107E-3
Standard value
chine
Overrun deg. Max. 100 Max. 130
when stop-
ping swing • Overswing of swing circle after 1 swing ( mm) (-) (-)
• Measurement posture: See “Machine posture and
procedure for measuring performance”, “Swing 1”.
• Hydraulic oil temperature: 45 to 90 ° 3.1±0.3 Max. 3.7
55 °C
Time re- sition
quired to • Working mode: P (Power Mode)
sec
start swing- • Time required to pass 90 ° and 180 ° 180 ° 4.4±0.4 Max. 5.3
ing
points after starting swing
• Measurement posture: See “Machine
posture and procedure for measuring
performance”, “Swing 1”.
20-18 PC210LCI-11

Engine SAA6D107E-3
Standard value
chine
Time re-
quired for sec 24.2±2.5 Max. 30
swinging • Time required to complete 5 swings after 1 swing
• Engine: Stopped
• On slope of 15 °, set the upper structure cross-
wise, and put matchmarks on the inner race and
Swing drift
outer race of the swing circle. mm 0 0
on a slope
• Distance that matchmarks move apart after 5 mi-
nutes
Leakage • Fuel control dial: MAX (High idle) position
from swing ℓ/min Max. 5 Max. 10
motor • Swing lock switch: ON
• Leakage for 1 minute during swing relief
Traveling
Engine SAA6D107E-3
Standard value
chine
• Hydraulic oil temperature: 45 to 55.9
Lo 48.6 to 63.8
55 °C (+3.9/-7.3)
• Fuel control dial: MAX (High idle) po- Mi 40.8±4.1 36.7 to 48.9
sition
Travel speed • Working mode: P (Power Mode)
(idle run- • Time required to complete 5 idle sec
ning) turns of track off ground after 1 idle
turn Hi 30.5±1.6 28.9 to 34.1

performance”, “Travel 1”.
PC210LCI-11 20-19

Engine SAA6D107E-3
Standard value
chine
• Hydraulic oil temperature: 45 to Lo 24 (+1.7/-3.1) 20.9 to 26.7
55 °C
Mi 17±2.5 14.5 to 20.5
sition
Travel speed
(actual run- sec
ning) • Time required to travel 20 m after
running up 10 m on a level ground Hi 13±1.0 12.0 to 15.0

performance”, “Travel 2”.
Travel devia- • Travel speed: Lo

mm Max. 150 Max. 250
tion • Travel deviation (x) in travel of 20 m after running
up 10 m on a firm and level ground
• Measurement posture: See Machine posture and
procedure for measuring performance, Travel 2
and Travel 3.
• Engine: Stopped
• Place the machine on a slope of 12 ° with sprocket
Machine drift toward uphill side.
mm 0 0
on a slope • Travel distance by machine drift on a slope for 5
minutes
procedure for measuring performance”, “Travel 4”.
Leakage • Fuel control dial: MAX (High idle) position
from travel ℓ/min 13.6 27.2
motor • Lock the sprocket with pin, etc.
• Leakage for 1 minute during travel relief
20-20 PC210LCI-11
Hydraulic drift of work equipment

Engine SAA6D107E-3
Standard value
chine
Whole work
equipment
(Hydraulic Max. 600 Max. 900
drift meas- • Hydraulic oil temperature: 45 to 55 °C
ured at tooth • Level ground
tip) • Bucket filled up with dirt and sand, or at the rated
Boom cylin- load (0.8 m3: 1440 kg)
der • Set the boom top face horizontally, fully retract the
(Retraction arm, fully extend the bucket cylinder Max. 18 Max. 27
amount of
• Engine: Stopped mm
cylinder)
• Work equipment control lever, control pedal: NEU-
Arm cylinder TRAL position
(Extension • Hydraulic drift for 15 minutes, measure it every 5 Max. 160 Max. 240
amount of
minutes from immediately after initial setting
cylinder)
Bucket cylin- procedure for measuring performance”, “Work
der equipment 1”.
(Retraction Max. 40 Max. 58
amount of
cylinder)
Work equipment speed

Engine SAA6D107E-3
Standard value
chine
• Hydraulic oil temperature: 45 to RAISE 3.6±0.4 Max. 4.7
55 °C
sition
Boom speed • Time required to move boom be- sec
LOWER 2.9±0.3 Max. 3.7
tween RAISE stroke end and ground
touch point of bucket
performance”, “Work equipment 2”.
PC210LCI-11 20-21

Engine SAA6D107E-3
Standard value
chine
• Hydraulic oil temperature: 45 to CURL 3.5±0.4 Max. 4.5
55 °C
sition
Arm speed • Time required to operate the bucket sec
DUMP 2.7±0.3 Max. 3.5
from the DUMP stroke end to the
CURL stroke end
• Hydraulic oil temperature: 45 to CURL 2.4±0.2 Max. 3.1
55 °C
sition
Bucket
• Time required to operate the bucket sec
speed DUMP 1.9±0.2 Max. 2.7
from the DUMP stroke end to the
CURL stroke end
Operation time lag

Engine SAA6D107E-3
Standard value
chine
• Fuel control dial: MIN (Low idle) position
• Set the boom at the maximum raising position.
Boom time Time required to raise the machine front after low- sec Max. 1.0 Max. 1.2
lag ering the work equipment to the ground by operat-
ing the boom control lever toward LOWER side
procedure for measuring performance”, “Work
equipment 5”.
20-22 PC210LCI-11

Engine SAA6D107E-3
Standard value
chine
• Set the arm at the maximum arm OUT position.
Arm time lag Operate the arm control lever to IN. Time required sec Max. 2.0 Max. 2.8
for arm to start moving toward arm IN side again
after stopping once around the vertical position
equipment 6”.
• Set the bucket at the maximum arm OUT position.
Bucket time Operate the bucket control lever to CURL. Time re-
quired for bucket to start moving toward CURL sec Max. 1.0 Max. 3.6
lag
side again after stopping once around the vertical
position
equipment 7”.
Oil leakage
Engine SAA6D107E-3
Standard value
chine
Oil leakage • Hydraulic oil temperature: 45 to 55 °C 4.5 20
from cylinder
Leakage cc/min
from center • Leakage for 1 minute during relief of cylinder to be 10 50
swivel joint measured or travel motor
PC210LCI-11 20-23
Pump performance
Engine SAA6D107E-3
Standard value
chine
Combined • Hydraulic oil temperature: 45 to 55 °C

operation • Fuel control dial: MAX (High idle) position
performance • Working mode: P (Power Mode)
(Travel devi-
• Travel speed: Lo
ation at si- mm Max. 200 Max. 220
multaneous • Travel deviation (x) in travel of 20 m after running
operation of up 10 m on a firm and level ground
work equip- • Measurement posture: See Machine posture and
ment + trav- procedure for measuring performance, Travel 2
el) and Travel 3.
• Hydraulic oil temperature: 45 to When all
55 °C control lev-
1.35±0.20 1.35±0.63
ers are in
Output volt- • Fuel control dial: MAX (High idle) po-
NEUTRAL
age of pump sition
At running V
swash plate • Working mode: P (Power Mode)
sensor track idle off
• Travel speed: Hi ground 3.35±0.20 3.35±0.63
• Travel operation: One-side track idle (At lever full
off the ground stroke)
PC flow con- • Working mode: P (Power Mode)
trol charac-
• Bucket filled up with dirt and sand, or at the rated
teristics
load (0.8 m3: 1440 kg) 4.2±0.4
(Time re- sec
quired for • Arm in vertical position and bucket back grounding (Reference value)
boom RAISE on firm and level ground
+ swing start • Time required for boom RAISE + swing start to
at 90 °.) pass 90 ° point after starting swing
procedure for measuring performance”, “Travel 8”.
• Pump speed: 1700 rpm
• PC-EPC current value: 440 mA
• Test pump discharged pressure ( MPa { kg/cm2} ): Q Q
Main pump P1
ℓ/min (See the (See the
performance • Other pump discharged pressure ( MPa graph) graph)
{ kg/cm2} ): P2
• Average pump discharged pressure ( MPa
{ kg/cm2} ): Pp=(P1+P2)/2
20-24 PC210LCI-11
REMARK
• Adjust the pump discharged pressures P1 and P2 as close to the average pressure as possible when meas-
uring.
• Avoid performing the test where the lines of the flow lower limit and the flow upper limit begin to drop sharp-
ly, as the margin of error increases.
• 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 discharged volume and the engine speed at the
time of measurement, and use them as a base for figuring out the pump discharged volume at the specified
speed.
PC210LCI-11 20-25
The intelligent Machine Control

Engine SAA6D107E-3
Standard value for
Item Measurement condition Unit Repair limit
new machine
Compensation • Perform “Calibration of IMU sensor”
value of IMU • Pitching angle: pitching angle before
sensor ±0.2Within ±0.2Within
swinging (a) + pitching angle after
(Pitching angle) swinging (c)
deg.
Compensation • Perform “Calibration of IMU sensor”
value of IMU • Rolling angle: rolling angle before
sensor ±0.2Within ±0.2Within
swinging (b) + rolling angle after
(Roll angle) swinging (d)
Compensation MAX position ±0.5Within ±0.5Within
value of work After “MS Cylinder calibra-
tion” is finished, read the Center posi-
equipment cylin- ±0.5Within ±0.5Within
value shown on the mation
der
chine monitor.
(Boom cylinder) MIN position ±0.5Within ±0.5Within

der
chine monitor.
(Arm cylinder) MIN position ±0.5Within ±0.5Within
Compensation MAX position mm ±5.0Within ±5.0Within

der
chine monitor.
(Bucket cylinder) MIN position ±5.0Within ±5.0Within

value of work After “MS Cylinder calibra- Center posi-
equipment cylin- tion” is finished, read the ±0.5Within ±0.5Within
tion
der value shown on the ma-
(Bucket tilt cylin- chine monitor.
MIN position ±0.5Within ±0.5Within
der)
Posture 1 ±0.042Within ±0.084Within
After “TS machine calibra-
Compensation Posture 2 ±0.042Within ±0.084Within
tion” is finished, read the
value at bucket m
value of bench mark com- Posture 3 ±0.042Within ±0.084Within
blade edge
parison.
Posture 4 ±0.042Within ±0.084Within
• Perform “IMU yaw angle adjust-
ment”
IMU yaw angle
• Figure out the difference of the m ±0.042Within ±0.084Within
adjustment
blade edge position coordinates be-
tween posture (a) and posture (b).
20-26 PC210LCI-11
Calibration for the PPC pressure sensor

Engine SAA6D107E-3
Lower limit val- Upper limit val-
Item Measurement condition Unit
ue ue
• Hydraulic oil temperature: Work equip-
40 to 60 °C ment control
lever: NEU- 0 0.15
• Fuel control dial: MAX
TRAL posi-
(High idle) position
tion
• Working mode: P (Power
Valve side Mode) Work equip- MPa
ment: Oper-
• Swing lock switch: ON ate the
• Work equipment posture: boom 2.45 2.45 or more
See TESTING AND AD- RAISE oper-
JUSTING, “PPC pressure ation to the
sensor calibration”. stroke end

lever: NEU- 0 0.15
TRAL posi-
Boom (High idle) position
tion
RAISE • Working mode: P (Power
Lever side Mode) Work equip- MPa
ment: Oper-
• Swing lock switch: ON ate the
• Work equipment posture: boom 2.45 2.45 or more
See TESTING AND AD- RAISE oper-

• Fuel control dial: MAX (High idle) posi-
Differential tion
pressure
(Valve side MPa -0.4 0.4
- lever • Swing lock switch: ON
side) • Work equipment posture: See TESTING
AND ADJUSTING, “PPC pressure sen-
sor calibration”.
PC210LCI-11 20-27

Engine SAA6D107E-3
ue ue
lever: NEU- 0 0.15
TRAL posi-
tion
ment lever:
• Swing lock switch: ON Operate the
• Work equipment posture: boom LOW- 2.45 2.45 or more
See TESTING AND AD- ER opera-
JUSTING, “PPC pressure tion to the
• “Hydraulic oil tempera- Work equip-

ture40 to 60 °C” ment control
lever: NEU- 0 0.15
TRAL posi-
tion
LOWER • Working mode: P (Power
ment lever:
• Work equipment posture: boom LOW- 2.45 2.45 or more
See TESTING AND AD- ER opera-
JUSTING, “PPC pressure tion to the

Differential tion
pressure
sor calibration”.
20-28 PC210LCI-11

Engine SAA6D107E-3
ue ue
lever: NEU- 0 0.15
TRAL posi-
tion
• Swing lock switch: ON ment lever:
Operate the
• Work equipment posture: 2.45 2.45 or more
arm IN oper-
See TESTING AND AD- ation to the
JUSTING, “PPC pressure stroke end
sensor calibration”.
lever: NEU- 0 0.15
TRAL posi-
Arm IN (High idle) position
tion
Lever side • Working mode: P (Power
Work equip- MPa
Mode)
ment lever:
• Work equipment posture: Operate the
See TESTING AND AD- 2.45 2.45 or more
arm IN oper-
Differential tion
pressure
sor calibration”.
PC210LCI-11 20-29

Engine SAA6D107E-3
ue ue
lever: NEU- 0 0.15
TRAL posi-
tion
ment lever:
• Work equipment posture: arm OUT 2.45 2.45 or more
See TESTING AND AD- operation to
JUSTING, “PPC pressure the stroke
sensor calibration”. end

lever: NEU- 0 0.15
TRAL posi-
Arm OUT tion
ment lever:
• Work equipment posture: arm OUT 2.45 2.45 or more

Differential tion
pressure
sor calibration”.
20-30 PC210LCI-11

Engine SAA6D107E-3
ue ue
lever: NEU- 0 0.15
TRAL posi-
tion
ment lever:
• Work equipment posture: bucket IN 2.45 2.45 or more

lever: NEU- 0 0.15
Bucket TRAL posi-
CURL tion
ment lever:
• Work equipment posture: bucket IN 2.45 2.45 or more

Differential • Fuel control dial: MAX (High idle) posi-
pressure tion
(Valve side • Working mode: P (Power Mode) MPa -0.4 0.4
- lever • Work equipment posture: See TESTING
side)
sor calibration”.
PC210LCI-11 20-31

Engine SAA6D107E-3
ue ue
lever: NEU- 0 0.15
TRAL posi-
tion
ment lever:
• Work equipment posture: bucket 2.45 2.45 or more
See TESTING AND AD- DUMP oper-

lever: NEU- 0 0.15
TRAL posi-
Bucket (High idle) position
tion
DUMP • Working mode: P (Power
ment lever:
• Work equipment posture: bucket 2.45 2.45 or more
See TESTING AND AD- DUMP oper-

Differential tion
pressure
sor calibration”.
20-32 PC210LCI-11
Characteristic map calibration

Engine SAA6D107E-3
ue ue
EPC current
• Hydraulic oil temperature:
value: 1.04 1.68
40 to 60 °C 500 mA
PPC pres-
• Fuel control dial: MAX MPa
sure EPC current
Boom value: 1.85 2.53
RAISE in- • Working mode: P (Power 700 mA
tervening Mode)
EPC current
EPC • Work equipment posture: value: 3.98 6.96
Spool
See TESTING AND AD- 500 mA
JUSTING, “CHARACTER- mm
stroke (*2) EPC current
ISTIC MAP CALIBRA-
value: 7.6 11.08
TION”.
700 mA
• Hydraulic oil temperature: EPC current
40 to 60 °C value: 1.04 1.68
500 mA
RAISE • Working mode: P (Power
PPC pres-
pressure Mode) MPa
sure EPC current
reducing
EPC
• Work equipment posture: value: 1.85 2.53
JUSTING, “CHARACTER-
ISTIC MAP CALIBRA-
TION”.
PPC pres- • Hydraulic oil temperature:
MPa 1.04 1.68
sure 40 to 60 °C
LOWER • Working mode: P (Power EPC current
pressure Mode) value:
reducing Spool 500 mA
• Work equipment posture: mm 3.8 6.33
EPC stroke (*2)
See TESTING AND AD-
ISTIC MAP CALIBRA-
TION”.
PC210LCI-11 20-33

Engine SAA6D107E-3
ue ue
EPC current
value: 0.94 1.58
475 mA
EPC current
PPC pres- • Hydraulic oil temperature:
value: MPa 1.25 1.80
sure 40 to 60 °C 550 mA
EPC current
Arm IN value: 1.85 2.53
pressure • Working mode: P (Power 700 mA
reducing Mode)
EPC current
ISTIC MAP CALIBRA- EPC current
Spool
value: mm - -
stroke (*2) TION”.
550 mA
EPC current
value: 8.28 11.93
700 mA
EPC current
• Hydraulic oil temperature:
value: 1.04 1.68
40 to 60 °C 500 mA
PPC pres-
• Fuel control dial: MAX MPa
sure EPC current
Arm OUT value: 1.85 2.53
pressure • Working mode: P (Power 700 mA
reducing Mode)
EPC current
Spool
JUSTING, “CHARACTER- mm
stroke (*2) EPC current
ISTIC MAP CALIBRA-
value: 7.41 10.62
TION”.
700 mA
40 to 60 °C value: 1.04 1.68
500 mA
CURL • Working mode: P (Power
PPC pres-
pressure Mode) MPa
sure EPC current
reducing
EPC
ISTIC MAP CALIBRA-
TION”.
20-34 PC210LCI-11

Engine SAA6D107E-3
ue ue
40 to 60 °C value: 1.04 1.68
500 mA
DUMP • Working mode: P (Power
PPC pres-
pressure Mode) MPa
sure EPC current
reducing
EPC
ISTIC MAP CALIBRA-
TION”.
*2: Valve stroke is indicated with minus on the machine monitor.
PC210LCI-11 20-35
MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
FORMANCE 20 STANDARD VALUE TABLE
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORM-

ANCE
Control valve
Spool stroke
Swing 1
Overrun when stopping swing, time required to start swinging,
time required to finish swinging
Swing 2
Swing drift on a slope
Travel 1
Travel speed (idle running)
20-36 PC210LCI-11
20 STANDARD VALUE TABLE FORMANCE
Travel 2
Travel speed (actual travel) and travel deviation
Travel 3
Travel deviation
Travel 4
Machine drift on a slope
Work equipment 1
PC210LCI-11 20-37
FORMANCE 20 STANDARD VALUE TABLE
Work equipment 2
Boom speed
Work equipment 3
Arm speed
Work equipment 4
Bucket speed
Work equipment 5
Boom time lag
20-38 PC210LCI-11
20 STANDARD VALUE TABLE FORMANCE
Work equipment 6
Arm time lag
Work equipment 7
Bucket time lag
Work equipment 8
PC flow rate control characteristics
PC210LCI-11 20-39
STANDARD VALUE TABLE FOR ELECTRICAL 20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ELECTRICAL

STANDARD VALUE TABLE FOR ELECTRICAL
Controller
Equipment name Procedure, measuring location, criteria, and remarks
1. Turn starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Insert T-adapter into connector ECM J2.
4. Turn the battery disconnect switch ON.
Continu- 5.
Measure voltage with starting switch at OFF position and when starting engine.
Engine ous pow-
controller er supply Between ECM J2 (1) and (73) 20 to 30 V
voltage
Between ECM J2 (25) and (49) 20 to 30 V
Voltage Between ECM J2 (26) and (50) 20 to 30 V
Continu- 3. Disconnect connector CP01 and connect T-adapter to female side.
ous pow- 4. Turn the battery disconnect switch ON.
er supply
voltage 5. Turn starting switch to ON position.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
Pump con-
troller
3. Disconnect connector CP02 and connect T-adapter to female side.
Solenoid
power
supply 5. Turn starting switch to ON position.
voltage
Between CP02 (female) (116) and ground 20 to 30 V
Voltage Between CP02 (female) (118) and ground 20 to 30 V
Between CP02 (female) (121) and ground 20 to 30 V
Continu- 3. Insert T-adapter into connector CM01.
Machine ous pow- 4. Turn the battery disconnect switch ON.
monitor er supply
voltage 5. Turn starting switch to ON position.
Between CM01 (1) and (3) 20 to 30 V
Voltage
20-40 PC210LCI-11
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ELECTRICAL
Engine control
2. Disconnect connector SEGR, and connect T-adapter to male side.
EGR valve solenoid
Between SEGR (male) (1) and (2) 5 to 10 Ω
Resistance
Between SEGR (male) (1) and ground Min. 1 MΩ
2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
KVGT solenoid
Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between VGT-SOL (male) (1) and ground Min. 1 MΩ
2. Disconnect connector MB03 and connect socket to male side.
AdBlue/DEF injector
11.4 to
Resistance Between MB03 (male) (1) and (2) 20 °C
12.6 Ω
Air cleaner clogging 2. Disconnect connector P23, and connect T-adapter to male side.
switch 3. Turn starting switch to ON position.
Resistance Between P23 (male) (1) and (2) Max. 1 Ω
2. Disconnect connector P44, and connect T-adapter to male side.
Engine oil level sensor
3. Turn starting switch to ON position.
Resistance Between P44 (male) (1) and ground Max. 1 Ω
2. Insert T-adapter into connector ECM J1 or BOOST PRESS & IMT.
Charge (Boost) pres-
sure sensor
Between ECM J1 (45) and (54), or between
Voltage Sensor output 0.3 to 4.7 V
BOOST PRESS & IMT (1) and (4)
2. Disconnect connector COOLANT TEMP and connect socket to male side.
0 °C 30 to 37 kΩ
9.3 to
25 °C
10.7 kΩ
Between COOLANT TEMP (male) (A) and 3.2 to
Coolant temperature 50 °C
(B) 3.8 kΩ
sensor
Resistance Coolant temperature characteristics 1.0 to
80 °C
1.3 kΩ
700 to
95 °C
800 Ω
Between COOLANT TEMP (male) (B) and All coolant tem-
Min. 1 MΩ
ground perature range
PC210LCI-11 20-41

2. Disconnect connector BOOST PRESS & IMT and connect socket to male side.
-40 °C 41 to 48 kΩ
-20 °C 14 to 16 kΩ
5.4 to
0 °C
6.1 kΩ
Charge temperature
sensor Between BOOST PRESS & IMT (male) (A) 1.6 to
and (B) 30 °C
Resistance 1.8 kΩ
Charge thermal characteristics 500 to
60 °C
600 Ω
230 to
90 °C
250 Ω
130 °C 80 to 90 Ω
2. Insert T-adapter into connector ECM J1 and AMB.AIR PRESSURE.
Ambient pressure sen-
sor
Between (54) and ECM J1 (female) (44), or
between (2) and AMB.AIR PRESSURE (3)
2. Disconnect connector P65 and connect socket to male side.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
0 °C 29 to 36 kΩ
Ambient temperature
sensor 7.3 to
30 °C
Resistance Between P65 (male) (A) and (B) 8.8 kΩ
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
2. Insert T-adapter into connector FUEL RAIL PRESS or ECM J1.
Common rail pressure
sensor
Between FUEL RAIL PRESS (female) (2)
and (3), or between ECM J1 (42) and (58)
2. Disconnect connector VGT REV. and connect T-adapter to female side.
KVGT speed sensor
600 to
Resistance Between VGT REV. (female) (1) and (2)
1600 Ω
20-42 PC210LCI-11

2. Disconnect connector P55 and connect T-adapter to male side.
-30 °C 25 to 28 Ω
5.5 to
0 °C
6.1 kΩ
Mass air flow (MAF)
sensor 1.9 to
Between P55 (male) (3) and (4) 25 °C
Resistance 2.1 kΩ
40 °C 1.1 to 1.2 Ω
180 to
100 °C
185 kΩ
Between P55 (male) (3) and ground Entire area Min. 1 MΩ
KDPF differential pres- 2. Insert T-adapter into connector E25.
sure sensor 3. Turn starting switch to ON position.
Voltage Between E25 (2) and (1) Sensor output 0.5 to 4.5 V
2. Insert T-adapter into connector ECM J1 or SEGR.
EGR valve lift sensor 3. Turn starting switch to ON position.
Between ECM J1 (88) and (57), or between SEGR (C) and
Voltage 1.0 to 4.0 V
(B)
2. Insert T-adapter into connector ECM J1 or SVGT.
KVGT position sensor 3. Turn starting switch to ON position.
Between ECM J1 (67) and (57), or between SVGT (C) and
(B)
2. Insert T-adapter into connector ECM J2 or MB02.
AdBlue/DEF pump
pressure sensor
Between ECM J2 (female) (16) and (32), or 0.25 to
Voltage Sensor output
between MB02 (female) (3) and (4) 4.75 V
PC210LCI-11 20-43

291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
0 °C 29 to 36 kΩ
Engine room tempera-
ture sensor 7.3 to
30 °C
Resistance Between P66 (male) (A) and (B) 8.8 kΩ
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
AdBlue/DEF tank 2. Disconnect connector V41, and connect T-adapter to male side.
heating valve
Resistance Between V41 (male) (1) and (2) 15 to 30 Ω
Machine control
2. Disconnect connector V01 and connect T-adapter to male side.
PPC lock solenoid
Between V01 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V01 (male) (1) and ground Min. 1 MΩ
2. Disconnect connector V02, and connect T-adapter to male side.
2-stage relief solenoid
Resistance
Swing parking brake
solenoid Between V03 (male) (1) and (2) 20 to 60 Ω
Resistance
Travel speed selector
Resistance
Travel junction sole-
noid Between V05 (male) (1) and (2) 20 to 60 Ω
Resistance
20-44 PC210LCI-11

Swing pressure cut off
Resistance
2. Disconnect connector M16, and connect T-adapter to male side.
Fan clutch solenoid
Between M16 (male) (3) and (4) 20 to 32 Ω
Resistance
Between M16 (male) (4) and ground Min. 1 MΩ
Attachment return se-
lector solenoid Between V07 (male) (1) and (2) 20 to 60 Ω
Resistance
PC-EPC(F) solenoid
Resistance
PC-EPC(R) solenoid
Resistance
LS-EPC solenoid
Resistance
Merge-divider LS sole-
noid Between V23 (male) (1) and (2) 3 to 14 Ω
Resistance
Merge-divider main
Resistance
Variable back pressure
Resistance
PC210LCI-11 20-45

ATT flow orifice EPC
Resistance
ATT flow adjustment
EPC1 solenoid Between V91 (male) (1) and (2) 7 to 14 Ω
Resistance
ATT flow adjustment
Resistance
ATT flow adjustment
Resistance
ATT flow adjustment
Resistance
Bucket CURL PPC 2. Insert T-adapter into connector P01.
pressure sensor 3. Turn starting switch to ON position.
Voltage Between P01 (2) and (1) Sensor output 0.5 to 4.5 V
Boom LOWER PPC 2. Insert T-adapter into connector P02.
Swing LEFT PPC 2. Insert T-adapter into connector P03.
Arm IN PPC pressure 2. Insert T-adapter into connector P04.
sensor 3. Turn starting switch to ON position.
Bucket DUMP PPC 2. Insert T-adapter into connector P05.
20-46 PC210LCI-11

Boom RAISE PPC 2. Insert T-adapter in connector P06.
Swing RIGHT PPC 2. Insert T-adapter into connector P07.
Arm OUT PPC pres- 2. Insert T-adapter into connector P08.
sure sensor 3. Turn starting switch to ON position.
Travel Forward L.H. 2. Insert T-adapter into connector P09.
PPC pressure sensor 3. Turn starting switch to ON position.
Travel Reverse L.H. 2. Insert T-adapter into connector P10.
Travel Forward R.H. 2. Insert T-adapter into connector P11.
Travel Reverse R.H. 2. Insert T-adapter into connector P12.
Approx.
10 °C
90 kΩ
Approx.
Hydraulic oil tempera- Between P22 (male) (1) and (2) 30 °C
35 kΩ
ture sensor (Temperature of oil temperature sensor -
Resistance Resistance characteristics) Approx.
80 °C
6.5 kΩ
Approx.
100 °C
3.5 kΩ
Between P22 (male) (2) and ground Min. 1 MΩ
PC210LCI-11 20-47

Front pump pressure 2. Insert T-adapter into connector P25.
Rear pump pressure 2. Connect T-adapter to connector P26.
Approx.
Between P27 (male) (A) and (B)
6 kΩ
Front pump swash
plate sensor Approx.
Between P27 (female) (B) and (C)
Resistance 6 kΩ
Approx.
Between P27 (female) (A) and (C)
170 Ω
Between P27 (male) (C) and ground Min. 1 MΩ
Approx.
Between P28 (male) (A) and (B)
6 kΩ
Rear pump swash
plate sensor Approx.
Between P28 (female) (B) and (C)
Resistance 6 kΩ
Approx.
Between P28 (female) (A) and (C)
170 Ω
Between P28 (male) (C) and ground Min. 1 MΩ
Machine monitor
3. Insert T-adapter into connector CM01.
Battery charge
5. Start engine and perform troubleshooting at engine speed medium or higher
Voltage Between CM01 (16) and (3) 20 to 30 V
20-48 PC210LCI-11

3. Insert T-adapter into connector CM01.
4. Disconnect heater relay terminal R16A.
Preheating k To perform checks without passing an electric current when starting switch is
in HEAT position
6. Turn starting switch to HEAT position.
Voltage Between CM01 (12) and (3) 20 to 30 V
2. Disconnect connector CM01, and connect T-adapter to male side.
Fuel Level (fuel level
sensor) Approx.
Between CM01 (female) (15) and ground FULL
Resistance 12 Ω
Fuel level sensor characteristics
EMPTY 85 to 110 Ω
PC210LCI-11 20-49
30 TESTING AND ADJUSTING
PC210LCI-11 30-1
CONTENTS 30 TESTING AND ADJUSTING
CONTENTS
RELATED INFORMATION ON TESTING AND ADJUSTING ....................................................................... 30-12
TOOLS FOR TESTING AND ADJUSTING............................................................................................ 30-12
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ...................................................................... 30-22
ENGINE AND COOLING SYSTEM.............................................................................................................. 30-23
TEST ENGINE SPEED ......................................................................................................................... 30-23
METHOD FOR TESTING ENGINE SPEED ................................................................................... 30-23
TEST BOOST PRESSURE................................................................................................................... 30-26
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR.................................... 30-26
METHOD FOR TESTING BOOST PRESSURE............................................................................. 30-27
TEST EXHAUST GAS COLOR ............................................................................................................. 30-28
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER .................... 30-28
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER ...................................... 30-29
TEST AND ADJUST VALVE CLEARANCE ........................................................................................... 30-31
METHOD FOR TESTING VALVE CLEARANCE ............................................................................ 30-31
METHOD FOR ADJUSTING VALVE CLEARANCE ....................................................................... 30-32
TEST COMPRESSION PRESSURE..................................................................................................... 30-33
METHOD FOR TESTING COMPRESSION PRESSURE............................................................... 30-33
TEST BLOWBY PRESSURE ................................................................................................................ 30-38
METHOD FOR TESTING BLOWBY PRESSURE .......................................................................... 30-38
TEST ENGINE OIL PRESSURE ........................................................................................................... 30-40
METHOD FOR TESTING ENGINE OIL PRESSURE ..................................................................... 30-40
TEST EGR VALVE AND VGT OIL PRESSURE .................................................................................... 30-41
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE .............................................. 30-41
TEST FUEL PRESSURE ...................................................................................................................... 30-43
METHOD FOR TESTING FUEL PRESSURE ................................................................................ 30-44
TEST FUEL DISCHARGE, RETURN AND LEAKAGE .......................................................................... 30-49
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE .................................... 30-50
BLEEDING AIR FROM FUEL SYSTEM ................................................................................................ 30-55
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM ................................................................ 30-55
TEST FUEL CIRCUIT FOR LEAKAGE ................................................................................................. 30-56
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE ........................................................... 30-56
HANDLE CYLINDER CUT-OUT MODE OPERATION........................................................................... 30-58
HANDLE NO-INJECTION CRANKING OPERATION ............................................................................ 30-59
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ........................................ 30-60
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT....................................... 30-60
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT ..................................... 30-60
TEST COOLING FAN SPEED ............................................................................................................. 30-62
METHOD FOR TESTING COOLING FAN SPEED ........................................................................ 30-62
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ....................... 30-63
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROL-
LER ............................................................................................................................................ 30-63
TEST SCR RELATED FUNCTIONS...................................................................................................... 30-64
TEST AdBlue/DEF PUMP RAISED PRESSURE ........................................................................... 30-68
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR ....................................................... 30-71
TEST AdBlue/DEF LINE HEATER RELAY 1 ................................................................................. 30-75
TEST AdBlue/DEF LINE HEATER RELAY 2 ................................................................................. 30-78
TEST AdBlue/DEF PUMP HEATER RELAY................................................................................... 30-81
TEST AdBlue/DEF TANK HEATER VALVE .................................................................................... 30-84
TEST DENITRATION EFFICIENCY OF SCR................................................................................. 30-87
CLEAN AdBlue/DEF TANK ................................................................................................................... 30-91
METHOD FOR CLEANING AdBlue/DEF TANK ............................................................................. 30-91
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK .......................................................... 30-95
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK .................... 30-95
POWER TRAIN............................................................................................................................................ 30-97
TEST SWING CIRCLE BEARING CLEARANCE .................................................................................. 30-97
30-2 PC210LCI-11
30 TESTING AND ADJUSTING CONTENTS
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE ............................................ 30-97

UNDERCARRIAGE AND FRAME................................................................................................................ 30-98
TEST AND ADJUST TRACK TENSION................................................................................................ 30-98
METHOD FOR TESTING TRACK TENSION ................................................................................. 30-98
METHOD FOR ADJUSTING TRACK TENSION ............................................................................ 30-98
HYDRAULIC SYSTEM................................................................................................................................30-100
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM...................................................30-100
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT ...............30-100
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ....30-101
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
..................................................................................................................................................30-102
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIR-
CUITS .......................................................................................................................................30-108
TEST OIL PRESSURE OF CONTROL CIRCUIT ................................................................................. 30-111
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT ........................................... 30-111
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ..........................................30-113
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) ..........................30-113
TEST PC-EPC VALVE OUTLET PRESSURE ...............................................................................30-114
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.......................30-115
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...........................................30-116
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR .................30-116
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL .........................30-117
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) .......
..................................................................................................................................................30-120
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE.................................................30-121
METHOD FOR ADJUSTING LS VALVE........................................................................................30-122
TEST OUTLET PRESSURE OF SOLENOID VALVE ...........................................................................30-123
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE .....................................30-123
OPERATING CONDITION OF SOLENOID VALVE .......................................................................30-124
TEST PPC VALVE OUTLET PRESSURE ............................................................................................30-127
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE ......................................................30-127
ADJUST WORK EQUIPMENT AND SWING PPC VALVES .................................................................30-129
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............30-129
TEST PUMP SWASH PLATE SENSOR...............................................................................................30-130
METHOD FOR TESTING PUMP SWASH PLATE SENSOR.........................................................30-130
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.......................................30-131
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND
BUCKET CYLINDER.................................................................................................................30-131
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER......30-131
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE .............30-132
TEST OIL LEAKAGE ...........................................................................................................................30-133
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER ...........................................30-133
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER ..............................................30-133
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER ........................................30-134
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR ...............................................30-134
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR..............................................30-134
BLEED AIR FROM HYDRAULIC CIRCUIT ..........................................................................................30-136
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT ....................................................30-138
CAB AND ITS ATTACHMENTS ..................................................................................................................30-140
TEST CAB TIPPING STOPPER ..........................................................................................................30-140
METHOD FOR TESTING CAB TIPPING STOPPER ....................................................................30-140
METHOD FOR ADJUSTING MIRRORS ..............................................................................................30-141
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A).....................................30-141
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)......
..................................................................................................................................................30-142
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) ..................................30-143
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)....
..................................................................................................................................................30-144
PC210LCI-11 30-3
CONTENTS 30 TESTING AND ADJUSTING
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) ......................................30-145

ELECTRICAL SYSTEM ..............................................................................................................................30-147
SET AND OPERATE MACHINE MONITOR.........................................................................................30-147
OPERATOR MODE .....................................................................................................................30-152
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN ............................30-152
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN .................................30-152
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) ..................................................30-153
CHECKING FUNCTION OF SERVICE METER ............................................................................30-153
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD ..........................30-153
SERVICE MODE...........................................................................................................................30-156
METHOD FOR OPERATING SERVICE MODE ............................................................................30-156
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION ................................30-159
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION .................................30-166
ABNORMALITY RECORD MENU.................................................................................................30-180
METHOD FOR CONFIRMING MAINTENANCE RECORD ...........................................................30-184
METHOD FOR OPERATING MAINTENANCE MODE SETTING..................................................30-185
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING .............................................30-189
DEFAULT MENU...........................................................................................................................30-191
DIAGNOSTIC TESTS MENU........................................................................................................30-199
ADJUSTMENT MENU ..................................................................................................................30-210
METHOD FOR PERFORMING NO-INJECTION CRANKING .......................................................30-248
KOMTRAX SETTINGS MENU ......................................................................................................30-250
METHOD FOR DISPLAYING SERVICE MESSAGE .....................................................................30-252
METHOD FOR STARTING UP KOMTRAX TERMINAL .......................................................................30-254
ADJUST REARVIEW CAMERA ANGLE ..............................................................................................30-259
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE .......................................................30-259
ADJUST KomVision CAMERA ANGLE ................................................................................................30-262
METHOD FOR ADJUSTING KomVision CAMERA ANGLE ..........................................................30-263
ADJUST KomVision RELATED ITEMS ................................................................................................30-267
SETTING OF KomVision (MAIN SETTING) ..................................................................................30-268
SETTING OF KomVision (CAMERA SETTING) ............................................................................30-270
SETTING OF KomVision (CAMERA CALIBRATION) ....................................................................30-271
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER ................................................................30-283
HANDLE BATTERY DISCONNECT SWITCH ......................................................................................30-284
TEST DIODES .....................................................................................................................................30-285
METHOD FOR TESTING DIODE USING DIGITAL TESTER ........................................................30-285
METHOD FOR TESTING DIODE USING ANALOG TESTER.......................................................30-285
ICT SYSTEM ..............................................................................................................................................30-286
SET AND OPERATE CONTROL BOX .................................................................................................30-286
METHOD FOR SETTING THE STARTING SWITCH INTERLOCK FUNCTION OF THE CONTROL
BOX...........................................................................................................................................30-288
METHOD FOR SETTING THE STARTING SWITCH INTERLOCK FUNCTION OF THE CONTROL
BOX...........................................................................................................................................30-288
METHOD FOR SELECTING EXCAVATOR MODEL AND IN THE CONTROL BOX......................30-291
METHOD FOR SELECTING EXCAVATOR MODEL AND IN THE CONTROL BOX......................30-291
CALIBRATE INTELLIGENT MACHINE CONTROL ..............................................................................30-295
PPC Pressure Sensor Calibration .................................................................................................30-297
Control Map Calibration ................................................................................................................30-378
METHOD FOR TESTING THE INTELLIGENT MACHINE CONTROL SYSTEM...........................30-527
CALIBRATE IMU SENSOR FOR YAW ANGLE.............................................................................30-533
IMU SENSOR CALIBRATION .......................................................................................................30-540
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF IMU SENSOR ....30-552
WORK EQUIPMENT CYLINDER CALIBRATION..........................................................................30-552
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF WORK EQUIPMENT
CYLINDER ................................................................................................................................30-578
GENERAL CALIBRATION OF BUCKET BLADE EDGE POSITION, BOOM DIMENSIONS, ARM DI-
MENSIONS, BUCKET LINK DIMENSIONS, AND GNSS ANTENNA POSITION WITH TOTAL STA-
TION..........................................................................................................................................30-580
30-4 PC210LCI-11
30 TESTING AND ADJUSTING CONTENTS
CALIBRATION OF BOOM DIMENSIONS AND ARM DIMENSIONS WITH TOTAL STATION .......30-632
CALIBRATION OF BUCKET LINK DIMENSIONS WITH TOTAL STATION ...................................30-652
CALIBRATION OF GNSS ANTENNA WITH TOTAL STATION......................................................30-689
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITH TOTAL STATION .........30-713
VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL STATION ....................................30-715
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITH TOTAL STATION ......
..................................................................................................................................................30-715
CALIBRATION OF GNSS ANTENNA WITHOUT TOTAL STATION ..............................................30-716
CALIBRATION OF BUCKET BLADE EDGE POSITION WITHOUT TOTAL STATION...................30-721
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITHOUT TOTAL STATION ..30-731
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITHOUT TOTAL STA-
TION..........................................................................................................................................30-731
Pm CLINIC..................................................................................................................................................30-733
Pm CLINIC SERVICE ..........................................................................................................................30-733
Pm CLINIC CHECK SHEET: PC210LCI-11 ...................................................................................30-735
PC210LCI-11 30-5
ABBREVIATION LIST 30 TESTING AND ADJUSTING
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
System
AJSS
VERSE).
ARAC
braking force.
Automatic Retarder
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
30-6 PC210LCI-11
30 TESTING AND ADJUSTING ABBREVIATION LIST

Abbrevia-
tion
component/system)
(Same as ECU)
(Same as ECM)
tion
FOPS Cab and canopy
Structure
Forward-Neutral-Re-
verse
tem
Plus) earth.

lite System

HSS
and communication.
IMV)
PC210LCI-11 30-7

Abbrevia-
tion
component/system)
Unit
trol motions.
IMA)
case Ventilation

KCSF Engine
tion Catalyst
fler.
late Filter
KTCS
road.
LIN
sponding to load.
LVDS
as MAF sensor.
Service
ic system
30-8 PC210LCI-11

Abbrevia-
tion
component/system)
ic system
PCCS
and transmission.
Control
oil pressure.
Hydraulic system
(D, PC, etc)
PTP

Structure
ISO 12117-2.
duction
al unit system)
plied.
flow.
TOPS Cab and canopy
PC210LCI-11 30-9

Abbrevia-
tion
component/system)
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
30-10 PC210LCI-11

T/M Transmission
PC210LCI-11 30-11
TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING

TOOLS FOR TESTING AND ADJUSTING
Tools for testing boost pressure
Symbol Part No. Part name Q'ty Remarks
- 799-201-2202 Boost gauge kit 1
Pressure range -101 to 200 kPa {-760 to
A 1 799-401-2311 Gauge 1
1500 mmHg}
2 799-101-5160 Nipple 1 Size: R1/8
- 799-401-2301 Pm kit 1
B
1 790-261-1130 Coupling 1
Tools for testing exhaust gas color

A 799-201-9002 Handy smoke checker 1
Commercially Bosch index: 0 to 9
B Smoke meter 1
available
Tools for testing and adjusting valve clearance

A 795-799-1131 Gear 1
Commercially
B Feeler gauge 1
available
Tools for testing compression pressure

A 795-502-1590 Gauge assembly 1 Pressure range: 0 to 7 MPa
B 795-799-6700 Puller 1
C 795-790-4411 Adapter 1
D 6754-11-3130 Gasket 1
Commercially
E Hose 1 Hose inside diameter: 15 mm
available
Tools for testing blowby pressure

- 799-201-1506 Blowby checker 1
1 799-201-1591 Gauge 1 Pressure range: 0 to 10 kPa
A 2 799-201-1511 Tool 1
3 799-201-1450 Adapter 1
4 07281-00359 Clamp 2
Commercially
B Plug 1 Hose inside diameter: 24 mm
available
Commercially
C Cap 2 Tube outside diameter: 25.4 mm
available
30-12 PC210LCI-11
30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING
Tools for testing engine oil pressure

- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Nipple 1 Size: R1/8
B 799-401-2320 Gauge 1 Pressure range: 1 MPa
Tools for testing EGR valve and VGT oil pressure

A 1 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 799-401-3100 Adapter 1
Tools for testing fuel pressure

A 1 799-101-5160 Nipple 1 Size: R1/8
2 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
B 795-790-4430 Adapter 1
C 6215-81-9710 O-ring 1
D 795-790-5110 Screw 1
E 799-401-2320 Gauge 1 Pressure range: 1 MPa
F 795-790-5120 Screw 1
G 1 799-101-5160 Nipple 1 Size: R1/8
2 799-401-2311 Gauge 1 Pressure range: -101 to 200 kPa
Tools for testing fuel discharge, return rate and leakage

A 795-790-4700 Tester kit 1
B 6164-81-5790 Joint 1
C 07206-30812 Joint bolt 1
D 6745-71-1130 Seal washer 1
Commercially
E Stopwatch 1
available
Commercially
F Hose 1 Inside diameter: Approximately 14 mm
available
Commercially
G Measuring cylinder 1
available
Commercially
H Hose 1 Inside diameter: Approximately 8 mm
available
PC210LCI-11 30-13
Tools for testing fuel system for leakage

Commercially Developer for dye penetrant (color
A 1
available checker)
Tools for testing injection amount from AdBlue/DEF injector

A 799-601-4340 Socket 1
B Commercially Multimeter 1
available
C Commercially Measuring cylinder 1 Capacity: 200 to 500 mℓ
available
Tools for testing AdBlue/DEF line heater relay 1

A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available

A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
Tools for testing AdBlue/DEF pump heater relay

A 799-601-9130 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available
Tools for testing AdBlue/DEF tank heater valve

A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available
30-14 PC210LCI-11
Device for cleaning AdBlue/DEF tank

Commercially
A Pail can 4 Made of plastic (for drained AdBlue/DEF)
available
Commercially
- Remote breather hose 1
available
Commercially
1 Valve 1 ASOH, CICCOLO:CY-2208 or equivalent
available
B
Commercially Approximately 2 m, TOYOX TOYOSILI-
2 Hose 1
available CONE: TSI-8 or equivalent
Commercially
3 Joint 1 Made of stainless steel
available
C Commercially
AdBlue/DEF 1 For flushing: 30 ℓ
available
Tools for testing swing circle bearing clearance

Commercially
A Dial gauge 1
available
Tools for testing track tension

A - Wooden block 1
Tools for testing and adjusting oil pressure in work equipment, swing and travel circuits
A 1 799-101-5110 Gauge 1 Pressure range: 60 MPa
2 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 2 Size: M10x1.25 mm
D 07002-11023 O-ring 2
Commercially
E Plate 1 Size: 250x260x32
available
Commercially
F Pin 1 Size: φ 200x80
available
Tools for testing and adjusting oil pressure in control circuit

A
D 07002-11023 O-ring 1
PC210LCI-11 30-15
Tools for testing and adjusting oil pressure in pump PC control circuit
D 07002-11023 O-ring 4
Tools for testing and adjusting oil pressure in pump LS control circuit
D 07002-11023 O-ring 4
E 799-401-2701 Differential pressure gauge 1 Pressure range: 50 MPa
F 796T-440-1101 Sensor adapter 1 Pressure range: 50 MPa
Tools for testing solenoid valve outlet pressure

2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 799-401-3200 Adapter 1 Size: 03
Tools for testing PPC valve output pressure

2 799-101-5160 Nipple 1 Size: R1/8
C 799-401-3100 Adapter 1 Size: 02
D 799-401-3200 Adapter 1 Size: 03
30-16 PC210LCI-11
Tools for testing oil leakage

A Commercially
Measuring cylinder 1
available
B 07379-00640 Flange 2 Size: 06
C 07376-70522 Plug 1 Size: 05
D 07376-70422 Plug 1 Size: 04
Commercially
available
Commercially
available
Tools for testing the intelligent machine control system

Commercially
A Tools for taking videos 1
available
PC210LCI-11 30-17
Tools for general calibration of bucket blade edge position, boom dimensions, arm dimensions, bucket
link dimensions, and GNSS antenna position with total station
Commercially
A Total station 1
available
Measurement target B is a component of
B 2A5-98-21210 Measurement target 1
the blade edge measuring jig K.
Commercially
C Marker 1
available
Commercially
D L-square 1
available
Commercially
E Tape measure 1
available
Commercially
F Magnet stand 1
available
Commercially
G Plumb 1
available
Commercially Accuracy: 0.1 ° or below, Resolution0.1 °
H Digital angle gauge 1
available or below
Commercially
J String 1
available
Special jig for measuring the cutting
- 2A5-98-05011 1
edge
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
8 2A5-98-21230 Reflecting plate 1
K 9 2A5-98-21240 Adapter 1
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
19 01640-20610 Washer 1
Commercially
L Rover 1
available
30-18 PC210LCI-11
Tools for calibration of boom dimensions and arm dimensions with total station
Commercially
A Total station 1
available
blade edge measuring jig D.
Commercially
C Marker 1
available
- 2A5-98-05011 1
edge
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
D 9 2A5-98-21240 Adapter 1
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
19 01640-20610 Washer 1
PC210LCI-11 30-19
Tools for calibration of bucket link dimensions with total station

Commercially
A Total station 1
available
the blade edge measuring jig K.
Commercially
C Marker 1
available
Commercially
D L-square 1
available
Commercially
E Tape measure 1
available
Commercially
F Magnet stand 1
available
Commercially
G Plumb 1
available
Commercially Accuracy: 0.1 ° or below, Resolution0.1 °
available or below
Commercially
J String 1
available
- 2A5-98-05011 1
edge
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
K 9 2A5-98-21240 Adapter 1
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
19 01640-20610 Washer 1
30-20 PC210LCI-11
Tools for calibration of GNSS antenna with total station

Commercially
A Total station 1
available
blade edge measuring jig E.
Commercially
C Marker 1
available
Commercially
D L-square 1
available
- 2A5-98-05011 1
edge
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
E 9 2A5-98-21240 Adapter 1
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
19 01640-20610 Washer 1
Tools for calibration of bucket blade edge position without total station
Commercially
A L-square 1
available
Commercially
B Tape measure 1
available
Commercially
C Magnet stand 1
available
PC210LCI-11 30-21
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Sensor adapter
Socket
30-22 PC210LCI-11
30 TESTING AND ADJUSTING TEST ENGINE SPEED
ENGINE AND COOLING SYSTEM

TEST ENGINE SPEED
The test of this section shall be performed with "Pre-defined Monitoring" or "Monitoring" of the machine monitor.
Test this item under the following conditions.
Engine coolant temperature: 60 to 100 °C
Hydraulic oil temperature: 45 to 55 °C
For testing of engine speed to perform troubleshooting or Pm Clinic, or periodic maintenance, etc. refer to this
section.
METHOD FOR TESTING ENGINE SPEED

Testing engine speed at high idle
1. Select “Engine Speed” on “Pre-defined Monitoring”
(01/24), or from “Monitoring Selection Menu” to display.
For details, see “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01002 “Engine Speed”
The drawing is an example of a “Pre-defined Monitoring”
(01/24) screen displayed.
The drawing is an example of a Monitoring code: 01002

“Engine Speed” screen displayed.
2. Set working mode to P (“Power Mode”), turn off auto-de-
celeration.
3. Turn swing lock switch ON.
4. Start the engine, and set the fuel control dial to MAX (High
idle) position.
5. Check the engine speed when all control levers and con-
trol pedals are in NEUTRAL position.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.
Testing engine speed at low idle

TOR”.
PC210LCI-11 30-23
TEST ENGINE SPEED 30 TESTING AND ADJUSTING

2. Start the engine, and set the fuel control dial to MIN (Low
idle) position.
3. Check the engine speed when all control levers and con-
trol pedals are in NEUTRAL position.
Engine speed test at 2-pump relief

TOR”.

2. Turn swing lock switch ON.
3. Start the engine and operate the arm to IN side stroke end.
4. Set the fuel control dial to MAX (High idle) position,
change working mode to P (“Power Mode”).
5. Operate left work equipment control lever to check the en-
gine speed when arm IN relief is performed.
“STANDARD VALUE TABLE FOR MACHINE”.
Testing the engine speed (Engine rated speed) when 2-pump relief and one-
touch power maximizing are operating
TOR”.
30-24 PC210LCI-11
30 TESTING AND ADJUSTING TEST ENGINE SPEED

2. Start the engine and operate the arm to IN side stroke end.
3. Set the fuel control dial to MAX (High idle) position,
change working mode to P (“Power Mode”).
4. While operating the L.H. work equipment control lever to
make arm IN relief and pressing the one-touch power max-
imizing switch, check the engine speed.
REMARK
• One-touch power maximizing function is automatically
released after approximately 8.5 seconds even if the
One-touch power maximizing switch is kept pressed.
Test the engine speed before the function is released.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
Engine speed test at auto-deceleration

TOR”.

2. Start the engine, set the fuel control dial to MAX (High idle)
position and turn ON auto-deceleration.
3. Check the engine speed when auto-decelerator is operat-
ed after setting all control levers and control pedals in
NEUTRAL position.
REMARK
After setting all control levers and control pedals in NEU-
TRAL position, the engine speed when engine speed auto-
matically decreases in approximately 5 second. is auto-de-
celerator speed. Check the engine speed then.
PC210LCI-11 30-25
TEST BOOST PRESSURE 30 TESTING AND ADJUSTING
TEST BOOST PRESSURE

Tools for testing boost pressure
Pressure range -101 to 200 kPa {-760 to
A 1 799-401-2311 Gauge 1
1500 mmHg}
2 799-101-5160 Nipple 1 Size: R1/8
- 799-401-2301 Pm kit 1
B
1 790-261-1130 Coupling 1
k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k Be careful not to touch any hot part when installing or removing the testing tools.
Check this item under the following conditions.
For testing of boost pressure to perform troubleshooting, Pm Clinic, or periodic maintenance refer to this sec-
tion.
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR

1. Start the engine, select and display “Charge Pressure” and
“Ambient Pressure” in either “Pre-defined Monitoring”
(05/24) or “Monitoring Selection” by referring “SET AND
OPERATE MACHINE MONITOR”.
Monitoring code: 36500 “Charge Pressure”
Monitoring code: 37400 “Ambient Pressure”
The figure shows monitoring code 36500 “Charge Pres-

sure” and 37400 “Ambient Pressure” screen.
2. Set the working mode to P (“Power Mode”), and turn the
swing lock switch ON.
If the swing lock switch is turned ON, the main relief valve
is set for high-pressure relief.
3. Set the fuel control dial to MAX (High idle) position, and
measure the boost pressure with arm IN relief + one-touch
power maximizing ON.
For standard values, see the absolute pressure in STAND-
ARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
REMARK
• The absolute pressure includes the atmospheric pressure. Check the atmospheric pressure because
the pressure changes with altitude.
• The relationship between the absolute pressure and the gauge pressure.
Absolute pressure = Gauge pressure + Atmospheric pressure
30-26 PC210LCI-11
30 TESTING AND ADJUSTING TEST BOOST PRESSURE
METHOD FOR TESTING BOOST PRESSURE

1. Open the engine hood and remove boost pressure pickup
plug (1).
2. Install nipple A2 of boost gauge kit A, and connect them to

gauge A1.
3. Start the engine and run it at medium speed or above.
4. Insert the gauge half-way into hose at the connecting part
to bleed the oil.
REMARK
• When the Pm kit B is available, you can use air bleed-
ing coupling B1 in the kit.
• If oil is left in the hose, the gauge does not work. Ac-
cordingly, be sure to bleed the oil.
5. Set the working mode to P (“Power Mode”) and turn the
measure the boost pressure with arm IN relief + one-touch
power maximizing ON.
REMARK
• The absolute pressure includes the atmospheric pressure. Check the atmospheric pressure because
the pressure changes with altitude.
• The relationship between the absolute pressure and the gauge pressure.
Gauge pressure = Absolute pressure - Atmospheric pressure
After finishing the test, remove the testing tools and restore the machine.
PC210LCI-11 30-27
TEST EXHAUST GAS COLOR 30 TESTING AND ADJUSTING
TEST EXHAUST GAS COLOR

Tools for testing exhaust gas color
A 799-201-9002 Handy smoke checker 1
Commercially Bosch index: 0 to 9
B Smoke meter 1
available
k Place the machine on a level ground, lower the work equipment to the ground in a stable posture, set
k Be careful not to touch any hot part when installing or removing the testing tools.
k Be careful not to burn yourself when the aftertreatment devices regeneration is performed since high
temperature exhaust gas is spouted from the inspection port. Be sure to perform “Regeneration Dis-
able” operation of aftertreatment devices with machine monitor before testing(For the detail of “Re-
generation Disable” of aftertreatment devices, see Operation and Maintenance Manual.).
• After having it kept for 5 seconds at normal condition, correct the exhaust gas.
If an air source and an electric power source are not available in the field, use handy smoke checker A. When
recording official data, etc., use smoke meter B.
For testing of exhaust gas color to perform troubleshooting or Pm Clinic, or periodic maintenance, etc. refer to
this section.
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER

1. Open the engine hood and remove step (1).
2. Remove plug (2).

3. Fit a sheet of filter paper to handy smoke checker A.
30-28 PC210LCI-11
30 TESTING AND ADJUSTING TEST EXHAUST GAS COLOR
4. Insert the exhaust gas intake pipe of handy smoke checker

A into port (3) for the removed plug.
Insert the gas intake pipe so that the probe tip will be at
the center of the piping, and it is in parallel with the piping.
5. Start the engine and run it with fuel control dial at MAX
(High idle) position, collect the exhaust gas to the filter pa-
per by operating the handle of smoke checker A with arm
IN relief.
REMARK
• In the case of testing exhaust gas color while fuel con-
trol dial is in MAX (High idle) position, set the fuel con-
trol dial to MAX (High idle) position and hold the dial in
place for 5 seconds before collecting the exhaust gas.
• Collecting time: 1.4±0.2 seconds
6. Remove the filter paper and compare it with the attached scale for judgment.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
3 Plug (2):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug (2):
Seizure prevention compound (LC-G)
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER

1. Open the engine hood, and remove step (1).
2. Remove plug (2).

3. Connect the probe hose, receptacle of the accelerator
switch and air hose to smoke meter B.
Limit the supplied air pressure to 1.5 MPa {15 kg/cm2} or
below.
4. Check that the power switch of smoke meter B is OFF, and
connect the power cable to the receptacle.
PC210LCI-11 30-29
TEST EXHAUST GAS COLOR 30 TESTING AND ADJUSTING
5. Insert the probe of smoke meter B into port (3) for the re-
moved plug.
Insert the probe so that its tip will be at the center of the
piping, and it is in parallel with the piping.
6. Loosen the cap nut of the suction pump, and place the fil-
ter paper.
REMARK
Place the filter paper securely so that the exhaust gas
does not leak.
7. Turn ON the power switch of smoke meter B.
8. Start the engine, perform the arm IN relief and run the en-
gine with fuel control dial at MAX (High idle) position. De-
press the accelerator pedal of smoke meter B to collect the
exhaust gas on the filter paper.
REMARK
In the case of testing exhaust gas color while fuel control
dial is in MAX (High idle) position, set the fuel control dial
to MAX (High idle) position and hold the dial in place for 5
seconds before collecting the exhaust gas.
9. Place the contaminated filter paper on the clean filter pa-
per (at least 10 sheets) in the filter paper holder and read the indicated value.
3 Plug (2):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug (2):
Seizure prevention compound (LC-G)
30-30 PC210LCI-11
30 TESTING AND ADJUSTING TEST AND ADJUST VALVE CLEARANCE
TEST AND ADJUST VALVE CLEARANCE

Tools for testing and adjusting valve clearance
A 795-799-1131 Gear 1
Commercially
B Feeler gauge 1
available
k Turn the battery disconnect switch to OFF position, and remove the key.
Engine coolant temperature: Normal temperature
For testing of valve clearance to perform troubleshooting or Pm Clinic, or periodic maintenance, etc. refer to this
section.
METHOD FOR TESTING VALVE CLEARANCE

1. Remove head cover (1) to be tested. For details, see Dis-
assembly and assembly, “REMOVE AND INSTALL INJEC-
TOR ASSEMBLY”.
2. Remove undercovers (2), (3), and (4).
3. Remove plate (5) and plug (6) on the bottom of starting

motor, and insert gear A into the position shown in the fig-
ure.
PC210LCI-11 30-31
TEST AND ADJUST VALVE CLEARANCE 30 TESTING AND ADJUSTING
4. Rotate the crankshaft forward with gear A, and align the

yellow paint (line) of vibration damper (7) with engine oil
pan mounting bolt (8) so that their positions become
straight line.
REMARK
• The tip of engine oil pan mounting bolt (8) is painted
with yellow paint.
• This alignment is not an alignment to obtain the com-
pression top dead center of No. 1 cylinder and No. 6
cylinder. (it will be 76 to 88 deg. before the compres-
sion top dead center.)
5. Check the valve clearance by confirming the movement of
rocker arm of No. 1 cylinder.
REMARK
• If you can move the rocker arm of air intake side (IN)
with the hand by the valve clearance amount, check
the valve clearance marked with ○ in the valve layout
drawing.
• If you can move the rocker arm of exhaust side (EX)
with the hand by the valve clearance amount, check
the valve clearance marked with ● in the valve layout
drawing.
6. Rotate the crankshaft in the normal direction by 1 turn and
check other valve clearance.
REMARK
See step 4. for the method for alignment.
NOTICE
Be sure to remove gear A.
METHOD FOR ADJUSTING VALVE CLEARANCE

After testing, adjust the valve clearance according to the following procedure, if necessary.
1. Loosen lock nut (10) with adjustment screw (9) fixed.
2. Insert feeler gauge B in the clearance between rocker arm
(11) and crosshead (12), and adjust the valve clearance
with adjustment screw (9).
Turn adjustment screw (9) with feeler gauge B inserted,
and adjust it with adjustment screw (9) until the feeler
gauge B can move lightly.
3. Tighten lock nut (10) with adjustment screw (9) fixed.
3 Locknut (10):
24±4 Nm {2.45±0.41 kgm}
Tighten lock nut (10), and check the valve clearance again.
After finishing the adjustment, restore the machine.
30-32 PC210LCI-11
30 TESTING AND ADJUSTING TEST COMPRESSION PRESSURE
TEST COMPRESSION PRESSURE

Testing tools for compression pressure
A 795-502-1590 Gauge assembly 1 Pressure range: 0 to 7 MPa
B 795-799-6700 Puller 1
C 795-790-4411 Adapter 1
D 6754-11-3130 Gasket 1
Commercially
E Hose 1 Hose inside diameter: 15 mm
available
k Turn the battery disconnect switch to OFF position, and remove the key.
k When testing the compression pressure, be careful not to burn yourself by touching the exhaust
manifold, KDPF, SCR, or AdBlue/DEF mixing piping, or get caught in a rotating part.
• At cranking (engine speed): 250 to 280 rpm (reference)
For testing of compression pressure to perform troubleshooting or Pm Clinic, or periodic maintenance, refer to
this section.
METHOD FOR TESTING COMPRESSION PRESSURE

1. Open the engine hood.
2. Set the cylinders to be checked to the compression top dead center. For details, see “TEST AND ADJUST
VALVE CLEARANCE”.
REMARK
Check that both of the intake rocker arm and exhaust rocker arm at the compression top dead center are
movable by hand as much as the valve clearance.
3. Remove fuel spray prevention cap (1), loosen the sleeve
nut, and disconnect high-pressure pipe (2).
REMARK
When measuring the compression pressure, the fuel
spurts out of the disconnected part on the common rail
side. Install hose E to a container in order to drain the fuel.
NOTICE
Do not bend high-pressure pipe to correct before in-
stalling.
4. Loosen injector terminal nuts (3) and remove the terminals
from the injector.
REMARK
Insulate the terminals with tape etc. so that adjacent terminals do not touch each other.
5. Remove rocker arm assembly (4).
REMARK
When removing rocker arm assembly (4), be careful not to drop the support and shaft.
6. Remove crosshead (5).
PC210LCI-11 30-33
TEST COMPRESSION PRESSURE 30 TESTING AND ADJUSTING
7. Remove retaining nut (6) and remove inlet connector (7).

8. Remove holder (8).
9. Remove injector (9).
REMARK
• Remove injector (9) with the impacts of the slide ham-
mer by using puller B.
• Do not pry the top of injector (9) to remove.
10. Install gasket D to the tip of adapter C, and insert them into
the injector mounting part.
11. Fix adapter C with holder (8).
REMARK
Tighten the holder (8) mounting bolts alternately.
3 Holder (8) mounting bolt:
8±0.8 Nm {0.82±0.08 kgm}
12. Install crosshead (5) and rocker arm assembly (4).
3 Rocker arm assembly (4) mounting bolt:
36±5 Nm {3.67±0.51 kgm}
13. Adjust the valve clearance. For details, see “TEST AND ADJUST VALVE CLEARANCE”.
14. Connect connectors (11) to (14).
• Connector (11): VGT position sensor (SVGT)
• Connector (12): VGT speed sensor (VGT_REV)
• Connector (13): Connector box (INTERCONNECT)
• Connector (14): Intermediate connector (INJ CYL
1&2)
15. Connect VGT control hydraulic circuit hose (16), VGT drive
hydraulic circuit hose (17), and EGR circuit tube (18).
3 Hose (16):
25±1.5 Nm {2.55±0.15 kgm}
3 Hose (17):
15±1 Nm {1.53±0.1 kgm}
3 Flange side of tube (18):
24±4 Nm {2.45±0.41 kgm}
3 Tube side of tube (18):
10.5±0.5 Nm {1.07±0.05 kgm}
30-34 PC210LCI-11
16. Connect gauge assembly A to adapter C.

REMARK
If a small amount of oil is applied to the connecting parts of
gauge assembly A and adapter C, air will not leak easily.
17. Turn the battery disconnect switch to ON position, then
turn the starting switch to ON position.
18. Set “No-Injection Cranking” by referring to “SET AND OP-

ERATE MACHINE MONITOR”.
k Engine will start and it is dangerous if “No-Injection
Cranking” mode is not set, Accordingly, be sure to
set the engine in this mode.
19. Measure the compression pressure when the engine is
cranked by the starting motor.
NOTICE
In order to protect the starting motor, it is prohibited to
continue cranking for more than 20 seconds.
REMARK
Read the compression pressure when the pointer of gauge
is stabilized.
Install the injector and high-pressure pipe according to the following procedure.
1. Align projection (a) of injector and groove (b) of holder.
2. Install the injector to the cylinder head while facing its fuel
inlet hole to the air intake manifold.
3. Tighten the holder mounting bolt by 3 to 4 threads.
4. Check inlet connector.
PC210LCI-11 30-35
TEST COMPRESSION PRESSURE 30 TESTING AND ADJUSTING
NOTICE
Check inlet connector on the following points. If any
abnormality is found, replace it.
• When burrs or wear are found on front-end part (a)
or rear-end part (b) of inlet connector
• When foreign matters are found in the edge filter at
rear-end (c) of the inlet connector
• When cracks or deterioration are found on the O-
ring of inlet connector upper part (d)
• When wear or uneven contact are found on seat
surface (e) at tip-end of the inlet connector.
REMARK
If high-pressure fuel leaks through the inlet connector, seat
surface has fine streaks or cracks due to erosion.
5. Apply engine oil to the O-ring and the cylinder head side of
inlet connector (7).
2 O-ring and cylinder head side of inlet connector
(7):
Engine oil
6. Insert inlet connector (7) into injector (9), and tighten re-
taining nut (6) lightly.
REMARK
• Retightening is to be performed after tightening. Re-
tighten each of them to the specified torque. If tighten-
ing torque is insufficient or too much, it will cause fuel
leakage inside the engine.
• Install inlet connector (7) so that its positioning ball fits
in guide groove part on the cylinder head side.
3 Retaining nut (6) (tightening lightly):
15±5 Nm {1.53±0.51 kgm}
7.
3 Mounting bolt (19):
Tighten mounting bolts (19) of holder (8) alternately.
8±0.8 Nm {0.82±0.08 kgm}
8.
3 Retaining nut (6) (tightening to the specified torque) :
Tighten retaining nut (6) of inlet connector (7).
50±5 Nm {5.1±0.51 kgm}
30-36 PC210LCI-11
9. Tighten sleeve nuts (20) of high-pressure pipe (2) in the or-

der of cylinder head (21) side and common rail (10) side.
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
3 Rocker arm assembly (4) mounting bolt (22):

(4).
36±5 Nm {3.67±0.51 kgm}
12. Adjust the valve clearance. For details, see “TEST AND
ADJUST VALVE CLEARANCE”.
13. Tighten injector terminal nut (3).
3 Injector terminal nut (3):
1.5±0.25 Nm {0.15±0.03 kgm}
REMARK
Check that the injector wiring harness does not interfere
with the rocker arm.
14. Install the cylinder head cover.
3 Cylinder head cover mounting nut:
24±4 Nm {2.45±0.41 kgm}
PC210LCI-11 30-37
TEST BLOWBY PRESSURE 30 TESTING AND ADJUSTING
TEST BLOWBY PRESSURE

Testing tools for blowby pressure
- 799-201-1506 Blowby checker 1
1 799-201-1591 Gauge 1 Pressure range: 0 to 10 kPa
A 2 799-201-1511 Tool 1
3 799-201-1450 Adapter 1
4 07281-00359 Clamp 2
Commercially
B Plug 1 Hose inside diameter: 24 mm
available
Commercially
C Cap 2 Tube outside diameter: 25.4 mm
available
• Perform with after treatment devices regeneration disabled
For testing of blowby pressure to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR TESTING BLOWBY PRESSURE

1. Open the engine hood and remove steps (1).
30-38 PC210LCI-11
30 TESTING AND ADJUSTING TEST BLOWBY PRESSURE
2. Disconnect outlet hose (2) of KCCV blowby gas, and in-

stall plug (B) to the disconnected hose.
3. Install cap C to KCCV outlet tube, and tighten it with clamp
A4.
4. Disconnect blowby gas inlet port hose (3).

5. Install tool A2 and adapter A3 of blowby checker A to inlet
port hose (3) of KCCV blowby gas, and connect gauge A1.
6. Install cap C to KCCV inlet tube, and tighten it with clamp
A4.
7. Start the engine, set the working mode to P (“Power
Mode”), and turn the swing lock switch ON.
measure the blowby pressure with arm IN relief + one-
touch power maximizing ON.
Read the blowby pressure when the pointer of gauge is
stabilized.
3 Hose clamp on inlet and outlet sides of KCCV blowby gas:
4.4±0.49 Nm {0.45±0.05 kgm}
PC210LCI-11 30-39
TEST ENGINE OIL PRESSURE 30 TESTING AND ADJUSTING
TEST ENGINE OIL PRESSURE

Testing tools for engine oil pressure
A
1 799-101-5160 Nipple 1 Size: R1/8
B 799-401-2320 Gauge 1 Pressure range: 1 MPa
Engine coolant temperature: 60 to 100 °C
For testing of engine oil pressure to perform troubleshooting or others, refer to this section.
METHOD FOR TESTING ENGINE OIL PRESSURE

1. Open the side cover on the right side of the machine.
2. Remove engine oil pressure pickup plug (1) on the upper
part of engine oil filter.
3. Install nipple A1 of hydraulic tester A, and connect them to

gauge B.
4. Start the engine, and turn the auto-decelerator switch OFF.
5. Test the engine oil pressure when fuel control dial is in MIN
(Low idle) and MAX (High idle) positions.
30-40 PC210LCI-11
30 TESTING AND ADJUSTING TEST EGR VALVE AND VGT OIL PRESSURE
TEST EGR VALVE AND VGT OIL PRESSURE

Tools for testing EGR valve and VGT oil pressure
A 1 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 799-401-3100 Adapter 1
k Place the machine on a level ground, lower the work equipment to the ground in a stable posture,
and set the lock lever to LOCK position, and then stop the engine.
For testing of EGR valve and VGT oil pressures to perform troubleshooting or Pm Clinic, periodic maintenance,
refer to this section.
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE

1. Open the engine hood, and remove step (1).
2. Disconnect hose (2).
PC210LCI-11 30-41
TEST EGR VALVE AND VGT OIL PRESSURE 30 TESTING AND ADJUSTING
3. Install adapter B, and connect hose (2).

3 Adapter B:
15±1.0 Nm {1.53±0.10 kgm}
4. Install nipple A2 of hydraulic tester A to adapter B, and
connect it to gauge A1.
5. Start the engine and measure the oil pressure with fuel
control dial at MIN (Low idle) position and MAX (High idle)
position.
3 Hose (2):
15±1.0 Nm {1.53±0.10 kgm}
30-42 PC210LCI-11
30 TESTING AND ADJUSTING TEST FUEL PRESSURE
TEST FUEL PRESSURE

Tools for testing fuel pressure
A 1 799-101-5160 Nipple 1 Size: R1/8
2 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
B 795-790-4430 Adapter 1
C 6215-81-9710 O-ring 1
D 795-790-5110 Screw 1
E 799-401-2320 Gauge 1 Pressure range: 1 MPa
F 795-790-5120 Screw 1
G 1 799-101-5160 Nipple 1 Size: R1/8
2 799-401-2311 Gauge 1 Pressure range: -101 to 200 kPa
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.
k Wait for 30 seconds at least after stopping the engine until the remaining pressure in the fuel circuit
is released, and perform removal and installation of the testing tools. (Do not start the work immedi-
ately after stopping the engine since pressure remains in the circuit.)
NOTICE
Check the fuel pressure of low pressure circuit between feed pump, fuel main filter, and supply pump,
and the return circuit between supply pump, common rail, injector, and fuel tank.
PC210LCI-11 30-43
TEST FUEL PRESSURE 30 TESTING AND ADJUSTING
A: Low-pressure circuit measuring position (fuel main C: Return circuit measuring position (supply pump
filter inlet side) drain port)
B: Low-pressure circuit measuring position (fuel main D: Negative pressure circuit measuring position (sup-
filter outlet side) ply pump inlet)
For testing of fuel pressure to perform troubleshooting or Pm Clinic, or periodic maintenance, refer to this sec-
tion.
METHOD FOR TESTING FUEL PRESSURE

Testing of low-pressure circuit (fuel main filter inlet side)
1. Open the side cover on the right side of the engine and re-
move fuel pressure pickup plug (1) on the inlet side of the
fuel main filter.
30-44 PC210LCI-11
2. Install adapter B, install nipple A1 of hydraulic tester A,

and connect it to gauge A2.
REMARK
When installing adapter B, be sure to install the O-ring.
3 Adapter B :
32±4 Nm {3.26±0.41 kgm}
3. Start the engine, and measure the low-pressure circuit
pressure with fuel control dial at MAX (High idle) position.
NOTICE
If the engine cannot be started, you may perform the
measurement while rotating the engine by using the
starting motor, but do not rotate the engine for more
than 20 seconds continuously to protect the starting
motor.
3 Fuel pressure pickup plug (1):
32±4 Nm {3.26±0.41 kgm}
Testing of low-pressure circuit (pressure difference)

1. Remove fuel pressure pickup plug (1) on the inlet side of
fuel main filter and fuel pressure pickup plug (2) on the
outlet side.
PC210LCI-11 30-45
2. Install adapters B to the measuring hole on the inlet side

and outlet side, install nipple A1 of hydraulic tester A, and
connect it to gauge A2.
REMARK
When installing adapter B, be sure to install the O-ring.
3 Adapter B :
32±4 Nm {3.26±0.41 kgm}
3. Start the engine, and measure the pressure of the inlet
and outlet of the low-pressure circuit with fuel control dial
at MAX (High idle) position.
NOTICE
motor.
4. Calculate the pressure difference of the low-pressure cir-
cuit.
Pressure difference in low-pressure circuit = Pressure on
fuel main filter inlet side - Pressure on fuel main filter outlet side
REMARK
If it exceeds the standard value, the fuel main filter may be clogged. Replace the fuel main filter, and test it
again.
3 Fuel pressure pickup plug (1) and (2):
32±4 Nm {3.26±0.41 kgm}
Testing of return circuit

1. Remove cover (1).
30-46 PC210LCI-11
2. Remove joint bolt (2) of the fuel return hose between sup-
ply pump and fuel cooler.
3. Install screw D and nipple A1 of hydraulic tester A instead

of joint bolt (2), and connect hose to gauge E.
REMARK
When installing screw D, be sure to install the seal washer.
3 Screw D:
19.6 to 29.4 Nm {2 to 3 kgm}
4. Start the engine, and measure the return circuit pressure
with fuel control dial at MAX (High idle) position.
NOTICE
motor.
3 Joint bolt (2):
19.6 to 29.4 Nm {2 to 3 kgm}
Testing of negative pressure circuit

1. Remove joint bolt (3) of the fuel supply hose between fuel
prefilter and supply pump.
PC210LCI-11 30-47
2. Install screw F and nipple G1 of boost gauge kit G instead

of joint bolt (3), and connect it to gauge G2.
REMARK
When installing screw F, be sure to install the seal washer.
3 Screw F:
25.4 to 34.3 Nm {2.59 to 3.5 kgm}
3. Start the engine, and measure the fuel negative pressure
circuit pressure with fuel control dial at MAX (High idle) po-
sition.
4. After finishing the test, remove the testing tools and re-
store the machine.
3 Joint bolt (3):
25.4 to 34.3 Nm {2.59 to 3.5 kgm}
30-48 PC210LCI-11
30 TESTING AND ADJUSTING TEST FUEL DISCHARGE, RETURN AND LEAKAGE
TEST FUEL DISCHARGE, RETURN AND LEAKAGE

Testing tools for fuel discharged volume, return rate and leakage
A 795-790-4700 Tester kit 1
B 6164-81-5790 Joint 1
C 07206-30812 Joint bolt 1
D 6745-71-1130 Seal washer 1
Commercially
E Stopwatch 1
available
Commercially
F Hose 1 Inside diameter: Approximately 14 mm
available
Commercially
G Measuring cylinder 1
available
Commercially
H Hose 1 Inside diameter: Approximately 8 mm
available
k Place the machine on a level ground, and lower the work equipment to the ground.
k Wait for 30 seconds at least after stopping the engine until the remaining pressure in the fuel circuit
is released. Then perform removing or installing the testing tools. (Do not start the work immediately
after the engine is stopped since remaining pressure is still in the circuit.)
REMARK
Since some fuel flows out during test, prepare a container of approximately 20 ℓ.
A: Measuring position of supply pump discharged vol- C: Measuring position of leakage from pressure limiter
ume D: Measuring position of injector return rate
B: Measuring position of supply pump return rate
PC210LCI-11 30-49
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30 TESTING AND ADJUSTING
For testing of fuel discharged volume, return rate and leakage to perform troubleshooting or PM Clinic, refer to
this section.
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE

Testing supply pump discharged volume
2. Remove fuel spray prevention cap (2).

3. Loosen clamp (4) fixing high-pressure pipe (3) on dis-
charge side of supply pump.
4. Install hose F to the connector on the discharge side of the

supply pump.
REMARK
• Clamp hose F with a hose band to prevent it from com-
ing off.
• Adjust the route of hose F so that it does not become
slack, and put its end in measuring cylinder G.
30-50 PC210LCI-11
5. Crank the engine for 30 seconds and measure the dis-

charged volume by using measuring cylinder G.
NOTICE
In order to protect the starting motor, it is prohibited to
continue cranking for more than 20 seconds. “Crank
the engine for 15 seconds, stop for 15 seconds and
then crank it again for 15 seconds.” Perform the meas-
urement according to this procedure.
3 High-pressure pipe (3) sleeve nut :
35±3.5 Nm {3.57±0.36 kgm}
3 Clamp (4) mounting bolt:
24±4 Nm {2.45±0.41 kgm}
Testing supply pump return rate

1. Remove joint bolt (1) and disconnect fuel return hose (2)
on the return side of supply pump.
2. Install cap nut [1] of tester kit A to fuel return hose side to
prevent the fuel from flowing out.
REMARK
When installing cap nut [1], be sure to install the seal
washer.
3. Install joint B to the supply pump side with joint bolt C.
REMARK
When installing joint bolt C, be sure to install the seal
3 Joint bolt C:

washer.
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
PC210LCI-11 30-51
4. Install hose H to joint B.

REMARK
Adjust the route of hose H so that it does not become slack, and put its end in measuring cylinder G.
5. Start the engine and measure the return rate of supply
pump for 30 seconds by measuring cylinder G with the fuel
control dial set to MIN (Low idle) position.
NOTICE
When the engine cannot be started, you may perform
the measurement while cranking the engine by the
starting motor. However, to protect the starting motor,
do not crank the engine for more than 20 seconds con-
tinuously. “Crank the engine for 15 seconds, stop for
15 seconds and then crank it again for 15 seconds.”
Perform the measurement according to this proce-
dure.
3 Joint bolt (1):
19.6 to 29.4 Nm {2.0 to 3.0 kgm}
Testing of leakage from pressure limiter

1. Remove joint bolt (1) of the pressure limiter and discon-
nect spill tube (2).
2. Install cap nut [1] of tester kit A to spill tube side to prevent
the fuel from flowing out.
REMARK
washer.
3. Install joint B to the pressure limiter side with joint bolt C.
30-52 PC210LCI-11
REMARK
3 Joint bolt C:

When installing joint bolt C, be sure to install the seal washer.
24±4 Nm {2.45±0.41 kgm}
REMARK
5. Start the engine and measure the leakage of pressure lim-
iter for 30 seconds by measuring cylinder G with the fuel
control dial set to MIN (Low idle) position.
NOTICE
dure.
3 Joint bolt (1):
24±4 Nm {2.45±0.41 kgm}
Testing fuel return rate from injector

REMARK
The fuel return rate from the injector is measured while spill tube of the pressure limiter is connected. According-
ly, before measuring the return rate from the injector, check that the leakage from the pressure limiter is normal.
1. Remove check valve (1) on the cylinder head, and discon-
nect spill tube (2).
PC210LCI-11 30-53
2. Install cap nut [1] of tester kit A to spill tube side to prevent
the fuel from flowing out.
REMARK
washer.
3. Install joint B to the cylinder head side with joint bolt C.
REMARK
When installing joint bolt C, be sure to install the seal
3 Joint bolt C:

washer.
24±4 Nm {2.45±0.41 kgm}
REMARK
5. Start the engine and measure the return rate of injector for
30 seconds by measuring cylinder G with the fuel control
dial set to the MIN (Low idle) position.
NOTICE
dure.
3 Check valve (1):
24±4 Nm {2.45±0.41 kgm}
30-54 PC210LCI-11
30 TESTING AND ADJUSTING BLEEDING AIR FROM FUEL SYSTEM
BLEEDING AIR FROM FUEL SYSTEM

Air bleeding is performed through fuel tank → prefilter → feed pump → main filter → metering unit → fuel tank.
For bleeding air from fuel system to perform troubleshooting or Pm Clinic, refer to this section.
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM

In the following cases, bleed air according to this procedure.
• When run out of fuel occurs
• When a device in the fuel circuit is removed, installed, or replaced.
1. Turn the starting switch to ON position, and refill the fuel tank with fuel until the fuel level monitor becomes
blue.
2. Turn the starting switch to OFF position.
3. Open the side cover on the right side of the machine.
4. Loosen hand primer (1), pull it out.
5. Move hand primer (1) forward and backward until its
movement becomes heavy, and bleed air.
The plug on the upper part of fuel main filter needs not to
be removed.
6. After bleeding air, push hand primer (1) in, and tighten it.
PC210LCI-11 30-55
TEST FUEL CIRCUIT FOR LEAKAGE 30 TESTING AND ADJUSTING
TEST FUEL CIRCUIT FOR LEAKAGE

Tools for testing fuel system for leakage
Commercially Developer for dye penetrant (color
A 1
available checker)
k Fuel leakage may result in a fire during engine is running since very high pressure is generated in
the high-pressure circuit of the fuel system, and that is dangerous. If check of the fuel circuit or re-
moval of the component is performed, check it for fuel leakage according to the following procedure.
Clean the engine and the parts around it, and degrease them in advance so that you can check it easily for fuel
leakage.
For testing of fuel system for leakage to perform troubleshooting, refer to this section.
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE

Testing method of fuel circuit for leakage at engine stopped
1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle), and stop it after the engine automatic warm-up func-
tion is canceled automatically and engine speed is stabilized.
REMARK
• Turn the fuel control dial to MAX (High idle), the engine automatic warm-up function is canceled.
• For the condition of canceling the engine automatic warm-up function, see “ENGINE AUTOMATIC
WARM-UP SYSTEM”.
3. Spray color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4. Check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 1 again.
Testing method of fuel circuit for leakage at engine low idle

REMARK
WARM-UP SYSTEM”.
4. Start the engine, and set the fuel control dial to MIN (Low idle).
5. Stop the engine and check the fuel piping and component for fuel leakage.
sprayed.
Testing method of fuel circuit for leakage at engine high idle

30-56 PC210LCI-11
30 TESTING AND ADJUSTING TEST FUEL CIRCUIT FOR LEAKAGE
REMARK
WARM-UP SYSTEM”.
4. Start the engine, and set the fuel control dial to MAX (High idle).
sprayed.
Testing method of fuel circuit for leakage at engine rated speed

REMARK
WARM-UP SYSTEM”.
5. Run the engine with “2 pumps relief + One-touch power maximizing” state. For details, see “TEST ENGINE
SPEED”.
sprayed.
PC210LCI-11 30-57
HANDLE CYLINDER CUT-OUT MODE OPERATION 30 TESTING AND ADJUSTING
HANDLE CYLINDER CUT-OUT MODE OPERATION

The cylinder cutout 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 cylinder cutout mode
operation are as follows.
• Cylinder cutout mode operation is used to find out a cylinder which does not output power normally (or,
combustion in it is abnormal).
• If the engine speed and output do not change from the normal operation (all-cylinder operation) when a cyl-
inder is cutout with the cylinder cutout mode operation, that cylinder has a failure.
The possible failures are as follows.
• Compression gas leakage from cylinder head gasket area
• Defective injection
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating system)
• Defective electrical system
• Common rail fuel injection system individually controls the injector of each cylinder electronically , so the
cylinder cutout test can be performed easily by the simple operations of the switches compared with the
mechanical fuel injection system. So, the defective cylinder can be found out easily.
30-58 PC210LCI-11
30 TESTING AND ADJUSTING HANDLE NO-INJECTION CRANKING OPERATION
HANDLE NO-INJECTION CRANKING OPERATION

No-injection cranking operation means to crank the engine by using the starting motor while disabling injection
in all cylinders electrically. The purpose and effect of this operation are as follows.
No-injection cranking is performed to lubricate the engine parts and to protect them from seizure. It is performed
before the engine is started after the machine or engine has been stored for a long period.
PC210LCI-11 30-59
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TEN-
SION 30 TESTING AND ADJUSTING
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, and
set the lock lever to LOCK position, and then stop the engine.
For testing and adjusting the tension of air conditioner compressor belt to perform troubleshooting, refer to this
section.
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT

1. Remove bolts (2) (3 pieces).
2. Remove guard (1).
3. Press the center between drive pulley (A) and compressor

pulley (B) with a finger (approximately 60 N {6.1 kg} ).
If deflection (C) is 6 to 9 mm {0.23 to 0.35 in} , the belt ten-
sion is normal.
If the deflection is out of the standard, adjust it to the
standard value.
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT

1. Remove bolts (2) (3 pieces).
2. Remove guard (1).
3. Loosen bolts (3) (3 pieces).

There is no need of removing bolt (3). Also, take care not
to loosen too much.
30-60 PC210LCI-11
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TEN-
30 TESTING AND ADJUSTING SION
4. Loosen nut (4) in direction (A).

Nut (4) is provided to prevent loosening of jack bolt (5).
5. Tighten jack bolt (5).
Compressor (6) moves in direction (A), and the compres-
sor belt is tensed.
6. Press the center between drive pulley (A) and compressor

pulley (B) with a finger (approximately 60 N {6.1 kg}).
If deflection (C) is 6 to 9 mm {0.24 to 0.35 in} , the belt ten-
sion is normal.
If the deflection is out of the standard, adjust it to the
standard value by repeating steps 4 and 6.
7. When the belt tension becomes appropriate, tighten bolts

(3) (3 pieces) and fix it.
Tightening torque: 59 to 74 Nm{6.0 to 7.5 kgm,43.4 to
54.2 lbft}
8. After tightening nut (4) until it touches boss (7), then tight-
en it further in direction (B) to prevent it from loosening.
Tightening torque: 108 to 132 Nm{11.0 to 13.5 kgm,79.6 to
97.6 lbft}
9. After fixing, check again that the belt tension is proper.
Adjust it again if the tension is not within the proper range.
10. Check each pulley for damage, wear of the V-groove, and the wear of the V-belt. In particular, be sure to
check that the V-belt is not touching the bottom of the V-groove.
11. Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has slipping
sound or squeak because of cuts or cracks of the belt.
NOTICE
• When the new V-belt is installed, readjust it after operating for 1 hour.
• When replacing the V-belt, be careful not to damage the electric wiring of the cooling fan.
PC210LCI-11 30-61
TEST COOLING FAN SPEED 30 TESTING AND ADJUSTING
TEST COOLING FAN SPEED

For checking cooling fan speed to perform troubleshooting or others, refer to this section.
METHOD FOR TESTING COOLING FAN SPEED

1. Start the engine and see the section of “SET AND OPERATE MACHINE MONITOR”. Select 100 % mode
on “Fan Speed Mode Select”.
2. Select “Fan Speed” on “Pre-defined Monitoring” (15/24), or
from “Monitoring Selection Menu” to display. For details,
see “SET AND OPERATE MACHINE MONITOR”.
Monitoring code: 10007 “Fan Speed”
The figure shows monitoring code 10007 “Fan Speed”

screen.
3. Check the cooling fan speed when fuel control dial is at
both MIN (Low idle) and MAX (High idle) position and par-
tial position (engine speed) at 1300 rpm.
REMARK
If engine coolant temperature becomes lower than 75 °C
and hydraulic oil temperature becomes lower than 80 °C
when 100 % mode is not selected in “Fan Speed Mode Se-
lect”, cooling fan speed becomes 400±100 rpm.
4. See the section of “SET AND OPERATE MACHINE MONITOR”. Select the mode to “Fan Speed Mode Se-
lect” and select normal control mode.
REMARK
If starting switch is turned to OFF position, cooling fan speed returns to normal control mode when the end-
ing is started again.
30-62 PC210LCI-11
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE
30 TESTING AND ADJUSTING CONTROLLER
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CON-

TROLLER
k Check that there is no person or combustible material around the machine (particularly in the direc-
tion of the exhaust gas flows).
• When starting the engine, ash contained in engine oil accumulates in KCSF and increases filter differential
pressure.
• Since filter differential pressure is used for calculation of soot accumulation in the engine controller, in-
crease amount of differential pressure by ash needs to be corrected.
• Correction amount of filter differential pressure increased by ash is calculated in the engine controller as
“Soot Correction by Ash Influence”.
• When engine controller is replaced with the new one, “Soot Correction by Ash Influence” becomes default
value, 0 g/ ℓ.
• When engine controller is replaced with the new one, perform applicable operation to obtain correct “Soot
Correction by Ash Influence”.
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO EN-

GINE CONTROLLER
Perform the applicable operation according to the following procedure.
• When only the engine controller is replaced.
Perform “Ash in Soot Accumulation Correction”. For detail, see “SETTING AND OPERATION OF MA-
CHINE MONITOR”.
• When both of engine controller and KCSF are replaced,
the value of “Soot Correction by Ash Influence” and Ash Accumulationaccumulated in KCSF become 0 g/ ℓ,
“Ash in Soot Accumulation Correction” needs not to be performed.
Perform applicable operation. For details, see TROUBLESHOOTING, “Precautions for KDPF (KCSF,
KDOC) cleaning and change”.
PC210LCI-11 30-63
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING
TEST SCR RELATED FUNCTIONS

For testing of SCR related function to perform troubleshooting, refer to this section.
Types of SCR Service Test

Code Item Purpose Reference page
AdBlue/DEF AdBlue/DEF pump is actuated singly. Damage of
TEST AdBlue/DEF PUMP
01 Pump Pressure AdBlue/DEF hose and failure in AdBlue/DEF pump
RAISED PRESSURE (30-68)
Up Test can be detected.
AdBlue/DEF injector for failure can be detected by TEST INJECTION AMOUNT
AdBlue/DEF Injec-
02 increasing the AdBlue/DEF pump pressure and in- FROM AdBlue/DEF INJECTOR
tion Quantity Test
jecting a certain amount of AdBlue/DEF. (30-71)
AdBlue/DEF Line
AdBlue/DEF line heater 1 can be actuated at any TEST AdBlue/DEF LINE HEAT-
03 Heater Relay 1
timing, and electrical action can also be checked. ER RELAY 1 (30-75)
Test
AdBlue/DEF Line
AdBlue/DEF line heater 2 can be actuated at any TEST AdBlue/DEF LINE HEAT-
04 Heater Relay 2
timing, and electrical action can also be checked. ER RELAY 2 (30-78)
Test
AdBlue/DEF
AdBlue/DEF pump heater can be actuated at any TEST AdBlue/DEF PUMP
05 Pump Heater Re-
timing, and electrical action can also be checked. HEATER RELAY (30-81)
lay Test
AdBlue/DEF tank heater valve can be actuated at
AdBlue/DEF Tank TEST AdBlue/DEF TANK HEAT-
06 any timing, and electrical action can also be
Heater Valve Test ER VALVE (30-84)
checked.
SCR Denitration Performance of AdBlue/DEF injection and catalyzer TEST DENITRATION EFFI-
07
Efficiency Test can be checked if necessary. CIENCY OF SCR (30-87)
Test State Category

Test State (a) Content
0 Waiting for execution of test (Test can be started by pressing start test switch)
1 Test is in preparation
When nor-
5 Abnormalities have been reported after performing the test
mal
10 Test is being executed
20 Test is completed successfully
11 to 18 Test is being performed but it is paused by external factor
When it is
30 to 41 Test cannot be performed or cannot be continued
abnormal
100 Key OFF/ECU shut down is necessary
(a): Test State
30-64 PC210LCI-11
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS
Parameter list of test state

Test
Content Details Required action
State
Regeneration disable state of af-
Wait for the start (de-
0 tertreatment devices by machine Press the start test switch to start the test.
fault)
monitor
AdBlue/DEF pump pres- System is moving to “Test State”
1 Wait “Test State” changes to “10”.
sure is being increased. “10”
It is on the following state de-
pending on the contents.
• Being pressure-fed by
AdBlue/DEF pump
• AdBlue/DEF is being inject-
ed. • Check the items to be performed dur-
ing the test.
• The operation of energiza-
10 Being tested • In case of “SCR Denitration Efficiency
tion cycle at a fixed time af-
ter specific time passes. Test” or “Ash in Soot Accumulation
Correction”, wait until test is finished.
• “SCR Denitration Efficiency
Test” is being performed
• “Ash in Soot Accumulation
Correction” is being per-
formed
Pressure drop of AdBl- Pressure drops (only when AdBl-
Perform the troubleshooting for the failure
ue/DEF pump is detect- ue/DEF pump is pressure-fed)
5 code [CA3574]. For details, see “TROUBLE-
ed (failure code while the display of “Test State” is
SHOOTING”.
[CA3574] is displayed) “10”.
• If “Please turn the key off.” is dis-
played, turn the starting switch to OFF
position and shut down the engine
• AdBlue/DEF is being controller. (*1)
purged.
20 Test has been finished. • If “STOP” is displayed, press the cor-
• Heater energizing has responding switch to return the test to
been completed. initial state.
Other than the above, the state automatically
returns to initial state.
• Turn the starting switch to OFF posi-
tion, and perform the test again after
Purging (energizing • AdBlue/DEF is being shutting down the engine controller.
temporarily stops) or purged. (*1)
11
test cannot be per- • A particular error message • If a specific error message is dis-
formed. is displayed. played, see “TROUBLESHOOT-
ING”and perform troubleshooting for
the failure code.
Wait for AdBlue/DEF tank temperature or
AdBlue/DEF tank or AdBlue/DEF tank temperature ex-
AdBlue/DEF pump temperature to be low-
AdBlue/DEF pump is at ceeds 70 °C or AdBlue/DEF
12 ered. After the display of “Test State”
high temperature (ener- pump temperature exceeds upper
changes to “10”, the test restarts automatical-
gizing temporarily stops) limit.
ly.
PC210LCI-11 30-65
Test
State
The test state is displayed when step is
SCR temperature is 450 °C or
switched during “SCR Denitration Efficiency
SCR temperature is out above or 250 °C or below (tem-
14 Test”. Wait for several minutes. After “Test
of specified range perature range is set by each test
State” becomes “10”, test restarts automati-
level)
cally.
Under the condition described on the left,
“SCR Denitration Efficiency Test” does not
Mass air flow is out of Mass air flow is above 0.40g/sec
15 finish successfully. Perform the troubleshoot-
specified range or below 0.03kg/sec.
ing for the failure code. See “TROUBLE-
SHOOTING”.
• Turbo outlet NOX concen- Under the condition described on the left,
NOX value at turbo- tration: Max. 100 ppm “SCR Denitration Efficiency Test” does not
16 charger outlet is out of finish successfully. Perform the troubleshoot-
specified range • NOX sensor at turbocharg- ing for the failure code. See “TROUBLE-
er outlet is unmeasurable SHOOTING”.
Injection of AdBlue/DEF Perform the troubleshooting for the failure
17 The failure code is displayed.
is prohibited code. See “TROUBLESHOOTING”.
• Ambient temperature is Under the condition described on the left,
Ambient temperature -30 °C or below “SCR Denitration Efficiency Test” does not
and ambient pressure
18 • Ambient pressure is 60 kPa finish successfully. Perform the troubleshoot-
are out of specified
or below, or 160 kPa or ing for the failure code. See “TROUBLE-
range
above SHOOTING”.
• Operate the work equipment lock lever

to LOCK position.
30 Machine state is unsafe Safety of machine is not secured
• Turn the fuel control dial to MIN (Low
idle) position.
Fuel low level caution is dis-
31 Fuel level has dropped Refill with fuel.
played
The error message is displayed
Test cannot be per- Perform the troubleshooting for the failure
32 to prohibit the regeneration of af-
formed (1) code. See “TROUBLESHOOTING”.
tertreatment devices
Within 20 seconds after Within 20 seconds after starting Start the engine, wait for 20 seconds or more,
33
starting the engine the engine and then restart the test.
The engine is stopped. Start the engine, and then restart the test.
Test cannot be per-
34 Perform the troubleshooting for the failure
formed (2) Specified error is being displayed
code. See “TROUBLESHOOTING”.
Fuel control dial is not in MIN po- Lower the engine speed, and then restart the
Test cannot be per- sition test.
35
formed (3) AdBlue/DEF tank temperature is Start the engine, thaw AdBlue/DEF, and then
below -1 °C restart the test.
A particular error is being dis- Perform the troubleshooting for the failure
Test cannot be per- played code. See “TROUBLESHOOTING”.
36
formed (4) The AdBlue/DEF level is below Refill with AdBlue/DEF, and then restart the
10 %. test.
30-66 PC210LCI-11
Test
State
• Engine operation is unsta-
ble Set the engine at low idle, and then restart
Test cannot be per- • Immediately after the en- the test.
37
formed (5) gine has started, etc.
AdBlue/DEF pump pressure does Perform the troubleshooting for the failure
not increase code. See “TROUBLESHOOTING”.
Test cannot be per- A particular error is being dis- Perform the troubleshooting for the failure
39
formed (6) played code. See “TROUBLESHOOTING”.
Engine control governor Set the engine at low idle, and then restart
40 Engine control is unstable
state is not conformable the test
Test cannot be per- Overheat or oil pressure low error Perform the troubleshooting for the failure
41
formed (7) is displayed code. See “TROUBLESHOOTING”.
• Shut down the engine controller for re-
setting. (*1)
Key OFF/ECU shut • Engine is running
100 down is necessary or • SCR Denitration Efficiency Test does
• Elapsed time exceeds
exceed specified time not finish successfully. Perform the
specified time
troubleshooting for the failure code.
See “TROUBLESHOOTING”.
*1: Shut down of engine controller will be completed when the system operating lamp goes out 1 to 6 minutes
after the starting switch is turned to OFF position.
PC210LCI-11 30-67
TEST AdBlue/DEF PUMP RAISED PRESSURE

k Place the machine on a level ground, lower the work equipment with a stable posture to the ground,
set the lock lever in LOCK position, and stop the engine.
NOTICE
• If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue (standard screen). In
that case, turn the starting switch to OFF position once, and then system operating lamp goes out,
and the engine controller shuts down to reset the test.
• AdBlue/DEF may freeze when the outside air temperature is low. AdBlue/DEF should be thawed com-
pletely before performing the test. Devices will get damaged if the calibration is performed when the
AdBlue/DEF is still frozen.
AdBlue/DEF Pump Pressure UP Test function can actuate AdBlue/DEF pump alone, and can check damaged
AdBlue/DEF or failed AdBlue/DEF pump.
For testing of AdBlue/DEF hose or AdBlue/DEF pump to perform troubleshooting or Pm Clinic, etc. refer to this
section.
METHOD FOR TESTING AdBlue/DEF PUMP RAISED PRESSURE

2. Check the AdBlue/DEF conditions.
1) Select the following monitoring items on “Monitoring
Selection Menu”. See “SET AND OPERATE MA-
CHINE MONITOR”.
Monitoring code 19305: “AdBlue/DEF Tank Heating
State”
Monitoring code 19309: “AdBlue/DEF Pump Heater
State”
Monitoring code 19306: “AdBlue/DEF Line Heater 1
State”
State”
2) Check the monitoring information of (a) to (d) on
“Monitoring” screen.
Details of monitoring information are as follows.
1: Being thawed
2: Being kept warm
3: OFF
• When the status of the monitoring information (a) to
(d) is “1”
AdBlue/DEF is being thawed because it is still frozen.
Keep the engine speed at low idle and wait until the
status of the monitoring information becomes “2” or
“3”, and then proceed to step 3.
• The status of the monitoring information (a) to (b) is
“2” or “3”:
AdBlue/DEF is not frozen. Proceed to step 3.
3. Stop the engine.
4. Turn the starting switch to ON position.
k Do not perform this test while engine is running for
the safety reasons.
30-68 PC210LCI-11
5. Check that AdBlue/DEF level is higher than (a) with the

sight gauge.
REMARK
When AdBlue/DEF level is below level (a), the
AdBlue/DEF level is low. Add AdBlue/DEF.
6. See “METHOD FOR OPERATING TESTING MENU (SCR

SERVICE TEST)” of “SET AND OPERATE MACHINE
MONITOR” and select “AdBlue/DEF Pump Pressure Up
Test”.
7. Check that “0” of “Test State” is flashing.

REMARK
Flashing of “0” indicates “Waiting for the start (default)”,
and test can be performed. Display other than “0” appears,
follow instructions according to “Parameter list of test
state”.
8. Press F1 to start “AdBlue/DEF Pump Pressure Up Test”.
F1: Starts “AdBlue/DEF Pump Pressure Up Test”.
F2: Stops “AdBlue/DEF Pump Pressure Up Test”. (When
“STOP” is displayed.)
F5: Returns the screen to “SCR Service Test” screen.
NOTICE
“Test State” does not change to “10” and test does not
start even if F1 is pressed, turn starting switch to OFF
position once, and repeat the testing procedure from
step 1.
REMARK
• Display of “Test State” changes to flashing of “10”, and
value of “AdBlue/DEF Pump Pressure” increases.
While the pressure is increasing, display of “Remaining
Permitted Test Time” is counted down from “1800 to 0
sec”, and when it reaches to “0 sec”, the test will be fin-
ished automatically.
• When the display of “Test State” is “11” to “41”, follow
“Parameter list of Test State”.
• When the value of “AdBlue/DEF Pump Pressure” ex-
ceeds “900 kPa” within 1800 seconds of “Remaining
Permitted Test Time”, AdBlue/DEF pump and
AdBlue/DEF pressure line are normal. Press F2 to
complete the test.
PC210LCI-11 30-69
• If the value of “AdBlue/DEF Pump Pressure” does not increase, check each part of AdBlue/DEF pres-
sure line for leakage, or check by sound and vibration that AdBlue/DEF pump operates. However, per-
form the checking of each part of AdBlue/DEF pressure line for leakage, and AdBlue/DEF pump for
operation, before “Remaining Permitted Test Time” becomes “0sec”.
• If the value of “AdBlue/DEF Pump Pressure” does not exceeds 800 kPa after approximately 200 sec-
onds are elapsed, AdBlue/DEF stops operation automatically and failure code [CA1682] is displayed. If
the failure code is displayed, perform troubleshooting.
9. When the display of “Test State” changes from flashing of
“20” to flashing of “0”, press F5.
REMARK
• The display of “20” of “Test State” indicates that AdBl-
ue/DEF purge is in progress, and it starts automatically
and stops in 5 minutes at maximum.
• The display of “0” of “Test State” indicates “Wait for the
start (default)”, and is ready for test again.
30-70 PC210LCI-11
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR

Tools for testing of injection amount from AdBlue/DEF injector
A 799-601-4340 Socket 1
Commercially
B Multimeter 1
available
Commercially
C Measuring cylinder 1 Capacity: 200 to 500 mℓ
available
Commercially
D Rubber gloves 1
available
k For handling AdBlue/DEF, see Operation and Maintenance Manual, “PRECAUTIONS FOR DEF”.
k When handling AdBlue/DEF injector by hand, be sure to wear the protective eyeglasses and rubber
gloves.
NOTICE
• If the testing of this item is performed without removing AdBlue/DEF injector, the machine may have
a trouble. Accordingly, be sure to remove AdBlue/DEF injector before starting the testing.
• AdBlue/DEF may freeze when the outside air temperature is low. AdBlue/DEF should be thawed com-
pletely before performing the test. Devices will get damaged if the calibration is performed when the
AdBlue/DEF is still frozen.
AdBlue/DEF Injection Test function can boost the pressure of AdBlue/DEF pump to inject constant amount, and
can check if AdBlue/DEF injector has any failure.
For testing of AdBlue/DEF injector to perform troubleshooting , refer to this section.
METHOD FOR TESTING INJECTION AMOUNT FROM AdBlue/DEF INJECTOR

2. Check the AdBlue/DEF conditions.
1) Select the following monitoring items on “Monitoring
Selection Menu”. See “SET AND OPERATE MA-
CHINE MONITOR”.
Monitoring code 19305: “AdBlue/DEF Tank Heating
State”
Monitoring code 19309: “AdBlue/DEF Pump Heater
State”
State”
State”
PC210LCI-11 30-71
2) Check the monitoring information of (a) to (d) on

“Monitoring” screen.
Details of monitoring information are as follows.
1: Being thawed
2: Being kept warm
3: OFF
• If one of the monitoring information from (a) to (d) is
“1”
AdBlue/DEF is being thawed because it is still frozen.
Keep the engine speed at low idle and wait until the
status of all the monitoring information from (a) to (d)
becomes “2” or “3”, and then proceed to step 3.
• The status of the monitoring information from (a) to (d)
is “2” or “3”:
AdBlue/DEF is not frozen. Proceed to step 3.
3. Stop the engine.
4. Check that the system operating lamp is not lit, turn the
battery disconnect switch to OFF position, and remove the
key.
5. Open engine hood.
6. Check that there is neither crack nor dissolution on AdBl-
ue/DEF injector (2).
7. Disconnect connector (MB03), connect socket A, and

measure the resistance value.
REMARK
• The resistance value becomes high when it is at high
temperature. Cool it down completely, and perform the
measurement.
• Measure the resistance between pin 1 and pin 2.
STANDARD VALUE TABLE FOR ELECTRICITY.
8. After the measurement is completed, remove measuring
instrument, and connect connector (MB3).
9. Turn the battery disconnect switch to ON position.
10. Remove AdBlue/DEF injector (2).
REMARK
• If the crystal of AdBlue/DEF is adhered at the tip of AdBlue/DEF injector (2), wipe it off with clean cloth.
• If the crystal of AdBlue/DEF is stuck and it is difficult to wipe it off, soak new AdBlue/DEF to clean cloth
and wipe crystal off with it. Or, wipe crystal off by using distilled water or deionized water instead of
AdBlue/DEF.
30-72 PC210LCI-11
11. Securely insert the injection port of AdBlue/DEF injector

(2) into measuring cylinder C.
12. Check that AdBlue/DEF level is higher than level (a) of the
sight gauge.
REMARK
When AdBlue/DEF level is below level (a), the
AdBlue/DEF level is low. Refill AdBlue/DEF.
the safety reasons.
14. Select “AdBlue/DEF Injection Quantity Test” by referring

“SET AND OPERATE MACHINE MONITOR”.

REMARK
and test can be performed. Screen other than “0” is dis-
played, follow “Parameter list of Test State”.
16. Press F1 to start “AdBlue/DEF Injection Quantity Test”.
F1: Starts “AdBlue/DEF Injection Quantity Test”.
(AdBlue/DEF is injected from AdBlue/DEF injector.)
F2: Stops “AdBlue/DEF Injection Quantity Test”. (When
PC210LCI-11 30-73
NOTICE
• “Test State” does not change to “10” and test does not start even if F1 is pressed, turn starting
switch to OFF position once, and repeat the testing procedure from step 10.
• Press F2 to stop AdBlue/DEF injection at halfway. (When F2 is pressed, the display of “Test
State” changes to the flashing of “20”.
• If you turn starting switch to OFF position by mistake during test, do not turn starting switch to
ON position immediately, but check that system operating lamp is off, and turn starting switch to
ON position again after engine controller shuts down.
• When the KOMNET communication error occurs within 1 second which the engine controller can
not detect, the test may be continued although the machine monitor does not continue the test
(standard screen). In that case, turn the starting switch to OFF position once, and then system
operating lamp goes out, and the engine controller shuts down to reset the test.
REMARK
• The display of “Test State” changes to the flashing of “10”, and as AdBlue/DEF pump pressure increas-
es, the value of “AdBlue/DEF Pump Pressure” increases.
• When the display of Test State is “11” to “41”, follow “Parameter list of test state”.
• When the display of Remaining Permitted Test Time becomes “0:00 min:sec”, injection is completed. At
that time, AdBlue/DEF purge action starts automatically, and the display of Test State changes to the
flashing of “20”.
• AdBlue/DEF purge action is finished in 5 minutes, display of “Test State” changes to the flashing of “0”,
and injection test of AdBlue/DEF injector is completed.
• Since the display of “Final Accumulated Quantity” is the target value, it does not change from
“100.0 mℓ”.
• If the value of “AdBlue/DEF Pump Pressure” does not increase, check each part of AdBlue/DEF supply
line for leakage, or check by sound and vibration that AdBlue/DEF pump operates.
• After approximately 200 seconds are elapsed, if the value of “AdBlue/DEF Pump Pressure” does not
exceeds 800 kPa, AdBlue/DEF stops operation automatically and failure code [CA1682] appears. If the
failure code is displayed, perform troubleshooting.
17. When the display of Remaining Permitted Test Time becomes “0:00 min : sec” and injection is completed,
measure the amount of AdBlue/DEF collected in measuring cylinder.
REMARK
If it is out of the standard value, replace the AdBlue/DEF injector. For replacing of AdBlue/DEF injector, see
Disassembly and assembly, “Installation and removal of AdBlue/DEF injector”.
For the standard value, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools, and restore the machine.
NOTICE
• Replace the gasket on the mounting face of the AdBlue/DEF injector with new one.
• For the installation procedure of AdBlue/DEF injector, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL AdBlue/DEF INJECTOR”.
30-74 PC210LCI-11
TEST AdBlue/DEF LINE HEATER RELAY 1

A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available
NOTICE
If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue (standard screen). In that
case, turn the starting switch to OFF position once, and then system operating lamp goes out, and the
engine controller shuts down to reset the test.
“AdBlue/DEF Line Heater 1 Relay Test” function can actuate AdBlue/DEF line heater 1 at any timing, and can
check electrical action.
For testing of AdBlue/DEF suction circuit, or purge circuit or to perform troubleshooting or others, refer to this
section.
METHOD FOR TESTING AdBlue/DEF LINE HEATER RELAY 1

1. After checking that the system operating lamp is off, turn the battery disconnect switch to OFF position, and
remove the key.
2. Open cover (1).
3. Disconnect the connector to be tested.

When testing the suction line heater relay of AdBlue/DEF:
Connector (MB04)
When testing the low temperature pressure line heater re-
lay of AdBlue/DEF: Connector (MB06A)
PC210LCI-11 30-75
4. Connect T-adapter A and T-adapter box B, and prepare

the multimeter C.
REMARK
Measure the voltage between pin 1 and pin 2.
5. Check that the system operating lamp is off, and then turn
the battery disconnect switch to ON position.
the safety reasons.
7. Select “AdBlue/DEF Line Heater Relay 1 Test” by referring


REMARK
9. Press F1 to start “AdBlue/DEF Line Heater Relay 1 Test”.
F1: Starts “AdBlue/DEF Line Heater Relay 1 Test”.
F2: Stops “AdBlue/DEF Line Heater Relay 1 Test”. (When
30-76 PC210LCI-11
NOTICE
ON position immediately. Check that system operating lamp is off, and turn starting switch to
REMARK
• Display of “Test State” changes to flashing of “10”, and display of “Remaining Time to Start Test” is
counted down from “60” to “0 sec”, and when it reaches to “0 sec”, the power is supplied automatically.
• When the display of “Test State” is “11” to “41”, follow “Parameter list of test state”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, “Line Heater 1 Command” is “ON”
and voltage will be outputted to the heater relay.
• The test stops automatically in the elapsed time of 16 minutes after F1 is pressed.
10. Measure the voltage between pin 1 and pin 2.
REMARK
• If an abnormality occurs during measurement, failure codes [CA3713], [CA5115], [CA3562], and
[CA3563] are displayed. If these failure codes are displayed, perform troubleshooting.
• If 24.5±1.5 V is measured within 900 seconds of “Remaining Permitted Test Time”, you can finish the
measurement by pressing F2.
11. When the voltage of 24.5±1.5 V is measured, press F2.
The display of “Test State” returns to flashing of “0”.
REMARK
When disconnecting connector, always turn the battery disconnect switch to OFF position.
PC210LCI-11 30-77
TEST AdBlue/DEF LINE HEATER RELAY 2

Testing tools for AdBlue/DEF line heater relay 2
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available
NOTICE
“AdBlue/DEF Line Heater 2 Relay Test” function can actuate AdBlue/DEF line heater 2 at any timing, and can
For testing of AdBlue/DEF pressure circuit relay to perform troubleshooting or others, refer to this section.
METHOD FOR TESTING AdBlue/DEF LINE HEATER RELAY 2

1. After checking that the system operating lamp is off, turn the battery disconnect switch to OFF position, and
remove the key.
2. Open the cover on the right side of the machine.
When testing the low temperature pressure line heater re-
lay of AdBlue/DEF: Connector (MB06B)
30-78 PC210LCI-11

the multimeter C.
REMARK
5. Check that the system operating lamp is off, and then turn
the battery disconnect switch to ON position.
the safety reasons.
7. Select “AdBlue/DEF Line Heater Relay 2 Test” by referring


REMARK
9. Press F1 to start “AdBlue/DEF Line Heater Relay 2 Test”.
F1: Starts “AdBlue/DEF Line Heater Relay 2 Test”.
F2: Stops “AdBlue/DEF Line Heater Relay 2 Test”. (When
PC210LCI-11 30-79
NOTICE
REMARK
counted down from “60” to “0 sec”, and when it reaches to “0 sec”, the power is supplied automatically.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, “Line Heater 2 Command” is “ON”
and voltage will be outputted.
• The test stops automatically in the elapsed time of 16 minutes after F1 is pressed.
REMARK
• If an abnormality occurs during measurement, failure codes [CA3713], [CA5115], [CA3562], and
[CA3563] are displayed. If these failure codes are displayed, perform troubleshooting.
The display of “Test State” changes to flashing of “0”.
After finishing the test, remove the testing tools, and restore the machine.
REMARK
30-80 PC210LCI-11
TEST AdBlue/DEF PUMP HEATER RELAY

Tools for testing AdBlue/DEF pump heater relay
A 799-601-9130 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available
NOTICE
• In this pump heater relay test, when the starting switch is turned to OFF position while testing (ener-
gizing), and turned to ON position again before system operating lamp goes out, then energizing re-
starts. If, by mistake, the starting switch is turned to ON position while testing (energizing) without
waiting that system lamp goes out, immediately turn the starting switch to OFF position regardless
of the display of machine monitor, and wait the system operating lamp goes out.
“AdBlue/DEF Pump Heater Relay Test” function can actuate AdBlue/DEF pump heater at any timing, and can
For testing of AdBlue/DEF pump heater relay to perform troubleshooting or others, refer to this section.
METHOD FOR TESTING AdBlue/DEF PUMP HEATER RELAY

1. Check that the system operating lamp is off, turn the battery disconnect switch to OFF position, and remove
the key.
2. Open the cover on the left side of the machine.
When the testing pump heater relay of AdBlue/DEF: Con-
nector (R53A)
PC210LCI-11 30-81

the multimeter C.
REMARK
the safety reasons.
7. Select “AdBlue/DEF Pump Heater Relay Test” by referring

“SETTING AND OPERATION OF MACHINE MONITOR”.

REMARK
and test can be performed. Display other than “0” appears,
follow instructions according to “Parameter list of test
state”.
9. Press F1 to start “AdBlue/DEF Pump Heater Relay Test”.
F1: Starts “AdBlue/DEF Pump Heater Relay Test”.
F2: Stops “AdBlue/DEF Pump Heater Relay Test”. (When
30-82 PC210LCI-11
NOTICE
• If KOMNET communication error remains less than 1 second, engine controller is unable to de-
tect it, and the test may be continued while the machine monitor does not continue the
test(standard screen). In that case, once the starting switch is turned to OFF position, system
REMARK
counted down from “60” to “0 sec”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, voltage will be outputted.
• The relay operates for 900 seconds at maximum, and the remaining operable time is displayed as “Re-
maining Permitted Test Time”. However, it stops operation automatically if the temperature of the pump
reaches the upper limit to protect pump heater. It re-starts operation automatically when the temperature
of the pump drops, and then turns ON and OFF repeatedly.
• Perform measuring when energization ON/OFF is not repeated to measure the stable voltage.
• When energization connection is repeatedly turned ON/OFF, press F2 and stop the test until pump tem-
perature drops.
• When the sum of Remaining time to start test + Heater operating time exceeds 15 minutes after F1 is
pressed, the test stops automatically.
• This check can be also performed by the following method; When AdBlue/DEF pump temperature is be-
low 45°C, perform “AdBlue/DEF Pump Heater Relay Test”. Abnormality of the pump can be checked
when the temperature rises more than 5°C.
REMARK
• If an abnormality occurs during measurement, failure codes [CA4115], [CA4156], and [CA4169] are dis-
played. If these failure codes are displayed, perform troubleshooting.
REMARK
AdBlue/DEF purge action starts automatically, and the dis-
play of “Test State” changes to the flashing of “20”.
REMARK
PC210LCI-11 30-83
TEST AdBlue/DEF TANK HEATER VALVE

Tools for testing AdBlue/DEF tank heater valve
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available
NOTICE
and the test may be continued while the machine monitor does not continue the test (standard screen).
In that case, once the starting switch is turned to OFF position, system operating lamp goes out, and
the engine controller shuts down to reset the test.
“AdBlue/DEF Tank Heater Valve Test” is a function to actuate AdBlue/DEF tank heater valve at any timing, and
to check electrical action.
For testing of AdBlue/DEF tank heater valve to perform troubleshooting or others, refer to this section.
METHOD FOR TESTING AdBlue/DEF TANK HEATER VALVE

1. Check that the system operating lamp is off, turn the battery disconnect switch to OFF position, and remove
the key.
3. Disconnect the connector (V41).
30-84 PC210LCI-11

the multimeter C.
REMARK
5. Check that the system operating lamp is off, and turn the
battery disconnect switch to ON position.
7. Select “AdBlue/DEF Tank Heater Valve Test” by referring

“Set and operate machine monitor”.

REMARK
played, follow instructions accrding to “Parameter list of
test state”.
9. Press F1 to start “AdBlue/DEF Tank Heater Valve Test”.
F1: Starts “AdBlue/DEF Tank Heater Valve Test”.
F2: Stops “AdBlue/DEF Tank Heater Valve Test”. (When
PC210LCI-11 30-85
NOTICE
• If KOMNET communication error remains less than 1 second, engine controller is unable to de-
tect it, and the test may be continued while the machine monitor does not continue the
test(standard screen). In that case, once the starting switch is turned to OFF position, system
REMARK
• When the display of “Remaining Time to Start Test” becomes “0 sec”, voltage will be outputted.
• The valve operates for 900 seconds at maximum, and the remaining operable time is displayed as “Re-
maining Permitted Test Time”.
• After pressing F1, (“Remaining Time to Start Test”1 minute + the heater drive time) the test stops auto-
matically after 16 minutes (cumulative time). Sometimes heater valve does not operate continuously,
check “Remaining Time to Start Test” and “Remaining Time to Complete Test” on the machine monitor
for the heater drive cumulative time.
• There are no abnormalities in cooling fan if cooling fan speed increases during test.
REMARK
• If an abnormality occurs during measurement, failure codes [CA1683] and [CA1684] are displayed. If
these failure codes are displayed, perform troubleshooting.
test by pressing F2.
• If AdBlue/DEF tank temperature rises too high because of this test, AdBlue/DEF may be deteriorated or
toxic ammonia (NH 3) odor is generated at refilling port. Observe the description in “Operation and Main-
tenance Manual”, “precautions for AdBlue/DEF”.
The display of “Test State” changes to flashing of “0”.
REMARK
30-86 PC210LCI-11
TEST DENITRATION EFFICIENCY OF SCR

k Check that there is no person or combustibles around the machine (especially the outlet of exhaust
pipe from where the exhaust gas spout out).
NOTICE
For testing of AdBlue/DEF injection performance and catalyst efficiency to perform troubleshooting or others, re-
fer to this section.
METHOD FOR TESTING DENITRATION EFFICIENCY OF SCR

1. Check that AdBlue/DEF level is higher than (a') with the
sight gauge.
2. Check that the system operating lamp is off, turn the start-
ing switch to ON position, and check fuel gauge for the re-
maining fuel.
REMARK
• “SCR Denitration Efficiency Test” uses fuel and AdBl-
ue/DEF, and it takes approximately 90 minutes at maxi-
mum. Make sure that the remaining amount of these
are at least the minimum amount.
• If the fuel and AdBlue/DEF are less than minimum
amount shown below, be sure to refill with them.
Gauge Minimum amount (gauge position)
Fuel gauge Position (a) and above
Sight gauge of AdBlue/DEF level Position (a') and above
3. Start the engine, and set the fuel control dial to MIN (Low idle) position.
4. See “METHOD FOR OPERATING TESTING MENU (SCR
SERVICE TEST)” of “SET AND OPERATE MACHINE
MONITOR” and select “SCR Denitration Efficiency Test”.
PC210LCI-11 30-87

REMARK
played, follow instructions according to “Parameter list of
test state”.
6. Press F1 to start “SCR Denitration Efficiency Test”.
F1: Starts “SCR Denitration Efficiency Test”.
F2: Stops “SCR Denitration Efficiency Test”. (When
“STOP” is displayed)
NOTICE
• “Test State” does not change to “10” and test does
not start even if F1 is pressed, turn starting switch
to OFF position once, and repeat the procedure
from step 1.
• When the test is stopped by pressing F2, “0” of
“Test State” flashes, but you can not restart the
test by pressing F1. To restart the test, turn the
starting switch to OFF position once. System oper-
ating lamp goes out, and engine controller shuts
down, and test is reset.
• If you turn starting switch to OFF position by mis-
take during test, do not turn starting switch to ON
position immediately. Check that system operating
lamp is off, and turn starting switch to ON position
again after engine controller shuts down.
• If KOMNET communication error remains less than
1 second, engine controller is unable to detect it,
and the test may be continued while the machine
monitor does not continue the test(standard
screen). In that case, once the starting switch is
turned to OFF position, system operating lamp
goes out, and the engine controller shuts down to
reset the test.
30-88 PC210LCI-11
REMARK
• The display of “Test State” changes to the flashing of “10”, and “SCR Denitration Efficiency Test” starts.
• “SCR Denitration Efficiency Test” will be normally completed in approximately 30 minutes, however it
may take approximately 90 minutes at maximum depending on the test state.
• When the display of “Test State” is “11” to “41” or “100”, follow “Parameter list of test state”.
• The test results of “AdBlue/DEF Injection Test Result” and “SCR Efficiency Test Result” are displayed as
“3” during test.
• When the display of “Test State” changes from flashing of “10” to flashing of “20”, the test is completed.
• “Test State” becomes “14” temporarily at the half way of the test, this state means the temperature is in
transition and it is not abnormal, so continue the test. (The display changes to “10” in a few minutes.)
• If you want to stop the test at halfway, press F2 to return the screen to the standard screen. (When F2 is
pressed, the display of “Test State” changes to the flashing of “20”.)
• If F2 is pressed and the operation stops halfway through the test, “AdBlue/DEF Injection Test Result”
and “SCR Efficiency Test Result” are displayed as “3”.
• The test results of “AdBlue/DEF Injection Test Result” and “SCR Efficiency Test Result” are displayed as
“0”, “1” or “4” after the test.
7. When “20” of “Test State” flashes, check the state of “AdBl-
ue/DEF Injection Test Result” and “SCR Efficiency Test
Result”.
REMARK
• “1” indicates a normal state, “0” indicates an abnormal
state, and “4” indicates that the test ends halfway due
to a failure.
• If “0” or “4” are displayed, perform procedure 8 and fail-
ure code is displayed.
After finishing the test, remove the testing tools and re-
store the machine. If failure code [CA3751] or [CA3755]
are displayed, perform troubleshooting.
Test Test result (indication on monitor)

AdBlue/DEF injection
1 0 1 0 4 4
performance
SCR catalyst perform-
1 1 0 0 4 4
ance
Failure code to be
- [CA3755] [CA3751] [CA3755] [CA1694] (*1)
displayed
*1: Failure codes other than [CA3751], [CA3755] and [CA1694] may be displayed. Take measures to trou-
bleshoot ongoing problem of failure code first.
8. Turn the starting switch to OFF position once, and then turn it to ON position.
PC210LCI-11 30-89
REMARK
• If failure codes [CA3751], [CA3755], [CA1694] appear, troubleshoot them.
• If the test result is “4” but the failure code [CA1694] does not appear, continue to troubleshoot ongoing
problem.
30-90 PC210LCI-11
30 TESTING AND ADJUSTING CLEAN AdBlue/DEF TANK
CLEAN AdBlue/DEF TANK

Testing tools for cleaning of AdBlue/DEF tank
Commercially
A Oil container 4 Made of plastic (for drained AdBlue/DEF)
available
Commercially
- Remote breather hose 1
available
Commercially ASOH Co., LTD ASOH CICCOLO:
1 Valve 1
available CY-2208 or equivalent
B
Commercially Approximately. 2 m, TOYOX TOYOSILI-
2 Hose 1
available CONE: TSI-8 or equivalent
Commercially
3 Joint 1 Stainless steel
available
C Commercially
AdBlue/DEF 1 For flushing: 30 ℓ
available
D Commercially
Rubber gloves
available
k For handling the AdBlue/DEF, see Operation and Maintenance Manual, “Precautions for AdBlue/
DEF.”
k When handling AdBlue/DEF injector, always wear the protective eyeglasses and rubber gloves.
For cleaning AdBlue/DEF tank to perform troubleshooting or others, refer to this section.
METHOD FOR CLEANING AdBlue/DEF TANK

1. Swing the upper structure by approximately 45 °.
2. Place a pale A on the top face of center frame (1) directly
under the AdBlue/DEF tank.
k Toxic gas or corroded material may be generated
by a chemical reaction if an iron or aluminum con-
tainer is used to catch the draining fluid waste of
AdBlue/DEF from the machine. Use a container
made of resin (PP, PE) or stainless steel to catch
the draining fluid waste of AdBlue/DEF.
3. Drain the AdBlue/DEF in AdBlue/DEF tank (2) according to

the following procedure.
1) Check that cap (3) of AdBlue/DEF tank (2) is closed
securely.
REMARK
If AdBlue/DEF tank cap (3) is not closed completely,
close it securely.
PC210LCI-11 30-91
CLEAN AdBlue/DEF TANK 30 TESTING AND ADJUSTING
2) Disconnect breather hose (4) from breather block (5),

and connect remote breather hose B.
REMARK
When connecting remote breather hose B, make sure
to close valve B1 of remote breather hose B.
3) Open valve B1 of remote breather hose B.
REMARK
Valve B1 does not need to be opened fully.
4) Select “AdBlue/DEF Pump Pressure Up Test” by refer-

ring “SET AND OPERATE MACHINE MONITOR”.
REMARK
By performing “AdBlue/DEF Pump Pressure Up Test”,
foreign matter stuck to AdBlue/DEF tank strainer can
be dropped inside the tank. Injection of AdBlue/DEF
injector is not executed.
5) On “AdBlue/DEF Pump Pressure Up Test” screen,

check that “0” is flashing in “Test State”.
REMARK
Flashing of “0” indicates “Waiting for the start (de-
fault)”, and test can be performed. Screen other than
“0” is displayed, follow “Parameter list of test state”.
6) Press F1 to start “AdBlue/DEF Pump Pressure Up
Test”.
F1: Starts “AdBlue/DEF Pump Pressure Up Test”.
F2: Stops “AdBlue/DEF Pump Pressure Up Test”.
(When “STOP” is displayed.)
REMARK
AdBlue/DEF pump operates.
30-92 PC210LCI-11
30 TESTING AND ADJUSTING CLEAN AdBlue/DEF TANK
7) When the value of “AdBlue/DEF Pump Pressure” ex-

ceeds “800 kPa”, press F2.
REMARK
• When the value of “AdBlue/DEF Pump Pressure”
exceeds “800 kPa”, the display of “Test State”
changes to flashing of “10”.
• At this point, 1st “AdBlue/DEF Pump Pressure Up
Test” is completed. Perform 3 times in total.
8) Repeat above steps 5) to 7) twice.
9) Close valve B1 of remote breather hose B securely.
10) Loosen drain plug (6) by 6 turn and drain AdBlue/DEF

into pail A.
REMARK
There is a slit (a) at threaded part of drain plug (6) so
that AdBlue/DEF is not drained too much and splash-
ed.
11) Draining amount decreases in approximately 2 mi-
nutes, remove drain plug (6).
12) Fully open valve B1 of remote breather hose B.

13) When pail can is almost filled up with AdBlue, close
valve B1 of remote breather hose B securely.
14) Draining amount decreases in approximately 15 sec-
onds, change pail A.
15) Repeat steps 12) to 14). When the AdBlue/DEF tank
becomes empty, install drain plug securely.
4. Clean the AdBlue/DEF tank according to the following pro-
cedure.
PC210LCI-11 30-93
CLEAN AdBlue/DEF TANK 30 TESTING AND ADJUSTING
1) Check that the drain plug is closed securely.

2) Refill the AdBlue/DEF tank with new AdBlue/DEF.
5 AdBlue/DEF tank:
30 ℓ
3) Repeat steps 10) to 15) of procedure 3, and drain
AdBlue/DEF.
6 AdBlue/DEF tank:
30 ℓ
Cleaning of the AdBlue/DEF tank is completed.
5. Refill the AdBlue/DEF tank with AdBlue/DEF according to the following procedure.
1) Check that drain plug (6) is closed securely.
2) Disconnect remote breather hose B from breather
block (5).
3) Connect breather hose (4) to breather block (5).
4) Refill the AdBlue/DEF tank with new AdBlue/DEF.
5 AdBlue/DEF tank:
39 ℓ
NOTICE
AdBlue/DEF freezes at –11 °C. Refill with
AdBlue/DEF to lowest level under an environment
with–11 °C or below. See Operation and Mainte-
nance Manual, “METHOD FOR CHECKING FUEL
LEVEL, ADDING FUEL”
Check the refilling amount of AdBlue/DEF through sight gauge.
30-94 PC210LCI-11
30 TESTING AND ADJUSTING BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK

k Place the machine on a level ground, lower the work equipment to the ground in a stable posture,
and set the lock lever to LOCK position, and then stop the engine.
When AdBlue/DEF tank coolant circuit is disconnected and connected, always bleed air according to this proce-
dure.
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK

1. Select “AdBlue/DEF Tank Heater Valve Test” by referring
“Set and operate machine monitor”.

REMARK
Flashing of “0” indicates “Waiting for the start (default)”.
Screen other than “0” is displayed, follow instructions ac-
cording to “Parameter list of test state” in “TEST SCR RE-
LATED FUNCTIONS”.
4. Turn the swing lock switch to ON position.
5. Set the auto-deceleration to OFF.
6. Set the fuel control dial to MAX (High idle) position.
7. Press F1, and bleed air from AdBlue/DEF tank coolant cir-
cuit by starting “AdBlue/DEF Tank Heater Valve Test”.
F1: Starts “AdBlue/DEF Tank Heater Valve Test”.
F2: Stops “AdBlue/DEF Tank Heater Valve Test”. (When
NOTICE
• “Test State” does not change to “10” and test does
not start even if F1 is pressed, turn starting switch
to OFF position once, and repeat the testing proce-
dure from step 1.
• If you turn starting switch to OFF position by mis-
take during test, do not turn starting switch to ON
position immediately. Check that system operating
lamp is off, and turn starting switch to ON position
again after engine controller shuts down.
• If KOMNET communication error remains less than
1 second, engine controller is unable to detect it,
and the test may be continued while the machine
monitor does not continue the test(standard
screen). In that case, once the starting switch is
turned to OFF position, system operating lamp
goes out, and the engine controller shuts down to
reset the test.
PC210LCI-11 30-95
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 30 TESTING AND ADJUSTING
REMARK
• When display of “Remaining Time to Start Test” becomes “0 sec”, engine controller starts driving AdBl-
ue/DEF tank heater valve.
• The valve is driven for 900 seconds at maximum, and the driving time is displayed as “Remaining Per-
mitted Test Time”.
• After pressing F1, (“Remaining Time to Start Test”1 minute + the heater drive time) the test stops auto-
matically after 16 minutes (cumulative time). Sometimes heater valve does not operate continuously,
check “Remaining Time to Start Test” and “Remaining Time to Complete Test” on the machine monitor
for the heater drive cumulative time.
• There are no abnormalities in cooling fan if cooling fan speed increases during test.
When display of “Remaining Permitted Test Time” becomes “0 sec”, air bleeding work is completed.
30-96 PC210LCI-11
30 TESTING AND ADJUSTING TEST SWING CIRCLE BEARING CLEARANCE
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
Tools for testing swing circle bearing clearance
Commercially
A Dial gauge 1
available
k Do not put your hand or foot under the truck during the test.
For testing of swing circle bearing clearance to perform troubleshooting, refer to this section.
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE

1. Fix dial gauge A to outer race (1) or inner race (2) of the
swing circle, and put the probe to the end surface of inner
race (2) or outer race (1) on the opposite side.
Set dial gauge A in the front or rear of the machine.
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.
The front side of the upper structure lowers and the rear
side rises.
3. Set dial gauge A 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.
The front side of the upper structure rises and the rear side
lowers.
5. Read the value indicated by dial gauge A.
The value indicated by dial gauge A is the clearance of the
bearing.
6. Return the machine to the state in step 2, and check that
dial gauge A indicates 0 point again.
If the dial gauge does not indicate 0 point, repeat steps 3
through 5.
PC210LCI-11 30-97
TEST AND ADJUST TRACK TENSION 30 TESTING AND ADJUSTING
UNDERCARRIAGE AND FRAME

TEST AND ADJUST TRACK TENSION
Tools for testing track tension
Commercially
A Wooden block 1
available
For testing and adjusting the tension of track shoe to perform troubleshooting, refer to this section.
METHOD FOR TESTING TRACK TENSION

1. Set the fuel control dial to MIN (Low idle), drive the machine forward by the length of track on ground, and
then slowly stop it.
2. Put a bar A on the track shoe between the idler and the
first carrier roller.
REMARK
Use an L shape steel bar, etc. which has few deformation
for bar A.
3. Measure the maximum clearance (a) between bar A and
track shoe.
Standard maximum clearance (a): 10 to 30 mm
METHOD FOR ADJUSTING TRACK TENSION

If the track tension is abnormal, adjust it according to the following procedure.
Method for increasing tension

1. Pump in grease through grease fitting (1) by using a
grease gun.
2. To check if the tension is correct, run the engine with the
fuel control dial at MIN (low idle) position, move the ma-
chine slowly forward by length of track on ground, then
stop the machine.
3. After finishing adjustment, recheck that the tension is cor-

rect according to the above procedure.
NOTICE
The grease can be pumped in until dimension (b) be-
tween the idler guide and the track frame end becomes
0 mm. If the tension is still loose, the wear of pins and
bushings is large. In such a case, the pins and bush-
ings need to be turned 180 deg. or replaced.
30-98 PC210LCI-11
30 TESTING AND ADJUSTING TEST AND ADJUST TRACK TENSION
Method for decreasing tension

1. Loosen valve (2), remove the grease, and tighten valve
(2).
k Do not loosen the valve more than one turn, be-
cause the valve may fly out due to the high internal
pressure of the grease.
2. To check if the tension is correct, run the engine with the
fuel control dial at MIN (low idle) position, move the ma-
chine slowly forward by length of track on ground, then
stop the machine.
3. After finishing adjustment, check that the tension is correct
according to the above procedure.
PC210LCI-11 30-99
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 TESTING AND ADJUSTING
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
For releasing the remaining pressure from hydraulic system to perform troubleshooting, refer to this section.
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIR-

CUIT
Release remaining pressure in hydraulic tank
The hydraulic tank is sealed and pressurized. Therefore, when removing a hose or a clamp connected to the
hydraulic tank, release the remaining pressure from the hydraulic tank according to the following procedure.
1. Lower the work equipment to the ground in a stable posture and stop the engine.
2. Loosen oil filler cap (1) of the hydraulic tank gradually to
release the air in the tank.
Release remaining pressure in hydraulic cylinder circuit

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. Lower the work equipment to the ground and release the remaining pressure in the hydraulic tank. For de-
tails, see “Release remaining pressure in hydraulic tank”.
Leave the oil filler cap of the hydraulic tank removed.
2. Turn the starting switch to ON position and set the lock lever to FREE position, and then operate the right
and left work equipment control levers forward, backward, rightward, and leftward.
REMARK
The control valve is operated by the pressure in the accumulator. However, the pressure in the accumulator
is lost after the control levers are operated 2 to 3 times.
3. Start the engine and run it with the fuel control dial at MIN (Low idle) for approximately 5 seconds to in-
crease the pressure in the accumulator.
Set the lock lever to LOCK position once to start the engine.
4. Repeat steps 2 and 3 two to three times, and all remaining pressure is released from the piping completely.
Release remaining pressure in swing motor circuit

The remaining pressure can be released by performing the same operation as that described in “Release re-
maining pressure in hydraulic cylinder” (Operate the lever to SWING direction only, however).
Release remaining pressure in travel motor circuit

The control valve spool of the travel motor circuit is an open type circuit, so the remaining pressure can be re-
leased by performing the same operation as that described in “Release remaining pressure in hydraulic tank”.
30-100 PC210LCI-11
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING,
30 TESTING AND ADJUSTING AND TRAVEL CIRCUITS
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND

TRAVEL CIRCUITS
Tools for testing and adjusting oil pressure in work equipment, swing and travel circuits
D 07002-11023 O-ring 2
Commercially
available
Commercially
available
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 hy-
draulic tank slowly to release the pressure in the tank.
When the oil flow is divided at pumps, front pump and rear pump act individually to each actuator as following
table. The valve to be relieved differs depending on the actuator.
When the work equipment circuit or swing circuit is relieved singly, the oil flows from the pumps are merged.
When the travel circuit is relieved singly, the oil flows from the pumps are divided.
The actuators in the following table are arranged in the order that the control valves are viewed from the front of
the machine. (As for the actuator service, the table shows an example of 1 attachment mounted.)
Combination of pump, actuator, and valve

Pump Actuator Valve to be relieved
(R unload valve) (R main relief valve)
Service Safety valve for Service
Rear Bucket R main relief valve
L.H. travel R main relief valve
Boom R main relief valve
(Merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
Swing Swing motor safety valve
Front R.H. travel F main relief valve
Arm F main relief valve
(F unload valve) (F main relief valve)
(Centralized safety valve) (Back pressure valve)
For testing and adjusting of oil pressure in work equipment, swing and travel circuits to perform troubleshooting
or Pm Clinic, and periodic maintenance, refer to this section.
PC210LCI-11 30-101
AND TRAVEL CIRCUITS 30 TESTING AND ADJUSTING
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND

TRAVEL CIRCUITS
METHOD FOR TESTING UNLOAD PRESSURE
Method for testing the unload pressure by machine monitor

1. Start the engine, select and display Charge Pressure and
Ambient Pressure in either “Pre-defined Monitoring”
(08/24) or “Self-define Monitoring” by referring “SET AND
Monitoring code: 01100 “Front Pump Pressure”
Monitoring code: 01101 “Rear Pump Pressure”
The figure shows monitoring code 01100 “Front Pump

Pressure” and 01101 “Rear Pump Pressure” screen.
2. Increase the hydraulic oil temperature to 45 to 55 °C.
celeration.
4. Set the fuel control dial to MAX (High idle) position and
check the oil pressure when all the control levers and ped-
als are in NEUTRAL.
Unloaded pressure of the unload valve is displayed.
30-102 PC210LCI-11
Method for testing unload pressure by testing tool

1. Open the cover on the right side of the machine, install
nipple C to pickup ports (PFC), (PRC) and connect it to
gauge A2 of hydraulic tester A.
REMARK
Gauge in digital hydraulic tester B can also be used in
place of gauge A2.
(PFC): Front pump discharge pressure pickup port
(PRC): Rear pump discharge pressure pickup port
2. Start the engine to increase the hydraulic oil temperature
to 45 to 55 °C.
celeration.
als are in NEUTRAL.
Unloaded pressure of the unload valve is displayed.
METHOD FOR TESTING WORK EQUIPMENT RELIEF PRESSURE

Method for testing work equipment relief pressure by machine monitor

PC210LCI-11 30-103

3. Operate the cylinders to check to the stroke end.
4. Set the working mode to P (“Power Mode”).
5. Set the fuel control dial in MAX (High idle) position and
measure the oil pressure when relieving the work equip-
ment circuit to check.
Relieved pressure of the main relief valve is displayed.
• If the one-touch power maximizing switch is not press-
ed, the low relief pressure is obtained. If the former is pressed, the high relief pressure is obtained.
• If the swing lock switch is set to ON position, 2-stage relief valve is kept ON and the relief valve is re-
lieved at high pressure. Therefore, keep the swing lock switch at OFF position.
Method for testing work equipment relief pressure by testing tools

REMARK
place of gauge A1.
to 45 to 55 °C.
3. Operate the cylinders to check to the stroke end.
measure the oil pressure when relieving the work equip-
ment circuit to check.
Relieved pressure of the main relief valve is displayed.
• If the one-touch power maximizing switch is not press-
ed, the low relief pressure is obtained. If the former is
pressed, the high relief pressure is obtained.
• If the swing lock switch is set to ON position, 2-stage
relief valve is kept ON and the relief valve is relieved
at high pressure. Therefore, keep the swing lock
switch at OFF position.
METHOD FOR TESTING SWING RELIEF PRESSURE

30-104 PC210LCI-11
Method for testing swing relief pressure by machine monitor


measure the oil pressure when relieving the swing circuit.
• Hydraulic oil pressure relieved by the swing motor is
displayed.
• The swing motor relief pressure is lower than that of
the main relief valve.
PC210LCI-11 30-105
Method for testing swing relief pressure by testing tools

REMARK
place of gauge A1.
to 45 to 55 °C.
measure the oil pressure when relieving the swing circuit.
• Hydraulic oil pressure relieved by the swing motor is
displayed.
• The swing motor relief pressure is lower than that of
the main relief valve.
METHOD FOR TESTING TRAVEL RELIEF PRESSURE

Method for testing travel relief pressure by machine monitor

30-106 PC210LCI-11

2. Insert plate E and pin F between the sprocket and the

track frame to securely lock the track.
to 45 to 55 °C.
measure the oil pressure when relieving the travel circuit.
k Before operating the travel lever and pedal, check
the sprocket position locked with pin and locked
direction of the travel again.
The pressure when the main relief valve is relieved is displayed. The travel circuit is always relieved at high
pressure.
PC210LCI-11 30-107
Method for testing travel relief pressure by testing tools

REMARK
place of gauge A1.
2. Insert plate E and pin F between the sprocket and the

track frame to securely lock the track.
to 45 to 55 °C.
measure the oil pressure when relieving the travel circuit.
k Before operating the travel lever and pedal, check
the sprocket position locked with pin and locked
direction of the travel again.
The pressure when the main relief valve is relieved is displayed. The travel circuit is always relieved at high
pressure.
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND

TRAVEL CIRCUITS
The unload valve cannot be adjusted.
30-108 PC210LCI-11
METHOD FOR ADJUSTING WORK EQUIPMENT AND TRAVEL RELIEF PRES-

SURE
If the work equipment and travel relief pressure are not normal,
adjust main relief valves (3) and (4) according to the following
procedure.
(3): Front main relief valve
(4): Rear main relief valve
• When adjusting the main relief valve (3) on the front pump
side, remove the lower cover of the control valve.
• When adjusting the main relief valve (4) on the rear pump
side, remove the upper cover of the control valve.
• The main relief valve regulates only the low-pressure relief
pressure. By adjusting the low-pressure relief pressure,
the high-pressure relief pressure is also set automatically.
• For the low-pressure relief pressure, the 2-stage relief solenoid valve is OFF. The pilot pressure is not ap-
plied to the selector port.
1. Disconnect the pilot hose (5).
The figure shows the rear main relief valve.
2. While fixing holder (6), loosen lock nut (7).

3. Turn holder (6) to adjust the pressure.
REMARK
• Turn holder (6) to the right to raise the pressure or turn
it to the left to lower the pressure.
• Quantity of pressure adjustment per turn: Approximate-
ly 20.5 kg/cm2 209 kg/cm2
4. While fixing holder (6), tighten lock nut (7).
3 Locknut:
49 to 58.8 Nm {5 to 6 kgm}
5. Connect the pilot hose (5).
After the adjustment, recheck the oil pressure according to the testing procedure described above.
METHOD FOR ADJUSTING SWING RELIEF PRESSURE

If the swing relief pressure is not normal, adjust swing 2-stage
relief valve (8) according to the following procedure.
PC210LCI-11 30-109
1. Disconnect the pilot hose (9).

2. While fixing holder (10), loosen lock nut (11).
3. Turn holder (10) to adjust the pressure.
REMARK
• Turn the holder to the right to raise the pressure or turn
it to the left to lower the pressure.
• Quantity of pressure adjustment per turn of
7.68 MPa{78.3 kg/cm2}
4. While fixing holder (10), tighten lock nut (11).
3 Locknut :
58.8 to 78.4 Nm {6 to 8 kgm}
5. Connect the pilot hose (9).
After the adjustment, recheck the oil pressure according to the testing procedure described above.
30-110 PC210LCI-11
30 TESTING AND ADJUSTING TEST OIL PRESSURE OF CONTROL CIRCUIT
TEST OIL PRESSURE OF CONTROL CIRCUIT

Testing and adjusting tools for oil pressure in control circuit
A
1 799-101-5130 Gauge 1 Pressure range : 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range : 70 MPa
C 799-101-5220 Nipple 1 Size: M10 x 1.25 mm
D 07002-11023 O-ring 1
draulic tank slowly to release the internal pressure.
Hydraulic oil temperature : 45 to 55 °C
For testing and adjusting of oil pressure of control circuit to perform troubleshooting or Pm Clinic, etc. refer to
this section.
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT

1. Take off control valve top cover to remove oil pressure
pickup plug (1).
2. Install nipple C and connect it to gauge A1 in hydraulic

tester A.
REMARK
place of gauge A1.
between 45 and 55 °C.
4. Set the working mode to P (“Power Mode”) and set the au-
to-deceleration to OFF position.
check the oil pressure when all the control levers and pedals are in NEUTRAL.
PC210LCI-11 30-111
TEST OIL PRESSURE OF CONTROL CIRCUIT 30 TESTING AND ADJUSTING
• Control circuit oil pressure can also be checked by using

the oil pressure pickup plug (PEPB) of oil pressure pump.
(PEPB): EPC source pressure pickup port
• Do not adjust the relief valve for the control circuit oil pres-
sure.
30-112 PC210LCI-11
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

Testing and adjusting tools for oil pressure in pump PC control circuit
A 1 799-101-5110 Gauge 1 Pressure range : 60 MPa
D 07002-11023 O-ring 4
Before testing this item, check that the oil pressure in the work equipment, swing, and travel circuits and control
circuit oil pressure is normal.
For testing of pump PC control circuit source pressure to perform troubleshooting or others, refer to this section.
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)

To measure the PC valve outlet pressure (servo piston inlet pressure), measure the pump discharge pressure
simultaneously and compare them.
1. Open the cover on the right side of the machine, and re-
move oil pressure pickup plugs (PFC), (PRC), (PENF),
(PENR).
(PENF): Front control pressure pickup port
(PENR): Rear control pressure pickup port
PC210LCI-11 30-113
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30 TESTING AND ADJUSTING
2. Install nipple C and connect it to gauge A1 of hydraulic

tester A.
REMARK
place of gauge A1.
4. Set the working mode to P (“Power Mode”) and set the
swing lock switch to ON position.
5. Set the fuel control dial in MAX (High idle) position to
measure the pump discharged pressure and PC valve out-
let pressure (servo piston inlet pressure) at the same time
when arm IN relief is performed.
For standard values, see "STANDARD VALUE TABLE",
If the PC valve or servo piston is abnormal, the PC valve
outlet pressure (servo piston inlet pressure) has the same
pressure as the pump discharge pressure or approximate-
ly 0.
TEST PC-EPC VALVE OUTLET PRESSURE

move oil pressure pickup plug (PMF), (PMR).
(PMF): Front PC mode selector pressure pickup port
(PMR): Rear PC mode selector pressure pickup port
2. Install nipple C and connect it to gauge A2 in the hydraulic

tester A.
REMARK
place of gauge A2.
4. Check the oil pressure when the fuel control dial is in MAX
(High idle) position or in MIN (Low idle) position after set-
ting all control levers and control pedals in NEUTRAL.
30-114 PC210LCI-11
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

When the phenomena shown below occur and PC valves (7) and (8) seem to be defective, adjust them accord-
ing to the following procedure.
• When the working load increases, the engine speed drops largely.
• The engine speed is normal but the work equipment speed is low.
(7): Front pump PC valve
(8): Rear pump PC valve
NOTICE
The width across flats of lock nut for PC valve is 13 mm,
and the width across flats (inside) of the adjustment screw
for PC valve is 4 mm.
Do not turn the other lock nuts and adjustment screws
since they affect the hydraulic pump performance.
1. Put a match mark on the end surface of adjustment screw

(10).
Mark a position clearly so that the adjustment screw can
be returned to the original position (even If it is turned
counterclockwise).
2. Loosen lock nut (9).
3. Rotate adjustment screw (10) clockwise or counterclock-
wise to adjust it.
REMARK
• Turn adjustment screw clockwise when the work equip-
ment speed is low (to increase the pump absorption
torque). Turn it counterclockwise when the engine
speed is low (to decrease the pump absorption torque).
• Adjustable range of adjustment screw (10) is as descri-
bed below.
Counterclockwise: Within 1 turn
Clockwise: Within 1 turn
4. Tighten lock nut (9).
3 Lock nut (9) :
27 to 34 Nm {2.8 to 3.5 kgm}
After the adjustment, see “TESTING PROCEDURE OF PC VALVE OUTLET PRESSURE (SERVO PISTON IN-
LET PRESSURE)” to check whether PC valve outlet pressure (servo piston inlet pressure) is normal.
PC210LCI-11 30-115
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30 TESTING AND ADJUSTING
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

Testing and adjusting tools for oil pressure in pump LS control circuit
A 1 799-101-5110 Gauge 1 Pressure range : 60 MPa
D 07002-11023 O-ring 4
E 799-401-2701 Differential pressure gauge 1 Pressure range : 50 MPa
796T - 440 -
F Sensor adapter 1 Pressure range : 50 MPa
1101
k Provide an enough work space to run the track idle off the ground.
Before testing this item, check that the oil pressure in the work equipment, swing, and travel circuits and control
circuit oil pressure is normal.
For testing of pump LS control circuit source pressure to perform troubleshooting or others, refer to this section.
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR

For the machine monitor operating method, see the section of “SET AND OPERATE MACHINE MONITOR”.
1. Select “Service Pressure Sensor” on “Pre-defined Monitor-
ing” (10/24) or from Monitoring Selection Menu to display.
For details, see “SETTING AND OPERATING MACHINE
MONITOR”.
Monitoring code: 01141 “Service Pressure Sensor”
The figure shows monitoring code 01141 “Service Pres-

sure Sensor” screen.
30-116 PC210LCI-11
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
2. Open the right side cover of the machine, and connect

service pressure connector (P49) to the connector of sen-
sor adapter assembly F.
3. Remove the oil pressure pickup plugs (PLSFC) and

(PLSRC), install nipple C, and connect it to sensor adapter
assembly F.
(PLSFC): Front load pressure pickup port
(PLSRC): Rear load pressure pickup port
The figure shows the rear side.
4. Start the engine. Increase the hydraulic oil temperature to

45 to 55 °C and raise the track of the side to be tested off
the ground.
When measuring front circuit: R.H. track
When measuring rear circuit: L.H. track
5. Change working mode to P (“Power Mode”), set the travel
speed to Hi, and set the fuel control dial to MAX (High idle)
position.
6. Check pump discharge pressure and LS pressure (actua-
tor load pressure) simultaneously when all the control lev-
ers and pedals are in NEUTRAL and the travel lever is at
half stroke.
k Run the raised track idle off the ground while securing the safety of the surroundings.
Calculating LS differential pressure: LS differential pressure = Pump discharge pressure - LS pressure
(service pressure)
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL

To obtain the LS differential pressure, measure the pump discharged pressure and LS pressure (actuator load
pressure) simultaneously, and calculate the difference.
PC210LCI-11 30-117
move oil pressure pickup plugs (PFC), (PRC), (PLSFC),
(PLSRC).
(PLSFC): Front load pressure pickup port
(PLSRC): Rear load pressure pickup port
30-118 PC210LCI-11
2. Install nipple C to pickup port and connect it to gauge A1

of hydraulic tester A or differential pressure gauge E.
• When using differential pressure gauge E, connect the
high-pressure side (rear side) to the pump discharged
pressure and the low-pressure side (bottom side) to
LS pressure.
REMARK
Differential pressure gauge needs 12 V DC power,
connect it to 1 battery.
• When using gauge A1, measure the pressure while
replacing the same gauge since the differential pres-
sure goes up to 4 MPa 40 kg/cm2 at maximum.
REMARK
place of gauge A1.
3. Start the engine. Increase the hydraulic oil temperature be-

tween 45 and 55 °C and raise the track of the side to be
tested off the ground.
4. Change working mode to P (“Power Mode”) to put the trav-
el speed to Hi and set the fuel control dial to MAX (High
idle) position.
5. Check pump discharge pressure and LS pressure (actua-
tor load pressure) simultaneously when all the control lev-
ers and pedals are in NEUTRAL and the travel lever is at
half stroke.
PC210LCI-11 30-119
k Run the raised track idle off the ground while paying enough attention to the surroundings for
safety.
Calculating LS differential pressure (when the pressure gauge is used): LS pressure = Pump discharge
pressure = LS pressure
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET

PRESSURE)
To measure the LS valve outlet pressure (servo piston inlet pressure), measure the pump discharge pressure
simultaneously and compare them.
move oil pressure pickup plugs (PFC), (PRC), (PENF),
(PENR).
(PENF): Front LS valve outlet pressure pickup port
(PENR): Rear LS valve outlet pressure pickup port
2. Install nipple C to pickup port and connect it to gauge A1

of hydraulic tester A.
REMARK
place of gauge A1.
30-120 PC210LCI-11
3. Start the engine. Increase the hydraulic oil temperature be-

tween 45 and 55 °C and raise the track of the side to be
tested off the ground.
4. Change working mode to P (“Power Mode”) and set the
fuel control dial to MAX (High idle) position.
5. Check pump discharge pressure and LS valve outlet pres-
sure (servo piston inlet pressure) simultaneously when all
the control levers and pedals are in NEUTRAL and the
travel lever is at half stroke.
k Run the raised track idle off the ground while paying enough attention to the surroundings for
safety.
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE

1. Remove oil pressure pickup plug (PSIG).
2. Install nipple C and connect it to gauge A2 in the hydraulic
tester A.
REMARK
place of gauge A2.
4. Turn the fuel control dial to MAX (High idle) position to
measure the oil pressure while the travel speed selector
switch and travel control lever are operated.
REMARK
Pressure can be tested by operating the travel control lev-
er to a degree that the PPC oil pressure switch is just
turned ON (position just before the machine starts mov-
ing).
PC210LCI-11 30-121
METHOD FOR ADJUSTING LS VALVE

If the LS differential pressure is abnormal, adjust LS valves (8)
and (9) according to the following procedure.
(8): Rear LS valve
(9): Front LS valve
1. Loosen lock nut (11) with adjustment screw (10) fixed.

2. Turn adjustment screw (10) to adjust differential pressure.
REMARK
• Turn adjustment screw (10) to the right to raise the dif-
ferential pressure or turn it to the left to lower the differ-
ential pressure.
• Quantity of pressure adjustment (LS differential pres-
sure) per turn of adjustment screw (10)1.110.8 kg/cm2
3. With adjustment screw (10) fixed, tighten lock nut (11).
3 Locknut (11):
49 to 68.6 Nm {5 to 7 kgm}
After the adjustment, see “TESTING PROCEDURE OF LS VALVE OUTLET PRESSURE (SERVO PISTON IN-
LET PRESSURE)” to check whether LS valve outlet pressure (servo piston inlet pressure) is normal.
30-122 PC210LCI-11
30 TESTING AND ADJUSTING TEST OUTLET PRESSURE OF SOLENOID VALVE
TEST OUTLET PRESSURE OF SOLENOID VALVE

Tools for testing solenoid valve outlet pressure
2 799-101-5160 Nipple 1 Size: R1/8
C 799-401-3100 Adapter 1 Size: 02
D 799-401-3200 Adapter 1 Size: 03
Before the test, check the control circuit oil pressure is normal.
For testing of solenoid valve outlet pressure to perform troubleshooting, refer to this section.
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE

1. Remove the lower cover (rear side) of the operator's cab
or the lower cover of the control valve and disconnect one
of outlet hoses (1) to (7) of the solenoid valve to be meas-
ured.
(1): PPC lock solenoid valve
(2): 2-stage relief solenoid valve
(3): Swing parking brake solenoid valve
(4). Travel speed increase solenoid valve
(5): Travel junction solenoid valve
(6): 2-stage swing relief solenoid valve
(7): Attachment selector solenoid valve (for the attachment
installed specification)
PC210LCI-11 30-123
TEST OUTLET PRESSURE OF SOLENOID VALVE 30 TESTING AND ADJUSTING
2. Install adapter C or D and connect the disconnected hose

again.
3. Install adapter C or D to nipple A2 and connect it to gauge
A1.
REMARK
place of gauge A1.
5. Set the fuel control dial to MAX (High idle) position and op-
erate each control lever and switch. Measure the outlet
pressure when the solenoid valve is turned ON or OFF.
REMARK
• For the conditions for turning the solenoid valve ON/
OFF, see “OPERATING CONDITION OF SOLENOID
VALVE”.
• Operating condition of solenoid valve can be checked
with monitoring function of the machine monitor. (For
the detail, see “SETTING AND OPERATION OF MA-
CHINE MONITOR”.)
Monitoring code: 02300 “Solenoid 1”
Monitoring code: 02301 “Solenoid 2”
OPERATING CONDITION OF SOLENOID VALVE

(1) PPC lock solenoid valve operation table
Operating
Operating condition of solenoid valve state of sole-
noid valve
When locked OFF
PPC lock lever
When disengaged ON
(2) 2-stage relief solenoid valve operation table

Operating
noid valve
Overheat 1st setting ON
When overheat 2nd setting is ON OFF
All signals of work equipment, swing, and travel OFF
30-124 PC210LCI-11
30 TESTING AND ADJUSTING TEST OUTLET PRESSURE OF SOLENOID VALVE
Operating
noid valve
When swing lock switch is ON
When travel signals ON
In L mode
ON
Boom LOWER signal ON
Signals other than swing single opera-
One-touch power maximizing tion signal ON
P-mode, E-mode
switch ON
Swing single operation signal ON
OFF
Other than the above conditions
(3) Swing parking brake solenoid valve operation table

Operating
noid valve
Signal of work equipment and swing (work equipment in- All OFF OFF
cluding services) Any one OFF ON
(4) Travel speed increase solenoid valve operation table

Operating
noid valve
When overheat 2nd setting is ON
Fuel control dial: Max.1500 rpm
Travel speed switch at Lo
OFF
When travel signals OFF
When F or R pump pressure is
When travel speed switch is at
When travel signals 33.3 MPa {340 kg/cm2} or higher
Mi, Hi
ON When F or R pump pressure is
19.6 MPa {200 kg/cm2} or higher ON
Other than the above conditions
(5) Travel junction solenoid valve operation table

Operating
noid valve
When signal of travel steering is ON
When travel single sig- When F or R pump pressure is ON
When signal of travel steering is nal is ON 24.5 MPa {250 kg/cm2} or higher
OFF
Other than the above conditions OFF
PC210LCI-11 30-125
TEST OUTLET PRESSURE OF SOLENOID VALVE 30 TESTING AND ADJUSTING
(6) Swing 2-stage relief solenoid valve operation table

Operating
noid valve
When F pump pres-
When boom raise
When boom sure is increasing and
PPC pressure is
RAISE signal is it is 20.6 MPa
When swing sig- ON 2.2 MPa {22 kg/cm2}
{210 kg/cm2} or high-
nal is ON (except or lower
When arm sig- er
repeating swing ON
nal is OFF When F pump pres-
to the right and
left) sure is decreasing
When pump pressure is divided and it is 25.5 MPa
{260 kg/cm2} or high-
er
Other than the above conditions OFF
(7) Attachment selector solenoid valve operation table (for the attachment installed specification)
Operating
noid valve
Working mode: Other than B OFF
Working mode: B ON
30-126 PC210LCI-11
30 TESTING AND ADJUSTING TEST PPC VALVE OUTLET PRESSURE
TEST PPC VALVE OUTLET PRESSURE

Tools for testing PPC valve outlet pressure
2 799-101-5160 Nipple 1 Size: R1/8
C 799-401-3100 Adapter 1 Size: 02
D 799-401-3200 Adapter 1 Size: 03
Before the test, check the control circuit oil pressure is normal.
Below PPC valve outlet pressure can be checked with monitoring function of the machine monitor. (For the de-
tail, see “SET AND OPERATE MACHINE MONITOR”.)
Monitoring code: 07400 “Boom Raise PPC Pressure”
Monitoring code: 07500 “Boom Lower PPC Pressure”
Monitoring code: 07200 “Arm IN PPC Pressure”
Monitoring code: 07600 “Arm OUT PPC Pressure”
Monitoring code: 07300 “Bucket CURL PPC Pressure”
Monitoring code: 07301 “Bucket DUMP PPC Pressure”
Monitoring code: 09001 “Swing Left PPC Pressure”
Monitoring code: 09002 “Swing Right PPC Pressure”
Monitoring code: 07102 “Travel Forward Left PPC Press”
Monitoring code: 07103 “Travel Forward Right PPC Press”
Monitoring code: 07104 “Travel Reverse Left PPC Press”
Monitoring code: 07105 “Travel Reverse Right PPC Press”
For testing of PPC valve outlet pressure to perform troubleshooting or Pm Clinic, periodic maintenance, refer to
this section.
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE

1. Remove upper cover of control valve.
PC210LCI-11 30-127
TEST PPC VALVE OUTLET PRESSURE 30 TESTING AND ADJUSTING
2. Disconnect hydraulic hose of PPC circuit to be tested and

install adapter C or D.
(1): Bucket CURL (White)
(2): Bucket DUMP (Black)
(3): Travel L.H. FORWARD (Red)
(4): Travel L.H. REVERSE (-)
(5): Boom LOWER (Brown)
(6): Boom RAISE (Green)
(7): Swing Right (-)
(8): Swing Left (Red)
(9): Travel R.H. FORWARD (Green)
(10): Travel R.H. REVERSE (Blue)
(11): Arm IN (Blue)
(12): Arm OUT (Yellow)
The colors in ( ) are the colors of the bands installed for
piping identification.
3. Install nipple A2 in hydraulic tester A to Adapter C or D
and connect it to gauge A1.
REMARK
place of gauge A1.
4. Start the engine, and set the working mode to P (“Power
Mode”).
5. Set the control fuel dial to MAX (High idle) position and
als are in NEUTRAL and when the travel lever to stroke
end.
30-128 PC210LCI-11
30 TESTING AND ADJUSTING ADJUST WORK EQUIPMENT AND SWING PPC VALVES
ADJUST WORK EQUIPMENT AND SWING PPC VALVES

If the right and left work equipment levers have large play, adjust them according to the following procedure.
Play at the lever end is 0.5 to 3 mm at the position of 200 mm away from the pivot of lever.
For adjusting the play of work equipment PPC valve and swing PPC valve to perform troubleshooting, refer to
this section.
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC

VALVES
1. Remove boot (1).
2. Loosen locknut (2) and tighten it until disc (3) touches the
heads of pistons (4) (4 pieces).
NOTICE
Do not move the piston at this time.
3. Fix the position of disc (3) and tighten locknut (2) to the
specified torque.
3 Locknut (2): :
69 to 88 Nm {7 to 9 kgm}
4. Install boot (1).
PC210LCI-11 30-129
TEST PUMP SWASH PLATE SENSOR 30 TESTING AND ADJUSTING
TEST PUMP SWASH PLATE SENSOR

• Hydraulic oil temperature : 45 to 55 °C
• Working mode: P mode
Before testing pump swash plate sensor, check that oil pressure in work equipment, swing, travel, control cir-
cuits, and travel speed at running track idle off ground are correct.
For testing of pump swash plate sensor to perform troubleshooting or Pm Clinic, or periodic maintenance, etc.
refer to this section.
METHOD FOR TESTING PUMP SWASH PLATE SENSOR

1. Start the engine, push the ground to raise the track to be
tested off the ground by using the work equipment, and
prepare for running track idle off the ground.
When testing front pump: R.H. track
When testing rear pump: L.H. track
k Provide enough work space to run the raised track
idle off the ground for testing.
2. Set the working mode to P (“Power Mode”) and set the
travel speed to Hi.
3. Set the swing lock switch to ON position.
4. Set the fuel control dial to MAX (High idle) position, set all
the control levers and pedals to NEUTRAL, and then set the travel lever to stroke end in order to run a track
idle off ground, and measure the voltage.
The output voltage of the pump swash plate sensor can be checked with monitoring function of the machine
monitor. (For the operation method, see “SET AND OPERATE MACHINE MONITOR”.)
Monitoring code: 01138 “F Pump Swash Plate Sensor volt”
Monitoring code: 01140 “R Pump Swash Plate Sensor volt”
k Run the raised track idle off the ground paying attention to the surroundings for safety.
30-130 PC210LCI-11
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
30 TESTING AND ADJUSTING MENT
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
If the cause of hydraulic drift is defective cylinder packing, lowering speed may increase during the test because
of the reasons as follows.
• Oil leaks from the bottom side to the head side when the machine is set in the measuring posture for hy-
draulic drift (where the holding pressure is applied to the bottom side). Since the volume on the head side is
less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the
oil flowing in from the bottom side.
• As the pressure in the bottom side (varies depending on the leakage amount) increases, the pressure in the
head side also increases. The pressures are balanced on both side, and then lowering speed decreases. At
this time, operate the lever to the direction that head side oil in tested cylinder is drained to tank circuit, and
head side oil flows to drain circuit (bottom side is blocked by check valve), and. Pressure balance between
head side and bottom side is lost, and then lowering speed increases.
For testing of the isolating of the part causing hydraulic drift in work equipment to perform troubleshooting, refer
to this section.
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM

CYLINDER AND BUCKET CYLINDER
1. Set the work equipment in the same posture as when
measuring hydraulic drift, and stop the engine
Put a weight equivalent to the rated load in the bucket or
fill the bucket with the earth and sand.
2. When testing the boom cylinder, set the boom control lever
to RAISE position. When testing the bucket cylinder, set
the bucket control lever to CURL position.
Judging method
• When the lowering speed is increased at this time:
The cylinder packing is defective.
• No change: The control valve is defective.
REMARK
• Operate the control lever when the starting switch is turned to ON position.
• If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the
pressure.
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM

CYLINDER
1. Move the arm cylinder, stop it at approximately 100 mm
before IN stroke end, and stop the engine.
2. Operate the arm control lever to IN to test.
Judging method
• When the lowering speed is increased at this time:
The cylinder packing is defective.
• No change: The control valve is defective.
REMARK
• Operate the control lever when the starting switch is
turned to ON position.
• If the accumulator pressure is reduced, run the engine
for approximately 10 seconds to accumulate the pres-
sure.
PC210LCI-11 30-131
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
MENT 30 TESTING AND ADJUSTING
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC

VALVE
Measure the hydraulic drift of the work equipment when the work equipment lock lever is in LOCK and FREE
positions with the accumulator charged fully.
In case there is a difference of hydraulic drift between LOCK and FREE positions, the PPC valve is defective
(internal defect).
REMARK
• Operate the control lever when the starting switch is turned to ON position.
• If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the
pressure.
30-132 PC210LCI-11
30 TESTING AND ADJUSTING TEST OIL LEAKAGE
TEST OIL LEAKAGE

Tools for testing oil leakage
A Commercially
Measuring cylinder 1
available
B 07379-00640 Flange 2 Size: 06
C 07376-70522 Plug 1 Size: 05
D 07376-70422 Plug 1 Size: 04
Commercially
available
Commercially
available

For testing of oil leakage to perform troubleshooting or Pm Clinic, or periodic maintenance, refer to this section.
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER

1. Set the boom cylinder at RAISE stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the boom cylinder head side. For details, see “RE-
LEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the boom RAISE direction only to release the remaining pressure.
3. Disconnect hose (1) on the cylinder head side, and block
the hose side by using a flange B.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
4. Start the engine, and perform boom RAISE relief with the
fuel control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Boom LOW-
ER” side.
5. Measure the amount of oil leakage for 1 minute in the
elapsed time of 30 seconds after starting relief.
After finishing the test, restore the machine.
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER

1. Set the arm cylinder at IN stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the arm cylinder head side. For details, see “RELEASE
REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the arm IN direction only to release the remaining pressure.
PC210LCI-11 30-133
TEST OIL LEAKAGE 30 TESTING AND ADJUSTING

der bottom side.
4. Start the engine, and perform arm IN relief with the fuel
control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Arm OUT”
side.
5. 30 seconds after starting relief, measure the amount of oil
leakage for 1 minute.
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER

1. Set the bucket cylinder at the CURL stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the bucket cylinder head side. For details, see “RE-
LEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the bucket CURL direction only to release the remaining pressure.
der bottom side.
4. Start the engine, and perform bucket CURL relief with the
fuel control dial at MAX (High idle) position.
k Be careful not to operate the lever to “Bucket
DUMP” side.
5. Measure the amount of oil leakage for 1 minute in the
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR

1. Disconnect drain hoses (4) (2 pieces), and plug C the ho-
ses.
2. Turn the swing lock switch to ON position.
3. Start the engine, and perform swing relief with the fuel
control dial at MAX (High idle) position.
4. 30 seconds after starting relief, measure the amount of oil
leakage for 1 minute.
5. After finishing the above test, swing 180 ° and test again.
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR

1. Remove the travel motor cover.
30-134 PC210LCI-11
30 TESTING AND ADJUSTING TEST OIL LEAKAGE
2. Start the engine, Insert plate E and pin F between the

sprocket and the track frame to securely lock the track,
and stop the engine.
3. Disconnect drain hose (5) of the travel motor, and block

the hose side by using a plug D.
4. Start the engine, and perform travel relief with the fuel con-
trol dial at MAX (High idle) position.
k Make signs and perform checks securely, since a
mistake in lever operation can cause an accident.
k Before operating the travel lever, check the sprock-
et position locked with pin and locked direction of
the travel again.
5. Measure the amount of leakage for 1 minute in the
6. Measure several times, moving the motor a little each time (changing the relative position between the
valve plate and cylinder and that between the cylinder and piston).
PC210LCI-11 30-135
BLEED AIR FROM HYDRAULIC CIRCUIT 30 TESTING AND ADJUSTING
BLEED AIR FROM HYDRAULIC CIRCUIT

posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
For bleeding air from hydraulic system to perform troubleshooting, Pm Clinic, or periodic maintenance, refer to
this section.
Bleed air in the hydraulic system which marked with ●. Start bleeding air from step 1.
Air in the hydraulic system which marked with “x” does not need to be bled.
30-136 PC210LCI-11
30 TESTING AND ADJUSTING BLEED AIR FROM HYDRAULIC CIRCUIT
Air bleeding procedure and items

1 2 3 4 5 6
Details of work
Bleeding air Bleeding air Bleeding air Check of oil
Start the en- Bleeding air
from main from swing from travel level and op-
gine. from cylinder
pump motor motor eration
• Hydraulic oil
change ● ●
● ● ● ●
• Strainer clean- (*1) (*1)
ing
• Replacement
of return filter × ● × × × ●
element
• Replacement
and repair of
main pump ● ● ● × × ●
• Removal of
suction piping
• Replacement
and repair of
control valve
× ● ● × × ●
• Removal of
control valve
piping
• Replacement
and repair of
cylinder × ● ● × × ●
• Removal of
cylinder piping
• Replacement
and repair of
swing motor
× ● × ● × ●
• Removal of
swing motor
piping
• Replacement
and repair of
travel motor
× ● × × ● ●
• Removal of
travel motor
piping
• Replacement
and repair of
swivel joint
× ● × × × ●
• Installation of
swivel joint pip-
ing
*1: Bleed air from the swing motor and travel motor only when the oil in the motor cases are drained.
PC210LCI-11 30-137
BLEED AIR FROM HYDRAULIC CIRCUIT 30 TESTING AND ADJUSTING
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT

Method for bleeding air from main pump
REMARK
Keep the oil filler cap of the hydraulic tank loosened during air bleeding work of the main pump.
1. Loosen air bleeder (1) of main pump, and check that oil
oozes out from the air bleeder.
2. When oil without air starts to flow out, tighten air bleeder
(1).
3 Air bleeder (1):
7.8 to 9.8 Nm 0.8 to 1.0 kgm
When starting the engine after performing “Bleeding air from main pump”, run the engine for 10 minutes with the
fuel control dial at MIN position (Low idle).
REMARK
When performing the automatic warm-up operation while engine coolant temperature is low, stop the engine
once and cancel the automatic warm-up function with fuel control dial. (Turn the starting switch to ON position
and keep the fuel control dial at MAX position for 3 seconds or more, and automatic warm-up function will be
canceled.)
Method for bleeding air from cylinder

REMARK
Perform this work before connecting the work equipment if the cylinder has been replaced. Especially, LOWER
side of the boom cylinder does not operate to the stroke end with the work equipment installed.
1. Start the engine, and run it for approximately 5 minutes with the fuel control dial at MIN position (Low idle).
2. Repeat raising the boom and lowering it 4 to 5 times while running the engine with the fuel control dial at
MIN position (Low idle).
REMARK
Be careful to stop the piston rod at approximately 100 mm before each stroke end to avoid relieving.
3. Repeat raising the boom and lowering it 4 to 5 times while running the engine with the fuel control dial at
MAX position (High idle).
REMARK
Be careful to stop the piston rod at approximately 100 mm before each stroke end to avoid relieving.
4. Move the piston rod to the stroke end to relieve the circuit while running the engine with the fuel control dial
at MIN position (Low idle).
5. Bleed air from the arm cylinder and bucket cylinder according to steps 2 to 4.
Bleed air from swing motor

1. Start the engine, and run it with the fuel control dial at MIN position (Low idle).
2. Swing the upper structure slowly to the right and left to bleed air.
Bleed air from travel motor

1. Start the engine, and run it with the fuel control dial at MIN position (Low idle).
30-138 PC210LCI-11
30 TESTING AND ADJUSTING BLEED AIR FROM HYDRAULIC CIRCUIT
2. Loosen air bleeder (2), and check that oil oozes out from
the air bleeder.
3. When oil without air starts to flow out, tighten air bleeder
(2).
3 Air bleeder (2):
27.5 to 35.3 Nm 2.8 to 3.6 kgm
4. Raise one track off the ground by using the work equip-
ment.
5. Run the raised track off the ground for 2 minutes.
REMARK
Run the raised track off the ground evenly in forward and
reverse.
6. Run the track off the ground on the opposite side for 2 mi-
nutes in same manner.
Method of checking oil level

1. Start the engine, retract the arm cylinder and bucket cylin-
der fully, lower the work equipment to the ground, and stop
the engine.
2. Check the oil level by sight gauge (6) at the rear of the hy-
draulic tank.
When the oil level is between the lines “H” and “L”, it is ap-
propriate.
When the oil level is below line L, it is insufficient. Add oil.
PC210LCI-11 30-139
TEST CAB TIPPING STOPPER 30 TESTING AND ADJUSTING
CAB AND ITS ATTACHMENTS

TEST CAB TIPPING STOPPER
For testing cab tipping stopper, refer to this section.
METHOD FOR TESTING CAB TIPPING STOPPER

Check the tightening torque of mounting bolt (2) of lock plate
3 Bolt (2):
(1).
98 to 123 Nm {10 to 12.5 kgm}
Note that the tightening torque for mounting bolt (4) of cab tip-
ping stopper (3) is different from that of a common bolt whose
thread diameter is 30 mm.
3 Bolt (4):
245 to 309 Nm {25 to 31.5 kgm}
30-140 PC210LCI-11
30 TESTING AND ADJUSTING METHOD FOR ADJUSTING MIRRORS
METHOD FOR ADJUSTING MIRRORS

k Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot se-
cure the visibility and may be injured or may lead to a serious personal injury or death.
k To prevent the machine from moving during the work, make sure that the following conditions are
met before starting the work.
k The machine is placed on a firm, level ground.
k The work equipment is lowered to the ground in secure posture.
k The lock lever is in LOCK position.
k The engine is stopped.
Mirror (A): Machine L.H. front mirror
Mirror (B): Machine R.H. front mirror
Mirror (C): Machine R.H. side mirror
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)

Adjust the mirror so that the operator can see a person at the rear left of the machine.
1. Adjust the mirror so that the side of the machine is reflect-
ed in the mirror as shown in the figure.
2. Check that you can see a person at the rear left end of the
machine.
3. If you cannot adjust, loosen mounting bolts (1) and (2) of

the mirror and stay, and adjust the angles.
PC210LCI-11 30-141
METHOD FOR ADJUSTING MIRRORS 30 TESTING AND ADJUSTING
If the mirror is adjusted by loosening the mounting bolts, be sure to adjust the mirror to its regular position. For
the adjustment method, see “PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT
FRONT MIRROR (A) (30-142)”.
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT

FRONT MIRROR (A)
When returning the mirror to its regular position, perform the
following adjustment.
1. Adjust stay (1).

Mounting position (2): 71 mm {3 in}
Mounting angle (3): 89 °
Tightening torque of mounting bolt (5): 6.0 to 7.0 Nm {0.61 to 0.71 kgm, 4.41 to 5.14 lbft}
2. Adjust mirror (6).
Tightening torque of mounting bolt (6): 6.0 to 7.0 Nm {0.61
to 0.71 kgm, 4.41 to 5.14 lbft}
Mounting position (7): 172 mm {6.8 in}
30-142 PC210LCI-11
NOTICE
• Tighten the right and left bolts of each bracket al-
ternately so that their right and left clearances (R)
and (L) become equal.
• If the mirror and stay mounting bolts are tightened
excessively, the bracket may be damaged. Be sure
to tighten bolts to the specified torque.
Adjust the mirror so that the side of the machine is reflect-

ed in the mirror as shown in the figure.
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)

Adjust the mirror so that you can see a person at the rear right
of the machine.
1. Adjust the mirror with your hand so that the side of the ma-
chine is reflected in the mirror as shown in the figure.
2. Check that you can see a person at the rear right of the
machine.
PC210LCI-11 30-143
3. If you cannot adjust, loosen mounting bolts (1) and (2) of

the mirror and stay, and adjust the angles.
If the mirror is adjusted by loosening the mounting bolts, be sure to adjust the mirror to its regular position. For
the adjustment method, see “PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT
FRONT MIRROR (B) (30-144)”.
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT

FRONT MIRROR (B)
When returning the mirror to its regular position, perform the following adjustment.
Adjust mirror (1).
Tightening torque of mounting bolt (2): 6.0 to 7.0 Nm {0.61 to
0.71 kgm,4.41 to 5.14 lbft}
Tightening torque of mounting bolt (7): 6.0 to 7.0 Nm {0.61 to
0.71 kgm,4.41 to 5.14 lbft}
30-144 PC210LCI-11
NOTICE
• Tighten the right and left bolts of each bracket alter-
nately so that their right and left clearances (R) and (L)
become equal.
• If the mirror and stay mounting bolts are tightened ex-
cessively, the bracket may be damaged. Be sure to
tighten bolts to the specified torque.
Adjust the mirror so that the side of the machine is reflected in

the mirror as shown in the figure.
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)

• Adjust it so that people within 1 m around the machine can
be seen from the operator's seat.
(W): 1 m
• The regular position of the mirror is as follows:
PC210LCI-11 30-145
Adjust mirror (1).

Tightening torque of mounting bolt (2): 6.0 to 7.0 Nm {0.61
to 0.71 kgm,4.41 to 5.14 lbft}
30-146 PC210LCI-11
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
PC210LCI-11 30-147
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING
Upper part of machine monitor

(a): Multi-information display
When starting the engine, the battery voltage may suddenly drop depending on the temperature and the battery
condition. If this happens, the display on the machine monitor may momentarily go out, but this does not indi-
cate any abnormality.
Upper part of machine monitor (switch part)
F1: F1 Function switch
The functions of the switches are indicated by the icon on the screen. Icons are displayed just above the func-
tion switches on the multi-information display panel (a).
If the icon for a function switch is not displayed, that function switch is not working.
Lower part of machine monitor (switch part)
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/Buzzer cancel switch
5: Numeral 5 input switch/Wiper switch
6: Numeral 6 input switch/Window washer switch
7: Numeral 7 input switch/Air conditioner switch
Each switch has the function indicated by the icon on it and the function of inputting a numeral.
The machine monitor automatically judges which function of each switch is currently enabled according to the
screen display of the multi-information display (a).
Operator mode and service mode of machine monitor
Machine monitor has operator mode and service mode. Various information is displayed on multi-information
display (a).
Some items are displayed automatically according to the configuration of the machine monitor whereas the oth-
er items can be displayed only when the machine monitor is operated with switches.
• Operator mode
The information items in this mode are displayed on home screen. The operator can display and set them
by the operation with switches. (Display and setting of some items need special operation of switches.)
For the details, see Operation and Maintenance Manual.
Operator mode
Display of KOMATSU logo
Display of password input screen
Display of check of breaker mode
Display of check before starting
Display of warning after "Check before starting"
30-148 PC210LCI-11
Operator mode
Display of maintenance due time over
Display of check of work equipment mode and travel speed
Display of standard screen
Display of AdBlue/DEF gauge low level warning
Display of end screen
Display of operation screen of engine shutdown secondary switch
Selection of auto-deceleration
Selection of working mode
Selecting of travel speed
Operation to cancel alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner
Operation to display camera mode
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode (including KOMTRAX messages for users)
Display of Eco guidance
Display of alarm monitor
Display of aftertreatment devices regeneration
Display of SCR information
Display function of action level and failure code
Following functions become operational by performing special operations.
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN (30-152)
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN (30-152)
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) (30-153)
CHECKING FUNCTION OF SERVICE METER (30-153)
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD (30-153)
• Service Mode
The information items in this mode are not displayed on home screen. Technicians can change display and
settings by operating the switches specially. This mode is used for testing, adjusting, or troubleshooting.
Service Mode
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION (30-159)
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION (30-166)
METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS) (30-181)
METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYSTEMS) (30-180)
METHOD FOR CONFIRMING MAINTENANCE RECORD (30-184)
METHOD FOR OPERATING MAINTENANCE MODE SETTING (30-185)
PC210LCI-11 30-149
Service Mode
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING (30-189)
METHOD FOR SETTING DEFAULT (KEY-ON MODE) (30-191)
METHOD FOR SETTING DEFAULT (UNIT) (30-192)
METHOD FOR SETTING DEFAULT (WITH/WITHOUT ATTACHMENT) (30-192)
METHOD FOR SETTING DEFAULT (CAMERA) (30-193)
METHOD FOR OPERATING TESTING MENU (AUTO IDLE STOP TIME FIXING) (30-195)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT QUICK COUPLER) (30-196)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT KomVision) (30-197)
METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION) (30-199)
METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE) (30-200)
METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET) (30-202)
METHOD FOR OPERATING TESTING MENU (MS CYLINDER FUNCTION CHECK) (30-203)
METHOD FOR OPERATING TESTING MENU (MS CYLINDER FUNCTION CHECK: Bucket Tilt MS Cylinder)
(30-203)
METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST) (30-204)
METHOD FOR OPERATING TESTING MENU (ENGINE CONTROLLER ACTIVE FAULT CLEAR) (30-205)
METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULATION CORRECTION) (30-206)
METHOD FOR OPERATING TESTING MENU (RESET NUMBER OF ABRUPT ENGINE STOP BY AIS) (30-207)
METHOD FOR OPERATING TESTING MENU (ENGINE STOP AdBlue/DEF INJ OVERHEAT COUNT RESET)
(30-208)
METHOD FOR ADJUSTING (Pump Absorption Torque (F)) (30-210)
METHOD FOR ADJUSTING (Pump Absorption Torque (R)) (30-211)
METHOD FOR ADJUSTING (Low Speed) (30-212)
METHOD FOR ADJUSTING (Attachment Flow Adjustment) (30-213)
METHOD FOR ADJUSTING (CAL F pump swash plate sensor) (30-214)
METHOD FOR ADJUSTING (CAL R pump swash plate sensor) (30-218)
METHOD FOR ADJUSTING (Fan Rotation Mode Selection) (30-220)
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (KomVision SETTING) (30-221)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC ADJUSTMENT) (30-221)(*1)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 2 ADJUSTMENT) (30-222)(*2)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Attachment EPC 2 Adjustment (Tilt)) (30-230)(*6)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Attachment EPC 3 Adjustment (Tilt)) (30-232)(*7)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Proportional Lever Adjustment (R)) (30-235)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Proportional Lever Adjustment (L)) (30-238)
METHOD FOR ADJUSTING (Pump calibration: Matching speed check) (30-241)
METHOD FOR ADJUSTING (Pump calibration: Matching speed calibration) (30-246)
30-150 PC210LCI-11
Service Mode
METHOD FOR ADJUSTING MENU (RESTORE TO DEFAULT SETTING) (30-247)
METHOD FOR PERFORMING NO-INJECTION CRANKING (30-248)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS) (30-250)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS) (30-250)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS) (30-251)
METHOD FOR DISPLAYING SERVICE MESSAGE (30-252)
• *1: For adjustment of Attachment flow selector EPC valve, perform “METHOD FOR ADJUSTING WITH AD-
JUSTMENT MENU (“Attachment EPC Adjustment”)”.
• *2: For adjustment of 1st service L.H. EPC valve, perform “METHOD FOR ADJUSTING WITH ADJUST-
MENT MENU (“Attachment EPC 2 Adjustment”)”.
• *3: For adjustment of 1st service R.H. EPC valve, perform “METHOD FOR ADJUSTING WITH ADJUST-
• *4: For adjustment of 2nd service L.H. EPC valve, perform “METHOD FOR ADJUSTING WITH ADJUST-
• *5: For adjustment of 2nd service R.H. EPC valve, perform “METHOD FOR ADJUSTING WITH ADJUST-
MENT MENU (“Attachment EPC 2 Adjustment (Tilt)”)”.
PC210LCI-11 30-151
OPERATOR MODE
The following are items which needs specific switch operation in operator mode.
For details of contents and operations of each function and display, see STRUCTURE AND FUNCTION, “MA-
CHINE MONITOR”or the “OPERATION AND MAINTENANCE MANUAL”.
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN

When the operator identification function is enabled, turn the
starting switch to ON position while pressing the numeral input
key 4, and the following technician identification state screen is
displayed for 2 seconds.
REMARK
The purpose of the display function of technician identification
status screen is to distinguish the operating state by technician
(maintenance work, etc.) and operating state by operator when
the customer controls operating state by operator, fuel con-
sumption, machine trouble by using operator ID function.
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN

After displaying the technician identification state screen, the operator ID input screen
• The screen shown in the figure is displayed only when the
operator ID No. input setting is enabled.
• Before performing checking and adjusting, check in ad-
vance that the input setting of ID of the operator identifica-
tion function has already been set by the customer.
• When the customer has done the ID input setting with
SKIP, press F1 after displaying the technician identification
state screen, and the engine can be started.
• When the customer has done the ID input setting without
SKIP, the engine cannot be started unless the registered
ID is provided for the technician to use, from a person in
charge of the machine on the customer side.
• When turning the starting switch to ON position, input ID,
press F6 or F1, and the screen changes to check before
starting screen without switch operation. Confirm that it is
not necessary to identify the technician beforehand by ask-
ing administrator of the machine.
30-152 PC210LCI-11
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)

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 (simultaneously): 4 + F2
• When finishing the operation of the switches, release F2
first.
• If there is a display error in the LCD, only that part is indi-
cated in black.
• To return to the former screen, press any one of the func-
tion switches.
CHECKING FUNCTION OF SERVICE METER

When checking the service meter with the starting switch in
OFF position, operate the numeral input switches as follows to
display only the service meter section.
Operate the switches (simultaneously): 4 + 1
REMARK
• There is some time lag in start of the LCD, so hold down
the switches until the service meter is displayed.
• If you release one of the switches, the monitor goes off.
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD

On the machine monitor, a password can be set as a user limitation setting. If the password has been set, a
password enter screen is displayed for resetting of maintenance items.
For the operating method for “Operator ID Change” see Operation and Maintenance Manual
Perform the Usage Limitation Setting and Change Password functions according to the following procedure.
PC210LCI-11 30-153
1. While the standard screen is displayed, perform the follow-

ing operation by using the numeral input switches.
Switch operation (While pressing 4, press other switches
in order): 4 + 5 → 5 → 5
REMARK
This operation of the switches is not accepted until 10 mi-
nutes elapsed after the starting switch is turned to ON po-
sition.
2. After “Usage Limitation Password” screen is displayed, in-

put the current password by using the numeral input
switches and confirm it by using the function switch.
F5: Clears input numbers/Returns to the standard screen
F6: Enters input password
REMARK
• Default password: 000000
• When the input password is correct, the screen
changes to the next screen.
• When the input password is incorrect, the screen dis-
plays message to request inputting the password
again.
• The password for the Usage Limitation and the engine
start lock password are not identical.
3. After “Usage Limitation Setting” screen is displayed, select
a setting by using the function switch.
F3: Moves the selection downward
F4: Moves the selection upward
F5: Cancels the selection and returns the screen to the
previous screen
F6: Enters the selection
30-154 PC210LCI-11
4. After “Usage Limitation ON/OFF” screen is displayed, se-

lect 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 ap-
pears.
F3: Moves the selection downward.
F4: Moves the selection upward.
previous screen.
F6: Enters the selection.
5. After “Usage Limitation New Password Input” screen is
displayed, input the new password by using the numeral
input switches and confirm it by using the function switch.
F5: Clears input numbers/Returns the screen to the pre-
ceding screen
F6: Enters input password.
REMARK
• Default password: 000000
• When the input password is correct, the screen
changes to the next screen.
• When the input password is incorrect, the screen dis-
plays message to request inputting the password
again.
• Set a new password of 4 to 6 digits (If it has only 3 or
less digits or has 7 or more digits, it is not accepted).
6. After “Usage Limitation New Password Input” screen is
displayed once more, input the new password for the sec-
ond time by using the numeral input switches and confirm
it by using the function switch.
F5: Clears input numbers/Returns to the standard screen.
F6: Enters input password.
REMARK
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 noti-
fy completion of setting is displayed, the password is
changed successfully.
PC210LCI-11 30-155
SERVICE MODE
METHOD FOR OPERATING SERVICE MODE
Perform the following operation to change the mode of the machine monitor from the operator mode to the serv-
ice mode.
This operation is always required when you use the service mode.
1. Press the numerical switches in order while pressing 4 as
4 + 1 → 2 → 3 on the standard screen.
REMARK
This switching operation is available only when the stand-
ard screen is displayed.
2. “Service Menu” screen is displayed, it means the service

mode is selected. Select an item on the service menu with
the function switches or numeral input switches.
F5: Screen returns to the standard screen (operator mode)
F6: Enters the selected item
When you input a 2-digit code by using the numeral input
switches, the corresponding menu is directly selected. Ac-
cordingly, you may enter the selected item by using F6.
Items selectable in the service menu

Code Item Reference page
METHOD FOR CHECKING PRE-DEFINED MONITORING IN-
01 Pre-defined Monitoring
FORMATION (30-159)
METHOD FOR CHECKING SELF-DEFINE MONITORING IN-
02 Self-define Monitoring
FORMATION (30-166)
Mechanical Sys Abnormali- METHOD FOR CONFIRMING ABNORMALITY RECORD
Abnormali- ty Record (ELECTRICAL SYSTEMS) (30-181)
03
ty Record Electrical Sys Abnormality METHOD FOR CONFIRMING ABNORMALITY RECORD (ME-
Record CHANICAL SYSTEMS) (30-180)
METHOD FOR CONFIRMING MAINTENANCE RECORD
04 Maintenance Record
(30-184)
METHOD FOR OPERATING MAINTENANCE MODE SET-
05 Maintenance Mode Setting
TING (30-185)
METHOD FOR OPERATING PHONE NUMBER ENTRY SET-
06 Phone Number Entry
TING (30-189)
30-156 PC210LCI-11

Key-on Mode METHOD FOR SETTING DEFAULT (KEY-ON MODE) (30-191)
Unit METHOD FOR SETTING DEFAULT (UNIT) (30-192)
METHOD FOR SETTING DEFAULT (WITH/WITHOUT AT-
With/Without Attachment
TACHMENT) (30-192)
Camera METHOD FOR SETTING DEFAULT (CAMERA) (30-193)
07 Default
METHOD FOR OPERATING TESTING MENU (AUTO IDLE
Auto Idle Stop Time Fixing
STOP TIME FIXING) (30-195)
METHOD FOR SETTING WITH DEFAULT SETTING MENU
With/Without Quick Coupler
(WITH/WITHOUT QUICK COUPLER) (30-196)
METHOD FOR SETTING WITH DEFAULT SETTING MENU
With/Without KomVision
(WITH/WITHOUT KomVision) (30-197)
Cylinder Cutout Mode Op- METHOD FOR OPERATING TESTING MENU (CYLINDER
eration CUT-OUT OPERATION) (30-199)
Active Regeneration for METHOD FOR OPERATING TESTING MENU (REGENERA-
Service TION FOR SERVICE) (30-200)
METHOD FOR OPERATING TESTING MENU (KDPF MEMO-
KDPF Memory Reset
RY RESET) (30-202)
METHOD FOR OPERATING TESTING MENU (MS CYLIN-
MS Cylinder function check
DER FUNCTION CHECK) (30-203)
MS Cylinder function check: METHOD FOR OPERATING TESTING MENU (MS CYLIN-
Diagnostic Bucket Tilt MS Cylinder DER FUNCTION CHECK: Bucket Tilt MS Cylinder) (30-203)
08
Tests METHOD FOR OPERATING TESTING MENU (SCR SERVICE
SCR Service Test
TEST) (30-204)
Engine Controller Active METHOD FOR OPERATING TESTING MENU (ENGINE CON-
Fault Clear TROLLER ACTIVE FAULT CLEAR) (30-205)
Ash in Soot Accumulation METHOD FOR OPERATING TESTING MENU (ASH IN SOOT
Correction ACCUMULATION CORRECTION) (30-206)
Reset Number of Abrupt METHOD FOR OPERATING TESTING MENU (RESET NUM-
Engine Stop by AIS BER OF ABRUPT ENGINE STOP BY AIS) (30-207)
Engine Stop at AdBlue/DEF METHOD FOR OPERATING TESTING MENU (ENGINE
Inj Overheat Count Reset STOP AdBlue/DEF INJ OVERHEAT COUNT RESET) (30-208)
PC210LCI-11 30-157

Pump Absorption Torque METHOD FOR ADJUSTING (Pump Absorption Torque (F))
(F) (30-210)
Pump Absorption Torque METHOD FOR ADJUSTING (Pump Absorption Torque (R))
(R) (30-211)
Travel Low Speed METHOD FOR ADJUSTING (Low Speed) (30-212)
Att Flow Adjust in Com- METHOD FOR ADJUSTING (Attachment Flow Adjustment)
bined Ope (30-213)
Calibrate F Pump Swash METHOD FOR ADJUSTING (CAL F pump swash plate sensor)
Plate Sensor (30-214)
Calibrate R Pump Swash METHOD FOR ADJUSTING (CAL R pump swash plate sen-
Plate Sensor sor) (30-218)
METHOD FOR ADJUSTING (Fan Rotation Mode Selection)
Fan Speed Mode Select
(30-220)
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU
KomVision Adjustment
(KomVision SETTING) (30-221)
Attachment EPC Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (AT-
ment(*1) TACHMENT EPC ADJUSTMENT) (30-221)
Attachment EPC 2 Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (AT-
ment(*2) TACHMENT EPC 2 ADJUSTMENT) (30-222)
09 Adjustment Attachment EPC 3 Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (AT-
Attachment EPC 2 Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (At-
ment (Tilt)(*6) tachment EPC 2 Adjustment (Tilt)) (30-230)
Attachment EPC 3 Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (At-
ment (Tilt)(*7) tachment EPC 3 Adjustment (Tilt)) (30-232)
Proportional Lever Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (Pro-
ment (R) portional Lever Adjustment (R)) (30-235)
Proportional Lever Adjust- METHOD FOR ADJUSTING WITH ADJUSTING MENU (Pro-
ment (L) portional Lever Adjustment (L)) (30-238)
Pump Calibration:Matching METHOD FOR ADJUSTING (Pump calibration: Matching
Speed Check speed check) (30-241)
Pump Calibration:Matching METHOD FOR ADJUSTING (Pump calibration: Matching
Speed Calibration speed calibration) (30-246)
Pump Calibration:Restore METHOD FOR ADJUSTING MENU (RESTORE TO DEFAULT
to Factory Setting SETTING) (30-247)
METHOD FOR PERFORMING NO-INJECTION CRANKING
10 No-Injection Cranking
(30-248)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMI-
Terminal Status
NAL STATUS) (30-250)
KOMTRAX GPS & Communication METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS
11
Settings State AND COMMUNICATION STATUS) (30-250)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MO-
Modem Information
DEM STATUS) (30-251)
30-158 PC210LCI-11

12 Service Message METHOD FOR DISPLAYING SERVICE MESSAGE (30-252)
• *1: For adjustment of Attachment flow selector EPC valve, perform “METHOD FOR ADJUSTING WITH AD-
JUSTMENT MENU (“Attachment EPC Adjustment”)”.
• *4: For adjustment of 2nd service L.H. EPC valve, perform “METHOD FOR ADJUSTING WITH ADJUST-
• *5: For adjustment of 2nd service R.H. EPC valve, perform “METHOD FOR ADJUSTING WITH ADJUST-
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION

The machine monitor can monitor the condition of the machine in real time by receiving signals from various
switches, sensors, and actuators installed to various parts of the machine and the information from the control-
lers which is controlling switches, etc.
In “Pre-defined Monitoring”, frequently used monitoring items in daily work are selected beforehand.
1. Select “Pre-defined Monitoring” on “Service Menu” screen.
2. After “Pre-defined Monitoring” screen is displayed, the

items displayed in it can be checked with the function
switch.
F1: Moves the selection to next page (screen)
F2: Moves the selection to previous page (screen)
F4: Selects HOLD or releasing hold (If HOLD is selected,
HOLD part is hatched.)
F5: Returns the screen to “Service Menu” screen.
PC210LCI-11 30-159
REMARK
• For the items not displayed in “Pre-defined Monitoring”,
you can freely select and check from “Pre-defined
Monitoring” items.
• When 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.
TABLE OF PRE-DEFINED MONITORING ITEMS

Pre-defined Monitoring (01/24) Machine basics
Unit Applicable
No. ID Item name
SI Metric Imperial equipment
1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C °F ENG
3 37212 Engine Oil Pressure SW - - - ENG
4 18400 Intake Temperature °C °C °F ENG
5 04401 Hydraulic Oil Temperature °C °C °F PUMP
6 03203 Battery Power Supply V V V ENG
Pre-defined Monitoring (02/24) Fuel injection system

Unit Applicable
No. ID Item name

2 47300 KDOC 1 Inlet Temperature °C °C °F ENG
3 36400 Rail Pressure MPa kg/cm2 psi ENG
4 36200 Rail Pressure Command MPa kg/cm2 psi ENG

5 48000 IMV Current A A A ENG
6 48001 IMV Command Current A A A ENG
Pre-defined Monitoring (03/24) EGR, VGT actuator

Unit Applicable
No. ID Item name

2 48100 Turbocharger Speed r/min rpm rpm ENG
3 18100 EGR Valve Position mm mm in ENG
4 48600 EGR Solenoid Current mA mA mA ENG
5 48700 VGT Position mm mm in ENG
6 48800 VGT Solenoid Current mA mA mA ENG
30-160 PC210LCI-11
Pre-defined Monitoring (04/24) Engine temperature

Unit Applicable
No. ID Item name

5 18500 Charge Temperature °C °C °F ENG
Pre-defined Monitoring (05/24) Intake and exhaust pressure system

Unit Applicable
No. ID Item name

2 37400 Ambient Pressure kPa kg/cm2 psi ENG
3 36500 Charge Pressure kPa kg/cm2 psi ENG

5 48200 MAF kg/min kg/min lb/min ENG
Pre-defined Monitoring (06/24) aftertreatment related

Unit Applicable
No. ID Item name
1 47000 KDPF Outlet Pressure kPa kg/cm2 psi KDPF
2 47100 KDPF Differential Pressure kPa kg/cm2 psi KDPF

3 47200 KDPF 1 Outlet Temperature °C °C °F KDPF
4 47300 KDOC 1 Inlet Temperature °C °C °F KDPF
5 47400 KDOC 1 Outlet Temperature °C °C °F KDPF
6 36400 Rail Pressure MPa kg/cm2 psi KDPF
Pre-defined Monitoring (07/24) Engine

Unit Applicable
No. ID Item name

2 37212 Engine Oil Pressure SW - - - ENG
3 48400 Crankcase Pressure kPa mmAq psi ENG
5 36500 Charge Pressure kPa kg/cm2 psi ENG
PC210LCI-11 30-161
Pre-defined Monitoring (08/24) F&R pump basic

Unit Applicable
No. ID Item name

2 01100 Front Pump Pressure MPa kg/cm2 psi PUMP
3 01101 Rear Pump Pressure MPa kg/cm2 psi PUMP

4 01300 PC-EPC Front Solenoid Current mA mA mA PUMP
5 01302 PC-EPC Rear Solenoid Current mA mA mA PUMP
Pre-defined Monitoring (09/24) F&R pump application

Unit Applicable
No. ID Item name


4 01137 Front Pump Displacement cc/rev cc/rev cc/rev PUMP
5 01139 Rear Pump Displacement cc/rev cc/rev cc/rev PUMP
Pre-defined Monitoring (10/24) F pump application

Unit Applicable
No. ID Item name

3 01141 Service Pressure Sensor MPa kg/cm2 psi PUMP

4 01300 PC-EPC Front Solenoid Current mA mA mA PUMP
5 01137 Front Pump Displacement cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC Solenoid Current mA mA mA PUMP
Pre-defined Monitoring (11/24) R pump application

Unit Applicable
No. ID Item name

3 01141 Service Pressure Sensor MPa kg/cm2 psi PUMP

4 01302 PC-EPC Rear Solenoid Current mA mA mA PUMP
5 01139 Rear Pump Displacement cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC Solenoid Current mA mA mA PUMP
30-162 PC210LCI-11
Pre-defined Monitoring (12/24) PPC pressure (1)

Unit Applicable
No. ID Item name

2 07400 Boom raise PPC pressure MPa kg/cm2 psi PUMP
3 07500 Boom lower PPC pressure MPa kg/cm2 psi PUMP
4 07200 Arm IN PPC Pressure MPa kg/cm2 psi PUMP
5 07600 Arm OUT PPC Pressure MPa kg/cm2 psi PUMP


Unit Applicable
No. ID Item name

2 09002 Swing Right PPC Pressure MPa kg/cm2 psi PUMP
3 09001 Swing Left PPC Pressure MPa kg/cm2 psi PUMP
4 07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
5 07301 Bucket DUMP PPC Pressure MPa kg/cm2 psi PUMP


Unit Applicable
No. ID Item name

2 07102 Travel Forward Left PPC Press MPa kg/cm2 psi PUMP
3 07103 Travel Forward Right PPC Press MPa kg/cm2 psi PUMP
4 07104 Travel Reverse Left PPC Press MPa kg/cm2 psi PUMP
5 07105 Travel Reverse Right PPC Press MPa kg/cm2 psi PUMP
Pre-defined Monitoring (15/24) Fan clutch

Unit Applicable
No. ID Item name

2 10010 Fan Speed Command r/min rpm rpm PUMP
3 10007 Fan Speed r/min rpm rpm PUMP
4 10019 Fan Speed Deviation r/min rpm rpm PUMP
PC210LCI-11 30-163
Pre-defined Monitoring (16/24) Engine running state

Unit Applicable
No. ID Item name

2 18600 Inject Fueling Command mg/st mg/st mg/st ENG
3 19200 Exhaust Gas Flow Rate kL/h kL/h kgal/h SCR
5 19300 SCR Temperature °C °C °F SCR
6 19302 SCR Outlet Temperature °C °C °F SCR
Pre-defined Monitoring (17/24) AdBlue/DEF injector

Unit Applicable
No. ID Item name
1 47200 KDPF 1 Outlet Temperature °C °C °F KDPF

2 19304 AdBlue/DEF Pump State - - - SCR
3 19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR
4 19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
5 19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
6 19209 SCR Outlet NOx Corrected ppm ppm ppm SCR
Pre-defined Monitoring (18/24) AdBlue/DEF pump

Unit Applicable
No. ID Item name

2 19108 AdBlue/DEF Pump Pressure kPa kPa psi SCR
3 19109 AdBlue/DEF Pump PressSensor Volt V V V SCR
5 19136 AdBlue/DEF Pump Temperature °C °C °F SCR
6 19114 AdBlue/DEF Reverting Valve Cmd - - - SCR
Pre-defined Monitoring (19/24) SCR catalyst/ NOX sensor/ NH3 sensor
Unit Applicable
No. ID Item name

2 19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
3 19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
4 19209 SCR Outlet NOx Corrected ppm ppm ppm SCR
5 19203 Turbo Outlet NOx Sensor State - - - SCR
6 19210 SCR Outlet NOx Sensor State - - - SCR
30-164 PC210LCI-11
Pre-defined Monitoring (20/24) AdBlue/DEF level, quality sensor

Unit Applicable
No. ID Item name
1 19100 AdBlue/DEF Concentration % % % SCR

2 19110 AdBlue/DEF Level % % % SCR
3 19111 AdBlue/DEF Level Corrected % % % SCR
4 19115 AdBlue/DEF Temperature in Tank °C °C °F SCR
5 19400 Ambient Temperature °C °C °F SCR
6 19305 AdBlue/DEF Tank Heating State - - - SCR
Pre-defined Monitoring (21/24) AdBlue/DEF tank thaw control

Unit Applicable
No. ID Item name
1 19305 AdBlue/DEF Tank Heating State - - - SCR

2 19102 AdBlue/DEF Tank HtrValve Command - - - SCR
6 19133 Engine Room Temperature °C °C °F SCR
Pre-defined Monitoring (22/24) AdBlue/DEF pump thaw control

Unit Applicable
No. ID Item name
1 19107 AdBlue/DEF Pump Heater 1 Command - - - SCR

2 19309 AdBlue/DEF Pump Heater State - - - SCR
3 19136 AdBlue/DEF Pump Temperature °C °C °F SCR
6 03203 Battery Power Supply V V V ENG
Pre-defined Monitoring (23/24) AdBlue/DEF hose thaw control

Unit Applicable
No. ID Item name
1 19306 AdBlue/DEF Line Heater 1 State - - - SCR

2 19106 AdBlue/DEF Line Heater 1 Command - - - SCR
3 19307 AdBlue/DEF Line Heater 2 State - - - SCR
4 19135 AdBlue/DEF Line Heater 2 Command - - - SCR
PC210LCI-11 30-165
Pre-defined Monitoring (24/24) Environmental condition

Unit Applicable
No. ID Item name
1 37400 Ambient Pressure kPa kg/cm2 psi ENG

METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION

The machine monitor can monitor the condition of the machine in real time by receiving signals from various
switches, sensors, and actuators installed to various parts of the machine and the information from the control-
lers which is controlling switches, etc.
“Self-define Monitoring”function is used to select a desired monitoring item.
1. Select “Self-define Monitoring” on “Service Menu” screen.
2. After “Monitoring Selection Menu” screen is displayed, se-

lect items to be monitored by using the function switches
or numeral input switches.
F1: Moves the selection leftward
F2: Moves the selection rightward
F5: Clears input numbers/Returns the screen to “Service
Menu” screen
• For setting of the monitoring, each time function switch F2 is pressed, sequential switching among
“ENG” → “KDPF” → “SCR” → “PUMP” → “ICT” →“W/E” → “MON” → “ENG” takes place in this order.
(When F1 is pressed, sequential switching takes place in the reverse order.)
• 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.
• Selection with numeral input switches: Enter a 5-digit code, and the item of that code is selected direct-
ly. Enter that item by using F6.
• If the color of the selected box changes from yellow to red, the selection of the item of that box is en-
tered.
• Up to six monitoring items are selectable at a time. However, the items may not be set up to six de-
pending on the form of display of the selected item.
30-166 PC210LCI-11
3. After selecting monitoring items, execute monitoring with

the function switch or numeral input switch.
• Execution with function switch: Double click or keep
pressing F6 (for approximately 2 seconds).
• Execution with numeral input switch: Input “99999”
and press F6.
• If monitoring items are selected up to the limit number,
monitoring is executed automatically.
REMARK
When monitoring only two items, select them and confirm
with F6. If F6 is pressed once more at this time, monitoring
is executed.
4. After “Monitoring” screen is displayed, perform the neces-
sary operation of the machine and check the monitoring in-
formation.
REMARK
• Monitoring information is indicated by value, ON/OFF,
or special display.
• The unit of display can be selected in “SI ”unit, “met-
ric”unit, or “inch”unit with “Default” function in service
mode.
5. You can hold and release holding of the monitoring infor-

mation by using the function switches.
F4: Selects hold or releasing hold (If the hold is selected,
“HOLD” part is hatched.)
F5: Returns the screen to “Monitoring Selection Menu”
screen
PC210LCI-11 30-167
6. To change the setting of the working mode, travel speed,

or auto-deceleration during monitoring, operate the corre-
sponding switch under the current condition, and the corre-
sponding mode is selected.
REMARK
• If the setting is changed during monitoring, the new
setting is held even after the screen returns to the ordi-
nary screen after monitoring is finished.
• When 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.
7. A function switch lets you save and delete the selected

monitoring item.
F1: Saves monitoring item
F2: Clears monitoring item
• When a monitoring item is saved, a confirmation
screen appears asking whether the saved item should
be displayed or not when “Self-define Monitoring” is
selected again.
• When an item is saved, it can be displayed as many
times as required unless it is cleared.
• If another item is saved while having the previous item
saved, the previously saved item is overwritten by the
latest one.
TABLE OF SELF-DEFINE MONITORING

Unit Applicable
Monitor- Self-define Monitoring items (screen dis-
compo- Remarks
ing code play) SI Metric Imperial nent
01002 Engine Speed r/min rpm rpm ENG
04107 Coolant Temperature °C °C °F ENG
30-168 PC210LCI-11
Unit Applicable
compo- Remarks
48000 IMV Current A A A ENG
48001 IMV Command Current A A A ENG
03203 Battery Power Supply V V V ENG
37212 Engine Oil Pressure SW ON/OFF ON/OFF 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 of abso-
lute value (in-
36500 Charge Pressure kPa kg/cm2 psi ENG
cluding ambient
pressure)
48100 Turbocharger Speed r/min rpm rpm ENG
48200 MAF kg/min kg/min lb/min ENG
48400 Crankcase Pressure kPa mmAq psi ENG
18100 EGR Valve Position mm mm in ENG
48600 EGR Solenoid Current mA mA mA ENG
48700 VGT Position mm mm in ENG
48800 VGT Solenoid Current mA mA mA ENG
36700 Engine Torque Ratio % % % ENG
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle Position Sensor Voltage V V V ENG
04105 Coolant Temperature Sensor Volt V V V ENG
37401 Ambient Pressure Sensor Voltage V V V ENG
18401 Intake Temperature Sensor Volt V V V ENG
18501 Charge Temperature Sensor Volt V V V ENG
36501 Charge Pressure Sensor Voltage V V V ENG
36401 Rail Pressure Sensor Voltage V V V ENG
48401 Crankcase Pressure Sensor Volt V V V ENG
18101 EGR Valve Position Sensor Volt V V V ENG
48701 VGT Position Sensor Voltage V V V ENG
17500 Engine Power Mode Selection - - - ENG
48900 Engine Operation Mode - - - ENG
08402 Droop SW Selection - - - ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Pressure Command MPa kg/cm2 psi ENG
PC210LCI-11 30-169
Unit Applicable
compo- Remarks
37300 Instantaneous Fuel Consumption(Note 1) ℓ/h ℓ/h gal/h ENG
WIF: Water In
18800 Water in Fuel Sensor State ON/OFF ON/OFF ON/OFF ENG
Fuel
18801 Water in Fuel Sensor Voltage V V V ENG
20216 Engine Controller Build Version - - - ENG
20217 Engine Con Calibration Data Ver - - - ENG
18900 Engine Con Internal Temperature °C °C °F ENG
20400 Engine Controller S/N - - - ENG
47000 KDPF Outlet Pressure kPa kg/cm2 psi KDPF
47001 KDPF Outlet Pressure Sensor Volt V V V KDPF
47100 KDPF Differential Pressure kPa kg/cm2 psi KDPF
47101 KDPF Diff Pressure Sensor Volt V V V KDPF
47300 KDOC 1 Inlet Temperature °C °C °F KDPF
47400 KDOC 1 Outlet Temperature °C °C °F KDPF
47200 KDPF 1 Outlet Temperature °C °C °F KDPF
47500 Dosing Instant Fuel Consumption ℓ/h ℓ/h gal/h KDPF
47700 Soot Accumulation g/L g/L g/gal KDPF
47802 Soot Correction by Ash Influence g/L g/L g/gal KDPF
19100 AdBlue/DEF Concentration % % % SCR
19200 Exhaust Gas Flow Rate kL/h kL/h kgal/h SCR
19201 Turbo Outlet NOx Concentration ppm ppm ppm SCR
19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
0: Unmeasura-
ble
19203 Turbo Outlet NOx Sensor State - - - SCR
1: Being meas-
ured
19204 SCR NH3 Concentration ppm ppm ppm SCR
19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
0: Unstable
19206 SCR NH3 Sensor Stability State - - - SCR 1: Stable
2: Error
0: Unmeasura-
ble
19207 SCR NH3 Sensor State - - - SCR
1: Being meas-
ured
19208 SCR Outlet NOx Concentration ppm ppm ppm SCR
19209 SCR Outlet NOx Corrected ppm ppm ppm SCR
30-170 PC210LCI-11
Unit Applicable
compo- Remarks
0: Unmeasura-
ble
19210 SCR Outlet NOx Sensor State - - - SCR
1: Being meas-
ured
0：CLOSED
19102 AdBlue/DEF Tank HtrValve Command - - - SCR
1：OPEN
19103 AdBlue/DEF Level Low Error 1 % % % SCR
0：OFF
19106 AdBlue/DEF Line Heater 1 Command - - - SCR
1：ON
0：OFF
19107 AdBlue/DEF Pump Heater 1 Command - - - SCR
1：ON
19108 AdBlue/DEF Pump Pressure kPa kg/cm2 psi SCR
19109 AdBlue/DEF Pump PressSensor Volt V V V SCR
19110 AdBlue/DEF Level % % % SCR
19111 AdBlue/DEF Level Corrected % % % SCR
0：OFF
19114 AdBlue/DEF Reverting Valve Cmd - - - SCR
1：ON
19300 SCR Temperature °C °C °F SCR
19302 SCR Outlet Temperature °C °C °F SCR
1: Stop injection
2: Pressure-fed
19304 AdBlue/DEF Pump State - - - SCR
3: Being injected
4: Being purged
1: Being thawed
2: Being kept
19305 AdBlue/DEF Tank Heating State - - - SCR
warm
3：OFF
1: Being thawed
2: Being kept
19306 AdBlue/DEF Line Heater 1 State - - - SCR
warm
3：OFF
1: Being thawed
2: Being kept
19307 AdBlue/DEF Line Heater 2 State - - - SCR
warm
3：OFF
0：OFF
1: Being thawed
19309 AdBlue/DEF Pump Heater State - - - SCR 2: Being kept
warm
3：OFF
PC210LCI-11 30-171
Unit Applicable
compo- Remarks
19115 AdBlue/DEF Temperature in Tank °C °C °F SCR
19119 Total AdBlue/DEF Injection Qty L L gal SCR
19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR
19400 Ambient Temperature °C °C °F SCR
19401 Ambient Temperature Sensor Volt V V V SCR
19130 AdBlue/DEF Key off Refill Count - - - SCR
19133 Engine Room Temperature °C °C °F SCR
19134 Engine Room Temp Sensor Voltage V V V SCR
0：OFF
19135 AdBlue/DEF Line Heater 2 Command - - - SCR
1：ON
19136 AdBlue/DEF Pump Temperature °C °C °F SCR
19137 Total AdBlue/DEF Heating Time h h h SCR
01601 2nd Engine Speed Command r/min rpm rpm PUMP
01100 Front Pump Pressure MPa kg/cm2 psi PUMP
01101 Rear Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm IN PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm OUT PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket DUMP PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing Left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing Right PPC Pressure MPa kg/cm2 psi PUMP
07102 Travel Forward Left PPC Press MPa kg/cm2 psi PUMP
07103 Travel Forward Right PPC Press MPa kg/cm2 psi PUMP
07104 Travel Reverse Left PPC Press MPa kg/cm2 psi PUMP
07105 Travel Reverse Right PPC Press MPa kg/cm2 psi PUMP
01137 Front Pump Displacement cc/rev cc/rev cc/rev PUMP
01138 F Pump Swash Plate Sensor volt V V V PUMP
01139 Rear Pump Displacement cc/rev cc/rev cc/rev PUMP
01140 R Pump Swash Plate Sensor volt V V V PUMP
04401 Hydraulic Oil Temperature °C °C °F PUMP
10007 Fan Speed r/min rpm rpm PUMP
10010 Fan Speed Command r/min rpm rpm PUMP
10019 Fan Speed Deviation r/min rpm rpm PUMP
01300 PC-EPC Front Solenoid Current mA mA mA PUMP
30-172 PC210LCI-11
Unit Applicable
compo- Remarks
01302 PC-EPC Rear Solenoid Current mA mA mA PUMP
01500 LS-EPC Solenoid Current mA mA mA PUMP
10018 Fan Clutch Solenoid PWM Command % % % PUMP
08000 Merge-divider Main Sol Current mA mA mA PUMP
08001 Merge-divider LS Sol Current mA mA mA PUMP
01700 Attachment Sol Current mA mA mA PUMP
01701 Attachment Sol 2 Current mA mA mA PUMP
42008 Lever Main Potentiometer 1 Volt V V V PUMP
42009 Lever Sub Potentiometer1 Voltage V V V PUMP
42010 Lever Main Potentiometer 2 Volt V V V PUMP
42011 Lever Sub Potentiometer2 Voltage V V V PUMP
42012 Lever Potentiometer 1 Stroke % % % PUMP
42013 Lever Potentiometer 2 Stroke % % % PUMP
76400 Att1 Left PPC Pressure MPa kg/cm2 psi PUMP
76401 Att1 Right PPC Pressure MPa kg/cm2 psi PUMP

03200 Battery Voltage V V V PUMP
04402 Hydraulic Oil Temp Sensor Volt V V V PUMP
01602 2nd Engine Speed Command % % % PUMP
17301 Dynamic Torque Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
01337 PC-EPC Calibration Torque 1 Nm kgm lbft PUMP
01341 PC-EPC Calibration Current 1 mA mA mA PUMP
01345 PC-EPC Calibration Torque 1 Nm kgm lbft PUMP
01349 PC-EPC Calibration Current 1 mA mA mA PUMP
Swing ON/OFF ON/OFF ON/OFF PUMP
Travel ON/OFF ON/OFF ON/OFF PUMP
Pressure SW Boom Lower ON/OFF ON/OFF ON/OFF PUMP

01900
1 Boom Raise ON/OFF ON/OFF ON/OFF PUMP
Arm IN ON/OFF ON/OFF ON/OFF PUMP
Arm OUT ON/OFF ON/OFF ON/OFF PUMP
PC210LCI-11 30-173
Unit Applicable
compo- Remarks
Bucket CURL ON/OFF ON/OFF ON/OFF PUMP
Pressure SW Bucket DUMP ON/OFF ON/OFF ON/OFF PUMP

01901
2 Service ON/OFF ON/OFF ON/OFF PUMP
Travel Diff Pressure ON/OFF ON/OFF ON/OFF PUMP
Travel Junction ON/OFF ON/OFF ON/OFF PUMP
Swing Brake ON/OFF ON/OFF ON/OFF PUMP
Solenoid
02300 Merge-divider ON/OFF ON/OFF ON/OFF PUMP
Valve 1
2-Stage Relief ON/OFF ON/OFF ON/OFF PUMP
Travel Speed ON/OFF ON/OFF ON/OFF PUMP
Swing Pressure Cut Off ON/OFF ON/OFF ON/OFF PUMP
Solenoid Service Return ON/OFF ON/OFF ON/OFF PUMP

02301
Valve 2 Variable Back Pressure ON/OFF ON/OFF ON/OFF PUMP
PPC Lock Relay ON/OFF ON/OFF ON/OFF PUMP
Knob SW ON/OFF ON/OFF ON/OFF PUMP
Swing P Brake Release
02200 SW Input 1 ON/OFF ON/OFF ON/OFF PUMP
SW
Swing Lock SW ON/OFF ON/OFF ON/OFF PUMP
Model Selection 1 ON/OFF ON/OFF ON/OFF PUMP
02201 SW Input 2
Overload Alarm ON/OFF ON/OFF ON/OFF PUMP
02202 SW Input 3 Key SW (ACC) ON/OFF ON/OFF ON/OFF PUMP
Lock Lever SW ON/OFF ON/OFF ON/OFF PUMP
Lock Lever SW 2 ON/OFF ON/OFF ON/OFF PUMP
PPC Lock Solenoid State ON/OFF ON/OFF ON/OFF PUMP
02203 SW Input 4 Lever AutoLock Relea-
ON/OFF ON/OFF ON/OFF PUMP
seSW
Breaker SW ON/OFF ON/OFF ON/OFF PUMP
Quick Coupler ON/OFF ON/OFF ON/OFF PUMP
Window Limit SW ON/OFF ON/OFF ON/OFF PUMP
02204 SW Input 5 P Limit SW ON/OFF ON/OFF ON/OFF PUMP
W Limit SW ON/OFF ON/OFF ON/OFF PUMP
20229 Pump Controller Assembly P/N - - - PUMP
20403 Pump Controller S/N - - - PUMP
20230 Pump Controller Program P/N - - - PUMP
20212 Pump Controller Program Version - - - PUMP
30-174 PC210LCI-11
Unit Applicable
compo- Remarks
04300 Battery Charge Voltage V V V MON
04200 Fuel Level Sensor Voltage V V V MON
Key SW ON/OFF ON/OFF ON/OFF MON
Start ON/OFF ON/OFF ON/OFF MON
Monitor Input
04500 Preheat ON/OFF ON/OFF ON/OFF MON
1
Light ON/OFF ON/OFF ON/OFF MON
Radiator Coolant Level ON/OFF ON/OFF ON/OFF MON
Air Cleaner ON/OFF ON/OFF ON/OFF MON
Monitor Input Engine Oil Level ON/OFF ON/OFF ON/OFF MON

04501
2 Battery Charge Voltage ON/OFF ON/OFF ON/OFF MON
Quick Coupler ON/OFF ON/OFF ON/OFF MON
Swing Parking Brake SW ON/OFF ON/OFF ON/OFF MON
Monitor Input
04502 Engine Shutdown 2nd SW ON/OFF ON/OFF ON/OFF MON
3
Seat Belt SW ON/OFF ON/OFF ON/OFF MON
F1 ON/OFF ON/OFF ON/OFF MON
Monitor F3 ON/OFF ON/OFF ON/OFF MON

04503
Function SW F4 ON/OFF ON/OFF ON/OFF MON
SW 1 ON/OFF ON/OFF ON/OFF MON
Monitor 1st & SW 3 ON/OFF ON/OFF ON/OFF MON

04504
2nd Row SW SW 4 ON/OFF ON/OFF ON/OFF MON
Monitor 3rd & SW 9 ON/OFF ON/OFF ON/OFF MON

04505
4th Row SW SW 10 ON/OFF ON/OFF ON/OFF MON
Monitor 5th
04506 SW 14 ON/OFF ON/OFF ON/OFF MON
Row SW
20227 Monitor Assembly P/N - - - MON
20402 Monitor S/N - - - MON
PC210LCI-11 30-175
Unit Applicable
compo- Remarks
20228 Monitor Program P/N - - - MON
20200 Monitor Program Version - - - MON
55300 A/C Compressor State ON/OFF ON/OFF ON/OFF MON
55000 A/C Fresh Air Temp Code - - - MON
55100 A/C Recirc Air Temp Code - - - MON
55200 A/C Mode Data (Monitor) - - - MON
55201 A/C Mode Data (A/C ECU) - - - MON
20260 KOMTRAX Assembly P/N - - - MON
20418 KOMTRAX S/N - - - MON
20261 KOMTRAX Program P/N - - - MON
20273 KOMTRAX Program Version - - - MON
20262 ID Key Controller Assembly P/N - - - MON
20419 ID Key Controller S/N - - - MON
20263 ID Key Controller Program P/N - - - MON
20479 KomVision Controller Ass'y P/N - - - MON
20480 KomVision Controller S/N - - - MON
20481 KomVision Controller Program P/N - - - MON
74200 ICT/S Controller SW Input ON/OFF ON/OFF ON/OFF ICT/S
74300 Boom Cylinder Speed mm/s mm/s in/s ICT/S
74301 Arm Cylinder Speed mm/s mm/s in/s ICT/S
74302 Bucket Cylinder Speed mm/s mm/s in/s ICT/S
76402 Bucket Tilt MS Cylinder Speed mm/s mm/s in/s ICT/S
74400 Boom Cylinder Stroke mm mm in ICT/S
74401 Arm Cylinder Stroke mm mm in ICT/S
74402 Bucket Cylinder Stroke mm mm in ICT/S
76403 Bucket Tilt MS Cylinder Stroke mm mm in ICT/S
74500 Boom Encoder Count Value - - - ICT/S
74501 Arm Encoder Count Value - - - ICT/S
74600 Boom MS Stroke Sensor Volt 1 V V V ICT/S
74601 Boom MS Stroke Sensor Volt 2 V V V ICT/S
74602 Arm MS Stroke Sensor Volt 1 V V V ICT/S
74603 Arm MS Stroke Sensor Volt 2 V V V ICT/S
74604 Bucket MS Stroke Sensor Volt 1 V V V ICT/S
74605 Bucket MS Stroke Sensor Volt 2 V V V ICT/S
76404 Bucket Tilt Stroke Sensor Volt 1 V V V ICT/S
76405 Bucket Tilt Stroke Sensor Volt 2 V V V ICT/S
74606 Bucket MS Reset Sensor Volt V V V ICT/S
30-176 PC210LCI-11
Unit Applicable
compo- Remarks
74800 Machine Pitch Offset Angle deg. deg. deg. ICT/S
74801 Machine Roll Offset Angle deg. deg. deg. ICT/S
74802 Machine Pitch Angle deg. deg. deg. ICT/S
74803 Machine Roll Angle deg. deg. deg. ICT/S
74900 Imu X Angular Speed deg/sec deg/sec deg/sec ICT/S
74901 Imu Y Angular Speed deg/sec deg/sec deg/sec ICT/S
74902 Imu Z Angular Speed deg/sec deg/sec deg/sec ICT/S
74903 Imu X Accel Speed m/sec2 m/sec2 m/sec2 ICT/S
74904 Imu Y Accel Speed m/sec2 m/sec2 m/sec2 ICT/S
74905 Imu Z Accel Speed m/sec2 m/sec2 m/sec2 ICT/S
75000 X31-> ICT/S cont. Startup State - - - ICT/S
75001 ICT/S Con -> X31 Startup Signal - - - ICT/S
75100 Boom Reset Position Count - - - ICT/S
75101 Arm Reset Position Count - - - ICT/S
75102 Bucket Reset Position Count - - - ICT/S
75103 Boom Stroke Reset Count - - - ICT/S
74104 Arm Stroke Reset Count - - - ICT/S
75105 Bucket Stroke Reset Count - - - ICT/S
76406 Bucket Tilt Stroke Reset Count - - - ICT/S
20292 Ass'y Part No. (ICT/S Cont.) - - - ICT/S
20431 Serial No. (ICT/S Cont.) - - - ICT/S
20293 Prog. Part No. (ICT/S Cont.) - - - ICT/S
20298 Prog. Version (ICT/S Cont.) - - - ICT/S
75300 Boom Angle deg. deg. deg. ICT/S
75301 Arm Angle deg. deg. deg. ICT/S
75302 Bucket Angle deg. deg. deg. ICT/S
75400 Swing Angular Speed Offset deg/sec deg/sec deg/sec ICT/S
75500 Tilt Sensor Raw Pitching Angle deg. deg. deg. ICT/S
75501 Tilt Sensor Raw Rolling Angle deg. deg. deg. ICT/S
75502 Bucket Tilt Angle deg. deg. deg. ICT/S
75503 Tilt Sensor Hold Pitching Angle deg. deg. deg. ICT/S
75504 Tilt Sensor Hold Rolling Angle deg. deg. deg. ICT/S
75505 Bucket Tilt Hold Angle deg. deg. deg. ICT/S
76200 Battery Relay Drive ON/OFF ON/OFF ON/OFF ICT/S
02724 Design Surface Up Offset SW ON/OFF ON/OFF ON/OFF ICT/S
02725 Design Surface Down Offset SW ON/OFF ON/OFF ON/OFF ICT/S
75600 Boom RAISE PPC Pressure Sensor 2 MPa kg/cm2 psi W/E
PC210LCI-11 30-177
Unit Applicable
compo- Remarks
75601 Boom RAISE PPC Pressure MPa kg/cm2 psi W/E
75602 Boom LOWER PPC Pressure Sensor 2 MPa kg/cm2 psi W/E
75603 Boom LOWER PPC Pressure MPa kg/cm2 psi W/E
75604 Arm IN PPC Pressure Sensor 2 MPa kg/cm2 psi W/E
75605 Arm IN PPC Pressure MPa kg/cm2 psi W/E
75606 Arm OUT PPC Pressure Sensor 2 MPa kg/cm2 psi W/E
75607 Arm OUT PPC Pressure MPa kg/cm2 psi W/E
75608 Bucket CURL PPC Pressure Sensor2 MPa kg/cm2 psi W/E
75609 Bucket CURL PPC Pressure MPa kg/cm2 psi W/E
75610 Bucket DUMP PPC Pressure Sensor2 MPa kg/cm2 psi W/E
75611 Bucket DUMP PPC Pressure MPa kg/cm2 psi W/E
75700 PPC Source Pressure MPa kg/cm2 psi W/E
09010 Swing Left PPC Pressure MPa kg/cm2 psi W/E
09011 Swing Right PPC Pressure MPa kg/cm2 psi W/E
75800 Boom RAISE Reduce Press EPC Curr mA mA mA W/E
75801 Boom LOWER Reduce Press EPC Curr mA mA mA W/E
75802 Arm IN Reduce Press EPC Current mA mA mA W/E
75803 Arm OUT Reduce Press EPC Current mA mA mA W/E
75804 Bucket CURL Reduce Press EPC Cur mA mA mA W/E
75805 Bucket DUMP Reduce Press EPC Cur mA mA mA W/E
75806 Boom RAISE Intervention EPC Curr mA mA mA W/E
75900 Boom Spool Stroke mm mm in W/E
75901 Arm Spool Stroke mm mm in W/E
75902 Boom Spool Sensor Voltage 1 V V V W/E
75903 Boom Spool Sensor Voltage 2 V V V W/E
75904 Arm Spool Sensor Voltage 1 V V V W/E
75905 Arm Spool Sensor Voltage 2 V V V W/E
76001 EPC Redundance SW ON/OFF ON/OFF ON/OFF W/E
76002 Boom RAISE Interv EPC Cut Relay ON/OFF ON/OFF ON/OFF W/E
76003 Boom RAISE Inter EPC Relay State ON/OFF ON/OFF ON/OFF W/E
Model Selection 1 ON/OFF ON/OFF ON/OFF W/E
W/E Control-
40981 Model Selection 3 ON/OFF ON/OFF ON/OFF W/E
ler SW Input
20244 Ass'y P/N (W/E Controller) - - - W/E
20405 S/N (W/E Controller) - - - W/E
30-178 PC210LCI-11
Unit Applicable
compo- Remarks
20245 Program P/N (W/E Controller) - - - W/E
20299 Program Version (W/E Controller) - - - W/E
76100 Machine Control Mode Change ON/OFF ON/OFF ON/OFF W/E
76101 Machine Control Mode Hold ON/OFF ON/OFF ON/OFF W/E
• Listing order in table

The items are listed in the same order as the display on the monitoring item selection menu screen.
• Unit
The display unit can be set to “SI”, “Metric”, or “Imperial” as required (Select a desired unit from “Unit” of
“Default” in Service Menu).
The display unit, “mg/st”, is an abbreviation for milligram/stroke.
• Applicable component
ENG: The engine controller detects the monitoring information.
KDPF: The engine controller detects the monitoring information of KDPF.
SCR: The engine controller detects the monitoring information of SCR.
PUMP: The pump controller detects the monitoring information.
ICT/S: ICT sensor controller detects the monitoring information.
W/E: The work equipment controller detects monitoring information.
MON: The machine monitor detects the monitoring information.
Note 1: Instantaneous fuel consumption (Code No.: 37300) is the theoretical fuel consumption ratio. (Since it is
a theoretical value, it is slightly different from the actual fuel consumption ratio.)
PC210LCI-11 30-179
ABNORMALITY RECORD MENU

METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYS-
TEMS)
The machine monitor logs the past and currently occurring failures classifying them into the mechanical system
abnormality and electrical system abnormality.
To check the mechanical system abnormality record, perform the following procedures.
For the failure code list, see “Failure code list”for troubleshooting.
1. Select “Abnormality Record” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.
2. On “Abnormality Record ”screen, select “Mechanical Sys

Abnormality Record” with the function switches or numeral
input switches.
REMARK
Input a code (2-digit) with the numeral input switches to di-
rectly select the item, and then press F6 to enter the selec-
tion.
3. On “Mechanical Sys Abnormality Record” screen, the fol-
lowing information is displayed.
a: Occurrence order of abnormalities from latest one/ Total
number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
f: Service meter reading at the last occurrence
F1: Moves the selection to next page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F2: Moves the selection to previous page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F5: Returns the screen to “Abnormality Record” screen.
F6: Display of contents of failure is scrolled from right to left again
30-180 PC210LCI-11
REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• In the mechanical systems abnormality record screen, up to 50 cases currently stored are displayed.
• 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 displayed, thus the above readings may not be the same.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not
confirmed.
• For all of the failure codes that the machine monitor can record, see “Troubleshooting”, “Failure code
list”.
• If the characters in the failure are many, the character strings display is scrolled.
• The contents of an abnormality record of the mechanical system cannot be deleted.
METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS)

The machine monitor logs the failures that occurred in the past and is occurring currently and classifies them
into the mechanical system abnormality and electrical system abnormality.
To check “Electrical Sys Abnormality Record”, perform the following procedures.
For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, “Failure code list”.
1. Select “Abnormality Record” on “Service Menu” screen.
REMARK
2. On “Abnormality Record” screen, select “Electrical Sys Ab-

normality Record” with the function switches or numeral in-
put switches.
F6: Enters the selection.
REMARK
Input a code (2-digit) by using the numeral input switches
to directly select the item, and then press F6 to enter the
selection.
3. On “Electrical Sys Abnormality Record” screen, the follow-
ing information is displayed.
a: Occurrence order of abnormalities from latest one/ Total
number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
PC210LCI-11 30-181
f: Service meter reading at the last occurrence

F1: Moves the selection to next page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F1: Moves the selection to previous page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F5: Returns the screen to “Abnormality Record”screen
F6: Display of contents of failure is scrolled to left again.
REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• In Electrical system abnormality record, up to 20 of stored records are displayed. If the 21st record is
stored, the oldest record will be deleted and the latest 20 records will be displayed.
• 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.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or it has not yet been
normally restored.
• For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, “Failure
code list”.
• If the characters in the failure are many, the character strings display is scrolled.
4. To delete a selected abnormality record, perform the fol-
lowing operation while “Electrical Sys Abnormality Record”
screen is displayed.
1) Switch operation (While pressing 4, press other

switches in order): 4 + 1 → 2 → 3
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.
REMARK
The screen is in deleting mode if “CLEAR” is dis-
played above F2.
F2: Clears all abnormality records.
30-182 PC210LCI-11
F5: Returns the screen to “Abnormality Record screen”.

F6: Clears the selected abnormality record.
REMARK
• To delete a selected abnormality record, select the abnormality record with F3 or F4, and then
press F6 to execute the deletion of abnormality record.
• To clear all abnormality records together, press F2, and then all the records are deleted regardless
of the selection.
• If “E” is displayed on the left of a failure code, the clearing operation is received but the information
is not cleared.
3) After the “Electrical Sys Abnormality Rec Reset” screen is displayed, operate the function switches to
delete all the records.
F5: Returns the screen to “Electrical Sys Abnormality Record” screen (deleting mode).
F6: Executes the deletion
REMARK
• This is the screen when a selected abnormality re-
cord is going to be deleted.
• This is the screen when all the abnormality records

are going to be deleted.
4) When the screen to notify the completion of the deletion is displayed and then “Electrical Sys Abnor-
mality Record” (deleting mode) screen is displayed, the deletion of the selected abnormality record is
completed.
PC210LCI-11 30-183
REMARK
• This is the screen displayed when the deletion of a
selected abnormality record is completed.
• This is the screen displayed when the deletion of

all abnormality records is completed.
METHOD FOR CONFIRMING MAINTENANCE RECORD

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 here.
1. Select “Maintenance Record” on “Service Menu” screen.
2. After “Maintenance Record” screen is displayed, select an

item to be checked with the function switches or numeral
input switches.
F1: Moves the selection to next page (screen).
F2: Moves the selection to previous page (screen).
30-184 PC210LCI-11
REMARK
You may enter a 2-digit code by using the numeral input switches to select the item of that code.
The following items can be selected on Maintenance Record.

Code Item
49 Air Cleaner Clean and Change
60 Coolant Change
68 Additional Hyd Oil Filter Change
30 Hydraulic Oil Pilot Filter Change
41 Fuel Prefilter Change
01 Engine Oil Change
02 Engine Oil Filter Change
05 Hydraulic Tank Breather Change
03 Fuel Main Filter Change
04 Hydraulic Oil Filter Change
07 Damper Case Oil Check/Refilling
09 Swing Machinery Case Oil Change
59 AdBlue/DEF Tank Breather Change
08 Final Drive Case Oil Change Interval
47 KCCV Filter Change
58 AdBlue/DEF Filter Change
48 KDPF Filter Change
67 AdBlue/DEF Tank Washing
10 Hydraulic Oil Change
Items displayed on Maintenance Record screen
a: Maintenance items
b: Number of replacements up to now
c: Service meter reading (SMR) at the last replacement
METHOD FOR OPERATING MAINTENANCE MODE SETTING

Following can be changed from the menu screen. Enable or disable the function of maintenance items and set
the replacement interval of maintenance items.
• Enable or disable the function of maintenance items.
• To change the replacement interval setting of maintenance items (by item).
• To initialize all of the replacement interval setting of maintenance items.
PC210LCI-11 30-185
1. Select “Maintenance Mode Setting” on “Service Menu”

screen.
2. On “Maintenance Mode Setting” screen, select an item to

be changed with the function switches or numeral input
switches.
F1: Moves the selection to next page (screen)
F2: Returns the screen to previous page (screen)
F5: Returns the screen to Service Menu screen
REMARK
Input a code (2-digit) with the numeral input switches to directly select the item.
The following items can be selected on "Maintenance Mode Setting" screen.

Code Item
00 Maintenance Mode Change
49 Air Cleaner Cleaning or Change Interval
60 Coolant Change Interval
68 Additional Hydraulic Oil Filter Change Interval
30 Hydraulic Oil Pilot Filter Change Interval
41 Fuel PreFilter Change Interval
01 Engine Oil Change Interval
02 Engine Oil Filter Change Interval
05 Hydraulic Oil Tank Breather Change Interval
03 Fuel Main Filter Change Interval
04 Hydraulic Oil Filter Change Interval
07 Damper Case Oil Check or Refilling Interval
09 Swing Machinery Case Oil Change Interval
08 Final Drive Case Oil Change Interval
10 Hydraulic Oil Change Interval
99 All Default Value
30-186 PC210LCI-11
3. Select “Maintenance Mode Change”. When the screen is

displayed, turn "ON" or "OFF" the maintenance mode with
function switch and enter.
ON: Functions of all maintenance items become effective
in operator mode
OFF: Functions of all maintenance items become ineffec-
tive in operator mode
F5: Cancels the selection and returns the screen to “Main-
tenance Mode Change” screen.
F6: Enters the selection and returns the screen to “Maintenance Mode Change” screen.
REMARK
Even if ON/OFF of each item has been set, if the above setting is changed, it overrides the individual set-
ting.
4. Select “Maintenance Notice Time Setting” and when
“Maintenance Notice Time Setting” screen is displayed,
perform the setting with the function switches.
Default value: Maintenance notice time set on the machine
monitor (Recommended by the manufacturer and not
changeable).
Set value: Maintenance time that can be freely set. Mainte-
nance reminder function works according to this set time
in operator mode (the time increases or decreases in
multiples of 10 hours).
F3: Decreases the set value
F4: Increases the set value
“Maintenance Mode Setting” screen
F6: Enters the setting and returns the screen to “Mainte-
nance Mode Change” screen
REMARK
• The setting becomes effective after you enter it with F6
and return the screen to “Maintenance Mode Setting”.
• If the value of an item which is set to “ON” is changed
after one operating hour or more from the setup, the
change is recognized as a reset operation.
5. Select one of each maintenance item and when the each
maintenance item screen is displayed, select “On or Off
Setting”.
F5: Cancels the selection and returns the screen to “Main-
tenance Mode Change” screen.
F6: Enter the selection and proceed to “ON” or “OFF” set-
ting of each maintenance item.
REMARK
• Displayed screen is an example of “Engine Oil Change
Interval”.
PC210LCI-11 30-187
6. When each maintenance item screen is displayed, select

“ON” or “OFF” with function switches.
“ON”: Function of the particular maintenance item be-
comes effective in “operator mode”.
“OFF”: Function of the particular maintenance item be-
comes ineffective in “operator mode”.
F5: Cancels the selection and returns the screen to each
maintenance item screen.
F6: Enters the setting and returns the screen to each
maintenance item screen.
7. Select “Set” of each maintenance item. When the screen
of each maintenance item is displayed, perform the setting
with the function switches.
Default value: Maintenance notice time set on the machine
monitor (Recommended by the manufacturer and not
changeable).
Set value: Maintenance time that can be freely set. Mainte-
nance reminder function works according to this set time
in operator mode (the time increases or decreases in
multiples of 25 hours).
F5: Cancels the set value and returns the screen to Main-
tenance Mode Change screen.
F6: Enters the set value and returns the screen to Mainte-
nance Mode Change screen.
REMARK
• The setting becomes effective after you enter it with F6
and return the screen to “Maintenance Mode Setting”.
• If the value of an item which is set to “ON” is changed
after one operating hour or more from the setup, the
change is recognized as a reset operation.
30-188 PC210LCI-11
8. The screen is shifted by selecting “All Default Value”, per-

form the setting with the function switches.
If the operation for this function is executed, the set values
of all the maintenance items return to the default values.
F5: Returns the screen to “Maintenance Mode Setting”
screen.
F6: Executes initialization.
REMARK
Press F6, and the initialization completion screen is dis-
played after a short while. “Maintenance Mode Setting”
screen is displayed after that, and initialization is complet-
ed.
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING

The telephone number can be displayed together with “Current Abnormality” in the operator mode. Phone num-
ber can be registered and changed according to the following procedure.
Phone number must be registered in order to display the number while in operator mode.
1. Select “Phone Number Entry” from the “Service Menu”
screen.
REMARK
PC210LCI-11 30-189
2. On “Phone Number Entry” screen, register/correct the

phone number with the function switches or numeral input
switches.
F2: Deletes all the numbers.
F3: Moves the input position to the next left place (if not
blank).
F4: Moves the input position to the right (if not blank)
F5: Returns the display to the “Service Menu” screen
F6: Enters the input.
REMARK
• Up to 14 digits can be inputted from the left. Leave the
surplus places without inputting any digit.
• If an inputted numeral is wrong, move the cursor (or-
ange background) to that digit and overwrite it with the
correct numeral.
• No telephone number is displayed in the operator
mode when F6 is pressed without inputting any digit,
since there is no information of telephone number for it.
30-190 PC210LCI-11
DEFAULT MENU
METHOD FOR SETTING DEFAULT (KEY-ON MODE)
Default menu is used to check or change default values of the machine monitor and machine.
Use “Key-on Mode” to set the working mode selected and displayed on the machine monitor when the starting
switch is turned to ON position.
1. Select “Default” on “Service Menu” screen.
2. On“Default” “Abnormality Record ”screen, select “Key-on

Mode” with the function switches or numeral input
switches.
REMARK
Selecting method is the same as on “Service Menu”
screen.
3. After “Key-on Mode” screen is displayed, select the mode

to be set by using the function switches.
F5: Cancels the selection and returns the screen to “De-
fault” screen.
F6: Enters the selection and returns the screen to “Default”
screen.
“Power mode”: “P” is displayed when the starting switch is
set to ON position
“Economy mode”: “E” is displayed when the starting switch
is set to ON position
“Lifting Operation Mode”: “L” is displayed when 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 ON position.
“Attachment/E-mode”: “ATT/E” is displayed when the starting switch is set to ON position.
“Mode at Previous Key-off”: Final mode in previous operation is displayed when the starting switch is turned
to ON position.
PC210LCI-11 30-191
REMARK
• Factory default is, Mode at “Previous Key-off”.
• If “With Attachment” is not selected, selection of the “Attachment/P-Mode” and “Attachment/E-mode” is
disabled.
• If you change the setting to “Without attachment” when “Attachment/P-mode” or “Attachment/E-mode” is
selected, Power mode P is displayed when the starting switch is turned to ON position.
• If the engine is stopped with the working mode set to “breaker mode” in the operator mode, “Breaker
Mode” (“B”) is always displayed when the starting switch is turned to ON position, regardless of the
above setting.
METHOD FOR SETTING DEFAULT (UNIT)

The unit selecting function is used to select the unit of the data to be displayed in monitoring, etc.
2. On “Default”screen, select “Unit” with the function switches

REMARK
screen.
3. After “Unit” screen is displayed, select the display unit to

be set by using the function switches.
fault” screen.
screen.
REMARK
Factory default is “SI Unit”.
METHOD FOR SETTING DEFAULT (WITH/WITHOUT ATTACHMENT)

Use the sub menu of “With/Without Attachment” to configure attachment setting when the attachment is instal-
led or removed.
30-192 PC210LCI-11
2. On “Default”screen, select “With/Without Attachment” with

REMARK
screen.
3. After “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 installed
fault” screen.
F6: Enters the selection and returns the screen the screen
to “Default” screen.
REMARK
When an attachment is installed, if this setting is not configured correctly, the attachment setting in the oper-
ator mode cannot be performed. As a result, the attachment may not work normally or the hydraulic compo-
nents may be damaged.
METHOD FOR SETTING DEFAULT (CAMERA)

Camera setting is for setting of camera when the camera is installed or removed.
PC210LCI-11 30-193
2. On “Default”screen, select “Camera” with the function

switches or numeral input switches.
REMARK
screen.
3. After “Camera” screen is displayed, select a setting by us-

ing the function switch.
“Not Use”: Camera is not used
“Use”: Images from connected camera are displayed as a
normal image (mirror images if it is used for rearview
monitor).
Я: Reverse images (mirror images if it is used for rear view
monitor) are displayed.
R: Normal images (visual images if it is used for front or
side monitor) are displayed.
F5: Cancels contents of setting before entry and returns
the screen to “Default” screen.
F6: Enters the selection in each line.
30-194 PC210LCI-11
REMARK
• By the settings as shown in the figure, movement of a
person or object can be displayed continuously in the
monitor just like using the rearview mirror up to the
R.H. of the machine body.
• When setting the camera 2 to “R”, the R.H. of the ma-

chine body can be displayed just like a visual image.
• If 2 or more cameras are connected, be sure to set the
use of them from camera 1 in order.
• The simultaneous display function of 2 images be-
comes effective when camera 1 and camera 2 are set
for use.
• You cannot switch camera 1 between “Я” and “R”.
• Enter the selection in each line with F6, and return to
“Default” screen with F5, and then your setting is vali-
dated.
• Unless setting is normally set with this function when
the camera is connected, the graphic mark of camera
is not displayed at F3 in the operator mode. According-
ly, the image of the camera cannot be used.
• When the camera is installed, check that the right and
left portions of the displayed image are correct.
METHOD FOR OPERATING TESTING MENU (AUTO IDLE STOP TIME FIXING)
Auto Idle Stop Time Fixing function is used to set the time which is selectable with Auto Idle Stop Time Setting
in the operator mode.
PC210LCI-11 30-195
2. On “Default”screen, select “Auto Idle Stop Time Fixing”

with the function switches or numeral input switches.
3. After “Auto Idle Stop Time Fixing” screen is displayed, se-

Variable: Selection from OFF to 60 minutes is available.
OFF: Auto Idle Stop function is not used.
X-minute fixing: OFF or, longer time than the selected time
is not available.
F5: Cancels contents of setting before entry and returns
the screen to “Default” screen.
F6: Enters the selection and returns the screen to “Default” screen.
REMARK
When this setting is “OFF”, Auto Idle Stop does not operate. Auto Idle Stop Time Setting in the operator
mode is disabled.
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT

QUICK COUPLER)
You can set the operation with or without the quick coupler according to the procedures in this section.
30-196 PC210LCI-11
2. On “Default”screen, select “With/Without Quick Coupler”

REMARK
screen.
3. After “With/Without Quick Coupler” screen is displayed, se-

Without Quick Coupler: Quick coupler is not installed.
With Quick Coupler: Quick coupler is installed.
F5: Returns the screen to “Default” screen.
screen.
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT Kom-

Vision)
NOTICE
Change the settings of KomVision after the installation, otherwise the setting mismatch error (“L01”) oc-
curs.
“With/Without KomVision” function enables or disables KomVison function depending on whether KomVision
system is installed or not.
PC210LCI-11 30-197
1. Select “Default” from the “Service Menu” screen.

REMARK
2. On the “Default” screen, select “With/Without KomVision”

with function switches or numeral input switches.
REMARK
3. On the “With/Without KomVision” screen, select a setting

with the function switch.
“Without KomVision”: When KomVison is not installed
“With KomVision”: When KomVison is installed
F3: Moves down the selected item
F4: Moves up the selected item
fault” screen
F6: Enters the selected item and returns the screen to “De-
fault” screen
REMARK
The KomVision screen can be displayed by changing the setting and performing the calibration.
30-198 PC210LCI-11
DIAGNOSTIC TESTS MENU

METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)
Testing menu checks the machine or resets the settings of the machine monitor.
Cylinder cutout mode operation means to run the engine with one or more fuel injectors disabled electrically to
reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power
normally (combustion in it is abnormal).
1. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
2. On the “Diagnostic Tests” screen, select “Cylinder Cutout

Mode Operation” with function switches or numeral input
switches.
REMARK
3. On the “Cylinder Cutout Mode Operation” screen, select

the cylinders and disable them with the function switches.
F1: Moves the selected item leftward
F2: Moves the selected item rightward
F4: Selects HOLD or releasing HOLD. (When HOLD is se-
lected, “HOLD” part is hatched.)
F5: Returns to the “Diagnostic Tests” screen
REMARK
• This operation can be performed while the engine is
running.
• If background (a) of the selected cylinder number be-
comes white after you press F6, the cylinder is cutout.
• If the machine monitor cuts out a cylinder but the en-
gine controller cannot cutout that cylinder, the back-
ground (a) of the cylinder number becomes yellow.
• One or more cylinders can be cutout.
• Auto-deceleration function can be selected in the cylin-
der cutout mode operation. When turning auto-deceler-
ation ON, auto-deceleration monitor (b) is displayed.
4. When changing a cylinder to be cutout or when cylinder cutout operation is finished, select a cutout cylinder
to be reset with the function switches.
PC210LCI-11 30-199
NOTICE
The cutout cylinder mode operation is not automatically released after the screen returns to the op-
erator mode. Accordingly, be sure to perform the releasing operation after the cylinder cutout mode
operation is finished.
REMARK
• This operation can be performed while the engine is running.
• When F6 is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset.
• If the machine monitor releases a cutout cylinder but the engine controller cannot release the cutout cyl-
inder, the background (a) of the cylinder number becomes red.
5. Each time F4 is pressed during the cylinder cutout opera-
tion, the displayed data is newly held (c) (the real-time da-
ta is kept displayed on the left side).
• Hold function can be unlocked by pressing F4 while
hold is turned on.
• The holding function is available for a cylinder regard-
less of whether it is cutout or not.
If a normally operating cylinder is cutout, the following phe-
nomena occur.
• Decrease in engine speed
• Increase in injection rate command
However, if the engine is running at around high idle, the engine speed may not decrease for the reason of
engine control. In this case, lower the engine speed with the fuel control dial and judge by increase of the
injection rate command.
METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)

Testing menu is used to check the machine or to reset the settings of machine monitor.
Active regeneration for service refers to the method of burning soot by performing aftertreatment devices regen-
eration, regardless of the soot accumulation.
1. Select “Diagnostic Tests” on “Service Menu” screen.
2. On “Diagnostic Tests”screen, select “Active Regeneration

for Service” with the function switches or numeral input
switches.
• Selecting method is the same as on “Service Menu”
screen.
• While the aftertreatment devices regeneration state is
in the manual stationary regeneration or stopped, “Ac-
tive Regeneration for Service” cannot be selected.
30-200 PC210LCI-11
3. When “Active Regeneration for Service” screen is dis-

played, the following information is displayed correspond-
ing to the aftertreatment devices regeneration condition.
Set the aftertreatment devices regeneration according to
the given messages.
a: Soot accumulation level
b: Regenerating condition of aftertreatment devices
c: Selectable items
d: Message
1) Select “Manual Stationary Regeneration” on “Active

Regeneration for Service” screen.
F5: Returns the screen to check screen.
F6: Executes manual stationary regeneration.
REMARK
• The screen changes to “Monitoring Selection
Menu” screen which enables monitoring of ma-
chine information during active regeneration by
performing the following switch operation during
Active Regeneration for Service.
• Switch operation (While pressing 4, press other
switches in order): 4 + 1 → 2 → 3
Press F6 on “Monitoring” screen to return the
screen to “Active Regeneration for Service”
screen.
• For the monitoring operation, see “Monitoring” of
“SETTING AND OPERATION OF MACHINE MONITOR”.
• Active Regeneration for Service can be performed only when the lock lever is in LOCK position and
the fuel control dial is in the MIN (Low idle) position.
• When performing "Manual Stationary Regeneration", secure full safety around the machine and
check that there is not a person or combustible around the machine. If it is required to move the
machine again for safety, move the machine to a safe place, and start the operation again.
• “Active Regeneration for Service” stops automatically 40 minutes later. However, if the regeneration
has been started after the soot accumulation reaches 4 g/ℓ and above, regeneration continues until
the soot accumulation decreases to 1.89 g/ℓ and below. In this case, it may continue over 40 mi-
nutes. .
2) After Active Regeneration for Service is complete,
“Regeneration completed” is displayed on the screen.
PC210LCI-11 30-201
REMARK
If F6 is pressed during the manual stationary regener-
ation, “Stop manual stationary regeneration?” is dis-
played on the screen. You can stop the regeneration
by pressing F6.
• F5: Does not stop regeneration (manual station-
ary regeneration is continued)
• F6: Stops regeneration.
METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)

Use the testing menu to check the machine or to reset the settings of machine monitor.
“KDPF Memory Reset” resets KDPF information saved in the machine. Refer to this section and reset KDPF
information after cleaning or replacing KDOC, and cleaning or replacing KCSF.
REMARK
2. On the “Diagnostic Tests” screen, select “KDPF Memory

Reset” with function switches or numeral input switches.
REMARK
3. On “KDPF Memory Reset” screen, select an item to be re-

set.
F3: Moves the selected item down by one item
F4: Moves the selected item up by one item
• Perform both “KDPF Cleaning” reset and “KDPF
Change” reset after cleaning or replacing KCSF.
• After cleaning or replacing KDOC, perform “KDOC
Change”.
REMARK
Perform the applicable operation. For details, see TROUBLESHOOTING, “PRECAUTIONS FOR CLEAN-
ING AND REPLACING KDPF (KCSF and KDOC)”.
30-202 PC210LCI-11
4. After “Do you want to reset?” is displayed, enter the reset

with the function switch.
F5: Returns the screen to previous screen
F6: Executes resetting
When the memory has been reset successfully, “Reset
completed.” appears on the screen. If an error occurs
while resetting the memory, “Reset failed.” appears on the
screen.
METHOD FOR OPERATING TESTING MENU (MS CYLINDER FUNCTION CHECK)

Testing menu checks the machine or resets the settings of the machine monitor.
For “Checking method of check menu (MS Cylinder function check)”, see “Calibrating work equipment cylinder”.
“MS Cylinder function check” verifies whether MS cylinder calibration has been successfully completed. Refer to
this item.
METHOD FOR OPERATING TESTING MENU (MS CYLINDER FUNCTION CHECK:

Bucket Tilt MS Cylinder)
“MS Cylinder function check: Tilt” verifies whether MS cylinder calibration for auto-tilt bucket has been success-
fully completed.
1. Select “Diagnostic Tests” on “Service Menu” screen.
REMARK
For how to select, see “Operating method of service mode”
in “SERVICE MODE”.
2. Select “MS Cylinder function check” with the function

switches or numeral input switches on “Diagnostic Tests”
screen.
REMARK
PC210LCI-11 30-203
3. On “MS Cylinder function check” screen, select “Bucket Tilt

MS Cylinder” with function switches or numeral input
switches.
F5: Screen returns to the “Diagnostic Tests” screen
4. On “MS Cylinder function check : Tilt” screen, operate the

proportional control lever of the work equipment control
lever in counterclockwise direction to the stroke end posi-
tion.
REMARK
Progress bar (a) is displayed. Perform testing as checking
the progress bar (a).
5. Operate the proportional control lever of the work equip-
ment control lever in clockwise direction to the stroke end
position.
REMARK
• It “beeps” when the stroke sensor of the progress bar (a) senses the MAX (c).
• If the progress bar (a) does not move, check it since there may be an abnormality.
6. Write down the compensation value (b) obtained when the stroke sensor reaches MAX (c).
7. Operate the proportional control lever of the work equipment control lever in counterclockwise direction to
the stroke end position.
REMARK
• It “beeps” when the stroke sensor of the progress bar (a) senses the MIN (e).
• If the progress bar (a) does not move, check it since there may be an abnormality.
8. Write down the compensation value (e) obtained when the stroke sensor reaches MIN (e), then compare
the value with the standard value.
9. Compare the compensation values (b) and (d) which have been written down with the standard value.
• For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR MACHINE”.
• If the compensation values (c) and (d)is out of range, perform the testing again after performing the
auto-tilt bucket replacing calibration by referring to “Auto-tilt bucket”, “Operation and Maintenance Man-
ual” for this machine.
METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)

In case of failure of devices related to SCR, you can select the test items according to the procedures in this
section.
30-204 PC210LCI-11

REMARK
2. On the “Diagnostic Tests” screen, select “SCR Service

Test” with function switches or numeral input switches.
REMARK
3. Select the test on “SCR Service Test”.

REMARK
You may enter a 2-digit code by using numeral input
switches to directly select the item.
The selectable items are indicated in “SCR Service Test
Table”.
SCR Service Test Table

Code Content
01 AdBlue/DEF Pump Pressure Up Test
02 AdBlue/DEF Injection Quantity Test
03 AdBlue/DEF Line Heater Relay 1 Test
04 AdBlue/DEF Line Heater Relay 2 Test
05 AdBlue/DEF Pump Heater Relay Test
06 AdBlue/DEF Tank Heater Valve Test
07 SCR Denitration Efficiency Test
To check the items listed in “SCR Service Test Table”, see the section “TEST SCR RELATED FUNCTIONS”.
METHOD FOR OPERATING TESTING MENU (ENGINE CONTROLLER ACTIVE

FAULT CLEAR)
The engine controller detects the occurred in-range error. Failure codes related to occurred error can be cleared
on the machine monitor.
PC210LCI-11 30-205
The failure codes listed in “FAILURE CODES TABLE” of TROUBLESHOOTING, “PROCEDURE FOR TROU-
BLESHOOTING” cannot be cleared by “Engine Controller Active Fault Clear”.
REMARK
2. On the “Diagnostic Tests” screen, select “Engine Controller

Active Fault Clear” with function switches or numeral input
switches.
REMARK
3. On the “Engine Controller Active Fault Clear” screen, se-

lect an item to be set by using the function switches.
F6: Clears the failure code
METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULATION

CORRECTION)
You can correct the ash accumulation quantity in the soot accumulation according to the procedures in this sec-
tion.
REMARK
30-206 PC210LCI-11
2. On the “Diagnostic Tests” screen, select “Ash in Soot Ac-

cumulation Correction” with function switches or numeral
input switches.
REMARK
3. Start the engine, and turn the fuel control dial to MIN (Low
idle) position.
4. Check that “0” in the “Test State” column is flashing.

When “0” is flashing, you can perform the test.
For the display of “Test State”, see the section “TEST SCR
RELATED FUNCTIONS”.
5. Start the calibration process by pressing F1.

REMARK
• The display of “Test State” changes to flashing of “Ash
in Soot Accumulation Correction”.
• “Ash in Soot Accumulation Correction” is completed in
approximately 2 hours.
6. When “20” in “Test State” column starts flashing, turn the

starting switch to OFF position.
REMARK
By turning the starting switch to OFF once, the correction
value is written in the engine controller.
METHOD FOR OPERATING TESTING MENU (RESET NUMBER OF ABRUPT EN-

GINE STOP BY AIS)
“Reset Number of Abrupt Engine Stop by AIS” function resets the counter of high engine speed which activates
the auto idle stop function. Use this function when VGT is replaced.
PC210LCI-11 30-207

REMARK
2. On the “Diagnostic Tests” screen, select “Reset Number of

Abrupt Engine Stop by AIS” with function switches or nu-
meral input switches.
REMARK
3. On the “Reset Number of Abrupt Engine Stop by AIS”

screen, select a setting with the function switch.
REMARK
Rest the number of abrupt stop after the turbocharger is
replaced.
METHOD FOR OPERATING TESTING MENU (ENGINE STOP AdBlue/DEF INJ

OVERHEAT COUNT RESET)
NOTICE
When performing this item, see TROUBLESHOOTING, Failure code [AS10NT] “AdBlue/DEF Injector
Overheat Caution” or Failure code [AS10KM] “AdBlue/DEF Injector Overheat Warning”, and instruct an
operator about operation.
This function is used to reset the number saved in the machine, the number which engine stop performed when
the temperature of exhaust gas and coolant is high.
Perform “Engine Stop at AdBlue/DEF Inj Overheat Count Reset” by referring to the procedures in this section.
30-208 PC210LCI-11

REMARK
2. Enter “95” with numeral input switches after the “Diagnos-

tic Tests” screen is displayed, and press F6.
REMARK
3. On the “Engine Stop at AdBlue/DEF Inj Overheat Count

Reset” screen, select an item to be set by using the func-
tion switches.
4. Execute the reset, then press F6. The screen returns to

“Diagnostic Tests”.
PC210LCI-11 30-209
ADJUSTMENT MENU
METHOD FOR ADJUSTING (Pump Absorption Torque (F))
Adjustment menu is used to check the various settings of the machine or to adjust the value.
The “Pump Absorption Torque (F)” finely adjusts the absorption torque of the main pump.
1. Select “Adjustment” on the “Service Menu” screen.
REMARK
2. On the “Adjustment” screen, select “Pump Absorption Tor-

que (F)” with function switches or numeral input switches.
REMARK
3. After the “Pump Absorption Torque (F)” screen is dis-

played, change the value on the right side by using the
function switches.
Set value: For the actual torque adjustment value, see the
table of relationship between set value and torque ad-
justment value.
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.
30-210 PC210LCI-11
A relation as a table (set value and torque adjustment value)

Code Set value Torque adjustment 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}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}
METHOD FOR ADJUSTING (Pump Absorption Torque (R))

Adjustment menu is used to check the various settings of the machine or to adjust those value.
Function of Pump Absorption Torque is used to finely adjust the absorption torque of the main pump.
1. Select “Adjustment” on “Service Menu” screen.
2. On “Adjustment” screen, select “Pump Absorption Torque

(R)” by using function switches or numeral input switches.
REMARK
Method of selecting is similar to “Service Menu” screen.
3. After the “Pump Absorption Torque (R)” screen is dis-

played, select the desired value at the right side by using
the function switches.
For torque adjustment value, see table.
F3: Decreases set value
F4: Increases set value
screen.
REMARK
PC210LCI-11 30-211
Relation between set value and torque adjustment value

Code Set Value Torque adjustment 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}
022 004 0 Nm{0 kgm}
005 -9.8 Nm{-1 kgm}
006 -19.6 Nm{-2 kgm}
007 -29.4 Nm{-3 kgm}
008 -39.2 Nm{-4 kgm}
METHOD FOR ADJUSTING (Low Speed)

Setting function of Travel Low Speed is used to finely adjust the speed at the travel Low speed.
2. On “Adjustment”screen, select “Travel Low Speed” with

REMARK
screen.
3. After “Travel Low Speed” screen is displayed, select the

desired value at the right side by using the function
switches.
For travel Low speed value, see table.
F6: Checks and enters setting. Returns the screen to “Ad-
justment” screen.
REMARK
30-212 PC210LCI-11
Relationship between set value and travel Low speed value

Code Set Value Travel Low speed value
000 3.0 km/h
001 2.8 km/h
020
002 3.2 km/h
003 3.4 km/h
METHOD FOR ADJUSTING (Attachment Flow Adjustment)

Adjusting function of Attachment Flow Adjustment is used to finely adjust the oil flow rate to the attachment in
combined operations.
2. On “Adjustment”screen, select “Att Flow Adjust in Com-

bined Ope” with the function switches or numeral input
switches.
REMARK
Selecting method is the same as on the “Service Menu”
screen.
3. After the “Attachment Flow Adjustment” screen is dis-

played, select the desired value at the right side by using
For distribution of oil flow, see table.
F6: Checks and enters setting. Returns the screen to “Ad-
justment” screen.
REMARK
PC210LCI-11 30-213
Relationship between set value and distribution of oil flow to attachment

Code Set Value Distribution of flow to attachment
000 50 %
001 70 %
037
002 100 %
003 40 %
METHOD FOR ADJUSTING (CAL F pump swash plate sensor)

The F pump swash plate sensor calibration 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/installed or
replaced with new one.
The pump swash plate sensor needs to be calibrated in the following cases.
Calibrating front pump Calibrating rear pump
swash plate sensor swash plate sensor
Removing, installing and replacing front side swash plate
Required -
sensor
Removing, installing and replacing rear side swash plate
- Required
sensor
Replacing main pump assembly Required Required
Replacing pump controller Required Required
Adjusting or disassembling front pump PC valve Required -
Adjusting or disassembling rear pump PC valve - Required
REMARK
Test the pump swash plate sensor to check that the pump swash plate sensor is normal, and then perform the
calibration of the pump swash plate sensor.
A rough flow of calibration of the pump swash plate sensor is
as follows. (Adjustment menu in Service Menu)
Before starting calibration, set the machine under the following
condition.
Working mode: P (“Power Mode”)
Travel speed: Hi
30-214 PC210LCI-11
2. On “Adjustment” screen, select “Calibrate F Pump Swash

Plate Sensor” by using function switches or numeral input
switches.
REMARK
3. After “Cal F pump swash plate sensor max” is displayed,

calibrate the front pump swash plate sensor for the maxi-
mum angle by running track idle off the ground and operat-
ing the function switches.
F1: Starts calibration
F2: Initializes calibration value
F5: Returns the screen to “Adjustment” screen.
F6: Confirms setting
4. Raise the left track off the ground by using the work equip-
ment and move the left travel lever to the stroke end to run
the left track idle off the ground.
Fuel control dial: MAX (High idle) position
L.H. travel lever: Full stroke (Both forward and reverse
travel may be set.)
Swing lock switch may be set in either ON or OFF.
k Provide enough work space to run the raised track
idle off the ground for testing.
k Run the raised track idle, paying enough attention
to the surroundings for safety.
5. When running speed of the track idle off the ground be-
comes steady, hold down button [F1] of machine monitor
to start the calibration. The state of process is displayed as
a bar on the screen during calibration, so keep running the
track idle off the ground until the end of calibration.
PC210LCI-11 30-215
6. When calibration is finished successfully, “OK” is displayed

for the State of Adjustment to show that calibration for the
maximum angle is completed. Press F6 to go to calibration
for the minimum angle.
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 repeat calibration.
7. After “Calibrate F Pump Swash Plate Sens Min” screen is

displayed, calibrate the front pump swash plate sensor for
the minimum angle by running track idle off the ground and
operating the function switches.
F2: Initializes calibration value
F5: Returns the screen to “Adjustment” screen.
F6: Confirms setting
8. Wait under the following conditions.
Neutral position of each control lever and control pedal
Fuel control dial may be at any position.
9. Hold down F1 of the machine monitor to start calibration.
The state of process is displayed as a bar on the screen
during calibration. Keep all control levers in NEUTRAL po-
sition until the calibration is finished.
10. When calibration is finished successfully, "OK" is displayed

for the State of Adjustment to show that calibration for the
minimum angle is completed. Press F6 and return the
screen to “Adjustment” screen.
30-216 PC210LCI-11
If calibration is finished unsuccessfully, "NG" is displayed

find out and remove the cause and repeat calibration for
the minimum angle by pressing F6.
REMARK
The calibration value can be initialized by holding down
“CLEAR” button F2. After the setting is initialized, state of
adjustment screen turns to “READY”.
Table 1. Failure cause codes (Displayed in descending order of priority)

Object
Cause MIN MAX

swash swash Pump IT Content Required action
code
plate cali- plate cali- calibration
bration bration
A-1 ● ● ● Engine speed signal is 0 rpm Check that engine is started
Check hydraulic oil temperature
A-2 ● ● ● Hydraulic oil temperature is low.
(Min. 45 °C).
Check hydraulic oil temperature.
(Calibration of swash plate: Max.
A-3 ● ● ● Hydraulic oil temperature is high.
85 °C, Calibration of pump: Max.
55 °C)
A-4 ● ● ● Overheating Check for overheating.
Pump pressure sensor (F, R) is Perform troubleshooting for pump
A-6 ● ● ●
defective. pressure sensor.
Pump swash plate (F, R) sensor Perform troubleshooting for pump
A-7 ● ● -
is defective swash plate sensor
Arm IN PPC pressure sensor is Perform troubleshooting for Arm
A-8 - - ●
defective. IN PPC pressure sensor
Perform troubleshooting for PC-
A-9 - - ● PC-EPC abnormality
EPC
CAN communication is defective
A-A - - ● Perform troubleshooting for CAN
(engine, monitor, pump)
Bucket CURL PPC pressure sen- Perform troubleshooting for buck-
A-B - - ●
sor is defective et CURL PPC pressure sensor
Pump pressure of calibrated Perform troubleshooting for relief
B-1 ● - -
pump is above standard value valve and pump
B-3 ● - - Lever is not in NEUTRAL Set lever in NEUTRAL
Pump pressure of calibrated Perform troubleshooting for relief
C-1 - ● -
pump is below standard value valve and pump
C-2 - ● - Travel speed setting is not Hi Set travel speed to Hi on monitor
Fuel control dial is not set to MAX Set fuel control dial to Max posi-
C-3 - ● ●
position tion
Set travel lever to full stroke and
Travel is not operated independ-
C-4 - ● - work equipment control lever to
ently
neutral
PC210LCI-11 30-217
Object
Cause MIN MAX

swash swash Pump IT Content Required action
code
plate cali- plate cali- calibration
bration bration
Check the service adjustment
C-5 - ● - Pump is not divided (normally divided during inde-
pendent travel operation)
Travel PPC pressure sensor is Perform troubleshooting for travel
C-6 - ● -
defective PPC
Travel PPC pressure is below
C-7 - ● - Set travel lever to full stroke
standard value
When arm IN is relieved, arm IN
PPC pressure is below specified
E-1 - - ● value or arm IN PPC pressure Set arm IN lever to full stroke
sensor is out of the normal range
(*1)
Pump pressure (F, R) is out of Perform troubleshooting for relief
E-2 - - ●
standard range valve and pump
Engine speed is out of standard
E-3 - - ● Run the engine at low idle
range
Engine torque is out of standard Perform troubleshooting for en-
E-4 - - ●
range gine and pump
PC-EPC current is out of stand- Perform troubleshooting for PC-
E-5 - - ●
ard range EPC current
When bucket CURL is relieved,
bucket CURL PPC pressure is
Set bucket CURL lever to full
E-6 - - ● below specified value or bucket
stroke
CURL PPC pressure is within the
normal range (*1)
Working mode is not set to P or
E-7 - - ● Set working mode to P or ATT/P
ATT/P
Set air conditioner to OFF posi-
E-A - - ● Air conditioner is ON
tion
Output voltage of pump swash
Perform troubleshooting for
FF ● ● - plate sensor is out of calibration
swash plate sensor
range
Aftertreatment devices regenera- Aftertreatment devices regenera-
G-1 - - ●
tion is in progress tion is complete
Perform troubleshooting for cool-
G-2 - - ● Abnormality in cooling fan control
ing fan
*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]).
METHOD FOR ADJUSTING (CAL R pump swash plate sensor)

The R pump swash plate sensor calibration is used to calibrate the sensor installed on the actual machine to
eliminate deviation of the sensor signal made when the rear pump swash plate sensor is removed/installed or
replaced with new one.
The pump swash plate sensor needs to be calibrated in the following cases.
30-218 PC210LCI-11
Calibrating front pump Calibrating rear pump

swash plate sensor swash plate sensor
Removing, installing and replacing front side swash plate
Required -
sensor
Removing, installing and replacing rear side swash plate
- Required
sensor
Replacing main pump assembly Required Required
Replacing pump controller Required Required
Adjusting or disassembling front pump PC valve Required -
Adjusting or disassembling rear pump PC valve - Required
REMARK
Test the pump swash plate sensor to check that the pump swash plate sensor is normal, and then perform the
calibration of the pump swash plate sensor.
A rough flow of calibration of the pump swash plate sensor is
as follows. (Adjustment menu in Service Menu)
condition.
Travel speed: Hi
PC210LCI-11 30-219
2. On “Adjustment” screen, select “Calibrate R Pump Swash

Plate Sensor” by using function switches or numeral input
switches.
REMARK
3. Perform the subsequent calibration procedure according to
“Calibrate F Pump Swash Plate Sensor”.
METHOD FOR ADJUSTING (Fan Rotation Mode Selection)

“Fan Speed Mode Select” is used to select the maximum cooling fan speed to normal control mode, 100 %
mode or 70 % mode.
2. On “Adjustment” screen, select “Fan Speed Mode Select”

with function switches or numeral input switches.
REMARK
3. After the “Fan Speed Mode Select” screen is displayed,

select the desired value at the right side by using the func-
tion switches.
Set value: For the actual fan speed, see table.
screen.
REMARK
30-220 PC210LCI-11
Relation between measurement value and mode (speed)

Code Set value Mode (speed)
000 Normal control
055 001 100 % (1345 rpm)
002 70 % (940 rpm)
REMARK
• Either "001" or "002" is selected as set value, selected fan speed mode is sustained as it is until “Fan
Speed Mode Select” screen is changed and starting switch is turned to OFF position.
• After finishing the test, return the fan speed mode to normal control mode by either selecting set value
as "000" or turning starting switch to OFF position and then restarting the engine.
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (KomVision SETTING)

The “KomVision Adjustment” adjusts KomVision system.
This function appears on the monitor only when KomVision is selected as “With KomVision” in “METHOD FOR
SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT KomVision)”.
Adjust each device by referring to “ADJUST KomVision RELATED DEVICES”.
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC AD-

JUSTMENT)
Use the adjustment menu to check the various settings of the machine or to adjust the value.
“Attachment EPC Adjustment” function adjusts the attachment EPC current. Perform adjustment of the ATT flow
selector EPC valve by referring to this section if it is necessary.
REMARK
2. Select “Attachment EPC Adjustment” with the function

switches or numeral input switches on “Adjustment”
screen.
REMARK
PC210LCI-11 30-221
3. On “Attachment EPC Adjustment” screen, select the de-

sired value at the right side by using the function switches.
table of "Relation between the set value and torque ad-
justment value".
F6: The setting is confirmed and entered. Screen returns
to “Adjustment” screen.
REMARK
The 3-digit number in the left column does not change.
This is the code for this function.
Relationship between set value and attachment EPC current adjustment value
000 -40 mA
001 -20 mA
002 -10 mA
003 -5 mA
045 004 0 mA
005 +5 mA
006 +10 mA
007 +20 mA
008 +40 mA
METHOD FOR ADJUSTING WITH ADJUSTING MENU (ATTACHMENT EPC 2 AD-

JUSTMENT)
“Attachment EPC 2 Adjustment” function adjusts the attachment EPC2 current. Perform adjustment of the 1st
service L.H. EPC valve by referring to this section if it is necessary.
REMARK
30-222 PC210LCI-11
2. Select “Attachment EPC 2 Adjustment” with the function

screen.
REMARK
3. On “Attachment EPC 2 Adjustment” screen, select the de-

justment value".
REMARK
PC210LCI-11 30-223
Relationship between set value and attachment EPC2 current adjustment value
000 -100 mA
001 -90 mA
002 -80 mA
003 -70 mA
004 -60 mA
005 -50 mA
006 -40 mA
007 -30 mA
008 -20 mA
009 -10 mA
049 010 0 mA
011 10 mA
012 20 mA
013 30 mA
014 40 mA
015 50 mA
016 60 mA
017 70 mA
018 80 mA
019 90 mA
020 100 mA

JUSTMENT)
“Attachment EPC 3 Adjustment” function adjusts the attachment EPC3 current. Perform adjustment of the 1st
service R.H. EPC valve by referring to this section if it is necessary.
REMARK
30-224 PC210LCI-11

screen.
REMARK

justment value".
REMARK
PC210LCI-11 30-225
000 -100 mA
001 -90 mA
002 -80 mA
003 -70 mA
004 -60 mA
005 -50 mA
006 -40 mA
007 -30 mA
008 -20 mA
009 -10 mA
048 010 0 mA
011 10 mA
012 20 mA
013 30 mA
014 40 mA
015 50 mA
016 60 mA
017 70 mA
018 80 mA
019 90 mA
020 100 mA

JUSTMENT)
“Attachment EPC 4 Adjustment” function adjusts the attachment EPC4 current. Perform adjustment of the 2nd
service L.H. EPC valve by referring to this section if it is necessary.
REMARK
30-226 PC210LCI-11

screen.
REMARK

justment value".
REMARK
PC210LCI-11 30-227
000 -100 mA
001 -90 mA
002 -80 mA
003 -70 mA
004 -60 mA
005 -50 mA
006 -40 mA
007 -30 mA
008 -20 mA
009 -10 mA
165 010 0 mA
011 10 mA
012 20 mA
013 30 mA
014 40 mA
015 50 mA
016 60 mA
017 70 mA
018 80 mA
019 90 mA
020 100 mA

JUSTMENT)
“Attachment EPC 5 Adjustment” function adjusts the attachment EPC5 current. Perform adjustment of the 2nd
service R.H. EPC valve by referring to this section if it is necessary.
REMARK
30-228 PC210LCI-11

screen.
REMARK

justment value".
REMARK
PC210LCI-11 30-229
000 -100 mA
001 -90 mA
002 -80 mA
003 -70 mA
004 -60 mA
005 -50 mA
006 -40 mA
007 -30 mA
008 -20 mA
009 -10 mA
164 010 0 mA
011 10 mA
012 20 mA
013 30 mA
014 40 mA
015 50 mA
016 60 mA
017 70 mA
018 80 mA
019 90 mA
020 100 mA
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Attachment EPC 2 Adjust-

ment (Tilt))
“Attachment EPC 2 Adjustment (Tilt)” function is a function that adjusts the attachment EPC2 current (smart-tilt
bucket). Perform adjustment of the 1st service L.H. EPC valve for machine equipped with auto tilt bucket by re-
ferring to this section if it is necessary.
This section explains about functions displayed only for machines equipped with auto-tilt bucket.
REMARK
30-230 PC210LCI-11
2. Select “Attachment EPC 2 Adjustment (Tilt)” with the func-

tion switches or numeral input switches on “Adjustment”
screen.
REMARK
3. On “Attachment EPC 2 Adjustment (Tilt)” screen, select

the desired value at the right side by using the function
switches.
justment value".
REMARK
The 3-digit number in the left column does not change. This is the code for this function.
Relation between the set value and ATT EPC2 current adjustment value (smart-tilt bucket)
000 -57.5 mA
001 -55.0 mA
002 -52.5 mA
003 -50.0 mA
004 -47.5 mA
005 -45.0 mA
006 -42.5 mA
007 -40.0 mA
171
008 -37.5 mA
009 -35.0 mA
010 -32.5 mA
011 -30.0 mA
012 -27.5 mA
013 -25.0 mA
014 -22.5 mA
015 -20.0 mA
PC210LCI-11 30-231

016 -17.5 mA
017 -15.0 mA
018 -12.5 mA
019 -10.0 mA
020 -7.5 mA
021 -5.0 mA
022 -2.5 mA
023 0.0 mA
024 2.5 mA
025 5.0 mA
026 7.5 mA
027 10.0 mA
028 12.5 mA
029 15.0 mA
030 17.5 mA
171 031 20.0 mA
032 22.5 mA
033 25.0 mA
034 27.5 mA
035 30.0 mA
036 32.5 mA
037 35.0 mA
038 37.5 mA
039 40.0 mA
040 42.5 mA
041 45.0 mA
042 47.5 mA
043 50.0 mA
044 52.5 mA
045 55.0 mA
046 57.5 mA
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Attachment EPC 3 Adjust-

ment (Tilt))
“Attachment EPC 3 Adjustment” function adjusts the current of attachment EPC3 current (smart-tilt bucket). Per-
form adjustment of the 1st service R.H. EPC valve for machine equipped with auto tilt bucket by referring to this
section if it is necessary.
30-232 PC210LCI-11

REMARK
2. Select “Attachment EPC 3 Adjustment (Tilt)” with the func-

screen.
REMARK
3. On “Attachment EPC 3 Adjustment (Tilt)” screen, select

the desired value at the right side by using the function
switches.
justment value".
REMARK
The 3-digit number in the left column does not change. This is the code for this function.
PC210LCI-11 30-233
Relation between the set value and ATT EPC3 current adjustment value (smart-tilt bucket)
000 -57.5 mA
001 -55.0 mA
002 -52.5 mA
003 -50.0 mA
004 -47.5 mA
005 -45.0 mA
006 -42.5 mA
007 -40.0 mA
170
008 -37.5 mA
009 -35.0 mA
010 -32.5 mA
011 -30.0 mA
012 -27.5 mA
013 -25.0 mA
014 -22.5 mA
015 -20.0 mA
30-234 PC210LCI-11

016 -17.5 mA
017 -15.0 mA
018 -12.5 mA
019 -10.0 mA
020 -7.5 mA
021 -5.0 mA
022 -2.5 mA
023 0.0 mA
024 2.5 mA
025 5.0 mA
026 7.5 mA
027 10.0 mA
028 12.5 mA
029 15.0 mA
030 17.5 mA
170 031 20.0 mA
032 22.5 mA
033 25.0 mA
034 27.5 mA
035 30.0 mA
036 32.5 mA
037 35.0 mA
038 37.5 mA
039 40.0 mA
040 42.5 mA
041 45.0 mA
042 47.5 mA
043 50.0 mA
044 52.5 mA
045 55.0 mA
046 57.5 mA
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Proportional Lever Adjust-

ment (R))
“Proportional Lever Adjustment (R)” is used for adjustment of current variation which is output from proportional
lever at RAISE Max position and LOWER Max position.
PC210LCI-11 30-235

REMARK
2. Select “Proportional Lever Adjustment (R)” with the func-

screen.
REMARK
3. When “Proportional Lever Adjustment (R)” for RAISE Max

position screen is displayed, push the proportional control
lever (1) of the R.H. work equipment control lever into di-
rection (a) to the RAISE Max position, and hold it.
4. Hold down the function switch F1 and start the calibration.

F1: Starts the calibration
F2: Initializes the calibration value
F5: Screen returns to “Adjustment” screen.
F6: Proceeds to the calibration of “Proportional Lever Adjustment (R)” at LOWER Max position.
30-236 PC210LCI-11
NOTICE
During the calibration, the progress bar is displayed.
Hold the calibration status until the calibration finish-
es.
5. When the calibration is finished and “OK” is displayed on

“State of Adjustment”, press F6 to proceed the calibration
for LOWER Max position.
• If calibration is finished unsuccessfully, “State of Ad-

justment” is “NG”, and the failure cause code is dis-
played. Find out the cause by referring to Failure
cause codes, and perform the calibration again.
6. When “Proportional Lever Adjustment (R)” for LOWER

Max position screen is displayed, push the proportional
control lever (1) of the R.H. work equipment control lever
into direction (b) to the LOWER Max position, , and hold it.

PC210LCI-11 30-237

NOTICE
es.

“State of Adjustment”, press F6 to finish the calibration.

9. For the calibration procedure that follows, see “Proportion-
al Lever Adjustment (L)”.
Failure cause code table

Cause
Content Required action
code
Proportional control lever potentiometer 1 system ab- Check for the abnormality in the electrical
WJ-1
normality system.
WJ-2
normality system.
Proportional control lever is not at the full stroke posi- Set the proportional control lever at the full
WJ-3
tion. stroke position.
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Proportional Lever Adjust-

ment (L))
“Proportional Lever Adjustment (L)” is used for adjustment of current variation which is output from proportional
lever at RAISE Max position and LOWER Max position.
30-238 PC210LCI-11

REMARK
2. Select “Proportional Lever Adjustment (L)” with the func-

screen.
REMARK
3. When “Proportional Lever Adjustment (L)” for RAISE Max

lever (2) of the L.H. work equipment control lever into di-
rection (a) to the RAISE Max position, and hold it.

F6: Proceeds to the calibration of “Proportional Lever Adjustment (L)” at LOWER Max position.
PC210LCI-11 30-239
NOTICE
es.

“State of Adjustment”, press F6 to proceed the calibration
for LOWER Max position.

6. When “Proportional Lever Adjustment (L)” for LOWER Max

lever (2) of the L.H. work equipment control lever into di-
rection (b) to the LOWER Max position, and hold it.

30-240 PC210LCI-11

NOTICE
es.

“State of Adjustment”, press F6 to finish the calibration.

Failure cause code table

Cause
code
WJ-1
normality system.
WJ-2
normality system.
Proportional control lever is not at the full stroke posi- Set the proportional control lever at the full
WJ-3
tion. stroke position.
METHOD FOR ADJUSTING (Pump calibration: Matching speed check)

The pump calibration (matching speed calibration) is required in the following cases.
Calibrating pump
Replacing engine -
Replacing main pump assembly Required
PC210LCI-11 30-241
Calibrating pump
Replacing pump controller Required
Adjusting or disassembling front pump PC valve Required
Adjusting or disassembling rear pump PC valve Required
Replacing main valve -
Adjusting and replacing main relief valve -
A rough flow of calibration of the pump is as follows. (Adjust-

ment menu in Service Menu)
condition.
Perform warm-up operation for at least 30 minutes.
Air conditioner: OFF
The pump calibration function is used to check the matching speed for arm IN relief and bucket CURL relief and
to set the matching speed to the engine correctly when the pump or pump controller is replaced.
30-242 PC210LCI-11
2. After “Adjustment” screen is displayed, input “40” by using

the numeral input switches and press F6.
REMARK
Since this function is required only when the pump is re-
placed, the PC valve is adjusted or disassembled, or the
pump controller is replaced, it is not displayed in the menu
list.
3. After the “Pump Calibration” screen is displayed, select

“Matching Speed Check” by using the function switches or
numeral input switches.
REMARK
Select this when it is required to check abnormality or cur-
rent condition of the machine.
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
4. When “Matching Speed Check” screen is displayed, check
the matching speed by arm IN relief and function switch.
F1: Starts the matching speed check
F5: Returns the screen to “Pump Calibration” screen
PC210LCI-11 30-243
5. Operate the arm or bucket control lever under the following

condition to check the relief matching.
Arm lever: IN full stroke (Operate during arm IN relief
matching)
Bucket lever: CURL full stroke (Operate during bucket
CURL relief matching)
k The work equipment must be operated when
checking. Secure sufficient area around the ma-
chine.
k When operating the work equipment, ensure the
safety of the surroundings.
REMARK
• Operate according to the arm IN relief and bucket CURL relief screen.
• Set bucket CURL relief matching after completing arm IN relief matching.
• There are no abnormalities in cooling fan if cooling fan speed increases pump calibration.
Before starting calibration, set the machine under the following condition.
(Condition)
6. Perform arm IN relief operation. When the engine speed is
stabilized, hold down F1 on the machine monitor to start
checking. During matching speed check, a bar is displayed
on the screen. Keep arm IN relief operation until the check
is finished.
REMARK
It takes approximately 10 seconds to start the bar graph
operation.
7. If the check is normally completed, the result is displayed.

Press F6 to go to bucket CURL relief.
30-244 PC210LCI-11

8. When “Matching Speed Check” screen is displayed, check

the matching speed by bucket CURL relief and function
switch.
F1: Starts the matching speed check
F5: Returns the screen to arm IN relief screen
9. Wait under the following conditions.
10. Hold down F1 of the machine monitor to start checking.
During matching speed check, a bar is displayed on the
screen. Keep relief operation until the check is finished.
11. If the check is normally completed, the result is displayed.

Press F6 and return to “Pump Calibration” screen.

PC210LCI-11 30-245
METHOD FOR ADJUSTING (Pump calibration: Matching speed calibration)

Before starting calibration, set the machine under the following condition.
• Perform warm-up operation for at least 30 minutes.
• Working mode: P (“Power Mode”)
• Air conditioner: OFF
The “Pump Calibration” function is used to check the matching speed for arm IN relief and bucket CURL relief
and to set the matching speed of the engine correctly when the pump or pump controller is replaced.
REMARK
2. Enter “40” with numeral input switches after the “Adjust-

ment” screen is displayed, and press F6.
REMARK
Since this function is required only when the pump is re-
placed, the PC valve is adjusted or disassembled, or the
pump controller is replaced, it is not displayed in the menu
list.
30-246 PC210LCI-11
3. On the “Pump Calibration” screen, select “Matching Speed

Calibration” with function switches or numeral input
switches.
REMARK
• Select this when it is required to check abnormality or
current condition of the machine.
• For selecting method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.
4. Perform the subsequent calibration procedure according to
“Matching Speed Check”.
METHOD FOR ADJUSTING MENU (RESTORE TO DEFAULT SETTING)

The “Pump Calibration” function is used to check the matching speed for arm IN relief and bucket CURL relief
and to set the matching speed of the engine correctly when the pump or pump controller is replaced.
REMARK
2. Enter “40” with numeral input switches after the “Adjust-

ment” screen is displayed, and press F6.
PC210LCI-11 30-247
3. On the “Pump Calibration” screen, select “Restore to De-

fault Setting” with function switches or numeral input
switches.
REMARK
4. Press F6 to perform the initialization.

When F6 is pressed, the “Pump Calibration” screen ap-
pears. When “D” appears on top right corner of the screen,
the initialization is completed.
METHOD FOR PERFORMING NO-INJECTION CRANKING

If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient
lubrication with oil. To prevent this, the machine has a function to crank the engine without injecting fuel to lubri-
cate the engine before starting it.
Setting of No-Injection cranking to be performed while the engine is stopped.
No-Injection cranking does not function while the engine is run-
ning.
This function can be selected even when the engine is running.
However, if you execute No-Injection cranking, “Engine is run-
ning. Please turn the key off once.” is displayed on the screen.
30-248 PC210LCI-11
Even if the confirmation screen is displayed and No-Injection

cranking is operated, the function does not become effective in
the following cases. Turn the starting switch OFF once to oper-
ate.
• The communication between the machine monitor and en-
gine controller is not normal.
• An engine start operation has been performed before the
message “No-injection cranking is possible” is displayed.
1. Select “No-Injection Cranking” on “Service Menu” screen.

REMARK
2. When “No-Injection Cranking” screen is displayed, confir-

mation for the execution of No-Injection cranking is dis-
played. Select the action with the function switch.
F5: Does not implement (returns the screen to “Service
Menu”).
F6: Executes.
3. If no-injection cranking (no fuel injection on every cylinder)

is enabled, “No-injection cranking is possible. Please turn
the key off after no-injection ends.” is displayed on the
screen. Crank the engine with the starting motor.
NOTICE
Do not crank the engine for 20 seconds or longer to
protect the starting motor.
REMARK
While the screen is changing to the screen as shown in the
figure, the screen of “Getting Ready” is displayed.
4. After the cranking is completed, turn the starting switch to OFF position.
You cannot change the screen described above to another screen.
PC210LCI-11 30-249
KOMTRAX SETTINGS MENU

METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)
On “KOMTRAX setting display” screen, select “Terminal Status” with the function switches or numeral input
switches.
"“Terminal Status”" is used to check the setting condition of the KOMTRAX terminal.
1. Select “KOMTRAX Settings” on “Service Menu” screen.
REMARK
2. On “KOMTRAX Settings”screen, select “Terminal Status”

REMARK
3. On “Terminal Status” screen, the following items are dis-

played.
Terminal Type: Model name of the KOMTRAX communica-
tion modem
KOMTRAX Communication Inspection: State of radio sta-
tion establishment
GMT time: Greenwich Mean Time (add 9 hours to it for Ja-
pan time)
F5: Returns the screen to “KOMTRAX Settings” screen
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION

STATUS)
The setting and operating state of KOMTRAX can be checked by using “KOMTRAX Settings” screen.
“GPS & Communication State” is used to check the positioning and communication state of the KOMTRAX ter-
minal.
30-250 PC210LCI-11

REMARK
2. On “KOMTRAX Settings” screen, select “GPS & Communi-

cation State” with the function switches or numeral input
switches.
REMARK
3. On “GPS & Communication State” screen, the following

items are displayed.
Positioning: GPS positioning state
Communication: Communication environment and connec-
tion state 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
F5: Returns the screen to “KOMTRAX Settings” screen
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)

The setting and operating state of KOMTRAX can be checked by using the menu of “KOMTRAX Settings”.
“Modem Information” is used to check the phone number and IMSI of the KOMTRAX communication modem.
REMARK
PC210LCI-11 30-251
2. On “KOMTRAX Settings”screen, select “Modem Informa-

tion” with the function switches or numeral input switches.
REMARK
3. Display the phone number and IMSI.

F5: Returns the screen to “KOMTRAX settings” screen.
METHOD FOR DISPLAYING SERVICE MESSAGE

Special messages for the technician sent from the KOMTRAX base station (a distributor, etc.) can be checked
with this function.
If a received message includes a setting operation, a return mail can be sent by using the numeral input
switches as well.
1. Select “Service Message” on “Service Menu” screen.
REMARK
2. Displaying message
• 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 screen to “Service Menu” screen
REMARK
• This message is different from that sent to the op-
erator with the machine monitor in the operator
mode.
• Since this message is special for the technician,
the message monitor is not displayed as it is dis-
played in the operator mode.
30-252 PC210LCI-11
• Display of message (with message return 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 KOM-
TRAX base station.
F5: Returns the screen to “KOMTRAX Settings”
screen
F6: Enters and sends the input value.
REMARK
• This message is different from that sent to the op-
erator in the operator mode.
• Since this message is special for the technician,
the message monitor is not displayed as it is dis-
played in the operator mode.
PC210LCI-11 30-253
METHOD FOR STARTING UP KOMTRAX TERMINAL 30 TESTING AND ADJUSTING
METHOD FOR STARTING UP KOMTRAX TERMINAL

Method for starting-up KOMTRAX
Observe the following when using KOMTRAX.
1. KOMTRAX key person performs “Machine Registration” by using KOMTRAX client PC.
2. Perform “KOMTRAX Communication Inspection”.
• For operation procedures, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.
When KOMTRAX terminal is replaced.

Observe the following when replacing KOMTRAX terminal and using it again.
1. Our technician provides a new terminal, and records the part number and serial number.
2. Our technician replaces the terminal, and perform “KOMTRAX Communication Inspection”. Our technician
notifies KOMTRAX key person of the completion of inspection work and new terminal information.
3. KOMTRAX key person performs “Terminal Replacement” by using KOMTRAX client PC.
4. KOMTRAX key person fills in required items on “Terminal Replacement Sheet”, and send it by email to
KOMTRAX support center via KOMTRAX administrator in the subsidiary.
• For details, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.
Machine side inspection for KOMTRAX Communication opening

• KOMTRAX Communication Inspection must be done to check whether normal communication is available
from the terminal when the KOMTRAX terminal is replaced or started up.
• By performing this inspection, KOMTRAX starts communication.
• GPS and data communication are checked during the KOMTRAX Communication Inspection. Accordingly,
it is preferable to place the machine under the open sky where radio wave from the satellite is not blocked.
The opening inspection may not be completed when the machine is placed indoor where radio wave from
the satellite is blocked.
1. Check the machine for KOMTRAX Communication Inspection
Observe the following when checking if KOMTRAX Communication Inspection is required or not.
1) On “Service Menu” screen, select “KOMTRAX Set-
tings” with function switches or numeral input
switches.
30-254 PC210LCI-11
30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX TERMINAL
2) On “KOMTRAX Settings” screen, select “Terminal Sta-

tus” with the function switches or numeral input
switches.
3) On “Terminal Status” screen, check the state of “KOM-

TRAX Communication Inspection”.
If “KOMTRAX Communication Not Open” is displayed
on the state of “KOMTRAX Communication Inspec-
tion”, Perform step 2. If “Already Open” is displayed,
KOMTRAX Communication Inspection is not needed.
2. KOMTRAX Communication Inspection
Observe the following when performing KOMTRAX Com-
munication Inspection.
1) On “Service Menu” screen, select “KOMTRAX Set-

tings” with function switches or numeral input
switches.
2) On “KOMTRAX Settings” screen, select “GPS & Com-

munication State” with the function switches or numer-
al input switches.
PC210LCI-11 30-255
3) After “GPS & Communication State” screen is dis-

played, press the numerical switches in order while
pressing 4 as 4 + 1 → 2 → 3.
4) After “Are you sure you want to inspect?” is displayed,

execute the inspection with the function switch.
F5: Returns the screen to “GPS & Communication
State” screen
F6: Executes KOMTRAX Communication Inspection.
5) The screen displays the state of KOMTRAX Commu-

nication inspection. Check on this screen that all item
are “OK”.
“Modem”: “OK” is displayed when communication area
is confirmed.
“GPS”: “OK” is displayed when it acquires GPS data.
“Transmission”: “OK” is displayed when it transmits
data correctly.
“Inspection State”: When all items of “Modem”, “GPS”,
and “Transmission” are “OK”, “OK” is displayed on
“Inspection State”.
• It takes 90 seconds to 15 minutes for all items to be “OK”.
• While waiting for all items to be “OK”, operation such as turning the starting switch to OFF position
or starting the engine will not be a problem.
If there is nothing abnormal, KOMTRAX Communication Inspection finishes automatically. Select
“KOMTRAX Settings” → “Terminal Status” of “Service Menu” to make sure that “Already Open” is
indicated for the item in “KOMTRAX Communication Inspection”.
• KOMTRAX Communication Inspection may not be completed when the machine is placed indoor
where radio wave from the satellite is blocked.
30-256 PC210LCI-11
30 TESTING AND ADJUSTING METHOD FOR STARTING UP KOMTRAX TERMINAL
6) When all items are “OK”, “Inspection finished normal-

ly.” screen automatically displayed.
Press ENTER switch. “GPS & Communication State”
appears, and the KOMTRAX Communication Inspec-
tion for machine side is completed.
Other than the above, perform step 3.
3. Troubleshooting when KOMTRAX Communication Inspec-
tion is finished unsuccessfully
• If any of 1) to 5) in step 2 is finished unsuccessfully,
perform inspection from 1) in step 2.
• If 6) in step 2 is finished unsuccessfully, following problems are suspected.
Troubleshooting when the failure occurs

Phenomenon Cause Required action
Something on the cab blocks off GPS sat- Remove the obstacle on the cab.
GPS does not be- ellites acquisition.
come OK. GPS antenna cable is not connected to Check for the connection. If the connection is loose,
the machine monitor, or they are loose. secure it.
The mobile phone is out of communication Check for state of in/out communication range with
range. your mobile phone.
If it is out of communication range, move into com-
munication reception range and perform inspection.
Modem does not Communication antenna cable is not con- Check for the connection. If the connection is loose,
become OK. nected to the KOMTRAX terminal, or they secure it.
are loose.
KOMTRAX terminal is not connected to Check for the connection. If the connection is loose,
machine side wiring harness, or they are secure it.
loose.
4. After troubleshooting, perform 1) in step 2 again.
PC210LCI-11 30-257
When the problems are not solved, contact your KOMTRAX support center.
30-258 PC210LCI-11
30 TESTING AND ADJUSTING ADJUST REARVIEW CAMERA ANGLE
ADJUST REARVIEW CAMERA ANGLE

• For the standard machine, adjust the camera angle by referring to “METHOD FOR ADJUSTING REAR-
VIEW CAMERA ANGLE”.
• For the machine with KomVision, adjust the devices by referring to “KomVision RELATED DEVICES”.
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE

k Always adjust the camera before starting work. If it is
not adjusted properly, you cannot secure the visibility
and a serious personal injury or death may result.
k When adjusting the angle of the camera, prepare a
scaffold first in order to provide a safe working plat-
form.
If you try to work standing on the counterweight, there
is a danger of serious injury or death due to falling off
from the machine.
Adjust the angle of the rearview camera so that people within 1

m {3 ft 3 in} away from the machine's rear part (W) can be seen
in the machine monitor at the operator's seat.
If the image on the monitor is not aligned correctly, adjust

mounting angle (A) of the rearview camera in the following pro-
cedure.
Angle (A) can be adjusted within the range from 32 to 53°.
PC210LCI-11 30-259
ADJUST REARVIEW CAMERA ANGLE 30 TESTING AND ADJUSTING
1. Insert a flat-head screwdriver or the like into hole (3) of

cover (2) and push inside tooth (B) to remove the cover.
2. Remove bolts (4) (2 places).

REMARK
• Shim (6) may be inserted in the cover mounting bolts to
adjust the clearance in the rim of the cover. When re-
moving cover (1), record the places and quantities of
the shims. When installing the cover, insert the shims
according to the record.
• Take care of shim (6), since it comes off together with
cover (1).
4. Loosen camera mounting bolts (5) (3 places) and adjust

camera mounting angle (A) so that corner (D) of mounting
bracket (C) is aligned with horizontal line (E).
5. After adjusting, tighten bolts (5).
30-260 PC210LCI-11
30 TESTING AND ADJUSTING ADJUST REARVIEW CAMERA ANGLE
Tightening torque:11.8 to 14.7 Nm{1.2 to 1.5 kgm,8.7 to 10.8 lbft}

REMARK
A part of the machine is shown on the monitor screen.
PC210LCI-11 30-261
ADJUST KomVision CAMERA ANGLE 30 TESTING AND ADJUSTING
ADJUST KomVision CAMERA ANGLE

Tools for adjusting KomVision camera angle
Commercially Niigata Seiki bevel box: BB-180 equiva-
A Digital angle gauge 1
available lent
k Before starting operation, always check the visibility of the KomVision camera. If it is improper, ad-
just it. If the KomVision camera is not adjusted properly, you cannot secure the visibility and a seri-
ous personal injury or death may result.
k When adjusting the angle of the KomVision camera, prepare a scaffold first in order to provide a safe
working platform.
If stand on the counterweight, there is a danger of serious injury or death due to falling off from the
machine.
k Adjust the angle of the KomVision camera on a safe working platform. When adjusting the camera
angle on a slope by necessity, measure the inclination of the counterweight and then calculate the
actual angle of the KomVision camera.
If the image on the monitor is not aligned correctly, adjust the
mounting angle (A) of the KomVision camera.
30-262 PC210LCI-11
30 TESTING AND ADJUSTING ADJUST KomVision CAMERA ANGLE
METHOD FOR ADJUSTING KomVision CAMERA ANGLE

Angle adjustment method for front right camera, rear right camera, and rear left
camera
1. Insert a flat-head screwdriver into hole (2) of bolt cover (1)
and remove the bolt cover (1) while pressing the internal
claw.
REMARK
The bolt cover (1) is made of plastic, so be careful not to
break it when removing.
2. Remove the bolt (3).

3. Remove the cover (4).
4. Loosen the mounting bolt (5).
PC210LCI-11 30-263
5. Put the angle gauge A on the (b) surface of KomVision

camera and adjust the installed angle of the KomVision
camera (a).
Angle (a): 45(+2/0) °
6. Tighten the mounting bolt (5).
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

Calibrate the KomVision camera after adjusting the angle of the camera by referring to “METHOD FOR SET-
TING OF KomVision (CAMERA CALIBRATION)”.
Angle adjustment method for rear camera

1. Insert a flat-head screwdriver into hole (2) of bolt cover (1)
and remove the bolt cover (1) while pressing the internal
claw.
REMARK
The bolt cover (1) is made of plastic, so be careful not to
break it when removing.
30-264 PC210LCI-11
30 TESTING AND ADJUSTING ADJUST KomVision CAMERA ANGLE
2. Remove the bolt (3).

REMARK
• Shim (5) may be installed to the mounting bolt of cover
(4) for adjustment of clearance in cover.
• Be careful when handling the shim (5). It comes off to-
gether with cover (4).
4. Loosen the mounting bolt (6).
5. Put the angle gauge A on the (b) surface of KomVision

camera and adjust the installed angle of the KomVision
camera (a).
Angle (a): 45(+2/0) °
6. Tighten the mounting bolt (6).
11.8 to 14.7 Nm {1.2 to 1.5 kgm}
PC210LCI-11 30-265

Calibrate the KomVision camera after adjusting the angle of the camera by referring to “METHOD FOR SET-
TING OF KomVision (CAMERA CALIBRATION)”.
30-266 PC210LCI-11
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS
ADJUST KomVision RELATED ITEMS

The following items are adjustment details of KomVision related items. If you performed the target works, be
sure to perform the applicable tests and the adjusting items.
List of KomVision adjustment items

Item Target work Purpose Reference page
• Replace the KomVision control- Check and select the model
ler SETTING OF KomVision
Main Setting name and the machine
(MAIN SETTING) (30-268)
• Initialize the set values specifications
The service is not needed even though SETTING OF KomVision

Camera Set-
this adjustment item is displayed on - (CAMERA SETTING)
ting
KomVision Adjustment Menu. (30-270)
• Replace the KomVision control- Adjust the installed location
ler SETTING OF KomVision
Camera Cali- and the angle parameter of
(CAMERA CALIBRATION)
bration • Initialize the set values each camera to compose
(30-271)
the camera images
• Replace the camera
PC210LCI-11 30-267
ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING
SETTING OF KomVision (MAIN SETTING)

Check and select the model name and the machine specifications.
METHOD FOR SETTING KomVision (MAIN SETTING)

1. From “Service Menu” screen, select “Adjustment”.
REMARK
2. On the “Adjustment” screen, select “KomVision Adjust-

ment” with function switches or numeral input switches.
REMARK
3. On the “KomVision Adjustment Menu” screen, select “Main

Setting” with the function switch.
F1: Returns to the “Service Menu” screen
“Adjustment” screen
4. On “Main Setting” screen, select “Machine Model” with the

function switch.
F1: Returns to the “Service Menu” screen without entering
the selected item
F5: Returns to “KomVision Adjustment Menu” without en-
tering the selected item
REMARK
When the selected item is entered, the icon (a) turns yel-
low.
5. Select the corresponding machine model code, by referring to “Machine Model Code List”.
F1: Returns to the “Service Menu” screen without entering the selected item
30-268 PC210LCI-11

F5: Returns to “KomVision Adjustment Menu” without entering the selected item
NOTICE
Do not change any value of “03 Front End from Cent” to “07 Number of Camera”.
Machine model code list

Machine Specifications/Optional devices
Machine
model
model With no optional device Long track specification
code
PC210 1022 ○ ○
When the machine model code is entered, the values of the following items are updated automatically, and
the icon (a) turns black again.
“03 Front End from Cent”
“04 Rear End from Cent”
“05 Right End from Cent”
“06 Left End from Cent”
“07 Number of Camera”
6. Select “Save” with the function switch.
F1: Returns to the “Service Menu” screen without entering
the selected item
F5: Returns to “KomVision Adjustment Menu” without en-
tering the selected item
• When the text color of “Save” button is green:
Settings is not changed. Restart the KomVision setting
from step 4.
• When the text color of “Save” button is orange:
Saving the new setting. Go to the next step.
7. Press F6 and save the settings.
When F6 is pressed, the text color of “Save” button is green, and the settings will be saved.
PC210LCI-11 30-269
SETTING OF KomVision (CAMERA SETTING)

METHOD FOR SETTING KomVision (CAMERA SETTING)
The service is not needed even though this adjustment item is
displayed on “KomVision Adjustment Menu”.
30-270 PC210LCI-11
SETTING OF KomVision (CAMERA CALIBRATION)

Testing tools for KomVision (camera calibration)
A - Angle setting calibration marker 1
B - Position setting calibration marker 1
Commercially
C Tripod 1
available
Commercially
D Traffic cone 2 Height : Approx. 70 cm
available

• On a flat and level ground, there are not any obstacles within 4 to 5 m of the machine
• Dust free environment (Avoid a place where the camera lens may get dirty during work).
Adjust each parameter to compose the multiple camera images.
METHOD FOR SETTING OF KomVision (CAMERA CALIBRATION)

NOTICE
Change the “Camera Angle Setting”, and then change the “Camera Position Setting”.
Operating method for “Camera Angle Setting”

1. Make the angle setting calibration marker A.
REMARK
• Make an enlarged photocopy of the angle setting calibration marker A in Fig. 1 at the end of this section.
• Ensure the figure size to be large enough to read on the machine monitor screen. The recommended
size is A3.
2. Fix the angle setting calibration marker A to the tripod C.
3. Horizontally install the angle setting calibration marker A to

the position (a) approximately 2 m apart from the camera.
REMARK
• “Angle calibration” can be performed from any camera.
• Perform the “Angle calibration” by each camera.
• Install the angle setting calibration marker A at the po-
sition shown in the figure.
• Adjust the height of angle setting calibration marker A
to the height of the center of the camera lens.
• Calibration accuracy is assured by setting the center of
the angle setting calibration marker A to the center of
the camera lens within ±40 mm.
PC210LCI-11 30-271
4. Select the “Adjustment” on the “Service Menu” screen.

REMARK
5. Select the “KomVision Adjustment” with the function

switches or numeral input switches on the “Adjustment”
screen.
REMARK
6. Select the “Camera Calibration” with the function switches

on the “KomVision Adjustment Menu” screen.
F1: Screen returns to the “Service Menu” screen.
F5: Cancels the selection. Screen returns to the “Adjust-
ment” screen.
7. Select the “01 Camera Angle Setting” with the function

switches on the “Camera Calibration” screen.
F5: Cancels the selection. Screen returns to the “KomVi-
sion Adjustment Menu” screen.
8. Select the camera to be adjusted with the function

switches on the “Camera Selection (Angle Calibration)”
screen.
F5: Cancels the selection. Screen returns to the “Camera
Calibration” screen.
30-272 PC210LCI-11
REMARK
“Bird's-eye Image Rate” and “Camera Image Size Rate” can be adjusted with the function switches.
9. When the angle calibration screen for the selected camera
is displayed, check that the angle setting calibration mark-
er A installed in step 1 is displayed in the box (b).
REMARK
If the angle setting calibration marker A is not displayed,
adjust the position of the angle setting calibration marker A
or the angle of the camera.
10. Select and enter the “Camera Pitch Angle” with the func-
tion switches.
When the selected item is entered, the back ground color
of icon (c) turns yellow.
11. Match the center of the angle setting calibration marker A
and the vertical direction position of the camera marker
with the function switches.
A: Angle setting calibration marker A
x: Camera marker
F3: Camera image is moved downward.
F4: Camera image is moved upward.
F5: Cancels the calibration item/the Cancels the changed
item. Screen returns to the “KomVision Adjustment
Menu” screen.
F6: Enters the calibration item/Enters the change
PC210LCI-11 30-273
12. Select and enter the “Camera Yaw Angle” with the function
switches.
of icon (d) turns yellow.
13. Match the center of the angle setting calibration marker A
and the lateral position of the camera marker with the func-
tion switches.
x: Camera marker
F3: Camera image is moved to the left.
F4: Camera image is moved to the right.
Menu” screen.
14. Select and enter the “Camera Roll Angle” with the function
switches.
of icon (e) turns yellow.
30-274 PC210LCI-11
15. Match the angle setting calibration marker A and the rota-
tion direction position of the camera marker with the func-
tion switches.
x: Camera marker
F3: Camera image rotates counterclockwise.
F4: Camera image rotates clockwise.
Menu” screen.
• Example of matching
x: Camera marker
• Example of unmatching
x: Camera marker
16. When the angle calibration marker A and the camera
marker match, select the “Save” with the function switches,
and press F6 to save the setting.
Perform the steps 1 to 16 for each camera.

REMARK
• When the controller is replaced or when the specifications are changed, calibrate all cameras.
• Perform the only necessary calibrations when replacing the cameras.
PC210LCI-11 30-275
Operating method for “Camera Position Setting”

1. Make the position setting calibration marker B.
REMARK
• Make the position setting calibration marker B accord-
ing to the figure.
• Stick some 50 mm wide black tapes on a board when
making the calibration marker.
2. Set the position setting calibration marker B according to the Table 1.

NOTICE
When 4 cameras are installed, perform “position calibration” of the rear R.H. camera first.
REMARK
Perform the “Position calibration” by each camera.
B: Position setting calibration marker B
y: Machine
Table 1
Dimension, Angle Positive value Allowable range
a 1.0 m ±0.5 m
b 1.0 m ±0.5 m
c 1.0 m ±0.5 m
d 2.0 m ±0.5 m
θ 90 ° ±9 °
3. Check the machine monitor and see if the position setting calibration marker B is in the image captured by
2 adjacent cameras.
30-276 PC210LCI-11
4. Select the “Adjustment” on the “Service Menu” screen.

REMARK
5. Select the “KomVision Adjustment” with the function

switches or numeral input switches on the “Adjustment”
screen.
REMARK
6. Select the “Camera Calibration” with the function switches

on the “KomVision Adjustment Menu” screen.
F5: Cancels the selection. Screen returns to the “Adjust-
ment” screen.
7. Select the “02 Camera Position Setting” with the function

switches on the “Camera Calibration” screen.
F5: Cancels the selection. Screen returns to the “KomVi-
sion Adjustment Menu” screen.
8. Select the camera to be adjusted with the function

switches on the “Position Calibration Camera Select”
screen.
PC210LCI-11 30-277
REMARK
Table 2 describes the calibrations target of cameras. The calibration targets change depending on the se-
lected camera on the “Position Calibration Camera Select” screen.
Table 2
Selection item Standard camera Adjustment target camera
Rear R.H. camera Rear camera R.H. camera
Front R.H. camera Rear R.H. camera Front R.H. camera
Rear L.H. camera Rear camera L.H. camera
9. When the position calibration screen for the selected cam-
era is displayed, check that the position setting calibration
marker B installed in step 1 is displayed in the box (f).
REMARK
• Check that the calibration marker is on both rear cam-
era image and R.H. camera image.
• If the position setting calibration marker B is not dis-
played, adjust “Bird's-eye Image Rate” or reinstall the
position setting calibration marker B.
10. Select and enter the “Camera Lateral Position” with the
function switches.
of icon (g) turns yellow.
11. Align the marker of the target camera and the lateral posi-
tion of the calibration marker B for position setting with the
function switches.
z: Marker of target camera
F3: Camera image is moved to the left.
F4: Camera image is moved to the right.
F5: Cancels the calibration item/Cancels the changed
item. Screen returns to the “Position Calibration Camera
Select” screen.
30-278 PC210LCI-11
12. Select and enter the “Camera Longitude Posit” with the
function switches.
of icon (h) turns yellow.
13. Align the marker of the target camera and the longitudinal
position of the calibration marker B for position setting with
F3: Camera image is moved downward.
F4: Camera image is moved upward.
F5: Cancels the calibration item/Cancels the changed
item. Screen returns to the “Position Calibration Camera
Select” screen.
• Example of matching
• Example of unmatching
14. Select the “Save” with the function switches, and press F6
to save the setting when the position calibration marker B
and the camera marker match.
After completing the calibration process, return to the
standard screen. Check that the failure code is not dis-
played.
Perform the steps 1 to 14 for each camera.
15. See the camera image to check the following items.
PC210LCI-11 30-279
1) Check if the line (a), (b), or (c) is displayed.

When the line (a) is displayed:
The rear R.H. camera is tilted upward out of the speci-
fied angle. Adjust the camera mounting angles to be
within the specified angle by referring to the “METH-
OD FOR ADJUSTING KomVision CAMERA ANGLE”.
When the line (b) is displayed:
The rear L.H. camera is tilted upward out of the speci-
fied angle. Adjust the camera mounting angles to be
within the specified angle by referring to the “METH-
OD FOR ADJUSTING KomVision CAMERA ANGLE”.
When the line (c) is displayed:
The front R.H. camera is tilted upward out of the specified angle. Adjust the camera mounting angles to
be within the specified angle by referring to the “METHOD FOR ADJUSTING KomVision CAMERA AN-
GLE”.
2) Check the displayed percentage of the counterweight.
When the displayed percentage of right side of the counterweight is large:
The rear R.H. camera is tilted downward out of the specified angle. Adjust the camera mounting angles
to be within the specified angle by referring to the “METHOD FOR ADJUSTING KomVision CAMERA
ANGLE”.
When the displayed percentage of left side of the counterweight is large:
The rear L.H. camera is tilted downward out of the specified angle. Adjust the camera mounting angles
to be within the specified angle by referring to the “METHOD FOR ADJUSTING KomVision CAMERA
ANGLE”.
When the displayed percentage of right side of the machine is large:
The front R.H. camera is tilted downward out of the specified angle. Adjust the camera mounting an-
gles to be within the specified angle by referring to the “METHOD FOR ADJUSTING KomVision CAM-
ERA ANGLE”.
3) Check if the images (i) are aligned correctly.
If the images are not aligned correctly, perform “Cam-
era Calibration” by referring to “Setting Method for
KomVision (Camera Calibration)”, and check them
again. If the images are still shifted after “Camera Cal-
ibration” is performed, adjust the camera mounting an-
gle into the specified angle range by referring to
“METHOD FOR ADJUSTING KomVision CAMERA
ANGLE”.
30-280 PC210LCI-11
4) Place the traffic cones D at the following positions,

and check that they can be seen in the camera image.
a: Approx. 1 m from rear end of the track shoe of the
machine
b: Approximately 1 m from width center line of the
track shoe of the machine
c: The center position between the front R.H. camera
and rear R.H. camera
If these cones are not displayed on the camera image,
perform “Camera Calibration” by referring to “Setting
Method for KomVision (Camera Calibration)”, and
check them again. If the cones are still not displayed
on the camera image after “Camera Calibration” is
performed, adjust the camera mounting angle into the
specified angle range by referring to “METHOD FOR
ADJUSTING KomVision CAMERA ANGLE”.
PC210LCI-11 30-281
Fig. 1
30-282 PC210LCI-11
30 TESTING AND ADJUSTING HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER

NOTICE
• Before connecting the wiring harness connector, be sure to completely remove sand, dust, water,
etc., inside the connector on the controller side.
• Disconnecting or connecting work of the connector between the engine controller and the engine
must be performed only when the starting switch and battery disconnect switch are in OFF position.
• Even when you perform troubleshooting, do not start the engine while a T-adapter is inserted into or
connected to the connector between the engine controller and engine.
REMARK
You may turn the starting switch to OFF or ON position but do not turn it to START position. (Do not
start the engine).
PC210LCI-11 30-283
HANDLE BATTERY DISCONNECT SWITCH 30 TESTING AND ADJUSTING
HANDLE BATTERY DISCONNECT SWITCH

k If battery disconnect switch (1) is turned to ON position
by unauthorized person, it is extremely dangerous.
(O): OFF position
(I): ON position
• Battery disconnect switch (1) is usually used in the follow-
ing cases in the same purpose of disconnecting the cable
from the negative terminal of the battery.
• When storing the machine for a long period (1 month
or longer)
• When servicing or repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
• When battery disconnect switch (1) is at OFF position (the
contact is opened), all the continuous power supplies for
the components including the starting switch B terminal
and controllers are all cut out. It is the same state as the
time when the battery is not connected, and all the electri-
cal system of the machine are out of operation.
NOTICE
When turning the battery disconnect switch (1) to OFF position, always remove switch key.
• The operating condition of each controller can be checked with the system operating lamp (2) to prevent
the abnormal end of the disconnection of the battery power supply circuit while the controllers are in opera-
tion.
• Before shutting off the battery power supply circuit, turn the starting switch to OFF position, and check that
system operating lamp (2) goes out, then turn the battery disconnect switch (1) to OFF position.
• If the battery disconnect switch (1) is turned to OFF position (battery power supply circuit is OFF) while the
system operating lamp (2) is lit, data loss error of controller may occur. Never operate the battery discon-
nect switch (1) while the system operating lamp (2) is lit.
• The system operating lamp (2) goes out in maximum. 6 minutes after the starting switch is turned to OFF
position.
• System operating lamp (2) may sometimes light up while the starting switch is turned to OFF position be-
cause KOMTRAX terminal may maintain its communication under this condition.
• Even if system operating lamp (2) is off, it may seem to be lit slightly because of a very little leakage current
inside the controller. This phenomenon does not indicate abnormality.
• The KOMTRAX terminal performs communication periodically even if the starting switch is kept in OFF
position, thus it repeats starting and stopping.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including
the communication state and machine stop time. It may be lit for a maximum of approximately 1 hour.
• When you want to open the battery circuit for maintenance but the system operating lamp (2) is lit, turn the
starting switch to ON position once, turn it to OFF position, and then the lamp goes out in 6 minutes. After
system operating lamp (2) goes out, turn the battery disconnect switch (1) to OFF position immediately.
30-284 PC210LCI-11
30 TESTING AND ADJUSTING TEST DIODES
TEST DIODES
Test the diode array (8-pin) and the single diode (2-pin) accord-
ing to the following procedure.
The continuity directions of the diode array are as shown in the
figure.
REMARK
The continuity direction of the single diode is indicated on the
surface of the diode.
METHOD FOR TESTING DIODE USING DIGITAL TESTER

1. Select the screen to the diode range to check the dis-
played values.
REMARK
When an ordinary circuit multimeter is used, the voltage of
the internal battery is indicated.
2. Apply the red (+) lead of the multimeter to the anode (P)
side of the diode and apply the black (-) lead to the cath-
ode (N) side, and check the indicated value.
3. Evaluate the condition of the diode by the indicated value.
Indicated value does not change: No continuity (defective)
Indicated value changes: Continuity (normal) (*)
In the case of a silicon diode, a value in the range between 460 to 600 mV is indicated.
METHOD FOR TESTING DIODE USING ANALOG TESTER

1. Selects the screen for resistance range.
2. Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the
cathode (N) side, and check that the pointer moves.
3. Apply the red (+) lead of the multimeter to the cathode (N) side of the diode and apply the black (-) lead to
the anode (P) side, and check that the pointer moves.
4. Evaluate the condition of the diode by the movement of the pointer.
Result of movement of the pointer
Judgment
Step 2 Step 3
Normal (however, the movement of
the pointer (resistance) varies by type
Moves Does not move
of tester, or selection of measuring
range).
Moves Moves Defective (internal short circuit)
Does not move Does not move Defective (internal open circuit)
PC210LCI-11 30-285
SET AND OPERATE CONTROL BOX 30 TESTING AND ADJUSTING
ICT SYSTEM
SET AND OPERATE CONTROL BOX
1: Auto/manual switch 2: USB port (for uploading and downloading the data
by a USB flash drive)
The control box has two functions, one of the function sets or adjusts the design surface to be used for the
boom automatic control, and the other function displays the GNSS satellite information. For operation, touch the
screen directly.
30-286 PC210LCI-11
30 TESTING AND ADJUSTING SET AND OPERATE CONTROL BOX
Details of each calibration screen

The location and the function (operation) of each button are as follows.
(1) “Start”: Starts the calibration by holding down the the button more than 0.5 second
(2) “Clear” Resets the parameter by holding down the button more than 0.5 second
(3) “Next”: Moves the screen to the next screen
(4) “Back”: Returns the screen to the previous screen
(5) “Return button”: Proceeds to the screen to stop the calibration If the calibration is interrupted, all of the input
values and coordinates are deleted.
PC210LCI-11 30-287
(6) “Set”: Saves the calibration values by holding down the button more than 0.5 second After the calibration
values are saved, the screen “Full Parameter Calibration [9/16]” and “Full Parameter Calibration [13/16]”
screens proceed to the next screens. If the calibrations other than full parameter calibrations are performed,
the screen returns to the “Machine Setup” menu screen.
(7) “Yes”: Initializes the input values, and returns the screen to the “Machine Setup” menu screen
(8) “No”: Returns the screen to the previous screen and restarts the calibration
(9) “Exit”: Displays the “Machine Setup” menu screen, and returns the screen to the standard screen
(10) “Enter button”: After finishing the calibration, returns the screen to the “Machine Setup” menu screen
(11) “OK”: Displays along with numeric keypad or input keypad, and enters the input values by pressing this but-
ton
(12) “Rename” Change the file name of the selected file
(13) “Copy”: Copies the file from the USB flash drive into the control box
(14) “Delete”: Deletes the selected file
(15) “New”: Creates a new file based on the selected file
METHOD FOR SETTING THE STARTING SWITCH INTERLOCK FUNCTION OF

THE CONTROL BOX
NOTICE
Be extra careful with disabling the starting switch interlock function. If the intelligent Machine Control
system crashes, the system does not operate normally. A single mistake may result in replacement of
the control box.
• Turn the control box power off after finishing the work or stopping the machine for long hours. It is
possible that the battery discharges electricity, if the control box battery cannot be charged properly.
• When the control box needs to be removed, the power supply of the control box must be switched
off before disconnecting the harness connector.
• The power supply of the control box must be switched off before turning the battery disconnect
switch to OFF position.
REMARK
When the starting switch interlock function is disabled, the following may occur, and do not indicate an abnor-
mality.
• The sound does not come out of the control box when the starting switch is turned off.
• The actual work equipment posture is different from the work equipment posture displayed on the control
box because of hydraulic drift of the work equipment.
The starting switch interlock function is available when the machine is delivered from a manufacturing plant.
If the starting switch interlock function is enabled, the control box power can be turned off when the starting
switch is turned to OFF position.
METHOD FOR SETTING THE STARTING SWITCH INTERLOCK FUNCTION OF

THE CONTROL BOX
30-288 PC210LCI-11
2. Press the main menu button (1) on the control box.
3. Press (2) at the upper right corner on the main menu

screen, and then press “Tools” (3).
4. Press “Service” (4) on the “Tools” menu screen.
5. After the input screen of password is displayed, press in-

put column (5).
PC210LCI-11 30-289
6. Use the input keypad (6) to input the password “khs3251”,

and then press “OK” (7).
7. When the screen of previously entered passwords is dis-

played, press the enter button (8).
8. Press “Exit without shutdown” (9) on the “Service” menu

screen.
9. “KOMATSU” logo mark is displayed first, and then “Ma-

chine Setup” menu screen is displayed. Press “Options”
(10).
REMARK
If “KOMATSU” logo is still displayed after several tens of
seconds, turn the starting switch to OFF position and turn
off the power supply of the control box. Repeat the above
procedure from step 2.
30-290 PC210LCI-11
10. When the “Options” screen is displayed, check the status

of the check box (12) of “To enable shutdown by key off”
(11).
• When the check box (12) is checked
The starting switch interlock function is enabled.
Unselect the check box (12) and disable the starting
switch interlock function by pressing “To enable
shutdown by key off” (11).
• When the check box (12) is unchecked
The starting switch interlock function is disabled.
Tick the check box (12) and enable the starting switch
interlock function by pressing “To enable shutdown by key off” (11).
11. Press the enter button (13).
When pressing the enter button (13), the setting of the
starting switch interlock function is saved in the control
box.
12. When the “Machine Setup” menu screen is displayed,

press “Exit” (14) and return to the standard screen.
METHOD FOR SELECTING EXCAVATOR MODEL AND IN THE CONTROL BOX

When the hydraulic excavator model must be changed or the setting of the control box must be restored, refer
to this section.
METHOD FOR SELECTING EXCAVATOR MODEL AND IN THE CONTROL BOX

2. Press the main menu button (1) on the control box.
PC210LCI-11 30-291
3. Press (2) at the upper right corner on the main menu

screen, and then press “Tools” (3).
4. Press “Service” (4) on the “Tools” menu.
5. After the input screen of password is displayed, press in-

put column (5).
6. Use the input keypad (6) to input the password “khs3251”,

and then press “OK” (7).
30-292 PC210LCI-11
7. When the screen of previously entered passwords is dis-

8. Press “Exit without shutdown” (9) on the “Service” menu

screen.
9. “KOMATSU” logo mark is displayed first, and then “Ma-

chine Setup” menu screen is displayed. Press “Options”
(10).
REMARK
10. When “Options” is displayed, press the “Excavator Model”

drop-down menu (11).
PC210LCI-11 30-293
11. Choose the suitable type (12) of the excavator model.
12. Press the enter button (13).

By pressing the enter button (13), the excavator model in
the control box can be saved.
13. When the “Machine Setup” menu screen is displayed,

press “Exit” (14) to return to the standard screen.
30-294 PC210LCI-11
30 TESTING AND ADJUSTING CALIBRATE INTELLIGENT MACHINE CONTROL
CALIBRATE INTELLIGENT MACHINE CONTROL

k Be sure to calibrate the intelligent Machine Control as needed, otherwise the automatic control may
not operate normally and the machine may move unexpectedly.
NOTICE
• If the work equipment weight of the boom or arm (other than the bucket) is largely changed, adjust
the weight by referring to the Operation and Maintenance Manual, “BOOM FINE CONTROL ADJUST-
MENT”.
• If the accuracy of the automatic control needs to be checked while the calibration is not required
when the pump or engine is replaced. See “Checking intelligent machine control”.
REMARK
The calibration can be performed even if the following error messages are displayed in the control box.
“No GPS localization...”
“Waiting for satellites...”
“Waiting for radio link...”
“Waiting to initialize...”
“Initializing...”
“Low precisions...”
“Out of design area...”
The calibration items for the intelligent Machine Control are listed below. If you performed the target works, be
sure to perform the applicable calibration items.
Works during calibration
Item Target work Reference page
Operation details
• Replacing PPC pressure sensor
PPC pressure sensor (*1) Operating work equip- PPC Pressure Sensor
calibration • Replacing work equipment con- ment control lever Calibration (30-297)
troller
• Replacing main valve and spool
(*1)
Operating work equip-
• EPC valve (*1)
ment control lever Control Map Calibration
Calibrating control map • Replacing spool stroke sensor
(Automatically calibrat- (30-378)
(*1) ed in part)
• Replacing work equipment con-
troller (*1)
• Replacing IMU sensor IMU SENSOR CALI-
IMU sensor calibration 180 ° swing
• Replacing ICT sensor controller BRATION (30-540)
• Replace the stroke sensing

boom cylinder
• Replace the stroke sensing arm
cylinder WORK EQUIPMENT
Work equipment cylin- Operating work equip-
CYLINDER CALIBRA-
der calibration • Replace the stroke/reset sens- ment control lever
TION (30-552)
ing bucket cylinder
• Replacing encoder
• Replacing ICT sensor controller
PC210LCI-11 30-295
CALIBRATE INTELLIGENT MACHINE CONTROL 30 TESTING AND ADJUSTING
Works during calibration

Item Target work Reference page
Operation details
GENERAL CALIBRA-
TION OF BUCKET
General calibration of • Operating work BLADE EDGE POSI-
boom dimensions, arm equipment control TION, BOOM DIMEN-
dimensions, bucket link • Replacing arm SIONS, ARM DIMEN-
lever
dimensions, and GNSS • Replacing ICT sensor controller SIONS, BUCKET LINK
antenna position by us- • Measuring by us- DIMENSIONS, AND
ing the total station ing tools GNSS ANTENNA PO-
SITION WITH TOTAL
STATION (30-580)
• Replacing boom • Operating work CALIBRATION OF
Calibration of boom di- equipment control BOOM DIMENSIONS
• Replace the stroke sensing
mensions and arm di- lever
boom cylinder AND ARM DIMEN-
mensions by using the
• Replace the stroke sensing arm • Measuring by us- SIONS WITH TOTAL
total station
ing tools STATION (30-632)
cylinder
CALIBRATION OF
Calibration of GNSS an-
Measuring by using GNSS ANTENNA WITH
tenna by using the total Replacing handrail
tools TOTAL STATION
station
(30-689)
CALIBRATION OF
Calibration of GNSS an-
Measuring by using GNSS ANTENNA
tenna without using the Replacing GNSS antenna (*2)
tools WITHOUT TOTAL STA-
total station
TION (30-716)
CALIBRATE IMU SEN-
Calibrate the yawing an- Measuring by using
Replacing IMU sensor SOR FOR YAW ANGLE
gle of IMU sensor (*3) tools
(30-533)
Calibration of bucket Measuring by using See Operation and
Replacing bucket
(*4) tools Maintenance Manual
*1: Perform the work only for the replaced axis.

*2: The height needs to be calibrated if different model is installed. If the model is the same, the height adjust-
ment is not required.
*3: Perform this work only when high-accuracy earthmoving operation is required on a slope after the IMU sen-
sor is installed to the machine without using the guide.
Calibrate the IMU sensor by using the guide. See DISASSEMBLY AND ASSEMBLY, “METHOD FOR INSTAL-
LING IMU SENSOR”.
*4 Perform the calibration by referring to the Operation and Maintenance Manual, “Procedure for calibrating the
standard bucket replacement” or “Procedure for calibrating the tilt bucket replacement”.
30-296 PC210LCI-11
Flow of calibration by the control box
PPC Pressure Sensor Calibration

Calibration is not required if only the PPC pressure sensor has removed and installed.
The sensor signals varies when replacing the PPC pressure sensor. Refer to this section and calibrate the sen-
sor.
PC210LCI-11 30-297
Table of required calibrations for the PPC pressure sensor

Target work PPC pressure sensor calibration
Replacing main pump assembly -
Replacing self-pressure reducing valve -
Replacing PPC pressure sensor (*1) Required
Replacing solenoid valve block Required
Replacing ICT sensor controller -
Replacing work equipment controller Required
Replacing control valve -
REMARK
• PPC pressure sensors that must be calibrated are listed below.
Boom RAISE PPC pressure sensor (valve side)
Boom RAISE PPC pressure sensor (lever side)
Boom LOWER PPC pressure sensor (valve side)
Boom LOWER PPC pressure sensor (lever side)
Arm IN PPC pressure sensor (valve side)
Arm IN PPC pressure sensor (lever side)
Arm OUT PPC pressure sensor (valve side)
Arm OUT PPC pressure sensor (lever side)
Bucket CURL PPC pressure sensor (valve side)
Bucket CURL PPC pressure sensor (lever side)
Bucket DUMP PPC pressure sensor (valve side)
Bucket DUMP PPC pressure sensor (lever side)
• This item can be performed even if the following error messages are displayed in the control box.
30-298 PC210LCI-11
List of required calibrations when the sensors have replaced

Replaced sensors Required calibrations
Boom RAISE PPC pressure sensor (valve side)
CALIBRATION OF BOOM RAISE PPC
Boom RAISE PPC pressure sensor (lever side)
PRESSURE SENSOR (30-301)
When replacing both or either of the above sensors
Boom LOWER PPC pressure sensor (valve side)
BOOM LOWER PPC PRESSURE
Boom LOWER PPC pressure sensor (lever side)
SENSOR CALIBRATION (30-313)
Arm IN PPC pressure sensor (valve side)
ARM IN PPC PRESSURE SENSOR
Arm IN PPC pressure sensor (lever side)
CALIBRATION (30-327)
Arm OUT PPC pressure sensor (valve side)
ARM OUT PPC PRESSURE SENSOR
Arm OUT PPC pressure sensor (lever side)
CALIBRATION (30-339)
Bucket CURL PPC pressure sensor (valve side)
BUCKET CURL PPC PRESSURE
Bucket CURL PPC pressure sensor (lever side)
Bucket DUMP PPC pressure sensor (valve side)
BUCKET DUMP PPC PRESSURE
Bucket DUMP PPC pressure sensor (lever side)
Solenoid valve block All ICT control calibration
(PPC pressure sensor calibration, con-
Work equipment controller trol map calibration)
Start with any calibration when the multiple calibrations need to be performed.
PC210LCI-11 30-299
Outline flow diagram of the PPC pressure sensor calibration
30-300 PC210LCI-11
CALIBRATION OF BOOM RAISE PPC PRESSURE SENSOR

posture. Set the lock lever to LOCK position, turn the swing lock switch to ON position, and then
stop the engine.
k Secure the safety around the machine before starting calibration because the work equipment
moves during the calibration.
NOTICE
Change the setting of the mounted bucket by referring to Operation and Maintenance Manual, “Bucket
Weight Setting”.
Perform the calibration under the following conditions.
METHOD FOR CHECKING CALIBRATION STATUS OF BOOM RAISE PPC PRES-

SURE SENSOR
The vehicle condition is not restricted only for checking the calibration status.
If checking data is required due to the aged change, poor operation of the automatic control, etc., refer to this
section and check the calibration status.
1. From the “Service Menu” screen, select “Adjustment”.
REMARK
2. Enter “45” with the numeral input switches after the “Ad-
justment” screen is displayed, and press F6.
F6: Enters the input value and moves to the “ICT Control
Calibration” screen
REMARK
This function is not listed on the menu because it is re-
quired only when replacing the PPC pressure sensor, the
solenoid valve block, or the work equipment controller.
PC210LCI-11 30-301
3. On the “ICT Control Calibration” screen, select “PPC Pres-

sure Sensor Calibration” with function switches or numeral
input switches.
F5: Returns the screen to the “Adjustment” screen
F6: Enters the selected item and moves to the “PPC Pres-
sure Sensor Calibration” screen
4. On the “PPC Pressure Sensor Calibration” screen, select

“Boom RAISE PPC Pressure Sensor” with function
F5: Returns to the “ICT Control Calibration” screen
F6: Enters the selected item and moves to the “Boom
RAISE PPC Pressure Sensor” screen
5. On the “Boom RAISE PPC Pressure Sensor” screen, se-

lect “PPC Pressure Sensor Calibration Check” with func-
tion switches or numeral input switches.
F5: Returns to the “PPC Pressure Sensor Calibration”
screen
RAISE PPC Press Sens Calib Check” screen
REMARK
the current calibration status saved in the work equipment
controller.
D: Default value
F: Factory default value
U: User calibration value (Technician calibration value)
6. Check the calibration value of the boom RAISE PPC pres-
sure sensor.
F5: Returns to the “Boom RAISE PPC Press Sens Calib
Check” screen
(a): Pressure detected by the PPC pressure sensor (valve
side) while the work equipment control lever is set to
NEUTRAL
(b): Pressure detected by the PPC pressure sensor (lever
NEUTRAL
(c): Differential pressure between (a) and (b)
30-302 PC210LCI-11
(d): Pressure detected by the PPC pressure sensor (valve side) when the work equipment control lever is
operated to the stroke end
(e): Pressure detected by the PPC pressure sensor (lever side) when the work equipment control lever is
(f): Differential pressure between (d) and (e)
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
METHOD FOR CALIBRATING BOOM RAISE PPC PRESSURE SENSOR

REMARK
REMARK
PC210LCI-11 30-303

input switches.


lect “PPC Pressure Sensor Calibration” with function
screen
RAISE PPC Pressure Sensor Calib” screen
7. Set the work equipment lock lever to FREE position.
8. When the “Boom RAISE PPC Pressure Sensor Calib”
screen is displayed, fully retract the boom cylinder, and
press F3.
F3: Moves to the “Boom RAISE PPC Pressure Sens Calib
1/2” screen
F5: Returns to the “Boom RAISE PPC Pressure Sensor”
screen
REMARK
Calibration can be performed as long as the machine is in
the posture that allows the boom RAISE circuit to be re-
lieved safely.
30-304 PC210LCI-11
9. On the “Boom RAISE PPC Pressure Sens Calib 1/2”

screen, adjust the hydraulic oil temperature within the
specified range for the calibration.
10. Turn the fuel control dial to MAX (High idle) position.
11. Set the work equipment control lever to NEUTRAL, and
hold down F1 to start calibration.
F2: Stops calibration and returns to the calibration start
screen of the “Boom RAISE PPC Pressure Sens Calib 1/2”
NOTICE
es.
REMARK
• The calibration takes approximately 5.5 seconds.
• During the calibration, the values are displayed in real
time on the machine monitor screen.
12. When a buzzer sounds and displayed, check the result of

the calibration and press F3.
F2: Cancels the calibration, and returns to the calibration
start screen
F3: Moves to the “Boom RAISE PPC Pressure Sens Calib
2/2” screen
(a): Value saved in the work equipment controller before
calibrating
NOTICE
If the calibration finishes abnormally, Failure Cause
Code is displayed. Take measures by referring to “Fail-
ure Cause Codes”. After measures are taken, start the
calibration again.
F1: Restarts the calibration
F5: Returns to “Boom RAISE PPC Pressure Sens Calib
1/2” screen
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.
PC210LCI-11 30-305
13. When the “Boom RAISE PPC Pressure Sens Calib 2/2”
screen is displayed, adjust the hydraulic oil temperature
within the specified range for the calibration.
F5: Returns to the “Boom RAISE PPC Pressure Sens Cal-
ib 1/2” screen
15. Relieve the boom circuit by boom RAISE operation to start

the calibration.
F2: Stops the calibration, and returns to the calibration
start screen
REMARK
• When the boom RAISE circuit is relieved, the calibra-
tion starts automatically.
• During the calibration, the screen shows the hydraulic
oil temperature, the engine speed, the PPC pressure
on the valve side, PPC pressure on the lever side, and
the pressure difference between the valve side and the
lever side in real time.
16. When a buzzer sounds and the calibration, check the re-
sult of the calibration and press F6.
start screen
F6: Finishes the calibration and returns the screen to the
“Boom RAISE PPC Pressure Sensor” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Boom RAISE PPC Pressure Sens Calib
1/2” screen
30-306 PC210LCI-11
Failure cause codes (Displayed in descending order of priority)

Object
PPC pressure sensor calibration
Cause
Boom Arm Bucket Content Required action
code
LOW-
RAISE IN OUT CURL DUMP
ER
Engine speed signal is
A-1 ● ● ● ● ● ● Check that engine is started
0 rpm
Check that the hydraulic oil
Hydraulic oil temperature is
A-2 ● ● ● ● ● ● temperature is 40 °C and
low
above
Hydraulic oil temperature is Check the hydraulic oil tem-
A-3 ● ● ● ● ● ●
high perature is 60 °C and below
A-4 ● ● ● ● ● ● Overheating Check for overheating
Defective CAN communica- Perform troubleshooting for
A-A ● ● ● ● ● ●
tion CAN
Lever is not set to NEU-
B-3 ● ● ● ● ● ● Set the lever to NEUTRAL
TRAL
Boom RAISE PPC pressure Perform troubleshooting for
WA-1 ● - - - - - sensor is defective (valve the boom RAISE PPC pres-
side) sure sensor
Boom LOWER PPC pres- Perform troubleshooting for
WA-2 - ● - - - - sure sensor is defective the boom LOWER PPC
(valve side) pressure sensor
Arm IN PPC pressure sen-
WA-3 - - ● - - - the arm IN PPC pressure
sor is defective (valve side)
sensor
Arm OUT PPC pressure Perform troubleshooting for
WA-4 - - - ● - - sensor is defective (valve the arm OUT PPC pressure
side) sensor
Bucket CURL PPC pres- Perform troubleshooting for
WA-5 - - - - ● - sure sensor is defective the bucket CURL PPC
Bucket DUMP PPC pres- Perform troubleshooting for
WA-6 - - - - - ● sure sensor is defective the bucket DUMP PPC
WB-1 ● - - - - - sensor is defective (lever the boom RAISE PPC pres-
side) sure sensor
WB-2 - ● - - - - sure sensor is defective the boom LOWER PPC
(lever side) pressure sensor
WB-3 - - ● - - - the arm IN PPC pressure
sor is defective (lever side)
sensor
WB-4 - - - ● - - sensor is defective (lever the arm OUT PPC pressure
side) sensor
PC210LCI-11 30-307
Object
Cause
code
LOW-
ER
WB-5 - - - - ● - sure sensor is defective the bucket CURL PPC
WB-6 - - - - - ● sure sensor is defective the bucket DUMP PPC
Boom RAISE reduce pres-
WD-2 ● ● - - - - the boom RAISE pressure
sure EPC is defective
reducing EPC
Boom LOWER pressure re-
WD-3 ● ● - - - - the boom LOWER pressure
ducing EPC is defective
reducing EPC
Arm IN pressure reducing
WD-4 - - ● ● - - the arm IN pressure reduc-
EPC is defective
ing EPC
Arm OUT pressure reduc-
WD-5 - - ● ● - - the arm OUT pressure re-
ing EPC is defective
ducing EPC
Bucket CURL pressure re-
WD-6 - - - - ● ● the bucket CURL pressure
reducing EPC
Bucket DUMP pressure re-
WD-7 - - - - ● ● the bucket DUMP pressure
reducing EPC
Boom has not moved to the Move the boom to the
WF-1 ● - - - - - stroke end on the RAISE stroke end on the RAISE
side side
WF-2 - ● - - - - stroke end on the LOWER stroke end on the LOWER
side side
Arm has not moved to the Move the arm to the stroke
WF-3 - - ● - - -
stroke end on the IN side end on the IN side
WF-4 - - - ● - -
stroke end on the OUT side end on the OUT side
Bucket has not moved to Move the bucket to the
WF-5 - - - - ● - the stroke end on the CURL stroke end on the CURL
side side
WF-6 - - - - - ● the stroke end on the stroke end on the DUMP
DUMP side side
Turn the fuel control dial to
WH-7 ● ● ● ● ● ● Engine speed is not Hi
MAX position
WH-8 ● ● ● ● ● ● PPC source pressure is low
PPC source pressure
30-308 PC210LCI-11
Object
Cause
code
LOW-
ER
Obtained calibration value Perform the calibration
FF ● ● ● ● ● ●
is out of normal range again
METHOD FOR RESTORING THE CALIBRATION VALUE OF BOOM RASIE PPC

PRESSURE SENSOR TO ITS DEFAULT VALUE
NOTICE
• After performing the work described in this item, be sure to perform the calibration without using the
default value.
• If the automatic leveling assist function or automatic stop control function is defective, perform trou-
bleshooting before performing the work described in this item. See “E-83 Blade edge position on de-
sign surface is not accurate when automatic leveling assist function is on.” and “E-84 Blade edge
stop position is not accurate for design surface when automatic stop control function is on.”
REMARK
REMARK
PC210LCI-11 30-309

input switches.


lect “Restore to Default Setting” with function switches or
F6: Enters the selected item, and displays the “Restore to
Default Setting” screen
6. When “Restore to Default Setting?” screen is displayed,

hold down F6 and restore the setting.
F5: Cancels the initialization and returns to “Boom RAISE
PPC Pressure Sensor” screen
F6: Executes the initialization
30-310 PC210LCI-11
7. After restoring, check that the alphabet letter at the right

top of the “Boom RAISE PPC Pressure Sensor screen” is
“D”.
REMARK
the value currently saved in the work equipment controller.
“D”: Default value
“F”: Factory default value
“U”: User calibration value (Technician calibration value)
METHOD FOR RESTORING THE CALIBRATION VALUE OF BOOM RASIE PPC

PRESSURE SENSOR TO ITS FACTORY DEFAULT VALUE
NOTICE
default value.
This function is to restore the parameter of the calibration value to the factory default value.
REMARK
PC210LCI-11 30-311
REMARK

input switches.

30-312 PC210LCI-11

lect “Restore to Factory Setting” with function switches or
Factory Setting” screen
6. Hold down F6 when “Restore to Factory Setting?” screen

is displayed.
F5: Cancels the setting and returns to “Boom RAISE PPC
Pressure Sensor” screen
F6: Confirm the setting
7. After restoring the calibration value, check that the alpha-

bet letter at the right top of the “Boom RAISE PPC Pres-
sure Sensor screen” is “F”.
REMARK
BOOM LOWER PPC PRESSURE SENSOR CALIBRATION

stop the engine.
NOTICE
Weight Setting”.
METHOD FOR CHECKING CALIRABTION STATUS OF BOOM LOWER PPC

PRESSURE SENSOR
PC210LCI-11 30-313
REMARK
REMARK

input switches.
30-314 PC210LCI-11

“Boom LOWER PPC Pressure Sensor” with function
LOWER PPC Pressure Sensor” screen
5. On the “Boom LOWER PPC Pressure Sensor” screen, se-

screen
LOWER PPC Press Sens Calib Check” screen
REMARK
controller.
D: Default value
6. Check the calibration value of the boom LOWER PPC
pressure sensor.
F5: Returns to the “Boom LOWER PPC Pressure Sensor”
screen
NEUTRAL
NEUTRAL
BOOM LOWER PPC PRESSURE SENSOR CALIBRATION

PC210LCI-11 30-315

REMARK
REMARK

input switches.
30-316 PC210LCI-11


screen
LOWER PPC Pressure Sensor Calib” screen
8. When the “Boom LOWER PPC Pressure Sensor Calib”
screen is displayed, press F3.
F3: Moves to the “Boom LOWER PPC Pressure Sens Cal-
ib 1/2” screen
F5: Returns to the “Boom LOWER PPC Pressure Sensor
Calib” screen
PC210LCI-11 30-317
9. Adjust the hydraulic oil temperature within the specified

range for the calibration. Set the machine in the calibrating
posture.
REMARK
• Calibration can be performed if the machine is in the
posture that allows the boom circuit to be relieved safe-
ly for approximately 2.5 seconds by the boom LOWER
operation.
10. Place the work equipment lock lever in LOCK position.
k For the calibration in the reference posture, check
the machine behavior in advance since the ma-
chine body is pushed when the boom circuit is re-
lieved by the boom LOWER operation. Check that
the calibration can be performed safely.
F2: Stops calibration and returns to the “Boom LOWER
PPC Pressure Sens Calib 1/2” screen
NOTICE
es.
REMARK
13. When the buzzer makes beep sound, check the calibration
result and press F3.
start screen
F3: Moves to the “Boom LOWER PPC Pressure Sens Cal-
ib 2/2” screen
calibrating
30-318 PC210LCI-11
NOTICE
calibration again.
F5: Returns to “Boom LOWER PPC Pressure Sens Calib
1/2” screen
14. When the “Boom LOWER PPC Pressure Sens Calib 2/2”
F5: Returns to the “Boom LOWER PPC Pressure Sens
Calib 1/2” screen
15. Set the work equipment lock lever to FREE position, and
relieve the boom circuit by the boom LOWER operation.
k For the calibration in the reference posture, check
the machine behavior in advance since the ma-
chine body is pushed when the boom circuit is re-
lieved by the boom LOWER operation. Check that
the calibration can be performed safely.
start screen
REMARK
• When the boom circuit is relieved by boom LOWER op-
eration, the calibration starts automatically.
• The pressure difference between the valve side and
the lever side is displayed in real time.
PC210LCI-11 30-319
16. After the calibration finishes, check the calibration result

and press F6.
start screen
“Boom LOWER PPC Pressure Sensor” screen
calibrating
REMARK
After the calibration finishes, a buzzer sounds and the cali-
bration result is displayed.
NOTICE
calibration again.
F5: Returns to the “Boom LOWER PPC Pressure Sens
Calib 2/2” screen

Object
Cause
code
LOW-
ER
0 rpm
low
above
A-3 ● ● ● ● ● ●
A-A ● ● ● ● ● ●
tion CAN
TRAL
side) sure sensor
30-320 PC210LCI-11
Object
Cause
code
LOW-
ER
sensor
side) sensor
side) sure sensor
sensor
side) sensor
reducing EPC
reducing EPC
EPC is defective
ing EPC
ducing EPC
reducing EPC
PC210LCI-11 30-321
Object
Cause
code
LOW-
ER
reducing EPC
side side
side side
WF-3 - - ● - - -
WF-4 - - - ● - -
side side
DUMP side side
MAX position
PPC source pressure
FF ● ● ● ● ● ●
METHOD FOR RESTORING THE CALIBRATION VALUE OF BOOM LOWER PPC

NOTICE
default value.
30-322 PC210LCI-11

REMARK
REMARK

input switches.
PC210LCI-11 30-323



F5: Cancels the initialization and returns to “Boom LOWER

bet letter at the right top of the “Boom LOWER LPPC Pres-
sure Sensor screen” is “D”.
REMARK
30-324 PC210LCI-11
METHOD FOR RESTORING THE CALIBRATION VALUE OF BOOM LOWER PPC

NOTICE
default value.
REMARK
REMARK
PC210LCI-11 30-325

input switches.



is displayed.
F5: Cancels the setting and returns to “Boom LOWER
30-326 PC210LCI-11

bet letter at the right top of the “Boom LOWER PPC Pres-
sure Sensor screen” is “F”.
REMARK
ARM IN PPC PRESSURE SENSOR CALIBRATION

stop the engine.
NOTICE
Weight Setting”.
METHOD FOR CHECKING CALIBARATION STATUS OF ARM IN PPC PRESSURE

SENSOR
REMARK
PC210LCI-11 30-327
REMARK

input switches.

“Arm IN PPC Pressure Sensor” with function switches or
F6: Enters the selected item and moves to the “Arm IN
30-328 PC210LCI-11
5. On the “Arm IN PPC Pressure Sensor” screen, select

“PPC Pressure Sensor Calibration Check” with function
screen
PPC Pressure Sensor Calib Check” screen
REMARK
controller.
D: Default value
6. Check the calibration value of the arm IN PPC pressure
sensor.
F5: Returns to the “Arm IN PPC Pressure Sensor” screen
NEUTRAL
NEUTRAL
(d): Pressure detected by the PPC pressure sensor (valve
side) when the work equipment control lever is operated to the stroke end
ARM IN PPC PRESSURE SENSOR CALIBRATION

REMARK
PC210LCI-11 30-329
REMARK

input switches.

30-330 PC210LCI-11
6. On the “Arm IN PPC Pressure Sensor” screen, select

“PPC Pressure Sensor Calibration” with function switches
screen
PPC Pressure Sensor Calibration” screen
8. When the “Arm IN PPC Pressure Sensor Calibration”
screen is displayed, fully extend the arm cylinder, and
press F3.
F3: Moves to the “Arm IN PPC Pressure Sensor Calib 1/2”
screen
F5: Returns to the “Arm IN PPC Pressure Sensor” screen
REMARK
Without the reference posture displayed on the monitor,
you can perform the calibration if the machine is in the
posture that allows the arm circuit to be relieved safely by
the arm IN operation.
range for the calibration.
F3: Stops calibration and returns to the calibration start
screen of the “Arm IN PPC Pressure Sensor Calib 1/2”
NOTICE
es.
REMARK
PC210LCI-11 30-331

start screen
F3: Moves to the “Arm IN PPC Pressure Sensor Calib 2/2”
screen
calibrating
NOTICE
calibration again.
F5: Returns to “Arm IN PPC Pressure Sensor Calib 1/2”
screen
13. When the “Arm IN PPC Pressure Sensor Calib 2/2” screen
is displayed, adjust the hydraulic oil temperature within the
F5: Returns to the “Arm IN PPC Pressure Sensor Calib
1/2” screen
15. Relieve the arm circuit by arm IN operation to start the cali-
bration.
start screen
REMARK
• When the arm circuit is relieved by arm IN operation,
the calibration starts automatically.
30-332 PC210LCI-11
start screen
“Arm IN PPC Pressure Sensor” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Arm IN PPC Pressure Sensor Calib 2/2”
screen

Object
Cause
code
LOW-
ER
0 rpm
low
above
A-3 ● ● ● ● ● ●
A-A ● ● ● ● ● ●
tion CAN
TRAL
side) sure sensor
sensor
PC210LCI-11 30-333
Object
Cause
code
LOW-
ER
side) sensor
side) sure sensor
sensor
side) sensor
reducing EPC
reducing EPC
EPC is defective
ing EPC
ducing EPC
reducing EPC
reducing EPC
30-334 PC210LCI-11
Object
Cause
code
LOW-
ER
side side
side side
WF-3 - - ● - - -
WF-4 - - - ● - -
side side
DUMP side side
MAX position
PPC source pressure
FF ● ● ● ● ● ●
METHOD FOR RESTORING THE CALIBRATION VALUE OF ARM IN PPC PRES-

SURE SENSOR TO ITS DEFAULT VALUE
NOTICE
default value.
REMARK
PC210LCI-11 30-335
REMARK

input switches.

30-336 PC210LCI-11
5. On the “Arm IN PPC Pressure Sensor” screen, select “Re-

store to Default Setting” with function switches or numeral
input switches.

F5: Cancels the initialization and returns to “Arm IN PPC

bet letter at the right top of the “Arm IN PPC Pressure Sen-
sor” is “D”.
REMARK
METHOD FOR RESTORING THE CALIBRATION VALUE OF ARM IN PPC PRES-

SURE SENSOR TO ITS FACTORY DEFAULT VALUE
NOTICE
default value.
PC210LCI-11 30-337

REMARK
REMARK

input switches.
30-338 PC210LCI-11

5. On the “Arm IN PPC Pressure Sensor” screen, select “Re-

store to Factory Setting” with function switches or numeral
input switches.

is displayed.
F5: Cancels the setting and returns to “Arm IN PPC Pres-
sure Sensor” screen

bet letter at the right top of the “Arm IN PPC Pressure Sen-
sor” is “F”.
REMARK
ARM OUT PPC PRESSURE SENSOR CALIBRATION

stop the engine.
PC210LCI-11 30-339
NOTICE
Weight Setting”.
METHOD FOR CHECKING CALIBARATION STATUS OF ARM OUT PPC PRES-

SURE SENSOR
REMARK
REMARK
30-340 PC210LCI-11

input switches.

“Arm OUT PPC Pressure Sensor” with function switches or
F6: Enters the selected item and moves to the “Arm OUT
5. On the “Arm OUT PPC Pressure Sensor” screen, select

“PPC Pressure Sensor Calibration Check” with function
D: Default value
screen
F6: Enters the selected item and moves to the “Arm OUT PPC Pressure Sens Calib Check” screen
REMARK
The alphabet letter at the right top of the screen indicates the current calibration status saved in the work
equipment controller.
D: Default value
6. Check the calibration value of the arm OUT PPC pressure
sensor.
F5: Returns to the “Arm OUT PPC Pressure Sensor”
screen
NEUTRAL
NEUTRAL
PC210LCI-11 30-341
METHOD FOR CALIBRATING ARM OUT PPC PRESSURE SENSOR

REMARK
REMARK

input switches.
30-342 PC210LCI-11


“PPC Pressure Sensor Calibration” with function switches
screen
PPC Pressure Sensor Calib” screen
8. When the “Arm OUT PPC Pressure Sensor Calib” screen
is displayed, fully retract the arm cylinder, and press F3.
F3: Moves to the “Arm OUT PPC Pressure Sensor Calib
1/2” screen
F5: Returns to the “Arm OUT PPC Pressure Sensor”
screen
REMARK
posture that allows the arm circuit to be relieved safely by
the arm OUT operation.
11. Set the work equipment control lever to NEUTRAL, and hold down F1 to start calibration.
F3: Stops calibration and returns to the calibration start screen of the “Arm OUT PPC Pressure Sensor Cal-
ib 1/2”
PC210LCI-11 30-343
NOTICE
es.
REMARK

start screen
F3: Moves to the “Arm OUT PPC Pressure Sensor Calib
2/2” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Arm OUT PPC Pressure Sensor Calib 1/2”
screen
13. When the “Arm OUT PPC Pressure Sensor Calib 2/2”
F3: Returns to the “Arm OUT PPC Pressure Sensor Calib
1/2” screen
30-344 PC210LCI-11
15. Relieve the arm circuit by arm OUT operation to start the
calibration.
start screen
REMARK
• When the arm circuit is relieved by arm OUT operation,
the calibration starts automatically.
start screen
“Arm OUT PPC Pressure Sensor” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Arm OUT PPC Pressure Sensor Calib 2/2”
screen

Object
Cause
code
LOW-
ER
0 rpm
low
above
PC210LCI-11 30-345
Object
Cause
code
LOW-
ER
A-3 ● ● ● ● ● ●
A-A ● ● ● ● ● ●
tion CAN
TRAL
side) sure sensor
sensor
side) sensor
side) sure sensor
sensor
side) sensor
30-346 PC210LCI-11
Object
Cause
code
LOW-
ER
reducing EPC
reducing EPC
EPC is defective
ing EPC
ducing EPC
reducing EPC
reducing EPC
side side
side side
WF-3 - - ● - - -
WF-4 - - - ● - -
side side
DUMP side side
MAX position
PPC source pressure
FF ● ● ● ● ● ●
PC210LCI-11 30-347
METHOD FOR RESTORING THE CALIBRATION VALUE OF ARM OUT PPC

NOTICE
default value.
REMARK
REMARK
30-348 PC210LCI-11

input switches.


“Restore to Default Setting” with function switches or nu-

F5: Cancels the initialization and returns to “Arm OUT PPC
PC210LCI-11 30-349

bet letter at the right top of the “Arm OUT PPC Pressure
Sensor” is “D”.
REMARK
METHOD FOR RESTORING THE CALIBRATION VALUE OF ARM OUT PPC

NOTICE
default value.
REMARK
30-350 PC210LCI-11
REMARK

input switches.

PC210LCI-11 30-351

“Restore to Factory Setting” with function switches or nu-

is displayed.
F5: Cancels the setting and returns to “Arm OUT PPC

bet letter at the right top of the “Arm OUT PPC Pressure
Sensor” is “F”.
REMARK
BUCKET CURL PPC PRESSURE SENSOR CALIBRATION

stop the engine.
NOTICE
Weight Setting”.
METHOD FOR CHECKING CALIBRATION STATUS OF BUCKET CURL PPC

PRESSURE SENSOR
30-352 PC210LCI-11
REMARK
REMARK

input switches.
PC210LCI-11 30-353

“Bucket CURL PPC Pressure Sensor” with function
F6: Enters the selected item and moves to the “Bucket
CURL PPC Pressure Sensor” screen
5. On the “Bucket CURL PPC Pressure Sensor” screen, se-

screen
CURL PPC Press Sens Calib Check” screen
REMARK
controller.
D: Default value
6. Check the calibration value of the bucket CURL PPC pres-
sure sensor.
F5: Returns to the “Bucket CURL PPC Pressure Sensor”
screen
NEUTRAL
NEUTRAL
METHOD FOR CALIBRATING BUCKET CURL PPC PRESSURE SENSOR

30-354 PC210LCI-11

REMARK
REMARK

input switches.
PC210LCI-11 30-355


screen
CURL PPC Pressure Sensor Calib” screen
8. When the “Bucket CURL PPC Pressure Sensor Calib”
screen is displayed, fully extend the bucket cylinder, and
press F3.
F3: Moves to the “Bucket CURL PPC Pressure Sens Calib
1/2” screen
F5: Returns to the “Bucket CURL PPC Pressure Sensor”
screen
REMARK
posture that allows the bucket CURL circuit to be relieved
safely.
F3: Stops calibration and returns to the calibration start screen of the “Bucket CURL PPC Pressure Sens
Calib 1/2”
30-356 PC210LCI-11
NOTICE
es.
REMARK

start screen
F3: Moves to the “Bucket CURL PPC Pressure Sens Calib
2/2” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Bucket CURL PPC Pressure Sens Calib
1/2” screen
13. When the “Bucket CURL PPC Press Sens Calib 2/2”
F3: Returns to the “Bucket CURL PPC Pressure Sens Cal-
ib 1/2” screen
PC210LCI-11 30-357
15. Relieve the bucket CURL circuit and start the calibration.
start screen
REMARK
• When the bucket CURL circuit is relieved, the calibra-
start screen
“Bucket CURL PPC Pressure Sensor” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Bucket CURL PPC Pressure Sens Calib
2/2” screen

Object
Cause
code
LOW-
ER
0 rpm
low
above
A-3 ● ● ● ● ● ●
30-358 PC210LCI-11
Object
Cause
code
LOW-
ER
A-A ● ● ● ● ● ●
tion CAN
TRAL
side) sure sensor
sensor
side) sensor
side) sure sensor
sensor
side) sensor
reducing EPC
PC210LCI-11 30-359
Object
Cause
code
LOW-
ER
reducing EPC
EPC is defective
ing EPC
ducing EPC
reducing EPC
reducing EPC
side side
side side
WF-3 - - ● - - -
WF-4 - - - ● - -
side side
DUMP side side
MAX position
PPC source pressure
FF ● ● ● ● ● ●
30-360 PC210LCI-11
METHOD FOR RESTORING THE CALIBRATION VALUE OF BUCKET CURL PPC

NOTICE
default value.
REMARK
REMARK
PC210LCI-11 30-361

input switches.



F5: Cancels the initialization and returns to “Bucket CURL
30-362 PC210LCI-11

bet letter at the right top of the “Bucket CURL PPC Pres-
sure Sensor” is “D”.
REMARK
METHOD FOR RESTORING THE CALIBRATION VALUE OF BUCKET CURL PPC

NOTICE
default value.
REMARK
PC210LCI-11 30-363
REMARK

input switches.

30-364 PC210LCI-11


is displayed.
F5: Cancels the setting and returns to “Bucket CURL PPC

top of the “Bucket CURL PPC Pressure Sensor” is “F”.
REMARK
BUCKET DUMP PPC PRESSURE SENSOR CALIBRATION

stop the engine.
NOTICE
Weight Setting”.
METHOD FOR CHECKING CALIBRATION STATUS OF BUCKET DUMP PPC

PRESSURE SENSOR
PC210LCI-11 30-365
REMARK
REMARK

input switches.
30-366 PC210LCI-11

“Bucket DUMP PPC Pressure Sensor” with function
DUMP PPC Pressure Sensor” screen
5. On the “Bucket DUMP PPC Pressure Sensor” screen, se-

screen
DUMP PPC Press Sens Calib Check” screen
REMARK
controller.
D: Default value
6. Check the calibration value of the bucket DUMP PPC
pressure sensor.
F5: Returns to the “Bucket DUMP PPC Pressure Sensor”
screen
NEUTRAL
NEUTRAL
METHOD FOR CALIBRATING BUCKET DUMP PPC PRESSURE SENSOR

PC210LCI-11 30-367

REMARK
REMARK

input switches.
30-368 PC210LCI-11


screen
DUMP PPC Pressure Sensor Calib” screen
8. When the “Bucket DUMP PPC Pressure Sensor Calib”
screen is displayed, fully retract the bucket cylinder, and
press F3.
F3: Moves to the “Bucket DUMP PPC Press Sens Calib
1/2” screen
F5: Returns to the “Bucket DUMP PPC Pressure Sensor”
screen
REMARK
posture that allows the bucket DUMP circuit to be relieved
safely.
F3: Stops calibration and returns to the calibration start screen of the “Bucket DUMP PPC Press Sens Calib
1/2”
PC210LCI-11 30-369
NOTICE
es.
REMARK

start screen
2/2” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Bucket DUMP PPC Press Sens Calib 1/2”
screen
13. When the “Bucket DUMP PPC Press Sens Calib 2/2” is
displayed, adjust the hydraulic oil temperature within the
1/2” screen
30-370 PC210LCI-11
15. Relieve the bucket DUMP circuit and start the calibration.
start screen
REMARK
• When the bucket DUMP circuit is relieved, the calibra-
start screen
“Bucket DUMP PPC Pressure Sensor” screen
calibrating
NOTICE
calibration again.
F5: Returns to “Bucket DUMP PPC Press Sens Calib 2/2”
screen

Object
Cause
code
LOW-
ER
0 rpm
low
above
A-3 ● ● ● ● ● ●
PC210LCI-11 30-371
Object
Cause
code
LOW-
ER
A-A ● ● ● ● ● ●
tion CAN
TRAL
side) sure sensor
sensor
side) sensor
side) sure sensor
sensor
side) sensor
reducing EPC
30-372 PC210LCI-11
Object
Cause
code
LOW-
ER
reducing EPC
EPC is defective
ing EPC
ducing EPC
reducing EPC
reducing EPC
side side
side side
WF-3 - - ● - - -
WF-4 - - - ● - -
side side
DUMP side side
MAX position
PPC source pressure
FF ● ● ● ● ● ●
PC210LCI-11 30-373
METHOD FOR RESTORING THE CALIBRATION VALUE OF BUCKET DUMP PPC

NOTICE
default value.
REMARK
REMARK
30-374 PC210LCI-11

input switches.



F5: Cancels the initialization and returns to “Bucket DUMP
PC210LCI-11 30-375

bet letter at the right top of the “Bucket DUMP PPC Pres-
sure Sensor” is “D”.
REMARK
METHOD FOR RESTORING THE CALIBRATION VALUE OF BUCKET DUMP PPC

NOTICE
default value.
REMARK
30-376 PC210LCI-11
REMARK

input switches.

PC210LCI-11 30-377


is displayed.
F5: Cancels the setting and returns to “Bucket DUMP PPC

top of the “Bucket DUMP PPC Pressure Sensor” is “F”.
REMARK
Control Map Calibration

Calibration is not required if only the PPC pressure sensor has removed and installed.
Table of requirements for control map calibration

Target work Calibrating control map
Replacing main pump assembly -
Replacing engine assembly -
Intelligent machine control EPC valve (*1) Required
Replacing solenoid valve block Required
Replacing ICT sensor controller -
Replacing work equipment controller Required
Replacing control valve Required
Replacing main spool (*1) (*2) Required
Replacing spool stroke sensor (*1) (*2) Required
*1: Perform the calibration only for the replaced axis.
30-378 PC210LCI-11
*2: The following axis must be calibrated.

• Boom spool
• Arm spool
• Bucket spool
REMARK
The calibration can be performed even if the following error messages are displayed in the control box.
List of calibration for replaced parts

Replaced parts Required calibrations
Boom RAISE intervening EPC CALIBRATION OF BOOM RAISE INTERVENING EPC (30-381)
CALIBRATION OF BOOM RAISE REDUCE PRESSURE EPC
Boom RAISE pressure reducing EPC
(30-403)
CALIBRATION OF BOOM LOWER REDUCE PRESSURE EPC
Boom LOWER pressure reducing EPC
(30-424)
Arm IN pressure reducing EPC CALIBRATION OF ARM IN REDUCE PRESSURE EPC (30-441)
Arm OUT pressure reducing EPC CALIBRATION OF ARM DUMP REDUCE PRESSURE EPC (30-464)
CALIBRATION OF BUCKET CURL REDUCE PRESSURE EPC
Bucket CURL pressure reducing EPC
(30-485)
CALIBRATION OF BUCKET DUMP REDUCE PRESSURE EPC
Bucket DUMP pressure reducing EPC
(30-506)
Control valve Calibrating all control maps
Control valve Calibrating all control maps

Boom spool
(30-424)
CALIBRATION OF ARM IN REDUCE PRESSURE EPC (30-441)
Arm spool
CALIBRATION OF ARM DUMP REDUCE PRESSURE EPC (30-464)
(30-485)
Bucket spool
(30-506)
CALIBRATION OF BOOM RAISE INTERVENING EPC (30-381)
Boom spool stroke sensor CALIBRATION OF BOOM LOWER REDUCE PRESSURE EPC
(30-424)
CALIBRATION OF ARM IN REDUCE PRESSURE EPC (30-441)
Arm spool stroke sensor
CALIBRATION OF ARM DUMP REDUCE PRESSURE EPC (30-464)
Replacing solenoid valve block All ICT control calibration
Replacing work equipment controller (PPC pressure sensor calibration, control map calibration)
PC210LCI-11 30-379
Start with any calibration when the multiple calibrations need to be performed.
Outline flow of control map calibration
30-380 PC210LCI-11
CALIBRATION OF BOOM RAISE INTERVENING EPC

stop the engine.
NOTICE
Weight Setting”.
METHOD FOR CHECKING THE PROGRESS OF BOOM RAISE INTERVENING

EPC CALIBRATION
REMARK
REMARK
PC210LCI-11 30-381
3. On the “ICT Control Calibration” screen, select “Control

Map Calibration” with function switches or numeral input
switches.
F6: Enters the selected item and moves to the “Control
Map Calibration” screen
4. On the “Control Map Calibration” screen, select “Boom

RAISE Intervention Control Map” with function switches or
RAISE Intervention Control Map” screen
5. On the “Boom RAISE Intervention Control Map” screen,

select “Control Map Calibration Check” with function
F5: Returns to the “Control Map Calibration” screen
RAISE Inter Control Map Calib 1/4” screen
REMARK
controller.
D: Default value
30-382 PC210LCI-11
6. Check the calibration value of the boom RAISE interven-

tion control map.
F1: Moves to the calibration value check screen around
the point where the boom starts moving
F5: Returns to the “Boom RAISE Intervention Control Map”
screen
(a): EPC current, boom RAISE PPC pressure, and boom
spool stroke when the boom RAISE operation starts
(b): Boom RAISE PPC pressure and boom spool stroke at
500 mA of EPC current when the boom RAISE operation
starts
(c): Boom RAISE PPC pressure and boom spool stroke at
starts
(d): Boom RAISE PPC pressure and boom spool stroke at
starts
(e): EPC current, boom cylinder speed, and boom spool
stroke when the boom RAISE operation starts
(f): Boom cylinder speed and boom spool stroke at +10 mA
of EPC current when the boom RAISE operation starts
(g): Boom cylinder speed and boom spool stroke at
+20 mA of EPC current when the boom RAISE operation
starts
(h): Boom cylinder speed and boom spool stroke at +30 mA of EPC current when the boom RAISE opera-
tion starts
(j): Boom cylinder speed and boom spool stroke at +40 mA of EPC current when the boom RAISE opera-
tion starts
(k): Boom cylinder speed and boom spool stroke at +50 mA of EPC current when the boom RAISE opera-
tion starts
METHOD FOR CALIBRATING BOOM RAISE INTERVENING EPC

REMARK
PC210LCI-11 30-383
REMARK

switches.

30-384 PC210LCI-11

select “Control Map Calibration” with function switches or
screen
RAISE Inter Control Map Calib” screen
7. When the “Boom RAISE Inter Control Map Calib 1/4”
screen of the calibration posture preparation screen is dis-
played, press F3.
F3: Moves to the “Boom RAISE Inter Control Map Calib
1/4” screen of the calibration start screen
screen

screen of the calibration start screen is displayed, check
that the hydraulic oil temperature is within the specified
range.
REMARK
• On the “Boom RAISE Inter Control Map Calib 1/4”
screen of the calibration start screen, the work equip-
ment cannot be moved.
• If the hydraulic oil temperature is out of the specified
range, press F5 and return to the “Boom RAISE Inter
Control Map Calib 1/4” screen of the calibration posture
preparation screen. Adjust the hydraulic oil tempera-
ture within the specified range.
9. Press F5 and return to the “Boom RAISE Inter Control Map Calib 1/4” screen of the calibration posture
preparation screen.
played, operate the arm to the position vertical to the
ground surface, and press F3.
screen
PC210LCI-11 30-385
12. When the “Boom RAISE Inter Control Map Calib

1/4”screen of the calibration start screen is displayed, set
the work equipment control lever to NEUTRAL.
F5: Returns to the “Boom RAISE Inter Control Map Calib
1/4” screen of the calibration posture preparation screen
13. Hold down F1 to start calibration.

F2: Stops calibration and returns to the “Boom RAISE Inter
Control Map Calib 1/4” screen of the calibration start
screen
NOTICE
es.
REMARK
• The work equipment cannot be moved during the cali-
bration.
• The calibration takes approximately 60 seconds.
• During the calibration, a buzzer sounds once approxi-
mately every 5.5 seconds.
• During the calibration, the values of each item are dis-
played in real time on the machine monitor screen.
14. When a buzzer sounds and the “Boom RAISE Inter Con-
trol Map Calib 1/4” screen of the calibration result screen is
displayed, check the result of the calibration.
F1: Returns to the calibration value check screen around
screen
2/4” screen
calibrating
REMARK
• When “EPC Current” increases, “Boom Cylinder
Speed” and “Spool stroke” also increase.
• The calibration value check screen shows the boom
RAISE PPC intervening EPC current values (+10 mA,
+20 mA, +30 mA, +40 mA, +50 mA of the boom RAISE
PPC intervening EPC current at starting), PPC pres-
sure, spool stroke speed, and boom cylinder speed.
Check the calibration value around the point where the
boom starts raising. See “Comparison table for values
around the point where boom starts moving”.
30-386 PC210LCI-11
Comparison table for values around the point where the boom starts moving
EPC Current Cylinder Speed Spool stroke
Item
mA mm/S mm
A 300 to 490
B A + 10
C A + 20
A<B<C<D<E<F A<B<C<D<E<F
D A + 30
E A + 40
F A + 50
NOTICE
calibration again.
15. After checking the calibration result, press F3.

2/4” screen
PC210LCI-11 30-387
F5: F5: Returns to the calibration value check screen of
“Boom RAISE Inter Control Map Calib 1/4”
range.
REMARK
preparation screen.
played, fully extend the arm cylinder, and press F3.
30-388 PC210LCI-11

the work equipment control lever to NEUTRAL, and hold
down F1 to start calibration.
screen
NOTICE
es.
REMARK
bration.
• EPC current value is 500 mA during the calibration.
screen
3/4” screen
calibrating
REMARK
• The screen shows the results of the calibration when
the boom starts moving and when the EPC current is at
500 mA.
PC210LCI-11 30-389
NOTICE
calibration again.

3/4” screen
F5: Returns to the calibration value check screen of “Boom
RAISE Inter Control Map Calib 2/4”
30-390 PC210LCI-11
range.
REMARK
preparation screen.

3/4” screen of the calibration posture screen
NOTICE
es.
REMARK
bration.
PC210LCI-11 30-391

screen
calibrating

screen
4/4” screen
REMARK
• The calibration results when the boom starts moving
and at 500 mA and 700 mA of EPC current are dis-
played.
•
30-392 PC210LCI-11
NOTICE
calibration again.

4/4” screen
PC210LCI-11 30-393
range.
REMARK
preparation screen.

NOTICE
es.
REMARK
The work equipment cannot be moved during the calibra-
tion.
screen
30-394 PC210LCI-11
calibrating

F6: Moves to “Control Map Calibration” of the calibration
selection screen
REMARK
• The calibration results when the boom starts moving
and at 500 mA and 700 mA of EPC current are dis-
played.
NOTICE
calibration again.
PC210LCI-11 30-395

Object
Boom Arm Bucket
Cause LOW-
RAISE IN OUT CURL DUMP Content Required action
code ER
RAISE pres- pres- pres- pres- pres-
pres-
inter- sure sure sure sure sure
sure
vening reduc- reduc- reduc- reduc- reduc-
reduc-
ing ing ing ing ing
ing
Engine speed signal Check that engine is
A-1 ● ● ● ● ● ● ●
is 0 rpm started
Check that the hy-
Hydraulic oil tempera- draulic oil tempera-
A-2 ● ● ● ● ● ● ●
ture is low ture is 40 °C and
above
Check the hydraulic
Hydraulic oil tempera-
A-3 ● ● ● ● ● ● ● oil temperature is
ture is high
60 °C and below
Check for overheat-
A-4 ● ● ● ● ● ● ● Overheating
ing
Defective CAN com- Perform troubleshoot-
A-A ● ● ● ● ● ● ●
munication ing for CAN
Lever is not set to Set the lever to NEU-
B-3 ● - - - - - -
NEUTRAL TRAL
Working mode is not Set the working mode
E-7 ● ● ● ● ● ● ● set to P (Power is to P (Power Mode)
Mode) or ATT/P or ATT/P
Perform troubleshoot-
Stroke sensor system
ing for the defective
SE-9 - - - - - ● ● for bucket cylinder is
bucket cylinder stroke
defective (*1)
sensor
SF-6 - - - ● ● - - for arm cylinder is de-
arm cylinder stroke
fective (*1)
sensor
SG-6 ● ● ● - - - - for boom cylinder is
stroke sensor system
defective (*1)
for the boom cylinder
Boom RAISE PPC
ing for the boom
WA-1 ● ● ● - - - - pressure sensor is de-
RAISE PPC pressure
fective (valve side)
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Arm IN PPC pressure Perform troubleshoot-
WA-3 - - - ● ● - - sensor is defective ing for the arm IN
(valve side) PPC pressure sensor
30-396 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Arm OUT PPC pres- Perform troubleshoot-
WA-4 - - - ● ● - - sure sensor is defec- ing for the arm OUT
tive (valve side) PPC pressure sensor
Bucket CURL PPC
ing for the bucket
WA-5 - - - - - ● ● pressure sensor is de-
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Boom RAISE PPC
ing for the boom
WB-1 ● ● ● - - - - pressure sensor is de-
RAISE PPC pressure
fective (lever side)
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
WB-3 - - - ● ● - - sensor is defective ing for the arm IN
(lever side) PPC pressure sensor
WB-4 - - - ● ● - - sure sensor is defec- ing for the arm OUT
tive (lever side) PPC pressure sensor
Bucket CURL PPC
ing for the bucket
WB-5 - - - - - ● ● pressure sensor is de-
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Stroke sensor for
ing for the stroke sen-
WC-1 ● ● ● - - - - boom spool is defec-
sor for the boom
tive
spool
Stroke sensor for arm
WC-2 - - - ● ● - - ing for the stroke sen-
spool is defective
sor for the arm spool
PC210LCI-11 30-397
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
● ●
(Hot (Hot Boom RAISE inter-
ing for the boom
WD-1 ● short short - - - - vening EPC is defec-
RAISE intervening
circuit circuit tive
EPC
only) only)
Boom RAISE reduce
ing for the boom
WD-2 ● ● ● - - - - pressure EPC is de-
RAISE pressure re-
fective
ducing EPC
Boom LOWER pres-
ing for the boom
WD-3 ● ● ● - - - - sure reducing EPC is
LOWER pressure re-
defective
ducing EPC
Arm IN pressure re-
ing for the arm IN
WD-4 - - - ● ● - - ducing EPC is defec-
pressure reducing
tive
EPC
Arm OUT pressure re-
ing for the arm OUT
pressure reducing
tive
EPC
Bucket CURL pres-
ing for the bucket
WD-6 - - - - - ● ● sure reducing EPC is
CURL pressure re-
defective
ducing EPC
Bucket DUMP pres-
ing for the bucket
DUMP pressure re-
defective
ducing EPC
Boom RAISE inter-
ing for the boom
WE-1 ● - - - - - - vening relay signal is
RAISE intervening re-
OFF
lay signal
Boom has not moved Move the boom to the
WF-1 - ● - - - - - to the stroke end on stroke end on the
the RAISE side LOWER side
Boom has not moved Operate the boom
WF-2 - - ● - - - - to the stroke end on LOWER lever to the
the LOWER side stroke end
Arm has not moved to Move the arm to the
WF-3 - - - ● - - - the stroke end on the stroke end on the IN
IN side side
30-398 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
WF-4 - - - - ● - - the stroke end on the stroke end on the
OUT side OUT side
Bucket has not moved Move the bucket to
WF-5 - - - - - ● - to the stroke end on the stroke end on the
the CURL side CURL side
WF-6 - - - - - - ● to the stroke end on the stroke end on the
the DUMP side DUMP side
Engine speed is not Turn the fuel control
WH-7 ● ● ● ● ● ● ●
Hi dial to MAX position
PPC source pressure
WH-8 ● ● ● ● ● ● ● ing for PPC source
is low
pressure
Obtained calibration
Perform the calibra-
FF ● ● ● ● ● ● ● value is out of normal
tion again
range
Ascending sequence
error (Judgment is Perform the calibra-
FF-1 ● ● ● ● ● ● ●
performed by multi- tion again
monitor.)
METHOD FOR RESTORING CALIBRATION VALUE OF BOOM RAISE INTERVEN-

ING EPC TO ITS DEFAULT VALUE
NOTICE
default value.
REMARK
PC210LCI-11 30-399
REMARK

switches.

30-400 PC210LCI-11

select “Restore to Default Setting” with function switches

Intervention Control Map” screen

bet letter at the right top of the “Boom RAISE Intervention
Control Map” is “D”.
REMARK
METHOD FOR RESTORING CALIBRATION VALUE OF BOOM RAISE INTERVEN-

ING EPC TO ITS FACTORY DEFAULT VALUE
NOTICE
default value.
PC210LCI-11 30-401

REMARK
REMARK

switches.
30-402 PC210LCI-11


select “Restore to Factory Setting” with function switches

is displayed.
F5: Cancels the setting and returns to “Boom RAISE Inter-
vention Control Map” screen

bet letter at the right top of the “Boom RAISE Intervention
Control Map” is “F”.
REMARK
CALIBRATION OF BOOM RAISE REDUCE PRESSURE EPC

stop the engine.
PC210LCI-11 30-403
NOTICE
Weight Setting”.
METHOD FOR CHECKING THE PROGRESS OF BOOM RAISE REDUCE PRES-

SURE EPC CALIBRATION
REMARK
REMARK
30-404 PC210LCI-11

switches.

RAISE Reduce Pressure Control Map” with function
RAISE Reduce Pressure Control Map” screen
5. On the “Boom RAISE Reduce Pressure Control Map”

screen, select “Control Map Calibration Check” with func-
RAISE Reduce Press Map Calib Chk” screen
REMARK
controller.
D: Default value
6. When the “Boom RAISE Reduce Press Map Calib Chk”
screen is displayed, check the calibration value of the
boom RAISE reducing pressure control map.
F5: Returns to the “Boom RAISE Reduce Pressure Control
Map” screen
(a): EPC current and boom RAISE PPC pressure when the
boom RAISE operation starts
(b): Boom RAISE PPC pressure at 500 mA of EPC current
when the boom RAISE operation starts
(c): Boom RAISE PPC pressure at 700 mA of EPC current
when the boom RAISE operation starts
(d): Boom RAISE PPC pressure at 930 mA of EPC current when the boom RAISE operation starts
PC210LCI-11 30-405
METHOD FOR CALIBRATING BOOM RAISE REDUCE PRESSURE EPC

REMARK
REMARK

switches.
30-406 PC210LCI-11


screen, select “Control Map Calibration” with function
Map” screen
RAISE Reduce Press Map Calib” screen
7. When the “Boom RAISE Reduce Press Map Calib 1/4”
played, press F3.
F3: Moves to the “Boom RAISE Reduce Press Map Calib
Map” screen

range.
REMARK
• On the “Boom RAISE Reduce Press Map Calib 1/4”
range, press F5 to return to the “Boom RAISE Reduce
Press Map Calib 1/4” screen of the calibration posture
9. Press F5 to return to the “Boom RAISE Reduce Press Map Calib 1/4” screen of the calibration posture
preparation screen.
PC210LCI-11 30-407
Map” screen
12. When the “Boom RAISE Reduce Press Map Calib

F2: Stops calibration and returns to the “Boom RAISE Re-
duce Press Map Calib 1/4” screen of the calibration start
screen
NOTICE
es.
REMARK
bration.
13. When a buzzer sounds and the “Boom RAISE Reduce

Press Map Calib 1/4” screen of the calibration result
screen is displayed, check the result.
screen
2/4” screen
calibrating
30-408 PC210LCI-11
NOTICE
ure Cause Cods”. After measures are taken, start the
calibration again.

F2: Returns to the “Boom RAISE Reduce Press Map Calib
2/4” screen
F5: Returns to the calibration value check screen.
PC210LCI-11 30-409
range.
REMARK
preparation screen.
played, fully extend the boom cylinder, and press F3.
F5: Returns to the calibration result screen around the
point where the boom starts moving

screen
NOTICE
es.
REMARK
bration.
30-410 PC210LCI-11

screen
3/4” screen
calibrating
NOTICE
calibration again.

3/4” screen
PC210LCI-11 30-411
F5: Returns to the calibration result screen at 500 mA of
EPC current
range.
REMARK
preparation screen.
EPC current

NOTICE
es.
30-412 PC210LCI-11
REMARK
• The work equipment cannot be moved during the calibration.
• During the calibration, the values of each item are displayed in real time on the machine monitor screen.
screen

screen
4/4” screen
calibrating
REMARK
The calibration results when the boom starts moving and
at 500 mA and 700 mA of EPC current are displayed.
PC210LCI-11 30-413
NOTICE
calibration again.

4/4” screen
EPC current
30-414 PC210LCI-11
range.
REMARK
preparation screen.
EPC current

NOTICE
es.
REMARK
bration.
screen
PC210LCI-11 30-415

selection screen
calibrating
NOTICE
calibration again.

Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
A-1 ● ● ● ● ● ● ●
is 0 rpm started
Check that the hy-
A-2 ● ● ● ● ● ● ●
above
30-416 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Check the hydraulic
ture is high
60 °C and below
Check for overheat-
ing
A-A ● ● ● ● ● ● ●
B-3 ● - - - - - -
NEUTRAL TRAL
defective (*1)
sensor
arm cylinder stroke
fective (*1)
sensor
defective (*1)
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
PC210LCI-11 30-417
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Stroke sensor for
sor for the boom
tive
spool
spool is defective
● ●
ing for the boom
RAISE intervening
EPC
only) only)
Boom RAISE reduce
ing for the boom
RAISE pressure re-
fective
ducing EPC
30-418 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Boom LOWER pres-
ing for the boom
LOWER pressure re-
defective
ducing EPC
Arm IN pressure re-
ing for the arm IN
pressure reducing
tive
EPC
ing for the arm OUT
pressure reducing
tive
EPC
Bucket CURL pres-
ing for the bucket
CURL pressure re-
defective
ducing EPC
Bucket DUMP pres-
ing for the bucket
DUMP pressure re-
defective
ducing EPC
Boom RAISE inter-
ing for the boom
OFF
lay signal
IN side side
OUT side OUT side
PC210LCI-11 30-419
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
WH-7 ● ● ● ● ● ● ●
PPC source pressure
is low
pressure
tion again
range
Ascending sequence
FF-1 ● ● ● ● ● ● ●
monitor.)
METHOD FOR RESTORING CALIBRATION VALUE OF BOOM RAISE REDUCE

PRESSURE EPC TO ITS DEFAULT VALUE
NOTICE
default value.
REMARK
30-420 PC210LCI-11
REMARK

switches.

PC210LCI-11 30-421

screen, select “Restore to Default Setting” with function

Reduce Pressure Control Map” screen

bet letter at the right top of the “Boom RAISE Reduce
Pressure Control Map” is “D”.
REMARK
METHOD FOR RESTORING CALIBRATION VALUE OF BOOM RAISE REDUCE

PRESSURE EPC TO ITS FACTORY DEFAULT VALUE
NOTICE
default value.
30-422 PC210LCI-11

REMARK
REMARK

switches.
PC210LCI-11 30-423


screen, select “Restore to Factory Setting” with function

is displayed.
F5: Cancels the setting and returns to “Boom RAISE Re-
duce Pressure Control Map” screen

top of the “Boom RAISE Reduce Pressure Control Map” is
“F”.
REMARK

stop the engine.
30-424 PC210LCI-11
NOTICE
Weight Setting”.
METHOD FOR CHECKING THE PROGRESS OF BOOM LOWER REDUCE PRES-

REMARK
REMARK
PC210LCI-11 30-425

switches.

LOWER Reduce Pressure Control Map” with function
LOWER Reduce Pressure Control Map” screen
5. On the “Boom LOWER Reduce Pressure Control Map”

LOWER Reduce Press Map Calib 1/4” screen
REMARK
controller.
D: Default value
6. Check the calibration value of the boom LOWER pressure
reducing control map.
F5: Returns to the “Boom LOWER Reduce Pressure Con-
trol Map” screen
(a): EPC current and boom LOWER PPC pressure when
the boom LOWER operation starts
(b): Boom LOWER PPC pressure at 500 mA of EPC cur-
rent when the boom LOWER operation starts
30-426 PC210LCI-11
METHOD FOR CALIBRATING BOOM LOWER REDUCE PRESSURE EPC

REMARK
REMARK

switches.
PC210LCI-11 30-427


trol Map” screen
LOWER Reduce Press Map Calib 1/2” screen
7. When the “Boom LOWER Reduce Press Map Calib 1/2”
played, press F3.
F3: Moves to the “Boom LOWER Reduce Press Map Calib
trol Map” screen

range.
REMARK
• On the “Boom LOWER Reduce Press Map Calib 1/2”
range, press F5 to return to the “Boom LOWER Re-
duce Press Map Calib 1/2” screen of the calibration
posture preparation screen, and adjust the hydraulic oil
temperature so that it is within the specified range.
9. Press F5 to return to the “Boom LOWER Reduce Press Map Calib 1/2” screen of the calibration posture
preparation screen.
30-428 PC210LCI-11
trol Map” screen
12. When the “Boom LOWER Reduce Press Map Calib

Reduce Press Map Calib 1/2” screen of the calibration
start screen
F5: Returns to the “Boom LOWER Reduce Press Map Cal-
ib 1/2” screen of the calibration posture preparation
screen
NOTICE
es.
REMARK
bration.
13. When a buzzer sounds and the “Boom LOWER Reduce

screen is displayed, check the calibration result.
start screen
2/2” screen
calibrating
PC210LCI-11 30-429
NOTICE
calibration again.

ib 1/2” screen of the calibration start screen
2/2” screen
30-430 PC210LCI-11
range.
REMARK
• On the “Boom LOWER Reduce Press Map Calib 2/2”
range, press F5 to return to the “Boom LOWER Re-
duce Press Map Calib 2/2” screen of the calibration
posture preparation screen, and adjust the hydraulic oil
17. Press F5 to return to the “Boom LOWER Reduce Press Map Calib 2/2” screen of the calibration posture
preparation screen.
played, set the machine in the reference posture shown in
the drawing, and press F3.
PC210LCI-11 30-431
19. When the “Boom LOWER Reduce Press Map Calib

start screen
screen
NOTICE
es.
REMARK
bration.
20. When a buzzer sounds and the “Boom LOWER Reduce
screen is displayed, check the calibration result.
calibrating
start screen
30-432 PC210LCI-11
NOTICE
calibration again.

Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
A-1 ● ● ● ● ● ● ●
is 0 rpm started
Check that the hy-
A-2 ● ● ● ● ● ● ●
above
Check the hydraulic
ture is high
60 °C and below
Check for overheat-
ing
A-A ● ● ● ● ● ● ●
B-3 ● - - - - - -
NEUTRAL TRAL
PC210LCI-11 30-433
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
defective (*1)
sensor
arm cylinder stroke
fective (*1)
sensor
defective (*1)
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
30-434 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Stroke sensor for
sor for the boom
tive
spool
spool is defective
● ●
ing for the boom
RAISE intervening
EPC
only) only)
Boom RAISE reduce
ing for the boom
RAISE pressure re-
fective
ducing EPC
Boom LOWER pres-
ing for the boom
LOWER pressure re-
defective
ducing EPC
Arm IN pressure re-
ing for the arm IN
pressure reducing
tive
EPC
ing for the arm OUT
pressure reducing
tive
EPC
PC210LCI-11 30-435
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Bucket CURL pres-
ing for the bucket
CURL pressure re-
defective
ducing EPC
Bucket DUMP pres-
ing for the bucket
DUMP pressure re-
defective
ducing EPC
Boom RAISE inter-
ing for the boom
OFF
lay signal
IN side side
OUT side OUT side
WH-7 ● ● ● ● ● ● ●
PPC source pressure
is low
pressure
tion again
range
Ascending sequence
FF-1 ● ● ● ● ● ● ●
monitor.)
30-436 PC210LCI-11
METHOD FOR RESTORING CALIBRATION VALUE OF BOOM LOWER REDUCE

NOTICE
default value.
REMARK
REMARK
PC210LCI-11 30-437

switches.



F5: Cancels the initialization and returns to “Boom LOWER
30-438 PC210LCI-11

bet letter at the right top of the “Boom LOWER Reduce
Pressure Control Map” is “D”.
REMARK
METHOD FOR RESTORING CALIBRATION VALUE OF BOOM LOWER REDUCE

NOTICE
default value.
REMARK
PC210LCI-11 30-439
REMARK

switches.

30-440 PC210LCI-11


is displayed.
F5: Cancels the setting and returns to “Boom LOWER Re-

bet letter at the right top of the “Boom LOWER Reduce
Pressure Control Map” is “F”.
REMARK
CALIBRATION OF ARM IN REDUCE PRESSURE EPC

stop the engine.
NOTICE
Weight Setting”.
METHOD FOR CHECKING THE PROGRESS OF ARM IN REDUCE PRESSURE

EPC CALIBRATION
PC210LCI-11 30-441
REMARK
REMARK

switches.
30-442 PC210LCI-11
4. On the “Control Map Calibration” screen, select “Arm IN

Reduce Pressure Control Map” with function switches or
F6: Enters the selected item and moves to the “Arm IN Re-
5. On the “Arm IN Reduce Pressure Control Map” screen, se-

lect “Control Map Calibration Check” with function switches
duce Pressure Map Calib Check” screen
REMARK
controller.
D: Default value
6. When the “Arm IN Reduce Pressure Map Calib Check”
screen is displayed, check the calibration value of the arm
IN reducing pressure control map.
F5: Returns to the “Arm IN Reduce Pressure Control Map”
screen
(a): EPC current and arm IN PPC pressure when the arm
IN operation starts
(b): Arm IN PPC pressure at 500 mA of EPC current when
the arm IN operation starts
(c): Arm IN PPC pressure at 700 mA of EPC current when
the arm IN operation starts
(d): Arm IN PPC pressure at 900 mA of EPC current when the arm IN operation starts
METHOD FOR CALIBRATING ARM IN REDUCE PRESSURE EPC

REMARK
PC210LCI-11 30-443
REMARK

switches.

30-444 PC210LCI-11

lect “Control Map Calibration” with function switches or nu-
screen
duce Pressure Map Calib 1/5” screen
7. When the “Arm IN Reduce Pressure Map Calib 1/5” screen
of the calibration posture preparation screen is displayed,
press F3.
F3: Moves to the “Arm IN Reduce Pressure Map Calib 1/5”
screen of the calibration start screen
screen

of the calibration start screen is displayed, check that the
hydraulic oil temperature is within the specified range.
REMARK
• On the “Arm IN Reduce Pressure Map Calib 1/5”
range, press F5 to return to the “Arm IN Reduce Pres-
sure Map Calib 1/5” screen of the calibration posture
preparation screen, and adjust the hydraulic oil temper-
ature so that it is within the specified range.
9. Press F5 to return to the “Arm IN Reduce Pressure Map Calib 1/5” screen of the calibration posture prepa-
ration screen.
operate the arm to the position vertical to the ground sur-
face, and press F3.
screen
PC210LCI-11 30-445
12. When the “Arm IN Reduce Pressure Map Calib 1/5”screen

of the calibration start screen is displayed, set the work
equipment control lever to NEUTRAL, and hold down F1 to
start calibration.
F2: Stops calibration and returns to the “Arm IN Reduce
Pressure Map Calib 1/5” screen of the calibration start
screen
F5: Returns to the “Arm IN Reduce Pressure Map Calib
NOTICE
es.
REMARK
bration.
13. When a buzzer sounds and the “Arm IN Reduce Pressure

Map Calib 1/5” screen of the calibration result screen is
displayed, check the calibration result.
screen
screen
calibrating
30-446 PC210LCI-11
NOTICE
calibration again.

screen
is displayed, press F3.
PC210LCI-11 30-447
REMARK
ration screen.
fully extend the arm cylinder, and press F3.

start calibration.
screen
NOTICE
es.
REMARK
bration.
30-448 PC210LCI-11

screen
screen
calibrating
NOTICE
calibration again.

screen
PC210LCI-11 30-449
EPC current
REMARK
ration screen.
EPC current

start calibration.
NOTICE
es.
30-450 PC210LCI-11
REMARK
• The work equipment cannot be moved during the calibration.
• During the calibration, the values of each item are displayed in real time on the machine monitor screen.
screen

screen
screen
calibrating
REMARK
PC210LCI-11 30-451
NOTICE
calibration again.

screen
EPC current
30-452 PC210LCI-11
REMARK
ration screen.
EPC current

start calibration.
NOTICE
es.
REMARK
bration.
screen
PC210LCI-11 30-453

screen
calibrating
NOTICE
calibration again.

screen
30-454 PC210LCI-11
EPC current
REMARK
ration screen.
EPC current

start calibration.
NOTICE
es.
PC210LCI-11 30-455
REMARK
bration.
screen
calibrating
selection screen
NOTICE
calibration again.
30-456 PC210LCI-11

Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
A-1 ● ● ● ● ● ● ●
is 0 rpm started
Check that the hy-
A-2 ● ● ● ● ● ● ●
above
Check the hydraulic
ture is high
60 °C and below
Check for overheat-
ing
A-A ● ● ● ● ● ● ●
B-3 ● - - - - - -
NEUTRAL TRAL
defective (*1)
sensor
arm cylinder stroke
fective (*1)
sensor
defective (*1)
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
PC210LCI-11 30-457
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Stroke sensor for
sor for the boom
tive
spool
spool is defective
30-458 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
● ●
ing for the boom
RAISE intervening
EPC
only) only)
Boom RAISE reduce
ing for the boom
RAISE pressure re-
fective
ducing EPC
Boom LOWER pres-
ing for the boom
LOWER pressure re-
defective
ducing EPC
Arm IN pressure re-
ing for the arm IN
pressure reducing
tive
EPC
ing for the arm OUT
pressure reducing
tive
EPC
Bucket CURL pres-
ing for the bucket
CURL pressure re-
defective
ducing EPC
Bucket DUMP pres-
ing for the bucket
DUMP pressure re-
defective
ducing EPC
Boom RAISE inter-
ing for the boom
OFF
lay signal
IN side side
PC210LCI-11 30-459
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
OUT side OUT side
WH-7 ● ● ● ● ● ● ●
PPC source pressure
is low
pressure
tion again
range
Ascending sequence
FF-1 ● ● ● ● ● ● ●
monitor.)
METHOD FOR RESTORING CALIBRATION VALUE OF ARM IN REDUCE PRES-

SURE EPC TO ITS DEFAULT VALUE
NOTICE
default value.
REMARK
30-460 PC210LCI-11
REMARK

switches.

PC210LCI-11 30-461


F5: Cancels the initialization and returns to “Arm IN Re-

bet letter at the right top of the “Arm IN Reduce Pressure
Control Map” is “D”.
REMARK
METHOD FOR RESTORING CALIBRATION VALUE OF ARM IN REDUCE PRES-

SURE EPC TO ITS FACTORY DEFAULT VALUE
NOTICE
default value.
30-462 PC210LCI-11

REMARK
REMARK

switches.
PC210LCI-11 30-463



is displayed.
F5: Cancels the setting and returns to “Arm IN Reduce
Pressure Control Map” screen

bet letter at the right top of the “Arm IN Reduce Pressure
Control Map” is “F”.
REMARK
CALIBRATION OF ARM DUMP REDUCE PRESSURE EPC

stop the engine.
30-464 PC210LCI-11
NOTICE
Weight Setting”.
METHOD FOR CHECKING THE PROGRESS OF ARM DUMP REDUCE PRES-

REMARK
REMARK
PC210LCI-11 30-465

switches.
4. On the “Control Map Calibration” screen, select “Arm

DUMP Reduce Pressure Control Map” with function
F6: Enters the selected item and moves to the “Arm DUMP
5. On the “Arm DUMP Reduce Pressure Control Map”

Reduce Press Map Calib Check” screen
REMARK
controller.
D: Default value
6. When the “Arm OUT Reduce Press Map Calib Check”
screen is displayed, check the calibration value of the arm
OUT reducing pressure control map.
(a): EPC current and arm OUT PPC pressure when the
arm OUT operation starts
(b): Arm OUT PPC pressure at 500 mA of EPC current
when the arm OUT operation starts
(c): Arm OUT PPC pressure at 700 mA of EPC current
(d): Arm OUT PPC pressure at 930 mA of EPC current
F5: Returns to the “Arm DUMP Reduce Pressure Control Map” screen
30-466 PC210LCI-11
METHOD FOR CALIBRATING ARM DUMP REDUCE PRESSURE EPC

REMARK
REMARK

switches.
PC210LCI-11 30-467


F5: Returns to the “Arm DUMP Reduce Pressure Control
Map” screen
Reduce Pressure Map Calib 1/4” screen
7. When the “Arm OUT Reduce Pressure Map Calib 1/4”
played, press F3.
F3: Moves to the “Arm OUT Reduce Pressure Map Calib
Map” screen

range.
REMARK
• On the “Arm OUT Reduce Pressure Map Calib 1/4”
range, press F5 to return to the “Arm OUT Reduce
Pressure Map Calib 1/4” screen of the calibration pos-
ture preparation screen, and adjust the hydraulic oil
9. Press F5 to return to the “Arm OUT Reduce Pressure Map Calib 1/4” screen of the calibration posture prep-
aration screen.
30-468 PC210LCI-11
Map” screen
12. When the “Arm OUT Reduce Pressure Map Calib

F2: Stops calibration and returns to the “Arm OUT Reduce
screen
F5: Returns to the “Arm OUT Reduce Pressure Map Calib
NOTICE
es.
REMARK
bration.
13. When a buzzer sounds and the “Arm OUT Reduce Pres-
sure Map Calib 1/4” screen of the calibration result screen
is displayed, check the calibration result.
screen
2/4” screen
calibrating
PC210LCI-11 30-469
NOTICE
calibration again.

2/4” screen
30-470 PC210LCI-11
range.
REMARK
aration screen.
played, fully retract the arm cylinder, and press F3.

screen
NOTICE
es.
REMARK
bration.
PC210LCI-11 30-471
screen
3/4” screen
calibrating
NOTICE
calibration again.

3/4” screen
30-472 PC210LCI-11
EPC current
range.
REMARK
aration screen.
EPC current
PC210LCI-11 30-473

NOTICE
es.
REMARK
bration.

screen
calibrating
screen
4/4” screen
REMARK
30-474 PC210LCI-11
NOTICE
calibration again.

4/4” screen
EPC current
PC210LCI-11 30-475
range.
REMARK
aration screen.
EPC current

NOTICE
es.
REMARK
bration.
screen
30-476 PC210LCI-11
calibrating
NOTICE
calibration again.

Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
A-1 ● ● ● ● ● ● ●
is 0 rpm started
Check that the hy-
A-2 ● ● ● ● ● ● ●
above
PC210LCI-11 30-477
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Check the hydraulic
ture is high
60 °C and below
Check for overheat-
ing
A-A ● ● ● ● ● ● ●
B-3 ● - - - - - -
NEUTRAL TRAL
defective (*1)
sensor
arm cylinder stroke
fective (*1)
sensor
defective (*1)
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
30-478 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Stroke sensor for
sor for the boom
tive
spool
spool is defective
● ●
ing for the boom
RAISE intervening
EPC
only) only)
Boom RAISE reduce
ing for the boom
RAISE pressure re-
fective
ducing EPC
PC210LCI-11 30-479
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Boom LOWER pres-
ing for the boom
LOWER pressure re-
defective
ducing EPC
Arm IN pressure re-
ing for the arm IN
pressure reducing
tive
EPC
ing for the arm OUT
pressure reducing
tive
EPC
Bucket CURL pres-
ing for the bucket
CURL pressure re-
defective
ducing EPC
Bucket DUMP pres-
ing for the bucket
DUMP pressure re-
defective
ducing EPC
Boom RAISE inter-
ing for the boom
OFF
lay signal
IN side side
OUT side OUT side
30-480 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
WH-7 ● ● ● ● ● ● ●
PPC source pressure
is low
pressure
tion again
range
Ascending sequence
FF-1 ● ● ● ● ● ● ●
monitor.)
METHOD FOR RESTORING CALIBRATION VALUE OF ARM DUMP REDUCE

NOTICE
default value.
REMARK
PC210LCI-11 30-481
REMARK

switches.

30-482 PC210LCI-11


F5: Cancels the initialization and returns to “Arm DUMP

bet letter at the right top of the “Arm DUMP Reduce Pres-
sure Control Map” is “D”.
REMARK
METHOD FOR RESTORING CALIBRATION VALUE OF ARM DUMP REDUCE

NOTICE
default value.
PC210LCI-11 30-483

REMARK
REMARK

switches.
30-484 PC210LCI-11



is displayed.
F5: Cancels the setting and returns to “Arm DUMP Reduce
Pressure Control Map” screen

bet letter at the right top of the “Arm DUMP Reduce Pres-
sure Control Map” is “F”.
REMARK

stop the engine.
PC210LCI-11 30-485
NOTICE
Weight Setting”.
METHOD FOR CHECKING THE PROGRESS OF BUCKET CURL REDUCE PRES-

SURE EPC
REMARK
REMARK
30-486 PC210LCI-11

switches.
4. On the “Control Map Calibration” screen, select “Bucket

CURL Reduce Press Control Map” with function switches
CURL Reduce Press Control Map” screen
5. On the “Bucket CURL Reduce Press Control Map” screen,

CURL Reduce Pres Map Calib Chk” screen
REMARK
controller.
D: Default value
6. When the “Bucket CURL Reduce Pres Map Calib Chk”
bucket CURL reducing pressure control map.
F5: Returns to the “Bucket CURL Reduce Press Control
Map” screen
(a): EPC current and bucket CURL PPC pressure when
the bucket CURL operation starts
(b): Bucket CURL PPC pressure at 500 mA of EPC current
when the bucket CURL operation starts
(c): Bucket CURL PPC pressure at 700 mA of EPC current
when the bucket CURL operation starts
(d): Bucket CURL PPC pressure at 930 mA of EPC current when the bucket CURL operation starts
PC210LCI-11 30-487
METHOD FOR CALIBRATING BUCKET CURL REDUCE PRESSURE EPC

REMARK
REMARK

switches.
30-488 PC210LCI-11


Map” screen
CURL Reduce Press Map Calib chk” screen
7. When the “Bucket CURL Reduce Press Map Calib 1/4”
played, press F3.
F3: Moves to the “Bucket CURL Reduce Press Map Calib
Map” screen

range.
REMARK
• On the “Bucket CURL Reduce Press Map Calib 1/4”
range, press F5 to return to the “Bucket CURL Reduce
9. Press F5 to return to the “Bucket CURL Reduce Press Map Calib 1/4” screen of the calibration posture
preparation screen.
PC210LCI-11 30-489
played, fully retract the bucket cylinder, and press F3.
Map” screen
screen of the calibration start screen is displayed, set the
work equipment control lever to NEUTRAL, and hold down
F1 to start calibration.
F2: Stops calibration and returns to the “Bucket CURL Re-
screen
F5: Returns to the “Bucket CURL Reduce Press Map Calib
NOTICE
es.
REMARK
bration.
13. When a buzzer sounds and the “Bucket CURL Reduce

screen is displayed, check the result of the calibration.
2/4” screen
calibrating
30-490 PC210LCI-11
NOTICE
calibration again.

2/4” screen
PC210LCI-11 30-491
range.
REMARK
preparation screen.
played, fully extend the bucket cylinder, and press F3.
screen
NOTICE
es.
REMARK
bration.
30-492 PC210LCI-11

screen
3/4” screen
calibrating
NOTICE
calibration again.

3/4” screen
PC210LCI-11 30-493
EPC current
range.
REMARK
preparation screen.
EPC current
30-494 PC210LCI-11
screen
NOTICE
es.
REMARK
bration.

screen
4/4” screen
calibrating
REMARK
PC210LCI-11 30-495
NOTICE
calibration again.

4/4” screen
EPC current
30-496 PC210LCI-11
range.
REMARK
preparation screen.
EPC current
screen
NOTICE
es.
REMARK
bration.
PC210LCI-11 30-497

calibrating
F6: Moves to “Control Map Calibration”
NOTICE
calibration again.

Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
A-1 ● ● ● ● ● ● ●
is 0 rpm started
Check that the hy-
A-2 ● ● ● ● ● ● ●
above
30-498 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Check the hydraulic
ture is high
60 °C and below
Check for overheat-
ing
A-A ● ● ● ● ● ● ●
B-3 ● - - - - - -
NEUTRAL TRAL
defective (*1)
sensor
arm cylinder stroke
fective (*1)
sensor
defective (*1)
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
PC210LCI-11 30-499
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Stroke sensor for
sor for the boom
tive
spool
spool is defective
● ●
ing for the boom
RAISE intervening
EPC
only) only)
Boom RAISE reduce
ing for the boom
RAISE pressure re-
fective
ducing EPC
30-500 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Boom LOWER pres-
ing for the boom
LOWER pressure re-
defective
ducing EPC
Arm IN pressure re-
ing for the arm IN
pressure reducing
tive
EPC
ing for the arm OUT
pressure reducing
tive
EPC
Bucket CURL pres-
ing for the bucket
CURL pressure re-
defective
ducing EPC
Bucket DUMP pres-
ing for the bucket
DUMP pressure re-
defective
ducing EPC
Boom RAISE inter-
ing for the boom
OFF
lay signal
IN side side
OUT side OUT side
PC210LCI-11 30-501
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
WH-7 ● ● ● ● ● ● ●
PPC source pressure
is low
pressure
tion again
range
Ascending sequence
FF-1 ● ● ● ● ● ● ●
monitor.)
METHOD FOR RESTORING CALIBRATION VALUE OF BUCKET CURL REDUCE

NOTICE
default value.
REMARK
30-502 PC210LCI-11
REMARK

switches.

PC210LCI-11 30-503


F5: Cancels the initialization and returns to “Bucket CURL
Reduce Press Control Map” screen

bet letter at the right top of the “Bucket CURL Reduce
Press Control Map” is “D”.
REMARK
METHOD FOR RESTORING CALIBRATION VALUE OF BUCKET CURL REDUCE

NOTICE
default value.
30-504 PC210LCI-11

REMARK
REMARK

switches.
PC210LCI-11 30-505



is displayed.
F5: Cancels the setting and returns to “Bucket CURL Re-
duce Press Control Map” screen

bet letter at the right top of the “Bucket CURL Reduce
Press Control Map” is “F”.
REMARK

stop the engine.
30-506 PC210LCI-11
NOTICE
Weight Setting”.
METHOD FOR CHECKING THE PROGRESS OF BUCKET DUMP REDUCE PRES-

SURE EPC
REMARK
REMARK
PC210LCI-11 30-507

switches.

DUMP Reduce Press Control Map” with function switches
DUMP Reduce Press Control Map” screen
5. On the “Bucket DUMP Reduce Press Control Map” screen,

DUMP Reduce Press Map Calib Chk” screen
REMARK
controller.
D: Default value
6. When the “Bucket DUMP Reduce Press Map Calib Chk”
bucket DUMP reducing pressure control map.
F5: Returns to the “Bucket DUMP Reduce Press Control
Map” screen
(a): EPC current and bucket DUMP PPC pressure when
the bucket DUMP operation starts
(b): Bucket DUMP PPC pressure at 500 mA of EPC cur-
rent when the bucket DUMP operation starts
(c): Bucket DUMP PPC pressure at 700 mA of EPC cur-
rent when the bucket DUMP operation starts
(d): Bucket DUMP PPC pressure at 930 mA of EPC current when the bucket DUMP operation starts
30-508 PC210LCI-11
METHOD FOR CALIBRATING BUCKET DUMP REDUCE PRESSURE EPC

REMARK
REMARK

switches.
PC210LCI-11 30-509


Map” screen
DUMP Reduce Press Map Calib chk” screen
7. When the “Bucket DUMP Reduce Press Map Calib 1/4”
screen of the calibration start screen is displayed, press
F3.
F3: Moves to the “Bucket DUMP Reduce Press Map Calib
Map” screen

range.
REMARK
• On the “Bucket DUMP Reduce Press Map Calib 1/4”
range, press F5 to return to the “Bucket DUMP Reduce
9. Press F5 to return to the “Bucket DUMP Reduce Press Map Calib 1/4” screen of the calibration posture
preparation screen.
30-510 PC210LCI-11
Map” screen
F2: Stops calibration and returns to the “Bucket DUMP Re-
screen
F5: Returns to the “Bucket DUMP Reduce Press Map Cal-
screen
NOTICE
es.
REMARK
bration.
13. When a buzzer sounds and the “Bucket DUMP Reduce

calibrating
2/4” screen
PC210LCI-11 30-511
NOTICE
calibration again.

2/4” screen
30-512 PC210LCI-11
range.
REMARK
preparation screen.
screen
screen
NOTICE
es.
REMARK
bration.
PC210LCI-11 30-513

calibrating
screen
3/4” screen
NOTICE
calibration again.

3/4” screen
30-514 PC210LCI-11
EPC current
range.
REMARK
preparation screen.
EPC current
PC210LCI-11 30-515
screen
ib 3/4” screen of the calibration posture screen
NOTICE
es.
REMARK
bration.

calibrating
screen
4/4” screen
REMARK
30-516 PC210LCI-11
NOTICE
calibration again.

4/4” screen
EPC current
PC210LCI-11 30-517
range.
REMARK
preparation screen.
EPC current
screen
ib 4/4” screen of the calibration posture screen
NOTICE
es.
REMARK
bration.
30-518 PC210LCI-11

calibrating
F6: Moves to “Control Map Calibration”
NOTICE
calibration again.

Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
A-1 ● ● ● ● ● ● ●
is 0 rpm started
Check that the hy-
A-2 ● ● ● ● ● ● ●
above
PC210LCI-11 30-519
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Check the hydraulic
ture is high
60 °C and below
Check for overheat-
ing
A-A ● ● ● ● ● ● ●
B-3 ● - - - - - -
NEUTRAL TRAL
defective (*1)
sensor
arm cylinder stroke
fective (*1)
sensor
defective (*1)
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
30-520 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Boom RAISE PPC
ing for the boom
RAISE PPC pressure
sensor
Boom LOWER PPC
ing for the boom
LOWER PPC pres-
sure sensor
Bucket CURL PPC
ing for the bucket
CURL PPC pressure
sensor
Bucket DUMP PPC
ing for the bucket
DUMP PPC pressure
sensor
Stroke sensor for
sor for the boom
tive
spool
spool is defective
● ●
ing for the boom
RAISE intervening
EPC
only) only)
Boom RAISE reduce
ing for the boom
RAISE pressure re-
fective
ducing EPC
PC210LCI-11 30-521
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
Boom LOWER pres-
ing for the boom
LOWER pressure re-
defective
ducing EPC
Arm IN pressure re-
ing for the arm IN
pressure reducing
tive
EPC
ing for the arm OUT
pressure reducing
tive
EPC
Bucket CURL pres-
ing for the bucket
CURL pressure re-
defective
ducing EPC
Bucket DUMP pres-
ing for the bucket
DUMP pressure re-
defective
ducing EPC
Boom RAISE inter-
ing for the boom
OFF
lay signal
IN side side
OUT side OUT side
30-522 PC210LCI-11
Object
Boom Arm Bucket
Cause LOW-
code ER
pres-
sure
reduc-
ing ing ing ing ing
ing
WH-7 ● ● ● ● ● ● ●
PPC source pressure
is low
pressure
tion again
range
Ascending sequence
FF-1 ● ● ● ● ● ● ●
monitor.)
METHOD FOR RESTORING CALIBRATION VALUE OF BUCKET DUMP REDUCE

NOTICE
default value.
REMARK
PC210LCI-11 30-523
REMARK

switches.

30-524 PC210LCI-11


F5: Cancels the initialization and returns to “Bucket DUMP
Reduce Press Control Map” screen

top of the “Bucket DUMP Reduce Press Control Map” is
“D”.
REMARK
METHOD FOR RESTORING CALIBRATION VALUE OF BUCKET DUMP REDUCE

NOTICE
default value.
PC210LCI-11 30-525

REMARK
REMARK

switches.
30-526 PC210LCI-11



is displayed.
F5: Cancels the setting and returns to “Bucket DUMP Re-
duce Press Control Map” screen

bet letter at the right top of the “Bucket DUMP Reduce
Press Control Map” is “F”.
REMARK
METHOD FOR TESTING THE INTELLIGENT MACHINE CONTROL SYSTEM

Tools for testing the intelligent machine control system
Commercially
A Video device 1
available
PC210LCI-11 30-527
stop the engine.
k Use the ropes and secure the safety around the machine before starting the calibration because the
work equipment moves during the calibration.
NOTICE
Weight Setting”.
• Road surface: Grade of 5 °or less
Refer to this section and test the function of the auto grade assist control after performing the PPC pressure
sensor calibration “” and “Control Map Calibration”.
METHOD FOR TESTING AUTO GRADE ASSIST CONTROL

2. Press the satellite receiving button (1) on the standard
screen of the control box.
3. When the screen is displayed, check that the values of

“Horizontal RMS” (2) and “Vertical RMS” (3) are 0.02 m or
less respectively on the “Fix” screen.
4. Select the “Flat Plane Surface” by referring to Operation
and Maintenance Manual, “Creating method of new design
data”, and create the design surface of the unlimited flat
plane approximately 0.5 m higher than the ground surface.
5. Record the current adjustment values of “Arm Initial
Speed” and “Arm Steady Speed”. See Operation and
Maintenance Manual, “Semi-Auto Adjustment”.
30-528 PC210LCI-11
6. Set the adjustment values of “Arm Initial Speed” and “Arm

Steady Speed” to “-8”. See Operation and Maintenance
Manual, “Semi-Auto Adjustment”.
REMARK
By setting the adjustment value to “-8”, not only the output
value of the arm IN EPC valve is limited to 1.3 MPa but al-
so the arm IN speed is limited.
7. Select and display the following monitoring items by refer-

ring to “SET AND OPERATE MACHINE MONITOR”.
Monitoring code: 04401 “Hydraulic Oil Temperature”
Monitoring code: 75301 “Arm Angle”
Monitoring code: 75302 “Bucket Angle”
range.
11. Set the upper structure and work equipment to the follow-
ing positions.
Upper structure: Cab in parallel with track
Arm angle (a): Approx. 137 °
Bucket angle (b): Approx. 190 °
Work equipment: Position of the bucket blade tip is higher
than the design surface (c)
PC210LCI-11 30-529
12. Press the auto/manual switch, and switch to the semi-auto

mode.
13. Slowly lower the boom, and stop the blade tip on the de-
sign surface (c).
REMARK
Operate the boom toward the LOWER side continuously
until the blade tip comes to the design surface (c) on the
control box screen (for approximately 10 seconds) and
then return the work equipment control lever to NEUTRAL
position.
14. Operate the arm toward the IN side stroke end, and record
the distance (4) between the blade tip and the design sur-
face (c) on the control box screen by using the video de-
vice A.
The auto grade assist control can be activated when the
arm is operated to the stroke end and the blade tip moves
along the design surface (c).
15. Read the recorded variation.
REMARK
Read the variation when the arm is stabilized without the arm drops at the start of the operation, and the
arm drops or floats more than the arm vertical position.
GNSS receiver status Best Worse
Reference for the blade tip variation Within ±10 mm Within ±40 mm
When the test is finished, restore the adjustment values of “Arm Initial Speed” and “Arm Steady Speed” to the
values before the test.
METHOD FOR TESTING OPERATION OF AUTO STOP CONTROL

30-530 PC210LCI-11
2. Press the satellite receiving button (1) on the standard

screen of the control box.
3. When the screen is displayed, check that the values of

“Horizontal RMS” (2) and “Vertical RMS” (3) are 0.02 m or
less respectively on the “Fix” screen.
4. Select the “Flat Plane Surface” by referring to Operation
and Maintenance Manual, “Creating method of new design
data”, and create the design surface of the unlimited flat
plane approximately 1.0 m above from the ground surface.
5. Record the current adjustment values of “Arm Initial
Speed” and “Arm Steady Speed”. See Operation and
Maintenance Manual, “Semi-Auto Adjustment”.

Monitoring code: 04401 “Hydraulic Oil Temperature”
Monitoring code: 75301 “Arm Angle”
Monitoring code: 75302 “Bucket Angle”
Monitoring code: 75602 “Boom LOWER PPC Pressure
Sensor 2”
range.
10. Set the upper structure and work equipment to the follow-
ing positions.
Arm angle (a): Approximately 137 °
Bucket angle (b): Approximately 190 °
Work equipment: Position where the bucket blade tip is ap-
proximately 1.5 m higher than the design surface (c)
PC210LCI-11 30-531
11. Press the auto/manual switch, and switch to the semi-auto

mode.
12. Slowly lower the boom, and stop the blade tip on the de-
sign surface (c).
REMARK
• Operate the work equipment control lever while “Boom
LOWER PPC Pressure Sensor 2” is 1.0 MPa or lower.
• Operate the boom toward the LOWER side continuous-
ly until the blade tip comes to the design surface (c) on
the control box screen After the values are stable (for
approximately 20 seconds) and then return the work
equipment control lever to NEUTRAL position.
13. After the values are stable check the values of distance (4)
between the blade tip and the design surface on the con-
trol box screen.
REMARK
The reference values of the distance (4) between the blade tip and the design surface after the values are
stable varys depending on the GNSS receiving status.
Guide for values After the values are stable

GNSS receiving status Best Worse
Distance between the blade tip and Within -5 mm Within -25 mm
the design surface After the values
are stable Within +30 mm Within +50 mm
If the value is not close to the reference value or make the distance between the blade tip and the design sur-
face as close as possible, adjust the control by referring to Operation and Maintenance Manual, “Semi-auto Ad-
justment”.
30-532 PC210LCI-11
CALIBRATE IMU SENSOR FOR YAW ANGLE

Calibration tools for yawing angle of IMU sensor
Commercially
A Total station 1
available
Commercially
B Marker 1
available
k Ensure the safety of the surroundings before traveling.

k The work equipment must be operated during the adjustment. Secure sufficient area around the ma-
chine.
k When inclining the machine, fix the machine at the safe angle to prevent it from tipping over during
operation.
IMU sensor controller corrects the effect to the blade tip position accuracy of the machine inclined due to the
installation status.
The adjustment by using the total station A must be done in pairs.
For the use of the total station A main unit, see the Operation and Maintenance Manual.
Compared to the accuracy of the machine control when the machine is on the level ground, accuracy deteriora-
tion of the machine control gets worse when the machine is on a slope. If the installation cannot be performed
by using the jig, this function enables to perform the adjustment.
CALIBRATION METHOD FOR IMU SENSOR FOR YAW ANGLE

REMARK
PC210LCI-11 30-533
F3: Moves the selected item down
F4: Moves the selected item up
REMARK
quired only when the machine control accuracy on a slope
becomes poorer than that on a level ground while IMU
sensor cannot be installed by using jigs, etc.
3. On the “ICT Control Calibration” screen, select “IMU Yaw

Angle Adjustment” with function switches or numeral input
switches.
F6: Enters the selected item and moves to the “IMU Yaw
Angle Adjustment” screen.
4. When the “IMU Yaw Angle Adjustment” screen is dis-

played, move the machine to a slope where the machine
can swing or incline.
30-534 PC210LCI-11
5. Operate the machine in the working posture (a) while it is

inclined.
6. Measure the coordinates of the blade tip by using the total
station A, and record the coordinates.
REMARK
• If it is difficult to measure the blade tip position by using
the total station A, you can measure the blade tip posi-
tion by digging the slope up to the same height in the
horizontal direction of the machine. Then, compare the
height of the digging surface.
• For the method of measuring the coordinates, see Op-
eration and Maintenance Manual for the total station A.
7. Display the “Blade edge position” screen by the control

box, check the blade tip coordinates, and record them.
REMARK
Select the the point of the bucket blade tip measured by
the total station A in “point” (1).
8. Press F1 on the machine monitor, and save the work

equipment status during the measurement on the machine
monitor.
REMARK
When the F1 is pressed on the machine monitor, the val-
ues of the column (d) becomes the same values as the
column (c). The value saved in the column (d) can be
cleared by pressing F1 again.
F1: Displays the same values in the column (c) and the
column (d)
F3: Reduces the compensation value (e).
F4: Increases the compensation value (e).
F6: Enters the compensation value (e) and returns the screen to the “ICT Control Calibration” screen
PC210LCI-11 30-535
9. Swing the upper structure 180 °, and set the machine in

the working posture (b).
10. Measure the blade tip position by using the total station A,
and record the position.
REMARK
Measuring the position of the blade edge in the work
equipment posture (a) is highly recommended.
11. Display the “Blade edge position” of the control box. Check
the blade tip coordinates, and record them.
REMARK
Select the the point of the bucket blade tip measured by
the total station A in “point” (1).
12. Check the difference between the height of the blade edge
position measured by using the total station A in step 6 to
step 10 and the height of the blade edge position recorded
by the control box.
13. Compare the differences in the positioning of the posture (a) and the posture (b) checked in the step 12.
• When the blade edge position in the posture (a) is higher than its position in the posture (b)
Press F4 on the machine monitor for adjustment.
• When the blade edge position in the posture (a) is lower than its position in the posture (b)
REMARK
• Compensation value can be adjusted with the range from “0” to “20”.
• If the correction needs to be stopped, restore the value to the default value when the correction started.
• The default value is “10”.
14. Press F6 on the machine monitor to finish “”, and return to
the “ICT Control Calibration” screen.
column (d)
F6: Enters the compensation value (e) and returns the
screen to the “ICT Control Calibration” screen
30-536 PC210LCI-11
Correcting method of IMU yawing angle by the control point

1. Move the machine to the control point.
REMARK
Anything with the same height in the horizontal direction of the machine can be substituted for the control
point.
REMARK
REMARK
quired only when the machine control accuracy on a slope
becomes poorer than that on a level ground while IMU
sensor cannot be installed by using jigs, etc.
4. On the “ICT Control Calibration” screen, select “” with func-

F6: Enters the selected item and moves to the “IMU Yaw
Angle Adjustment” screen.
PC210LCI-11 30-537
5. When the “” screen is displayed, move the machine to a

slope where the machine can swing or incline.
6. Set the work equipment in the working posture (a) on a

slope while it touches the control point (f).
7. Display the “Blade edge position” screen by the control

box, check the blade tip coordinates, and record them.
REMARK
Select the position of the bucket blade edge in “point” (1)
column while the work equipment touches the control
point.
8. Press F1 on the machine monitor, and save the work

equipment status during the measurement on the machine
monitor.
REMARK
When the F1 is pressed on the machine monitor, the val-
ues of the column (d) becomes the same values as the
column (c). The value saved in the column (d) can be
cleared by pressing F1 again.
column (d)
30-538 PC210LCI-11

F6: Enters the compensation value (e) and returns the screen to the “ICT Control Calibration” screen
9. Compare the height of the blade edge position measured by the control box in the work equipment posture
(a) with the height of the control point (f).
• When the blade edge position on the control box is higher than the control point (f)
• When the blade edge position on the control box is lower than the control point (f)
REMARK
10. Change the inclining direction, and set the work equipment
in the work equipment posture (b) while it touches the con-
trol point (g).
REMARK
• Change the posture from the work equipment posture
(a) to the work equipment posture (b) by changing the
machine inclining direction.
• When changing the posture from the work equipment
posture (a) to the work equipment posture (b), adjust
the angle of inclination as well.
• Set the work equipment angle to the angle saved in
step 8. Operate the work equipment and touch the con-
trol point.
11. Display the “Blade edge position” of the control box. Check
the blade tip coordinates, and record them.
REMARK
Select the position of the bucket blade edge in “point” (1)
column while the work equipment touches the control
point.
12. Compare the height checked by the control box and re-
corded in the work equipment posture (b) with the height of
the control point (g).
• When the blade edge position on the control box is
higher than the control point (g)
• When the blade edge position on the control box is lower than the control point (g)
PC210LCI-11 30-539
REMARK
13. Repeat the step 6 to step 12 until the blade tip precision accuracy in the working posture (a) and working
posture (b) is within the standard value range.
IMU SENSOR CALIBRATION

stop the engine.
k To move the upper structure 180 ° during calibration, secure the safety around the machine before
starting calibration.
NOTICE
IMU sensor starts initialization by turning the starting switch to ON position. At this time, the initializa-
tion may fail due to vibration. Therefore, be sure to turn the starting switch to ON position, and hold for
10 seconds before starting the engine.
REMARK
• Calibration can be performed indoors since the calibration does not require GNSS antenna to receive the
radio waves from the satellite.
• Perform the calibration while the fuel control dial is in MIN position (low idle).
• Calibration can still be performed even if any of the following error messages are displayed.
“ No GPS localization...”
Calibration of IMU sensor is the menu calibrates the IMU sensor installation angle to the machine.
After the ICT sensor controller is replaced or after IMU sensor is replaced, removed and installed, be sure to
perform the calibration.
Road surface: At inclination angle of 5 °or less
METHOD FOR CALIBRATING IMU SENSOR

1. Turn the starting switch to ON position and hold it for 10 seconds.
30-540 PC210LCI-11
3. Set the upper structure and each cylinder of the work

equipment to the following positions.
• Upper structure: Cab in parallel with track
• Boom cylinder: Fully extended
• Arm cylinder: Fully extended
• Bucket cylinder: Fully extended
4. Press the menu button (1) on the control box.
5. Press (2) at the upper right corner on the “Menu” screen,

and then press “Tools” (3).
6. When the “Tools” screen is displayed, press “Service” (4).
PC210LCI-11 30-541
7. After the “Enter service password” screen is displayed,

press input column (5).
8. When the input keypad (6) is displayed, input a password

“khs3251”, and then press “OK” (7).
9. When the screen of previously entered password is dis-

10. When the “Service” screen is displayed, press “Exit without

shutdown” (9).
30-542 PC210LCI-11
11. When the “Machine Setup” screen is displayed after “KO-

MATSU” logo mark is displayed, press “IMU Calibration”
(10).
REMARK
12. When the “Machine Angle (Front)” screen is displayed, cal-
ibrate the front side of the machine.
• When the “Status” is “READY” (11)

REMARK
This indicates the calibration has never been per-
formed.
1) Hold down “Start” (12) for 0.5 second or more to
start the calibration.
REMARK
If an error code appears, take actions by referring to
“ACTION TO BE TAKEN IF AN ERROR OCCURS
DURING CALIBRATION OF IMU SENSOR”.
When the calibration starts, the progress bar (15) ap-
pears and the control box calculates the mean value
of leaning of the machine within approximately 20 sec-
onds.
• When the “Status” is “OK” (13)

REMARK
This shows the calibration has already been per-
formed.
1) Reset the parameter by holding down “Clear” (14)
for 0.5 second or more.
PC210LCI-11 30-543
2) When the “Status” changes to “READY” (11), hold

down “Start” (12) for 0.5 second or more to start
the calibration.
NOTICE
• When the progress bar (15) is moving, never
operate the work equipment control lever.
• If an error code appears, take actions by refer-
ring to “ACTION TO BE TAKEN IF AN ERROR
OCCURS DURING CALIBRATION OF IMU SEN-
SOR”.
When the calibration starts, the progress bar (15) appears
and the control box calculates the mean value of leaning of
the machine within approximately 20 seconds.
13. When the calibration on the front side of the machine suc-
cessfully finishes, the “Status” changes to “OK” (16). Press
“Next” (17).
14. Turn the swing lock switch to OFF position.
16. While keeping the posture of the work equipment, swing

the upper structure 180 °, and then stabilize the machine
for approximately 10 seconds.
REMARK
Set the upper structure so that the cab is in parallel with
the track.
17. Turn on the swing lock switch.
18. When the “Machine Angle (Rear)” screen is displayed, cal-
ibrate the rear side of the machine.
30-544 PC210LCI-11
• When the “Status” is “READY” (18)

REMARK
This indicates the calibration has never been per-
formed.
1) Hold down “Start” (19) for 0.5 second or more to

start the calibration.
NOTICE
When the progress bar (20) is moving, never oper-
ate the work equipment control lever.
REMARK
onds.
• When the “Status” is “OK” (20)

REMARK
This shows the calibration has already been per-
formed.
PC210LCI-11 30-545

for 0.5 seconds or more.
2) When the “Status” changes to “READY” (18), hold

down “Start” (19) for 0.5 seconds or more to start
the calibration.
NOTICE
When the progress bar (20) is moving, never oper-
ate the work equipment control lever.
REMARK
onds.
19. When the calibration on the rear side of the machine suc-
cessfully finishes, the “Status” changes to “OK” (22). Press
“Set” (23).
30-546 PC210LCI-11
20. When the “Machine Setup” screen is displayed, press “Ex-

it” (24).
21. When the standard screen is displayed, press the menu

button (1).
PC210LCI-11 30-547



27. When the “Service” screen is displayed, select the “Re-

ceived Data” tab (25).
REMARK
By pressing the select button (26), the selected item
moves.
30-548 PC210LCI-11
28. When the list of the received data is displayed, record the
angle (a) of “Pitch angle(deg)” and angle (b) of “Roll An-
gle(deg)” in “23: Vehicle Angles 100Hz” (27).
29. Turn the swing lock switch to OFF position.
30. Swing the upper structure 180 ° while keeping the same
working posture.
REMARK
Set the upper structure so that the cab is in parallel with
the track.
32. Record the angle (c) of “Pitch angle(deg)” and angle (d) of
“Roll Angle(deg)” in “23: Vehicle Angles 100Hz” (27).
33. Calculate the angle of the machine before and after swing-
ing the machine in step 28, and in step 33. Check that the
values are within the standard value range.
Pitching angle: pitching angle (a) before swinging + pitch-
ing angle (c) after swinging
Rolling angle: rolling angle (b) before swinging + rolling an-
gle (d) after swinging
REMARK
• If the calculated value is out of the standard value
range, installation of IMU sensor may be defective.
Check the installation for bolt looseness, etc. and cali-
brate IMU sensor again.
• If the calculated value is still out of the standard value
range after the calibration is performed again, perform
troubleshooting for IMU sensor. For details, see TROU-
BLESHOOTING, “Failure code [DK80KT] IMU Internal
Failure” or “E-86 NG frequently occurs in IMU calcula-
tion diagnosis”.
PC210LCI-11 30-549
34. Press “Exit without shutdown” (28).


MATSU” logo mark is displayed, press “Exit” (29).
REMARK
36. Turn the starting switch to OFF position when the standard
screen is displayed.
37. After checking the control box power supply is turned off
and the screen disappears, turn the starting switch to ON
position.
REMARK
When the starting switch is turned to ON position again,
the calibration result is reflected to the control box.
When the calibration is done, test the accuracy of the blade edge by referring to “Adjustment flow chart of IMU
sensor”.
30-550 PC210LCI-11
Adjustment flow chart of IMU sensor
*1: Check for the positioning accuracy of the blade tip. See the procedure 111.-15 of “METHOD FOR CALI-
BRATING BUCKET BLADE EDGE POSITION, BOOM DIMENSIONS, ARM DIMENSIONS, BUCKET LINK DI-
MENSIONS, AND GNSS ANTENNA POSITION WITH TOTAL STATION”.
*2: The following factors made the calibration of IMU sensor on the monitor more difficult.
• Unable to collect all the necessary equipments for the calibration
• Problem with weak satellite signal at the job site
PC210LCI-11 30-551
*3: Calibrate the yaw angle by referring to “CALIBRATE IMU SENSOR FOR YAW ANGLE”.
*4: Use the jigs and calibrate the IMU sensor by referring to DISASSEMBLY AND ASSEMBLY, “METHOD FOR
INSTALLING IMU SENSOR”
*5: Examine the possible causes of the problem by referring to the following items.
• TROUBLESHOOTING “E-79 WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE
VALUE IS DIFFERENT FROM ACTUAL MACHINE”
• The procedure 111.-15 of “When the difference (100) displayed on the monitor is out of the standard value
range” in “METHOD FOR CALIBRATING BUCKET BLADE EDGE POSITION, BOOM DIMENSIONS, ARM
DIMENSIONS, BUCKET LINK DIMENSIONS, AND GNSS ANTENNA POSITION WITH TOTAL STATION”
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF IMU

SENSOR
When an error occurs during calibration, see this section to respond to the occurrence of an error.
METHOD FOR TAKING ACTION IF AN ERROR OCCURS DURING CALIBRATION

OF IMU SENSOR
If “NG” (2) is displayed in ERROR code (1) and “Status”, take
measures by referring to “Error code table”.
Error code table

Error code Content Required action
Press the return button (3), start the engine, and
A–1 Engine speed signal is 0 rpm
execute the calibration again.
Open circuit in wiring harness of IMU sensor CAN
A-A • Press the return button (3), and performing
circuit
troubleshooting for IMU sensor.
SH-1 Defective IMU sensor
• Enable the function by referring to “Control
Failure of IMU sensor initialization, or low power box starting switch interlock function”.
SH-2
supply voltage
Stabilize the machine, and then perform the cali-
FF IMU sensor stabilization error
bration again.
WORK EQUIPMENT CYLINDER CALIBRATION

stop the engine.
30-552 PC210LCI-11
REMARK
• Calibration can be performed indoors since the calibration does not require GNSS antenna to receive the
radio waves from the satellite.
• Perform the calibration while the fuel control dial is in MIN position (low idle).
• Calibration can still be performed even if any of the following error messages are displayed.
Calibration of the work equipment cylinder calibrates the position of the reset sensor which installed to the
stroke sensing hydraulic cylinder.
Be sure to perform the calibration after replacement of the ICT controller, the stroke sensing hydraulic cylinder,
the encoder, or the reset sensor.
METHOD FOR CALIBRATING WORKEQUIPMENT CYLINDER

Monitoring code: 75601 “Boom RAISE PPC Pressure”
Monitoring code: 75603 “Boom LOWER PPC Pressure”

• Arm cylinder: Fully retracted
• Bucket cylinder: Fully retracted
5. Set the work equipment lock lever in LOCK position.
PC210LCI-11 30-553


30-554 PC210LCI-11



shutdown” (9).

MATSU” logo mark is displayed, press “TS Machine Cali-
bration” (10).
REMARK
PC210LCI-11 30-555
14. When the “TS Machine Calibration” screen is displayed,

press the “Status” (11).
“Status” messages are as follows.
“OK”: The stroke sensing hydraulic cylinder has already
been calibrated.
“READY”: The stroke sensing hydraulic cylinder has not
been calibrated yet.
“SETTING”: The stroke sensing hydraulic cylinder is under
calibration.
“NG”: The calibration of the stroke sensing hydraulic cylin-
der has failed.
• When the “Status” of all work equipments is “READY”
(11)
Perform the calibration according to the procedure in
step 14 or after.
• When the “Status” of all work equipments is “OK” (12)

or at least one of the work equipment status is
“READY”.
for 0.5 seconds or more
2) Check that the “Status” changes from “OK” to

“READY” (11).
30-556 PC210LCI-11
15. Hold down “Start” (14) for 0.5 seconds or more.

REMARK
Leave the swing lock switch in ON position.
17. When the “Step” is “1” (15-1) on the screen, slowly operate
the bucket to the stroke end in DUMP direction.
REMARK
Operate the work equipment control lever while “Bucket
DUMP PPC Pressure” is 1.3 MPa or lower.
18. Relieve the bucket DUMP circuit until the “Status” of

“Bucket” changes from “DUMP” (15) to “Digging”.
REMARK
• Operate the work equipment control lever while “Buck-
et DUMP PPC Pressure” is 1.3 MPa or higher.
• If an error code appears, take actions by referring to
“ACTION TO BE TAKEN IF AN ERROR OCCURS”.
When the bucket cylinder reaches the stroke end and the
bucket cylinder circuit is relieved, the “Status” display
changes to “Digging”.
As soon as the “Status” changes to “Digging”, “Step” also
changes to “2”.
the bucket to the stroke end in DIG direction.
REMARK
CURL PPC Pressure” is 1.3 MPa or lower.
PC210LCI-11 30-557
20. Relieve the bucket CURL circuit until the “Status” of “Buck-
et” changes from “Digging” (16) to “OK”.
REMARK
et CURL PPC Pressure” is 1.3 MPa or higher.
When the reset sensor at the bucket cylinder senses the
reset position, the “Status” changes from “Digging” to
“OK”.
As soon as the “Status” changes to “OK”, “Step” changes
to “3”.
At this time, the bucket cylinder parameter is saved in ICT sensor controller.
21. When the “Step” is “3” (17-1), slowly operate the arm to
the stroke end in DUMP direction.
REMARK
Operate the work equipment control lever while “Arm OUT
PPC Pressure” is 1.3 MPa or lower.
22. Relieve the bucket DUMP circuit until the “Status” of “Arm”
changes from “DUMP” (17) to “Digging”.
REMARK
• Operate the work equipment control lever while “Arm
OUT PPC Pressure” is 1.3 MPa or higher.
When the arm cylinder reaches the stroke end and the arm
cylinder circuit is relieved, the “Status” changes to “Dig-
ging”.
changes to “4”.
the arm to the stroke end in DIG direction.
REMARK
Operate the work equipment control lever while “Arm IN
30-558 PC210LCI-11
24. Relieve the arm CURL cylinder circuit until the “Status” of
“Arm” changes from “DIG” (18) to “OK”.
REMARK
IN PPC Pressure” is 1.3 MPa or higher.
When the reset sensor of the arm cylinder senses the re-
set position, the “Status” changes from “DIG” to “OK”.
to “5”.
At this time, the arm cylinder parameter is saved in ICT sensor controller.
the boom to the stroke end in RAISE direction.
REMARK
Operate the work equipment control lever while “Boom
RAISE PPC Pressure” is 1.3 MPa or lower.
26. Relieve the boom circuit by boom RAISE operation until

the “Status” display of “Boom” changes from “UP” (19) to
“DOWN”.
REMARK
RAISE PPC Pressure” is 1.3 MPa or higher.
When the boom cylinder reaches the stroke end and the
cylinder circuit is relieved, the “Status” display changes to
“DOWN”.
As soon as the “Status” display changes to “DOWN”, “Step” changes to “6”.
the boom in LOWER direction until the work equipment
touches the ground.
REMARK
LOWER PPC Pressure” is 1.3 MPa or lower.
When the encoder at the boom senses the reset position,
the “Status” display changes from “DOWN” to “OK”.
At this time, the boom cylinder parameter is saved in ICT
sensor controller.
PC210LCI-11 30-559

slowly operate each work equipment.
Bucket:Reciprocating operation between arm IN stroke
end and DUMP stroke end
Arm:Reciprocating operation between arm IN stroke end
and DUMP stroke end
Boom:Reciprocating operation between the position where
the bucket touches the ground and RAISE stroke end
REMARK
• Perform the calibration process in any order.
• However, calibration may not be performed correctly
during combined operations. Accordingly, operate the
boom, the arm, or the bucket independently.
29. After completion of reciprocating operation of each work
equipment, press the enter button (21).
it” (22).
31. Select “MS Cylinder function check”, and display it by re-

ferring to “SET AND OPERATE MACHINE MONITOR”.
F6: Enters the selected item and moves to the “MS Cylin-
der function check” screen.
32. When the “MS Cylinder function check” screen is dis-

played, select “Boom MS Cylinder”.
der function check: Boom” screen.
30-560 PC210LCI-11
33. When the “MS Cylinder function check: Boom” is dis-

played, operate the boom from the position where it touch-
es the ground to the boom RAISE stroke end. When the
progress bar reaches the MAX position (d), the control box
“beeps”. Record the compensation value (a) and compare
it with the standard value.
F1: Turn on (operate) or off (not operate) the Encoder Re-
set (for boom and arm)
F1: Turn on (operate) or off (not operate) the MID Reset
(for bucket)
F4: Enters the values, etc. displayed on the monitor screen
F5: Returns to the “MS Cylinder function check” screen
REMARK
• The control box “beeps” when the stroke sensor senses the center position (c) and MAX position (d).
• If the compensation value (a) is out of the standard value range, perform the calibration process of all
the stroke sensing hydraulic cylinders again from step 2.
34. Operate the work equipment until it touches the ground.
REMARK
The control box “beeps” when the stroke sensor senses the center position (c) and MAX position (d).
35. Operate the boom to approximately 100 mm before the boom RAISE stroke end.
REMARK
• Stop the piston rod approximately 100 mm before the stroke end to avoid relieving.
• If the cylinder circuit is relieved, the stroke sensor senses the MAX position (d) of the cylinder, and the
control box “beeps”. In such case, operate the work equipment again from the position where the work
equipment is lowered to a ground.
When the progress bar reaches the center position, the
control box “beeps”. Record the compensation value (a)
and compare it with the standard value.
(for bucket)
REMARK
• Press F4 and use HOLD function to read the center po-
sition (c).
• The control box “beeps” when the stroke sensor
senses the center position (c) and MAX position (d).
• The compensation value of the center position (c) may
be larger when the stroke sensor has been corrected at
MIN position (b) or MAX position (d). This does not in-
dicate abnormality.
• If the compensation value (a) is out of the standard val-
ue range, perform the calibration process of all the
stroke sensing hydraulic cylinders again from step 2.
PC210LCI-11 30-561
37. Press F5.

(for bucket)
38. On the “MS Cylinder function check” screen, select “Arm

switches.
der function check: Arm” screen
39. When the MS “Cylinder function check: Arm” screen is dis-
played, operate the arm to the arm OUT stroke end.
40. Operate the arm to approximately 100 mm before the arm
IN stroke end.
(for bucket)
REMARK
• Stop the piston rod approximately 100 mm before the
stroke end to avoid relieving.
• If the cylinder circuit is relieved, the stroke sensor
senses the MAX position (d) of the cylinder, and the
control box “beeps”. In such case, operate the arm
again from the arm OUT stroke end.
senses the center position (c).
41. Operate the arm to approximately 100 mm before the arm OUT stroke end.
REMARK
control box “beeps”. In such case, operate the arm again from the arm IN stroke end.
• The control box “beeps” when the stroke sensor senses the center position (c).
30-562 PC210LCI-11

IN stroke end. When the progress bar reaches the center
position, the control box “beeps”. Record the compensa-
tion value (a) and compare it with the standard value.
(for bucket)
REMARK
sition (c).
MIN position (b) or MAX position (d). This phenomenon
does not indicate abnormality.
43. Operate the arm to the arm OUT stroke end. When the
progress bar reaches MIN position, the control box
(for bucket)
REMARK
senses the center position (c), MAX position (d), and
MIN position (b).
PC210LCI-11 30-563
44. Press F5.

(for bucket)
45. On the “MS Cylinder function check” screen, select “Buck-

et MS Cylinder” with function switches or numeral input
switches.
der function check: Bucket” screen
46. When the MS “Cylinder function check: Bucket” screen is
displayed, operate the bucket to the bucket DUMP stroke
end.
47. Operate the bucket to approximately 100 mm before the
bucket CURL stroke end.
(for bucket)
REMARK
• If it cylinder circuit is relieved, the stroke sensor senses
the MAX position (d) of the cylinder, and the control
box “beeps”. In such case, operate the bucket to the
bucket DUMP stroke end and restart the operation.
senses MIN position (b) and center position (c).
48. Operate the bucket to approximately 100 mm before the bucket DUMP stroke end.
REMARK
control box “beeps”. In such case, operate the bucket to the bucket CURL stroke end and restart the
operation.
• The control box “beeps” when the stroke sensor senses MIN position (b) and center position (c).
30-564 PC210LCI-11

bucket CURL stroke end. When the progress bar reaches
the center position, the control box “beeps”. Record the
compensation value (a) and compare it with the standard
value.
(for bucket)
REMARK
• Press F4 and use HOLD function to read the center position (c).
• The compensation value of the center position (c) may be larger when the stroke sensor has been cor-
rected at MIN position (b) or MAX position (d). This phenomenon does not indicate abnormality.
50. Operate the bucket to the bucket DUMP stroke end. When
the progress bar reaches MIN position, the control box
(for bucket)
REMARK
MIN position (b).
52. After checking the control box power supply is turned off,turn the starting switch to ON position again.
When the starting switch is turned to ON position again, the result of the calibration is reflected to the con-
trol box.
METHOD FOR CALIBRATING WORKEQUIPMENT CYLINDER

PC210LCI-11 30-565

Monitoring code: 75601 “Boom RAISE PPC Pressure”
Monitoring code: 75603 “Boom LOWER PPC Pressure”

• Arm cylinder: Fully retracted
• Bucket cylinder: Fully retracted

30-566 PC210LCI-11



PC210LCI-11 30-567

shutdown” (9).

bration” (10).
REMARK

press the “Status” (11).
“Status” messages are as follows.
“OK”: The stroke sensing hydraulic cylinder has already
been calibrated.
“READY”: The stroke sensing hydraulic cylinder has not
been calibrated yet.
“SETTING”: The stroke sensing hydraulic cylinder is under
calibration.
“NG”: The calibration of the stroke sensing hydraulic cylin-
der has failed.
• When the “Status” of all work equipments is “READY”
(11)
Perform the calibration according to the procedure in
step 14 or after.
30-568 PC210LCI-11
• When the “Status” of all work equipments is “OK” (12)

or at least one of the work equipment status is
“READY”.
for 0.5 seconds or more
2) Check that the “Status” changes from “OK” to

“READY” (11).
15. Hold down “Start” (14) for 0.5 seconds or more.

REMARK
Leave the swing lock switch in ON position.
the bucket to the stroke end in DUMP direction.
REMARK
DUMP PPC Pressure” is 1.3 MPa or lower.
PC210LCI-11 30-569
18. Relieve the bucket DUMP circuit until the “Status” of

“Bucket” changes from “DUMP” (15) to “Digging”.
REMARK
et DUMP PPC Pressure” is 1.3 MPa or higher.
When the bucket cylinder reaches the stroke end and the
bucket cylinder circuit is relieved, the “Status” display
changes to “Digging”.
changes to “2”.
the bucket to the stroke end in DIG direction.
REMARK
CURL PPC Pressure” is 1.3 MPa or lower.
20. Relieve the bucket CURL circuit until the “Status” of “Buck-
et” changes from “Digging” (16) to “OK”.
REMARK
et CURL PPC Pressure” is 1.3 MPa or higher.
When the reset sensor at the bucket cylinder senses the
reset position, the “Status” changes from “Digging” to
“OK”.
to “3”.
At this time, the bucket cylinder parameter is saved in ICT sensor controller.
21. When the “Step” is “3” (17-1), slowly operate the arm to
the stroke end in DUMP direction.
REMARK
Operate the work equipment control lever while “Arm OUT
30-570 PC210LCI-11
22. Relieve the bucket DUMP circuit until the “Status” of “Arm”
changes from “DUMP” (17) to “Digging”.
REMARK
OUT PPC Pressure” is 1.3 MPa or higher.
When the arm cylinder reaches the stroke end and the arm
cylinder circuit is relieved, the “Status” changes to “Dig-
ging”.
changes to “4”.
the arm to the stroke end in DIG direction.
REMARK
Operate the work equipment control lever while “Arm IN
24. Relieve the arm CURL cylinder circuit until the “Status” of
“Arm” changes from “DIG” (18) to “OK”.
REMARK
IN PPC Pressure” is 1.3 MPa or higher.
When the reset sensor of the arm cylinder senses the re-
set position, the “Status” changes from “DIG” to “OK”.
to “5”.
At this time, the arm cylinder parameter is saved in ICT sensor controller.
the boom to the stroke end in RAISE direction.
REMARK
RAISE PPC Pressure” is 1.3 MPa or lower.
PC210LCI-11 30-571
26. Relieve the boom circuit by boom RAISE operation until

the “Status” display of “Boom” changes from “UP” (19) to
“DOWN”.
REMARK
RAISE PPC Pressure” is 1.3 MPa or higher.
When the boom cylinder reaches the stroke end and the
cylinder circuit is relieved, the “Status” display changes to
“DOWN”.
As soon as the “Status” display changes to “DOWN”, “Step” changes to “6”.
the boom in LOWER direction until the work equipment
touches the ground.
REMARK
LOWER PPC Pressure” is 1.3 MPa or lower.
When the encoder at the boom senses the reset position,
the “Status” display changes from “DOWN” to “OK”.
At this time, the boom cylinder parameter is saved in ICT
sensor controller.

slowly operate each work equipment.
Bucket:Reciprocating operation between arm IN stroke
end and DUMP stroke end
Arm:Reciprocating operation between arm IN stroke end
and DUMP stroke end
Boom:Reciprocating operation between the position where
the bucket touches the ground and RAISE stroke end
REMARK
• Perform the calibration process in any order.
• However, calibration may not be performed correctly
during combined operations. Accordingly, operate the
boom, the arm, or the bucket independently.
29. After completion of reciprocating operation of each work
equipment, press the enter button (21).
it” (22).
30-572 PC210LCI-11
31. Select “MS Cylinder function check”, and display it by re-

ferring to “SET AND OPERATE MACHINE MONITOR”.
der function check” screen.
32. When the “MS Cylinder function check” screen is dis-

played, select “Boom MS Cylinder”.
der function check: Boom” screen.
33. When the “MS Cylinder function check: Boom” is dis-

played, operate the boom from the position where it touch-
es the ground to the boom RAISE stroke end. When the
progress bar reaches the MAX position (d), the control box
(for bucket)
REMARK
REMARK
The control box “beeps” when the stroke sensor senses the center position (c) and MAX position (d).
35. Operate the boom to approximately 100 mm before the boom RAISE stroke end.
REMARK
control box “beeps”. In such case, operate the work equipment again from the position where the work
equipment is lowered to a ground.
PC210LCI-11 30-573

When the progress bar reaches the center position, the
control box “beeps”. Record the compensation value (a)
and compare it with the standard value.
(for bucket)
REMARK
sition (c).
MIN position (b) or MAX position (d). This does not in-
dicate abnormality.
37. Press F5.
(for bucket)
38. On the “MS Cylinder function check” screen, select “Arm

switches.
der function check: Arm” screen
39. When the MS “Cylinder function check: Arm” screen is dis-
played, operate the arm to the arm OUT stroke end.
30-574 PC210LCI-11

IN stroke end.
(for bucket)
REMARK
• If the cylinder circuit is relieved, the stroke sensor
senses the MAX position (d) of the cylinder, and the
control box “beeps”. In such case, operate the arm
again from the arm OUT stroke end.
senses the center position (c).
41. Operate the arm to approximately 100 mm before the arm OUT stroke end.
REMARK
control box “beeps”. In such case, operate the arm again from the arm IN stroke end.
• The control box “beeps” when the stroke sensor senses the center position (c).
IN stroke end. When the progress bar reaches the center
position, the control box “beeps”. Record the compensa-
tion value (a) and compare it with the standard value.
(for bucket)
REMARK
sition (c).
MIN position (b) or MAX position (d). This phenomenon
does not indicate abnormality.
PC210LCI-11 30-575
43. Operate the arm to the arm OUT stroke end. When the
progress bar reaches MIN position, the control box
(for bucket)
REMARK
MIN position (b).
44. Press F5.
(for bucket)
45. On the “MS Cylinder function check” screen, select “Buck-

et MS Cylinder” with function switches or numeral input
switches.
der function check: Bucket” screen
46. When the MS “Cylinder function check: Bucket” screen is
displayed, operate the bucket to the bucket DUMP stroke
end.
bucket CURL stroke end.
(for bucket)
30-576 PC210LCI-11
REMARK
• If it cylinder circuit is relieved, the stroke sensor senses the MAX position (d) of the cylinder, and the
control box “beeps”. In such case, operate the bucket to the bucket DUMP stroke end and restart the
operation.
48. Operate the bucket to approximately 100 mm before the bucket DUMP stroke end.
REMARK
control box “beeps”. In such case, operate the bucket to the bucket CURL stroke end and restart the
operation.
bucket CURL stroke end. When the progress bar reaches
the center position, the control box “beeps”. Record the
compensation value (a) and compare it with the standard
value.
(for bucket)
REMARK
• Press F4 and use HOLD function to read the center position (c).
• The compensation value of the center position (c) may be larger when the stroke sensor has been cor-
rected at MIN position (b) or MAX position (d). This phenomenon does not indicate abnormality.
50. Operate the bucket to the bucket DUMP stroke end. When
the progress bar reaches MIN position, the control box
(for bucket)
PC210LCI-11 30-577
REMARK
• The control box “beeps” when the stroke sensor senses the center position (c), MAX position (d), and
MIN position (b).
52. After checking the control box power supply is turned off,turn the starting switch to ON position again.
When the starting switch is turned to ON position again, the result of the calibration is reflected to the con-
trol box.
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF

WORK EQUIPMENT CYLINDER

OF WORK EQUIPMENT CYLINDER
If “NG” is displayed in ERROR code (1) and “Status” (2), take
measures by referring to “Error code table”.
30-578 PC210LCI-11
Error code table

Error
code
Press the return button (3),
A-1 Engine speed signal is 0 rpm start the engine, and exe-
cute the calibration again.
SC-1 Defective operation of arm cylinder stroke reset encoder
Open circuit, ground fault, and hot short circuit of arm cylinder stroke reset
SC-2
encoder phases A and B
Open circuit, ground fault, and hot short circuit of arm cylinder stroke reset
SC-3
encoder phase Z
SD-1 Defective operation of boom cylinder stroke reset encoder
Open circuit, ground fault, and hot short circuit of boom cylinder stroke re-
SD-2
set encoder phases A and B
Open circuit, ground fault, and hot short circuit of boom cylinder stroke re-
SD-3
set encoder phase Z
SE-1 Open circuit of bucket cylinder stroke sensor phase A
SE-2 Short circuit of bucket cylinder stroke sensor phase A
SE-3 Open circuit of bucket cylinder stroke sensor phase B
SE-4 Short circuit of bucket cylinder stroke sensor phase B
Press the return button (2),
SE-5 Over range of bucket cylinder stroke sensor and performing trouble-
SE-6 Open circuit of bucket cylinder stroke reset sensor shooting for IMU sensor.
SE-7 Short circuit of bucket cylinder stroke end reset sensor

SE-8 Over range of bucket cylinder stroke reset sensor
SF-1 Open circuit of arm cylinder stroke sensor phase A
SF-2 Short circuit of arm cylinder stroke sensor phase A
SF-3 Open circuit of arm cylinder stroke sensor phase B
SF-4 Short circuit of arm cylinder stroke sensor phase B
SF-5 Over range of arm cylinder stroke sensor
SG-1 Open circuit of boom cylinder stroke sensor phase A
SG-2 Short circuit of boom cylinder stroke sensor phase A
SG-3 Open circuit of boom cylinder stroke sensor phase B
SG-4 Short circuit of boom cylinder stroke sensor phase B
SG-5 Over range of boom cylinder stroke sensor
• If a communication error occurs

The error screen (3) appears if a communication error oc-
curs between the ICT controller and the control box during
the calibration process.
1) Press the return button (4) to stop the calibration proc-
ess.
2) When the “Machine Setup” screen appears, perform
troubleshooting by referring to TROUBLESHOOTING.
PC210LCI-11 30-579
GENERAL CALIBRATION OF BUCKET BLADE EDGE POSITION, BOOM DIMEN-

SIONS, ARM DIMENSIONS, BUCKET LINK DIMENSIONS, AND GNSS ANTENNA
POSITION WITH TOTAL STATION
Full-parameter calibrating device for the bucket blade edge position, boom dimensions, arm dimen-
sions, bucket link dimensions, GNSS antenna position by using the total station
Commercially
A Total station 1
available
The measurement target B is a compo-
B 2A5-98-21210 Measurement target 1 nent of the special blade edge measuring
jig K.
Commercially
C Marker 1
available
Commercially
D L-square 1
available
Commercially
E Convex rule 1
available
Commercially
F Magnet stand 1
available
Commercially
G Plumb 1
available
Commercially Accuracy: 0.1 ° or lower, Resolution 0.1 °
available or lower
Commercially
J String 1
available
30-580 PC210LCI-11

- 2A5-98-05011 Special blade edge measuring jig 1
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
8 2A5-98-21230 Reflector plate 1
9 2A5-98-21240 Adapter 1
K
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
20 01640-20610 Washer 1
Commercially
L Rover 1
available
stop the engine.
After the arm and ICT controller is replaced, be sure to perform this work.
The full parameter calibration of the bucket blade tip, boom dimensions, arm dimensions, bucket link dimen-
sions, and GNSS antenna position by using the total station also calibrates the dimensions between various
work equipment pins, angle, shape of the bucket, and dimension from GNSS antenna to the boom foot pin.
The measurement of the work equipment dimensions must be done in pairs.
“Full Parameter Calibration” is for when the conventional bucket is installed. When the tilt bucket is installed, be
sure to perform the tilt bucket calibration after completing “Full Parameter Calibration”.
For the calibration method of the tilt bucket, see Operation and Maintenance Manual.
METHOD FOR CALIBRATING BUCKET BLADE EDGE POSITION, BOOM DIMEN-

SIONS, ARM DIMENSIONS, BUCKET LINK DIMENSIONS, AND GNSS ANTENNA
POSITION WITH TOTAL STATION
1. Remove the AdBlue/DEF case, and the front cover of the fuel tank. See “Disassembly and assembly”, RE-
MOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.
PC210LCI-11 30-581
2. Place the total station A at the following distance from R.H.

of the machine.
Place the total station A at a position from which it can col-
limate the boom foot pin, according to the reference dis-
tance.
(x) forward of boom foot pin: Approx. 3 m
(y) front right of boom foot pin: Approx. 10 m
3. Level the total station A.
REMARK
For the leveling method, see the Operation and Mainte-
nance Manual for the total station A.
4. Measure the vertical height (machine height) from the
ground level to the center of the total station A main unit.
REMARK
• Measure the machine height in 1 mm unit.
• For the center position of the total station A main unit,
see the Operation and Maintenance Manual for the to-
tal station A.
5. Input the measured machine height to the total station A.
REMARK
For the inputting method of the machine height, see the
Operation and Maintenance Manual for the total station A.
6. Input the prism constant of the prism used for this calibration to the total station A.
REMARK
• When the measurement target B is used, the prism constant is 26 mm.
• For inputting method of the prism constant, see the Operation and Maintenance Manual for the total sta-
tion A.
7. Set the coordinates of the total station A as N-E-Z or X-Y-H.
NOTICE
Input the negation of the Y-coordinate value into the control box screen when only the coordinates
of N-E-Z and X-Y-H are available.
REMARK
For details of the method for setting the station, see the Operation and Maintenance Manual for total station
A.
8. Set the position to which the total station A is set as the “origin”.
REMARK
For the method for setting the “station”, see the Operation and Maintenance Manual for the total station A.
1) Set the collimating direction to the front, and select “0”.
REMARK
When the setting is “0”, the front of the machine is set as X axis, R.H. direction as Y axis, and vertical
direction as Z axis.
2) Check that the point coordinate of the total station A is “0” on each axis.
9. Set the measurement mode to the coordinate measurement mode.
REMARK
For the method of changing the coordinate measurement mode, see the Operation Maintenance Manual for
the total station A.
30-582 PC210LCI-11
10. Set the measurement mode to the prism mode.

REMARK
For the method of changing the prism mode, see the Oper-
ation Maintenance Manual for the total station A.
11. Draw the mark (T) at the center of the bucket blade edge
to be measured by using the marker C.
REMARK
If a tooth is installed, draw the mark (T) at the tip of the
tooth.
12. Turn the starting switch to ON position, hold this state for
approximately 10 seconds, and then start the engine.
PC210LCI-11 30-583



30-584 PC210LCI-11

shutdown” (9).

bration” (10).

press “Full Parameter Calibration” (102).
22. When the “Work Equipment Files” screen is displayed, se-
lect the file of the work equipment currently mounted to the
machine.
• When the work equipment file is on the list

Select the corresponding work equipment file name.
REMARK
The background color of the selected line changes to yellow.
1) Press “Next” (11).
PC210LCI-11 30-585
• When the selected work equipment file is

correct
The “Work Equipment Files” screen is switch-
ed to the “Conventional Bucket Files” screen.
• When the selected work equipment file is not

correct
ed to the “Check Error” screen.
2) Press “Back” (103) to return to the “Work Equip-
ment Files” screen and select the work equipment
file again.
• When the work equipment file is not on the list

1) Insert the USB memory (12) containing the work
equipment file of the work equipment currently
mounted to the machine into the control box.
REMARK
• The password which unlocks the USB memo-
ry (12) cannot be inputted on the control box,
use the USB memory (12) which has no pass-
word.
• Be sure to save the work equipment file in the
root directory of the USB memory (12).
2) Press “Copy” (13).
30-586 PC210LCI-11
3) When the “Copy files” screen is displayed, press

the pull-down menu (14).
4) Select the “D:to 3DMC folder ”(15) from the pull-
down menu.
5) When the list of the work equipment files saved in
the USB memory is displayed, select the name of
the corresponding work equipment file.
The background color of the selected line
changes to yellow.

7) The work equipment file is copied to the control
box, and the work equipment file list is displayed.
Check the name of the copied file.

correct
PC210LCI-11 30-587

correct
9) Press “Back” (103) to return to the “Work Equip-
ment Files” screen and select the work equipment
file again.
23. Select the bucket file of the bucket currently mounted to
the machine on the “Conventional Bucket Files” screen.
• When the bucket file is listed

1) Select the corresponding bucket file name.
REMARK
• When the selected bucket file is correct

The “Conventional Bucket Files” screen is switched to the “Full Parameter Calibration [1/16]”
screen.
• When the selected bucket file is not correct
The “Conventional Bucket Files” screen is
switched to the “Check Error” screen.
Press “Back” (103) to return to the “Conven-
tional Bucket Files” screen and select the
bucket file again.
30-588 PC210LCI-11
3) Measure the dimensions “Lbk3”, “L3”, and “Lbkw”

of the bucket.
“Lbk3”: The distance between the center of the
arm mounting pin and the bucket mounting pin
to the center of the link mounting pin and the
bucket mounting pin
“L3”: The distance between the center of the arm
mounting pin and the bucket mounting pin to
the bucket tooth pin
“Lbkw”: The length of the side cutters (the widest
bucket width if the side cutters are not installed)
REMARK
• Measure the dimensions as accurately as
possible by using the square D, convex rule
R, and magnet stand F on R.H. surface of the
bucket.
• Measure the dimensions in 1 mm unit.
4) Compare the measured dimensions with dimen-

sions “Lbk3” (104), “L3” (105), and “Lbkw” (106)
displayed on the “Full Parameter Calibration
[1/16]” screen.
• When the measured dimensions and the di-
mensions on the screen are matched
The currently mounted bucket is matched
with the selected bucket file. Set the bucket
in the posture suitable to calculate the swing
surface.
mensions on the screen are not matched
The selected bucket file is not correct. Return to the “Conventional Bucket Files” screen and
select the bucket file again.
PC210LCI-11 30-589
• When the bucket file is not on the list and the file
needs to be copied from the USB memory
1) Insert the USB memory (16) containing the buck-
et file of the bucket currently mounted to the ma-
chine into the control box.
REMARK
word.
• Be sure to save the bucket file in the root di-
rectory of the USB memory (16).

down menu.
5) When the list of the bucket files saved in the USB

memory is displayed, select the name of the cor-
responding bucket file.
REMARK
changes to yellow.
7) The bucket file is copied to the control box, and
the bucket file list is displayed. Check the name of
the copied file.
8) Select the corresponding bucket file name on the
“Conventional Bucket Files” screen.
REMARK
30-590 PC210LCI-11

The “Conventional Bucket Files” screen is switched to the “Full Parameter Calibration [1/16]”
screen.
10) Press “Back” (103) to return to the “Conventional
Bucket Files” screen and select the bucket file
again.
PC210LCI-11 30-591
11) Measure dimensions “Lbk3”, “L3”, and “Lbkw” of

the bucket.
bucket mounting pin
the bucket tooth pin
“Lbkw”: The length of the side cutters (the widest
REMARK
bucket.
Compare the measured dimensions with dimen-

[1/16]” screen.
surface.
• When the bucket file does not exist and the bucket dimensions need to be measured to create a new
bucket file
Measure the bucket dimensions, and input the values in the control box.
30-592 PC210LCI-11
REMARK
• Measure the dimensions as accurately as possible by using the square D, convex rule R, and mag-
net stand F on R.H. surface of the bucket.
• Measure the angle in 0.1 ° unit.
1) Measure the dimension “Lbk3” of the bucket.
REMARK
Measure the distance between the center of the
arm mounting pin and the boom mounting pin on
both sides to the center of the link mounting pin
and the bucket mounting pin. Then, input the
average value.
2) Measure the dimension “L3” of the bucket.

REMARK
arm mounting pin and the bucket mounting pin to
the bucket tooth tip which marked as (T).
3) Measure the dimension “Lbkw” of the bucket.

REMARK
Measure the length of the side cutters (the widest
PC210LCI-11 30-593
4) Measure the dimension “Ltooth” of the bucket.

REMARK
Measure the distance between the tooth root and
the blade tip of the tooth (the length of the blade
width if the tooth is not installed).
30-594 PC210LCI-11
5) Draw a cross hairs at the mounting pin center (f)

of the arm and the bucket on R.H. of the machine
by using the marker C.
REMARK
The cross hairs will be a guide for the magnet
stand F to be installed.
6) Draw the dots (a) to (e) for the bucket shape rec-
ognition on R.H. of bucket by using the marker C.
Dot (a): Intersection point of the bucket bottom
straight line and the corner of the bucket
Dot (e): Point on an extended line from the
mounting pin center of the arm and bucket to
the mounting pin center of the link and bucket
Dot (d): Contact point of the tangent line drawn
from the dot (e) to the bucket outside diameter
Dot (b), dot (c): Approximately and equally
spaced points of the distance between the dot
(a) and dot (d)
REMARK
Recognize the bucket shape as a polygon con-
sisting of the dots (a) to (e).
7) Install the magnet stand F so that the center (f) of the arm mounting pin and the bucket mounting
pin are aligned with the center point of the magnet stand F.
REMARK
Install the magnet stand F according to the cross hairs.
8) Install the plumb G to the pole of the magnet stand F.
9) Install the string J to the pole of the magnet stand F.
10) Adjust the bucket position so that the straight line from the center of the arm mounting pin and the
bucket mounting pin to the bucket blade tip is vertical.
NOTICE
• The work equipment may lower gradually due to the hydraulic drift during measurement.
Check the position of the plumb G, and adjust the bucket position for the measurement
if it lowers due to the hydraulic drift.
• When adjusting the bucket position, be careful to prevent the plumb G and string J from
touching the blade tip. If the string J touches the blade tip, the blade tip pushes the the
string J and measurement cannot be performed correctly.
11) Stretch the string J to each of the shape recogni-
tion dots (a) to (e) in this order, and measure the
angle (α) of the string J by using the digital angle
gauge H.
PC210LCI-11 30-595
NOTICE
• The measurement error of the angle at the shape recognition dot (e) largely affects the
accuracy of the calibration. Accordingly, perform measurement accurately, observing
Operation and Maintenance Manual for the digital angle gauge H.
• Measure the angle (α) at the shape recognition dot (e) before the hydraulic drift of the
work equipment starts.
• Complete measurement of all the angles within 3 minutes after the bucket position is ad-
justed according to step 10).
If 3 minutes have elapsed, adjust the bucket position again, and then measure the shape
recognition dot.
• Measure the angle (α) at the shape recognition dot (e) on both right and left sides of the
bucket, whenever possible. When the difference between the measurement value on
both sides is 0.1 ° or more, input the mean value of those values.
Stretch the convex rule E (substitute for the string J) from the center of the arm mount-
ing pin and the bucket mounting pin to the center of the link mounting point and the
bucket mounting point. Measure the angle (α) at the shape recognition dot (e) on L.H. by
using the digital angle gauge H.
• When measuring the angle, set the roll direction of the digital angle gauge H vertically.
REMARK
• Record the angle (α) of the string J in absolute value (positive real number).
• Use the “ °” unit for the measured angle.
• Calculate the angle (θ) at each shape recognition dot.
Shape recognition dot (a), (b), (c), (d): (θ) = 90 - (α)
Shape recognition dot (e): (θ) = 90 + (α)
12) Stretch the string J to each of shape recognition
dots (a) to (e). Mark a dot on the string J at each
shape recognition point.
13) Remove the string J on which the shape recogni-

tion points are made from the pole. Measure the
distance between the center of the arm mounting
pin and the bucket mounting pin (end of the string
J) to each mark of the shape recognition points by
using the convex rule F.
30-596 PC210LCI-11
14) Press “New” (18).
15) When the input keypad (19) is displayed, input

the bucket file name to be created newly, and
then press “OK” (20).
The newly created file name is displayed on the
16) Select the new bucket file.
REMARK
changes to yellow.
PC210LCI-11 30-597
18) When the “Conventional Bucket Exchange”

screen is displayed, input the dimensions (Lbk3,
L3, LbkW, Ltooth) of the bucket and the meas-
ured values of the shape recognition dots (a) to
(e) of the bucket.
REMARK
• Press the input columns (22) to (27) to display
the numeral keypad (28), input the value, and
• For the input range, see “INPUT RANGE OF
THE MEASURED VALUES IN CALIBRATION
WITH TOTAL STATION”.
• When the input value is within the range

The screen is switched to the “Full Parameter
Calibration [2/16]” screen.
• When the input value is out of the range
The screen is switched to the “Check Error”
screen.
tional Bucket Files” screen and check the in-
put value.
REMARK
For the input range, see “INPUT RANGE OF
THE MEASURED VALUES IN CALIBRA-
TION WITH TOTAL STATION”.
30-598 PC210LCI-11
Boom cylinder: Fully extended
Arm cylinder: Fully extended
Bucket cylinder: Fully extended
25. Install the prism (35) to the special blade edge measuring
jig K and combine them with the assisting block (34).
k Be careful not to get your fingers caught in the as-
sisting block (34) while installing it. The assisting
block is installed by using the attracting force of a
powerful magnet.
26. Attach the special blade edge measuring jig K assembled

in step 23 to the counterweight mounting bolt (g).
k Be careful not to get your fingers caught in the spe-
cial blade edge measuring jig K while installing it.
The jig is installed by using the attracting force of a
powerful magnet.
REMARK
Install the special blade edge measuring jig K to the coun-
terweight mounting bolt (g) on R.H. of the machine. Direct
the prism (35) toward the front of the machine so that the
jig can be collimated through the total station A.
PC210LCI-11 30-599
27. Swing the upper structure and direct the work equipment
toward the “PS1” position on the “Full Parameter Calibra-
tion [2/16]” screen.
REMARK
• Do not move the work equipment or track when swing-
ing the upper structure.
• Guide for the “PS1” position
Angle (c) between track direction (a) and work equip-
ment direction (b): Approx. 60±15 °
28. Rotate the prism (35) so that it faces forward to the total
station A as directly as possible.
NOTICE
When the special blade edge measuring jig K is adjust-
ed by rotation of the prism (35), the measuring jig
should not be moved if possible. A few millimeters of
displacement should not be a problem.
29. The operator of the total station A must measure the coor-
dinates of the special blade edge measuring jig K, and re-
cord it.
REMARK
For the method of measuring the coordinates, see Opera-
tion and Maintenance Manual for the total station A.
REMARK
31. Rotate the prism (35) so that it faces directly forward to the
total station A as directly as possible.
NOTICE
cord it.
REMARK
30-600 PC210LCI-11
REMARK
ment direction (b) when swinging toward the rear of the
machine: 180 °
34. Rotate the prism (35) so that it faces forward to the total
station A as directly as possible.
NOTICE
cord it.
REMARK
36. Input the coordinates of the special blade edge measuring jig K at the “PS1” to “PS3” positions.
1) Press each input column (37) to display the numeric
keypad (28), and then input the value.
2) Press “OK” (29).
REMARK
For the input range, see “INPUT RANGE OF THE
MEASURED VALUES IN CALIBRATION WITH TO-
TAL STATION”.
PC210LCI-11 30-601
37. Swing the upper structure 180 ° from the “PS3” position
displayed on the “Full Parameter Calibration [2/16]”
screen, and set it in the posture shown below.
NOTICE
After this step, do not swing the upper structure until
the calibration is completed and the blade tip position
accuracy is checked. If the upper structure is swung
halfway, calibration cannot be performed correctly.
39. Press “Next” (38).

The screen is switched to the “Full Parameter Calibration
[3/16]” screen.
40. Collimate the center of the boom foot pin by using the total
station A. Determine the position to stick the reflector plate
K8.
41. Install the reflector plate K8 to the center of the boom foot
pin.
• When the center of the boom foot pin can be collimat-
ed correctly according to step 38
Install the reflector plate K8 to the center of the boom
foot pin.
• When the center of the boom foot pin cannot be colli-
mated correctly according to step 38
Draw a cross hairs at the center of the boom foot pin
with the marker C, and install the reflector plate K8 ac-
cording to the cross hairs.
42. The operator of the total station A must change the meas-
urement mode to the non-prism mode.
REMARK
For the method of changing the measurement mode, see the Operation Maintenance Manual for the total
station A.
43. Measure the central coordinates of the reflector plate K8, and record it.
30-602 PC210LCI-11
REMARK
For the method of measuring the coordinates, see Operation and Maintenance Manual for the total station
A.
44. Input the recorded coordinates.
2) Press “OK” (29).
REMARK
TAL STATION”.

[4/16]” screen.
47. Lower the bucket to the ground slowly so that the track is
not lifted.
REMARK
Hold the swing lock switch in ON position.
PC210LCI-11 30-603
49. Install the reflector plate K8 to the center of the cross hairs
(center (f) of the arm mounting pin and the bucket mount-
ing pin) drawn in step 21.
50. Draw a mark (W) at the center of the pin of the arm end by
using the marker C.
REMARK
Draw a mark (W) so that the virtual straight line between
the mark (W) and mark (T) is in parallel with the arm.
51. Measure the distance (k) between the mark (W) at the
center of the arm end to the reflecting face (P) of the re-
flector plate K8 stuck to the center (f) of the arm mounting
in and the bucket mounting pin by using the square D.
30-604 PC210LCI-11
52. Press the input column (42) to display the numeric keypad
(28), and then input the value.
53. Press “OK” (29).

[5/16]” screen.
55. Perform the reciprocating operation of each work equip-
ments.
REMARK
• When operating the cylinders of each work equipments
to the stroke end, slowly operate the cylinders so that
the machine position or direction is not misaligned due
to the impact.
• Operation can be started from any part of the work
equipment in any order.
Bucket: Reciprocating operation between arm IN stroke end and DUMP stroke end
Arm: Reciprocating operation between arm IN stroke end and DUMP stroke end
Boom: Reciprocating operation between the position where the bucket touches the ground and RAISE
stroke end
56. Move the work equipment to adjust the bucket blade tip
position so that “sensor value” (44) of the boom cylinder
and the arm cylinder length on the “Full Parameter Calibra-
tion [5/16]” screen matches with “target value” (45).
REMARK
• When operating the cylinders of each parts of the work
equipment to the stroke end, slowly operate the cylin-
ders so that the machine position or the direction is not
misaligned due to the impact.
• Reduce the difference between “sensor value” (44) and
“target value” (45) to ±0.010 m or less.
• You may adjust the bucket cylinder to the desired length.
PC210LCI-11 30-605
• If the bucket is lowered to the ground and the difference cannot be adjusted within ±0.010, leave the
bucket on the ground.
• Lower the bucket to the ground gently so that the track do not lift up.
57. The operator of the total station A must measure the coordinates of the center of reflector plate K8 installed
to the center of the pin at the arm end, and record the values. Right after recording the coordinates, the
total station operator must make a signal of measurement completion of coordinates to the machine opera-
tor.
REMARK
For the measuring method of the coordinates, see Operation and Maintenance Manual for the total station
A.
58. When the operator of the total station A makes a signal of
the measurement completion of the coordinates, press
“Cylinder Length” (46).
REMARK
Press “Cylinder Length” (46) right after checking the sig-
nal.
The cylinder length is saved in the control box, and the
check box (47) will be checked.
By pressing “Cylinder Length” (46) again, the check box
will be unchecked, and the cylinder length can be saved
again.
59. Input the coordinates of the center of the pin at the arm
end recorded in the step 55.
1) Press the input column (48) to display the numeric
keypad (28), and then input the coordinates.
2) Press “OK” (29).
REMARK
TAL STATION”.
30-606 PC210LCI-11

[6/16]” screen.
position so that “sensor value” (50) of the boom/arm cylin-
der length on the “Full Parameter Calibration [6/16]”
screen matches with “target value” (51).
REMARK
• Lower the bucket to the ground gently so that the track
do not lift up.
tor.
REMARK
A.
REMARK
nal.
again.
PC210LCI-11 30-607
2) Press “OK” (29).
REMARK
TAL STATION”.

[7/16]” screen.
position so that “sensor value” (56) of the boom/arm cylin-
der length on the “Full Parameter Calibration [7/16]”
screen matches with “target value” (57).
REMARK
tor.
30-608 PC210LCI-11
REMARK
A.
REMARK
nal.
again.
2) Press “OK” (29).
REMARK
TAL STATION”.

The control box automatically detects whether the input
value is correct or incorrect.
PC210LCI-11 30-609
• When the input value is correct

The “Full Parameter Calibration [8/16]” screen is dis-
played, and parameter calculation of each part of the
work equipment starts automatically.
• When the input value is incorrect

The screen is switched to the “Calculating Error”
screen. Press “Back” (62) to return to the correspond-
ing screen, and check the input value.
Input the value again. See “INPUT RANGE OF THE
TAL STATION”.
71. When the automatic parameter calculation of each part of

the work equipment finishes, the “Full Parameter Calibra-
tion [9/16]” screen is displayed again. Check the value (a)
displayed in “Accuracy RMS of arm top 3-point's coordi-
nates”.
• When the value (a) is highlighted in red

Accuracy of the calculation result may be lower. Press “Back” (63) to return to the corresponding
screen, and check the input value.
Input the correct value.
REMARK
Input the value again. See “VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL STA-
TION”.
30-610 PC210LCI-11

Perform the measurement again according to the
flow.
REMARK
When high accuracy earthmoving operation is not
required, you may proceed to the next operation
by pressing “Set” (64) for 0.5 second or more.
• When the value (a) is not highlighted in red

The automatic calculation is correctly finished and ac-
curacy of the result of the calculation is higher. Press
“Set” (64) for 0.5 second or more.
The dimensions between the boom pins and the arm pins,
and also the angle of the pins are saved in ICT controller,
then “Full Parameter Calibration [10/16]” screen is dis-
played.
73. Move the work equipment to set it in the posture shown in

the drawing. Lower the bucket to the ground so that the
track is not lifted, and lift the blade tip from the ground by a
few cm.
REMARK
PC210LCI-11 30-611
75. Install the special blade edge measuring jig K to the blade
tip (42) closest to the total station A.
k Be careful not to get your fingers in the special
blade edge measuring jig K while installing it. The
jig is installed by using the attracting force of a
powerful magnet.
REMARK
Install the special blade edge measuring jig K so that there
is no backlash between the blade tip (42) and the surfaces
A and B of the jig.
76. Adjust the position vertically with the hexagonal socket

head bolts (44) (2 pieces) so that the surface A touches
the blade tip end (42) at the center of the hole (43).
REMARK
• If the position is adjusted correctly, the end position of
the blade tip (42) is aligned with the center of the prism
(35).
• Width across flats of hexagonal socket head bolt (44):
4 mm
77. After adjustment is completed, install the prism (35) to the
special blade edge measuring jig K.
NOTICE
If there is a difference between the distnace the length from the center of the arm mounting pin and
the bucket mounting pin to the center of the prism (35) and the inputted distance of “L3” on the
“Full Parameter Calibration [1/16]” screen, the accuracy of the calibration lowers.
• When the length of the tooth varies
1) Offset the special blade edge measuring jig K as
shown in the drawing, and install it so that the
“L3” measurement point (T) is aligned with the
surface A of the special blade edge measuring jig
K.
30-612 PC210LCI-11
• When the jig cannot be aligned as shown in the draw-

ing due to distortion of the bucket shape, and it cannot
be installed
1) Press “Back” up to the “Full Parameter Calibration
[1/16]” screen.
2) Measure the distance from the center (a) of the
the center (b) of the prism (35), and then input the
value as “L3”.
3) Press “Next” to proceed to the “Full Parameter
78. Adjust the prism (35) as shown in the drawing so that the
prism is at an angle of approx. 90 ° (c) to the work equip-
ment center and it is approximately parallel with the
ground.
position so that “sensor value” (65) of each cylinder length
on the “Full Parameter Calibration [10/16]” screen matches
with “target value” (66).
NOTICE
Operate the work equipment slowly so that the posi-
tions or the directions of the machine and the special
blade edge measuring jig K do not move due to the im-
pact.
REMARK
• When the work equipment cylinder reaches the stroke
end, the background color of the sensor value be-
comes red.
• Hold the swing lock switch in ON position.
PC210LCI-11 30-613
81. The operator of the total station A must measure the coordinates of the blade tip, and record the values.
Right after recording the coordinates, the total station operator must make a signal of the measurement
completion of the coordinates to the machine operator.
REMARK
A.
REMARK
nal.
again.
83. Input the coordinates of the blade edge position recorded
in the procedure 79.

2) Press “OK” (29).
REMARK
TAL STATION”.

[11/16]” screen.
30-614 PC210LCI-11
on the “Full Parameter Calibration [11/16]” screen matches
NOTICE
pact.
REMARK
comes red.
REMARK
A.
REMARK
nal.
again.
PC210LCI-11 30-615

2) Press “OK” (29).
REMARK
TAL STATION”.


The “Full Parameter Calibration [12/16]” screen is dis-
played, and parameter calculation of each part of the
work equipment starts automatically.
30-616 PC210LCI-11

MEASURED VALUES IN CALIBRATION WITH TOTAL
STATION”.

the work equipment finishes, the “Full Parameter Calibra-
tion [13/16]” screen is displayed again. Check the value (a)
displayed in “Accuracy RMS of bucket 2-point's coordi-
nates”.

1) Accuracy of the result of the calculation may lower. Press “Back” (107) to return to the correspond-
REMARK
Input the value again. See “VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL
STATION”.
Perform the measurement again according to
the flow.
REMARK
When high accuracy earthmoving operation
is not required, you may proceed to the next
operation by pressing “Set” (108) for 0.5 sec-
ond or more.
PC210LCI-11 30-617

1) The automatic calculation is correctly finished and
accuracy of the result of the calculation is higher.
Press “Set” (108) for 0.5 second or more.
“Full Parameter Calibration [14/16]” screen is dis-
played when the dimensions between the arm
pins, the side link pins, and the front link pins, and
the angle of all the pins, and the bucket shape are
saved in ICT controller.
92. Move the work equipment to set it in the posture shown in

the drawing. Lower the bucket to the ground so that the
track is not lifted, and lift the blade tip from the ground by a
few cm.
REMARK
93. Remove the special blade edge measuring jig K from the
bucket.
94. Input the height (d) of the prism on the “Full Parameter
2) Press “OK” (29).
REMARK
• The prism height (d) of the target B measurement
kits: 130 mm (0.130 m)
• For the input range, see “INPUT RANGE OF THE
MEASURED VALUES IN CALIBRATION WITH
TOTAL STATION”.
30-618 PC210LCI-11
• When using the target B measurement kits

For the length of each devices, see the following di-
mensions.
Length (c) of center of the prism to the bottom of the
measurement target B: 80 mm (0.080 m)
Length (b) of ferrule (a): 50 mm (0.050 m)
95. Set the end of the measurement target B to the hole (PA1)
at the edge of GNSS antenna (Main) on L.H. of the ma-
chine. Level it so that the prism (35) faces directly forward
to the total station A.
REMARK
• GNSS antenna has holes used for setting the ferrule.
• Adjust the levelness so that bubbles of the level (36)
are at the center in the standard circle.
dinates of GNSS antenna position, and record the coordi-
nates.
REMARK
• If the prism (35) of the measurement target B cannot
be collimated accurately due to the handrail, adjust the
height of the prism. At this time, be sure to change the
input height of the prism as well.
PC210LCI-11 30-619
at the diagonal position of the position where the measure-
ment target B is installed in step 93. Level it so that the
prism (35) faces directly forward to the total station A.
REMARK
Adjust the levelness so that bubbles of the level (36) are at
the center in the standard circle.
nates.
REMARK
99. Set the end of the measurement target B to the hole at the
edge of GNSS antenna (Aux) on R.H. of the machine. Lev-
el it so that the prism (35) faces directly forward to the total
station A as accurately as possible.
REMARK
nates.
REMARK
A.
101. Set the end of the measurement target B to the hole at the diagonal position of the position where the
measurement target B is installed in step 97. Level it so that the prism (35) faces directly forward to the total
station A.
REMARK
Adjust the levelness so that bubbles of the level are at the center in the standard circle.
102. An operator of the total station A must measure the coordinates of the GNSS antenna (Aux) position, and
record the coordinates.
REMARK
A.
30-620 PC210LCI-11
103. Input the coordinates of the recorded GNSS antenna

(Main) position.
1) Press the input column (79) of “PA1”.
2) When the numeric keypad (28) is displayed, input the
coordinates, and press “OK” (29).

NOTICE
Do not mistake the input values of the coordinates
of L.H. (Main) and R.H. (Aux) of the machine.
REMARK
• If the input value is out of the range, or the dis-
tance between PA1 and PA2 is 0.5 mor longer,
“Next” (81) button becomes inactive and grayed
out.
TOTAL STATION”.
104. Press “Next” (81).
The screen is switched to the “Full Parameter Calibration [15/16]” screen.
PC210LCI-11 30-621
105. When the “Full Parameter Calibration [15/16]” screen is

displayed, input the coordinates of the recorded GNSS an-
tenna (Aux) position.

NOTICE
REMARK
out.
MEASURED VALUES”.
106. Press “Next” (84).
The screen is switched to the “Full Parameter Calibration [16/16]” screen.
107. When the “Full Parameter Calibration [16/16]” screen is
displayed, press “Set” (85) for 0.5 second or more.
The horizontal and vertical distances from the GNSS an-
tenna to the boom foot pin are saved in ICT sensor con-
troller.
30-622 PC210LCI-11
108. When the “TS Machine Calibration” menu screen is dis-

played after calibration is completed, press “Back” (86).

it” (87).
111. After checking the control box power supply is turned off,
When the starting switch is turned to ON position again,
the result of the calibration is reflected to the control box.
112. Check the blade tip precision accuracy.

• When the control point (or alignment marker) is not set
in the operation site
1) Set the work equipment lock lever to FREE posi-
tion.
2) Set the work equipment in posture 1, and place
the work equipment lock lever to LOCK position.
Arm cylinder: Fully retracted
Bucket: Bottom at an angle of Approx. 90 ° to the
ground surface
3) Press the satellite receiving status check button

(88).
PC210LCI-11 30-623
4) When the “GNSS Status” screen is displayed,

check the satellite accuracy.
REMARK
• There is no problem with “Horizontal RMS”
(89) and “Vertical RMS” (90) if they are 0.020
mor lower respectively.
• If the satellite accuracy is 0.020 mor higher,
wait until the satellite receiving status is im-
proved, and then check the status again.
5) Press “Back” (91).
6) When the standard screen is displayed, press the

blade tip check button (92).
7) When the detailed screen of “position” is dis-

played, select “Bucket: Middle” (93).
8) Press “Measure...” (94).

The coordinates (95) of the blade tip position is
displayed.
9) Press “Save” (96).
saved.
30-624 PC210LCI-11
10) Make a mark at the position on the ground sur-

face directly under the mark (T) at the center of
the bucket blade tip.
11) Swing the upper structure up to the position

where reception status of the rover L does not be-
come poor.
12) Measure the coordinates of the point marked in
step 10) by using the rover L, and write down the
coordinates on any notes.
REMARK
For the method of measuring the coordinates, see
the Operation and Maintenance Manual for the
rover L.
13) Press the tab (97) of “Comp. BM”.
PC210LCI-11 30-625
14) When the detailed screen of “Comp. BM” is dis-

played, input the coordinates measured by the ro-
ver L.
Press the input column (98) to display the numer-
al keypad (28), input the coordinates, and then
press “OK” (29).
15) When the difference (100) between the coordi-

nates (95) of the blade tip position measured by
the control box and the coordinates (99) meas-
ured by the rover L is displayed, compare it with
the standard value.
For the standard value, see “STANDARD VALUE
TABLE, STANDARD VALUE TABLE FOR MA-
CHINE”.
• When the difference (100) displayed on the

monitor is within the standard value range
Check the accuracy of the blade tip position
in postures 2 to 4 according to the same pro-
cedure as posture 1. Do not change the posi-
tion of the point measured with posture 1.
Change the posture of the work equipment
only.
Posture 2
• Fully retract the arm cylinder.
• Lower the bottom face of the bucket to
the ground.
Posture 3
• Set the arm vertically.
• Set the bottom face of the bucket at approximately 90 degrees toward the ground.
Posture 4
• Lower the bottom face of the bucket to the ground.
30-626 PC210LCI-11
• When the difference (100) displayed on the monitor is out of the standard value range
Check the blade tip accuracy 2 or 3 times while paying attention to the following items.
• Deterioration of satellite accuracy
The satellite accuracy deteriorates depending on the satellite status. Wait until the satel-
lite receiving status is improved, and then check the blade tip accuracy.
• Defective reset position of the stroke sensing hydraulic cylinder
The reset position of the stroke sensing hydraulic cylinder may be misaligned. Fully re-
tract the cylinders of each part of the work equipment, and then fully extend them. Per-
form the same operation repeatedly. Then, check the accuracy of the blade tip position.
• Incorrect input
Check if the GNSS antenna coordinates on L.H. (Main) of the machine and the GNSS an-
tenna coordinates on R.H. (Aux) of the machine are reversely inputted.
• When the difference (100) displayed on the monitor is still out of the standard value range
Check the following items.
1] Check if the mounting bracket (handrail) of the GNSS antenna is not bent.
2] Check if the GNSS antenna is correctly installed with no looseness or play.
3] Check if the position where measurement was performed by using the control box is
matched with the position where the measurement was performed by using the rover
L.
4] Check if the satellite accuracy is within the range of ±0.020 m.
If the value is still out of the standard value range even though there is no problem with the above
items, take countermeasures as described below.
• Failure in initialization of IMU sensor
Stop the engine once, turn the starting switch
to ON position, and hold it for 10 seconds to
initialize IMU sensor again. Then, start the
engine, and check the blade tip position ac-
curacy.
• Accuracy of the satellite is low
By using the control box function, offset the
coordinates of the blade tip position.
For the offsetting method, see the Operation
and Maintenance Manual of the control box.
• The coordinates of the height position are
misaligned in the same direction.
Calibrate IMU sensor again if the coordinates in the height direction of the blade tip in pos-
tures 1 to 4 is misaligned upper or lower in the same direction than the coordinates of the ro-
ver L.
• The coordinates of the height position are misaligned in the different direction.
There is a high possibility that the value detected by IMU sensor is false if the coordinates in
the height direction of the blade tip in postures 1 to 4 is misaligned in the different direction
(upper or lower than the rover L). If the coordinates are misaligned even though IMU sensor is
calibrated again, perform troubleshooting for IMU sensor.
For details of the troubleshooting, see TROUBLESHOOTING.
• When the control point (or alignment marker) is set in the operation site
1) Move the control point (or alignment marker).
PC210LCI-11 30-627
2) Press the satellite receiving status check button

(88).
3) When the “GNSS Status” screen is displayed,

check the satellite accuracy.
REMARK
• For the satellite accuracy, there is no problem
with “Horizontal RMS” (89) and “Vertical RMS”
(90) if they are 0.020 mor lower respectively.
• If the satellite accuracy is 0.020 mor higher,
wait until the satellite receiving status is im-
proved, and then check the status again.
4) Press the RETURN button (91).
5) When the standard screen is displayed, press the

blade tip position check button (92).
6) When the detailed screen of “position” is dis-

played, push the pull-down menu, and select
“Bucket: Middle” (93).
30-628 PC210LCI-11
7) Set the work equipment in posture 1.

Arm cylinder: Fully retracted
Set the bottom face of the bucket at approx. 90 °
position toward the ground.
8) Set the blade tip at the center of the bucket to the

control point (or alignment marker) (101) while
keeping the posture 1.
9) Place the work equipment lock lever in LOCK po-
sition.
10) Press “Measure...” (94).

displayed.
11) Press “Save” (96).
The coordinates of the blade tip position is saved.
12) Press the tab (97) of “Comp. BM”.
PC210LCI-11 30-629
13) When the detailed screen of “Comp. BM” is dis-

played, input the coordinates of the control point
or the alignment marker.
Press the input column (98) to display the numer-
al keypad (28), input the coordinates, and then
press “OK” (29).
14) Compare the standard value with the difference

(100) between the coordinates (95) of the blade
tip position calculated by the control box and the
coordinates (99) of the control point or the align-
ment marker.
For the standard value, see “STANDARD VALUE
TABLE, STANDARD VALUE TABLE FOR MA-
CHINE”.
• When the difference (100) displayed on the monitor is within the standard value range
Check the accuracy of the blade tip position in postures 2 to 4 according to the same proce-
dure as the posture 1.
Posture 2
• Fully retract the arm cylinder.
• Set the bottom face of the bucket in par-
allel with the ground and set the center
of the blade tip of the bucket to the con-
trol point or the alignment marker.
30-630 PC210LCI-11
Posture 3
• Set the bottom face of the bucket at an
angle of approximately 90 degrees to the
ground and set the center of the blade
edge of the bucket to the control point or
the alignment marker.
Posture 4
• Set the bottom face of the bucket in par-
allel with the ground and set the center
of the blade tip of the bucket to the con-
trol point or the alignment marker (101).
• When the difference (100) displayed on the
monitor is out of the standard value range
Perform the operation according to the same
procedure as “When the control point (or the
alignment marker) is not set in the operation
site”.
PC210LCI-11 30-631
CALIBRATION OF BOOM DIMENSIONS AND ARM DIMENSIONS WITH TOTAL

STATION
Tools for calibration of boom dimensions and arm dimensions with total station
Commercially
A Total station 1
available
jig D.
Commercially
C Marker 1
available
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
9 2A5-98-21240 Adapter 1
D
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
20 01640-20610 Washer 1
stop the engine.
Be sure to perform this adjustment after replacing the boom, boom cylinder or arm cylinder.
This calibration menu calibrates the accuracy of the dimensions between various boom pins and arm pins, and
the angles of the boom and the arm which measured by the total station.
“Arm Top Calibration” is for when the conventional bucket is installed. When the tilt bucket is installed, be sure to
perform the tilt bucket calibration after completing “Arm Top Calibration”.
30-632 PC210LCI-11
METHOD FOR CALIBRATING BOOM DIMENSIONS AND ARM DIMENSIONS

WITH TOTAL STATION
of the machine.
tance.
REMARK
REMARK
tal station A.
REMARK
REMARK
tion A.
NOTICE
REMARK
A.
REMARK
1) Set the collimating direction to the front, and set the coordinates to “0”.
REMARK
When setting the coordinates to “0”, the front of the machine is set as X axis, R.H. direction as Y axis,
and vertical direction as Z axis.
PC210LCI-11 30-633

REMARK
REMARK
REMARK
tooth.
30-634 PC210LCI-11



PC210LCI-11 30-635

shutdown” (9).

bration” (10).

press “Arm Top Calibration” (102).
machine.

1) Select the corresponding work equipment file name.
REMARK
30-636 PC210LCI-11

correct

correct
Press “Back” (103) to return to the “Work
Equipment Files” screen and select the work
equipment file again.

REMARK
word.
PC210LCI-11 30-637

down menu.
REMARK
changes to yellow.


correct
ed to the “Arm Top Calibration [1/7]” screen.
30-638 PC210LCI-11

correct
23. Draw a cross hairs at the center of the arm mounting pin
(a) and the bucket mounting pin on R.H. of the machine by
using the marker C.
PC210LCI-11 30-639
jig D and combine them with the assisting block (34).
k Be careful not to get your fingers in the assisting
block (34) while installing it. The assisting block is
installed by using the attracting force of a powerful
magnet.
26. Attach the special blade edge measuring jig D assembled

powerful magnet.
REMARK
toward the “PS1” position on the “Arm Top Calibration
[1/7]” screen.
REMARK
30-640 PC210LCI-11
total station A.
NOTICE
dinates of the special blade edge measuring jig D, and re-
cord it.
REMARK
[1/7]” screen.
REMARK
total station A.
NOTICE
dinates of the special blade edge measuring jig D, and re-
cord it.
REMARK
[1/7]” screen.
REMARK
machine: 180 °
PC210LCI-11 30-641
total station A.
NOTICE
When the special blade edge measuring jig D is adjust-
cord it.
REMARK
36. Input the coordinates of the special blade edge measuring jig D at the “PS1” to “PS3” positions.
2) Press “OK” (17).
REMARK
TAL STATION”.
30-642 PC210LCI-11
37. Swing the upper structure 180 ° from the position of “PS3”
displayed on the “Arm Top Calibration [1/7]” screen, and
set it in the posture shown below.
Upper structure: Work equipment direction in parallel with
track direction
NOTICE

The screen is switched to the “Arm Top Calibration [2/7]”
screen.
station A, and determine the position to stick the reflector
plate D8.
41. Install the reflector plate D8 to the center of the boom foot
pin.
Install the reflector plate D8 to the center of the boom
foot pin.
with the marker C, and install the reflector plate D8 according to the cross hairs.
42. The operator of the total station A must change the measurement mode to the non-prism mode.
REMARK
station A.
43. Measure the central coordinates of the reflector plate D8, and record it.
PC210LCI-11 30-643
REMARK
A.
2) Press “OK” (17).
REMARK
TAL STATION”.

screen.
not lifted.
REMARK
30-644 PC210LCI-11
49. Install the reflector plate D8 to the center of the cross hairs
(mounting pin center (a) of the arm and bucket) drawn in
step 21.
position so that “sensor value” (22) of the boom
cylinder/arm cylinder length on the “Arm Top Calibration
[3/7]” screen matches with “target value” (23).
REMARK
do not lift up.
51. The operator of the total station A must measure the coordinates of the center of reflector plate D8 installed
to the center of the pin at the arm end, and record the values. Right after recording, the total station opera-
tor must make a signal of measurement completion of coordinates to the machine operator.
REMARK
A.
REMARK
nal.
again.
53. Input the coordinates of the center of the arm end recorded in the step 49.
PC210LCI-11 30-645

2) Press “OK” (17).
REMARK
TAL STATION”.

screen.
REMARK
do not lift up.
• If the bucket is lowered to the ground and the bucket blade edge position cannot be adjusted within
±0.010m, leave the bucket on the ground.
30-646 PC210LCI-11
REMARK
A.
REMARK
nal.
again.
58. Input the coordinates of the center of the pin at the arm end recorded in the step 54.
2) Press “OK” (17).
REMARK
For the input range, see “INPUT RANGE OF THE MEAS-
URED VALUES IN CALIBRATION WITH TOTAL STA-
TION”.

screen.
PC210LCI-11 30-647
REMARK
do not lift up.
REMARK
A.
REMARK
nal.
again.
30-648 PC210LCI-11

2) Press “OK” (17).
REMARK
URED VALUES IN CALIBRATION WITH TOTAL STA-
TION”.


“Arm Top Calibration [6/7]” screen is displayed, and
calculation of parameters of each portion of work
equipment starts automatically.
PC210LCI-11 30-649

TAL STATION”.

the work equipment finishes, the “Arm Top Calibration
[7/7]” screen is displayed again. Check the value (a) dis-
played in “Accuracy RMS of arm top 3-point's coordinates”.

1) Accuracy of the result of the calculation may lower. Press “Back” (41) to return to the correspond-
REMARK
Input the value again. See “VERIFY THE INPUT VALUES”.
Perform the measurement again according to
the flow.
REMARK
When high accuracy earthmoving operation
is not required, you may proceed to the next
operation by pressing “Set” (42) for 0.5 sec-
ond or more.
30-650 PC210LCI-11

1) The automatic calculation is correctly finished and
accuracy of the result of the calculation is higher.
Press “Set” (42) for 0.5 second or more.
The dimensions between the boom pins and arm pins, and
its angles are saved in ICT controller.
When the “TS Machine Calibration” screen is displayed,
the calibration is completed.
66. Press “Back” (43) to return to the “Machine Setup” screen.
67. Press “Exit” (44) to return to the standard screen.
PC210LCI-11 30-651
CALIBRATION OF BUCKET LINK DIMENSIONS WITH TOTAL STATION

Tools for calibration of bucket link dimensions with total station
Commercially
A Total station 1
available
jig K.
Commercially
C Marker 1
available
Commercially
D L-square 1
available
Commercially
E Convex rule 1
available
Commercially
F Magnet stand 1
available
Commercially
G Plumb 1
available
Commercially Accuracy: 0.1 ° or lower, Resolution 0.1 °
available or lower
Commercially
J String 1
available
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
9 2A5-98-21240 Adapter 1
K
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
20 01640-20610 Washer 1
30-652 PC210LCI-11
stop the engine.
Be sure to perform this adjustment after replacing the side link, front link, or bucket cylinder.
“Bucket Link Calibration” is for when the conventional bucket is installed. When the tilt bucket is installed, be
sure to perform the tilt bucket calibration after completing “Bucket Link Calibration”.
METHOD FOR CALIBRATION OF BUCKET LINK DIMENSIONS WITH TOTAL STA-

TION
of the machine.
tance.
REMARK
REMARK
tal station A.
REMARK
REMARK
tion A.
NOTICE
PC210LCI-11 30-653
REMARK
A.
REMARK
REMARK
REMARK
REMARK
REMARK
tooth.
30-654 PC210LCI-11


PC210LCI-11 30-655


shutdown” (9).

bration” (10).

press “Bucket Link Calibration” (102).
machine.

REMARK
30-656 PC210LCI-11

correct

correct

REMARK
word.
PC210LCI-11 30-657

down menu.
REMARK
changes to yellow.

8) Press the corresponding bucket file name on the

“Work Equipment Files” screen to select it.
REMARK
changes to yellow.
30-658 PC210LCI-11

correct

correct
23. Select the bucket file of the bucket currently mounted to
the machine on the “Conventional Bucket Files” screen.
• When the bucket file is listed

1) Select the corresponding bucket file name.
REMARK

The “Conventional Bucket Files” screen is switched to the “Bucket Link Calibration [1/10]”
screen.
PC210LCI-11 30-659

bucket file again.

the bucket.
bucket mounting pin.
the bucket tooth tip.
“Lbkw”: The length of the side cutters. (the widest
REMARK
bucket.
30-660 PC210LCI-11

displayed on the “Bucket Link Calibration [1/10]”
screen.
surface.
• When the bucket file is not on the list and the file
needs to be copied from the USB memory
1) Insert the USB memory (16) containing the buck-
et file of the bucket currently mounted to the ma-
chine into the control box.
REMARK
word.
• Be sure to save the bucket file in the root di-
rectory of the USB memory (16).

down menu.
PC210LCI-11 30-661
5) When the list of the bucket files saved in the USB

memory is displayed, select the name of the cor-
responding bucket file.
REMARK
changes to yellow.
7) The bucket file is copied to the control box, and
the bucket file list is displayed. Check the name of
the copied file.
REMARK

The “Conventional Bucket Files” screen is switched to the “Bucket Link Calibration [1/10]”
screen.
bucket file again.
30-662 PC210LCI-11

the bucket.
bucket mounting pin.
the bucket tooth tip.
“Lbkw”: The length of the side cutters. (the widest
REMARK
bucket.

[1/16]” screen.
surface.
• When the bucket file does not exist and the bucket dimensions need to be measured to create a new
bucket file
Measure the bucket dimensions, and input the values in the control box.
PC210LCI-11 30-663
REMARK
• Measure the dimensions as accurately as possible by using the square D, convex rule R, and mag-
net stand F on R.H. surface of the bucket.
• Measure the angle in 0.1 ° unit.
1) Measure the dimension “Lbk3” of the bucket.
REMARK
arm mounting pin and the boom mounting pin on
both sides to the center of the link mounting pin
and the bucket mounting pin. Then, input the
average value.
2) Measure the dimension “L3” of the bucket.

REMARK
the bucket tooth tip which marked as (T).
3) Measure the dimension “Lbkw” of the bucket.

REMARK
Measure the length of the side cutters (the widest
30-664 PC210LCI-11
4) Measure the dimension “Ltooth” of the bucket.

REMARK
Measure the distance between the root and the
blade tip of the tooth (the length of the blade
width if the tooth is not installed).
PC210LCI-11 30-665
5) Draw a cross hairs at the mounting pin center (f)

of the arm and the bucket on R.H. of the machine
by using the marker C.
REMARK
The cross hairs will be a guide for the magnet
stand F to be installed.
6) Draw the dots (a) to (e) for the bucket shape rec-
ognition on R.H. of bucket by using the marker C.
Dot (a): Intersection point of the bucket bottom
straight line corner
Dot (e): Point on an extended line from the
mounting pin center of the arm and bucket to
Dot (d): Contact point of the tangent line drawn
from the dot (e) to the bucket outside diameter
Dot (b), dot (c): Approximately and equally
spaced points of the distance between the dot
(a) and dot (d)
REMARK
Recognize the bucket shape as a polygon con-
sisting of the dots (a) to (e).
7) Install the magnet stand F so that the center (f) of the arm mounting pin and the bucket mounting
pin are aligned with the center point of the magnet stand F.
REMARK
Install the magnet stand F according to the cross hairs.
8) Install the plumb G to the pole of the magnet stand F.
9) Install the string J to the pole of the magnet stand F.
10) Adjust the bucket position so that the straight line from the center of the arm mounting pin and the
bucket mounting pin to the bucket blade tip is vertical.
NOTICE
• The work equipment may lower gradually due to the hydraulic drift during measurement.
Check the position of the plumb G, and adjust the bucket position for the measurement
if it lowers due to the hydraulic drift.
• When adjusting the bucket position, be careful to prevent the plumb G and string J from
touching the blade tip. If the string J touches the blade tip, the blade tip pushes the the
string J and measurement cannot be performed correctly.
11) Stretch the string J to each of the shape recogni-
tion dots (a) to (e) in this order, and measure the
angle (α) of the string J by using the digital angle
gauge H.
30-666 PC210LCI-11
NOTICE
• Complete measurement of all the angles within 3 minutes after the bucket position is ad-
justed according to step 10).
If 3 minutes have elapsed, adjust the bucket position again, and then measure the shape
recognition dot.
• The measurement error of the angle at the shape recognition dot (e) largely affects the
accuracy of the calibration. Accordingly, perform measurement accurately, observing
Operation and Maintenance Manual for the digital angle gauge H.
• Measure the angle (α) at the shape recognition dot (e) before the hydraulic drift of the
work equipment starts.
• Measure the angle (α) at the shape recognition point (e) on both sides of the bucket,
whenever possible. When the difference between the measurement value on both sides
is 0.1 °or more, input the mean value of those values.
Stretch the convex rule E (substitute for the string J) from the center of the arm mount-
ing pin and the bucket mounting pin to the center of the link mounting point and the
bucket mounting point. Measure the angle (α) at the shape recognition dot (e) on L.H. by
using the digital angle gauge H.
• When measuring the angle, set the roll direction of the digital angle gauge H vertically.
REMARK
• Record the angle (α) of the string J in absolute value (positive real number).
• Use the “ °” unit for the measured angle.
• Calculate the angle (θ) at each shape recognition dot.
Shape recognition dot (a), (b), (c), (d): (θ) = 90 - (α)
Shape recognition dot (e): (θ) = 90 + (α)
12) Stretch the string J to each of shape recognition
dots (a) to (e). Mark a dot on the string J at each
shape recognition point.
13) Remove the string J on which the shape recogni-

tion points are made from the pole. Measure the
distance between the center of the arm mounting
pin and the bucket mounting pin (end of the string
J) to each mark of the shape recognition points by
using the convex rule F.
PC210LCI-11 30-667
14) Press “New” (18).
15) When the input keypad (19) is displayed, input

the bucket file name to be created newly, and
The newly created file name is displayed on the
16) Select the new bucket file.
REMARK
changes to yellow.
30-668 PC210LCI-11
18) When the “Conventional Bucket Exchange”

screen is displayed, input the dimensions (Lbk3,
L3, LbkW, Ltooth) of the bucket and the meas-
ured values of the shape recognition dots (a) to
(e) of the bucket.
REMARK
• Press the input columns (22) to (27) to display
the numeral keypad (28), input the value, and
• For the input range, see “INPUT RANGE OF
THE MEASURED VALUES”.
• When the input value is within the range

The screen is switched to the “Bucket Link
PC210LCI-11 30-669
• When the input value is out of the range

The screen is switched to the “Check Error”
screen.
tional Bucket Files” screen and check the in-
put value.
REMARK
For the input range, see “INPUT RANGE OF
THE MEASURED VALUES”.
jig K and combine them with the assisting block (34).
magnet.
30-670 PC210LCI-11
26. Attach the special blade edge measuring jig K assembled

powerful magnet.
REMARK
toward the “PS1” position on the “Bucket Link Calibration
[2/10]” screen.
REMARK
total station A.
NOTICE
cord it.
REMARK
[2/10]” screen.
REMARK
PC210LCI-11 30-671
total station A.
NOTICE
cord it.
REMARK
[2/10]” screen.
REMARK
machine: 180 °
total station A.
NOTICE
cord it.
REMARK
36. Input the coordinates of the special blade edge measuring jig K at the “PS1” to “PS3” positions.
30-672 PC210LCI-11

2) Press “OK” (29).
REMARK
URED VALUES”.
displayed on the “Bucket Link Calibration [2/10]” screen,
and set it in the posture shown below.
NOTICE
PC210LCI-11 30-673

The screen is switched to the “Bucket Link Calibration
[3/10]” screen.
station A. Determine the position to stick the reflector plate
K8.
41. Install the reflector plate K8 to the center of the boom foot
pin.
Install the reflector plate K8 to the center of the boom
foot pin.
with the marker C, and install the reflector plate K8 according to the cross hairs.
42. The operator of the total station A must change the measurement mode to the non-prism mode.
REMARK
station A.
43. Measure the central coordinates of the reflector plate K8, and record it.
REMARK
A.
30-674 PC210LCI-11

2) Press “OK” (29).
REMARK
URED VALUES”.

[4/10]” screen.
not lifted.
REMARK
PC210LCI-11 30-675
position so that “sensor value” (40) of the
boomcylinder /arm cylinder length on the “Bucket Link Cal-
ibration [4/10]” screen matches with “target value” (41).
REMARK
tor.
REMARK
A.
REMARK
nal.
again.
30-676 PC210LCI-11

2) Press “OK” (29).
REMARK
URED VALUES”.

[5/10]” screen.
REMARK
do not lift up.
• If the bucket is lowered to the ground and the bucket blade edge position cannot be adjusted within
±0.010m, leave the bucket on the ground.
PC210LCI-11 30-677
total station operator must make a signal of measurement completion of coordinates to the machine
operator.
REMARK
A.
REMARK
nal.
again.
2) Press “OK” (29).
REMARK
URED VALUES”.

[6/10]” screen.
30-678 PC210LCI-11
REMARK
do not lift up.
tor.
REMARK
A.
REMARK
nal.
again.
PC210LCI-11 30-679

2) Press “OK” (29).
REMARK
URED VALUES”.


The “Bucket Link Calibration [7/10]” screen is displayed.
MEASURED VALUES”.
30-680 PC210LCI-11
65. Move the work equipment and set it in the position shown
in the drawing. Lower the bucket to the ground slowly so
that the track do not lift up. Lift the blade tip from the
ground by a few centimeters.
REMARK
67. Install the special blade edge measuring jig K to the blade
tip (42) closest to the total station A.
powerful magnet.
REMARK
Install the special blade edge measuring jig K so that there
is no backlash between the blade tip (42) and the surfaces
A and B of the jig.
68. Adjust the position vertically with the hexagonal socket
head bolts (44) (2 pieces) so that the surface A touches
the blade tip end (42) at the center of the hole (43).
REMARK
• If the position is adjusted correctly, the end position of
the blade tip (42) is aligned with the center of the prism
(35).
• Width across flats of hexagonal socket head bolt (44):
4 mm
69. After adjustment is completed, install the prism (35) to the

special blade edge measuring jig K.
NOTICE
If there is a difference between the length from the
center of the arm mounting pin and the bucket mount-
ing pin to the center of the prism (35) and the “L3” dis-
tance input on the “Bucket Link Calibration [1/10]”
screen, the accuracy of the calibration lowers.
PC210LCI-11 30-681
• When the length of the tooth varies

1) Offset the special blade edge measuring jig K as
shown in the drawing, and install it so that the
“L3” measurement point (T) is aligned with the
surface A of the special blade edge measuring jig
K.
• When the jig cannot be aligned as shown in the draw-

ing due to distortion of the bucket shape, and it cannot
be installed
1) Press “Back” until the “Bucket Link Calibration
[1/10]” screen.
2) Measure the distance from the center (a) of the
the center (b) of the prism (35), and then input the
value as “L3”.
3) Press “Next” and proceed to the “Bucket Link Cal-
ibration [7/10]” screen.
70. Adjust the prism (35) as shown in the drawing so that the
prism is at an angle of approx. 90 ° (c) to the work equip-
ment center and it is approximately parallel with the
ground.
30-682 PC210LCI-11
on the “Bucket Link Calibration [7/10]” screen matches
NOTICE
pact.
REMARK
comes red.
REMARK
A.
REMARK
nal.
again.
PC210LCI-11 30-683

2) Press “OK” (29).
REMARK
MEASURED VALUES”.

[8/10]” screen.
on the “Bucket Link Calibration [8/10]” screen matches
NOTICE
pact.
REMARK
comes red.
30-684 PC210LCI-11
REMARK
A.
REMARK
nal.
again.
81. Input the coordinates of the blade edge position recorded in the procedure 77.
2) Press “OK” (29).
REMARK
MEASURED VALUES”.

PC210LCI-11 30-685

The “Bucket Link Calibration [9/10]” screen is dis-
played, and the control box automatically starts to cal-
culate the parameter of each parts of the work equip-
ment.

MEASURED VALUES”.

the work equipment finishes, the “Bucket Link Calibration
[10/10]” screen is displayed again. Check the value (a) dis-
played in “Accuracy RMS of bucket 2-point's coordinates”.

Accuracy of the calculation result may be lower. Press “Back” (72) to return to the corresponding
screen, and check the input value.
REMARK
Input the value again. See “VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL STA-
TION”.
30-686 PC210LCI-11
Perform the measurement again according to the

flow.
REMARK
When high accuracy earthmoving operation is not
required, you may proceed to the next operation
by pressing “Set” (73) for 0.5 second or more.

The automatic calculation is correctly finished and ac-
curacy of the result of the calculation is higher. Press
“Set” (73) for 0.5 second or more.
“TS Machine Calibration” screen is displayed when the di-
mensions between the arm pins, the side link pins, and the
front link pins, the angle of all the pins, and the bucket
shape are successfully saved in ICT controller.
84. Move the work equipment to set it in the position shown in

the drawing.
85. Lower the bucket to the ground slowly so that the track do
not lift up. Lift the blade tip from the ground by a few centi-
meters.
REMARK

press “Back” (74) to return to the “Machine Setup” screen.
PC210LCI-11 30-687
30-688 PC210LCI-11
CALIBRATION OF GNSS ANTENNA WITH TOTAL STATION

Tools for calibration of GNSS antenna with total station
Commercially
A Total station 1
available
special blade edge measuring jig E.
Commercially
C Marker 1
available
Commercially
D L-square 1
available
1 2A5-98-21111 Bracket 1
2 2A5-98-21121 Bracket 1
3 2A5-98-21130 Bracket 1
4 2A5-98-21140 Bracket 1
5 2A5-98-21151 Pin 2
6 2A5-98-21161 Block 1
7 2A5-98-21220 Magnet 6
9 2A5-98-21240 Adapter 1
E
10 2A5-98-21250 Bolt 2
11 2A5-98-21260 Bolt 2
12 2A5-98-21270 Bolt 3
13 2A5-98-21310 Washer 2
14 17A-711-7850 Washer 2
15 2A5-98-21330 Pole 1
16 2A5-98-21340 Collar 1
17 22J-973-3520 Bolt 1
18 01252-90616 Washer 3
19 01640-20610 Washer 1
stop the engine.
k To move the upper structure 180 °C during calibration, secure the safety around the machine before
Be sure to perform the calibration when the handrail is replaced, remove, or installed, or when GNSS antenna
position is largely changed due to removal or installation of the exterior cover or deformation of the handrail.
When GNSS antenna position is calibrated by using the total station, the horizontal distance and vertical dis-
tance from GNSS antenna to the boom foot pin is calibrated by using the total station.
“TS GPS Antenna Calibration” is for when the conventional bucket is installed. When the tilt bucket is installed,
be sure to perform the tilt bucket calibration after completing “TS GPS Antenna Calibration”.
PC210LCI-11 30-689
METHOD FOR CALIBRATING GNSS ANTENNA WITH TOTAL STATION

of the machine.
tance.
REMARK
REMARK
tal station A.
REMARK
REMARK
tion A.
NOTICE
REMARK
A.
REMARK
REMARK
30-690 PC210LCI-11
REMARK
REMARK
REMARK
tooth.
PC210LCI-11 30-691



30-692 PC210LCI-11

shutdown” (9).

bration” (10).

press “TS GPS Antenna Calibration” (102).
machine.

REMARK
PC210LCI-11 30-693

correct

correct

REMARK
word.
30-694 PC210LCI-11

down menu.
REMARK
changes to yellow.


“Work Equipment Files” screen.

correct
ed to the “TS GPS Antenna Calibration [1/9]”
screen.
PC210LCI-11 30-695

correct
23. Draw a cross hairs at the center of the arm mounting pin
(a) and the bucket mounting pin on R.H. of the machine by
using the marker C.
REMARK
The cross hairs will be a guide for the reflector plate E8 to
be installed.
30-696 PC210LCI-11
jig E and combine them with the assisting block (34).
magnet.
26. Attach the special blade edge measuring jig E assembled

blade edge measuring jig E while installing it. The
powerful magnet.
REMARK
Install the special blade edge measuring jig E to the coun-
toward the “PS1” position on the “TS GPS Antenna Cali-
bration [1/9]” screen.
REMARK
PC210LCI-11 30-697
total station A.
NOTICE
When the special blade edge measuring jig E is adjust-
dinates of the special blade edge measuring jig E, and re-
cord the coordinates.
REMARK
REMARK
total station A.
NOTICE
REMARK
REMARK
machine: 180 °
30-698 PC210LCI-11
total station A.
NOTICE
REMARK
36. Input the coordinates of the special blade edge measuring jig E at the “PS1” to “PS3” positions.
2) Press “OK” (17).
REMARK
TAL STATION”.
PC210LCI-11 30-699
displayed on the “TS GPS Antenna Calibration [1/9]”
screen, and set it in the posture shown below.
Upper structure: Work equipment direction in parallel with
track direction
NOTICE

The screen is switched to the “TS GPS Antenna Calibra-
station A, and determine the position to stick the reflector
plate E8.
41. Install the reflector plate E8 to the center of the boom foot
pin.
Install the reflector plate E8 to the center of the boom
foot pin.
with the marker C, and install the reflector plate E8 ac-
cording to the cross hairs.
42. The operator of the total station A must change the meas-
urement mode to the non-prism mode.
REMARK
station A.
43. Measure the central coordinates of the reflector plate E8, and record the coordinates.
30-700 PC210LCI-11
REMARK
A.
2) Press “OK” (17).
REMARK
TAL STATION”.

not lifted.
REMARK
PC210LCI-11 30-701
50. Draw a mark (W) at the center of the pin of the arm end by
using the marker C.
REMARK
Draw a mark (W) so that the virtual straight line between
the mark (W) and mark (T) is in parallel with the arm.
51. Measure the distance (k) between the mark (W) at the
center of the arm end to the reflecting face (P) of the re-
flector plate E8 stuck to the center (a) of the arm mounting
pin and the bucket mounting pin by using the square D.
52. Press the input column (22) to display the numeric keypad
(16), and then input the value.
30-702 PC210LCI-11
53. Press “OK” (17).

55. Perform the reciprocating operation of each work equip-
ments slowly.
REMARK
• When operating the cylinders of each work equipments
to the stroke end, slowly operate the cylinders so that
the machine position or direction is not misaligned due
to the impact.
• Operation can be started from any part of the work
equipment in any order.
Bucket: Reciprocating operation between arm IN stroke end and DUMP stroke end
Arm: Reciprocating operation between arm IN stroke end and DUMP stroke end
Boom: Reciprocating operation between the position where the bucket touches the ground and RAISE
stroke end
position so that the“sensor value” (24) of the boom cylin-
der/arm cylinder length on the “TS GPS Antenna Calibra-
REMARK
57. The operator of the total station A must measure the coordinates of the center of reflector plate E8 installed
REMARK
A.
PC210LCI-11 30-703

REMARK
nal.
again.
2) Press “OK” (17).
REMARK
TAL STATION”.

30-704 PC210LCI-11
REMARK
do not lift up.
REMARK
A.
REMARK
nal.
again.
PC210LCI-11 30-705

2) Press “OK” (17).
REMARK
TAL STATION”.

REMARK
30-706 PC210LCI-11
REMARK
A.
REMARK
nal.
again.
2) Press “OK” (17).
REMARK
TAL STATION”.

PC210LCI-11 30-707

The “TS GPS Antenna Calibration [7/9]” screen is dis-
played.

TAL STATION”.
71. When the “TS GPS Antenna Calibration [7/9]” screen is

displayed, input the prism height (d).
2) Press “OK” (17).
REMARK
• The prism height (d) of the target B measurement
kits: 130 mm (0.130 m)
• For the length of each device when using the kit of
the measurement target B, see the following di-
mensions.
Length (c) from the center of the prism (35) to the bot-
tom of the measurement target B: 80 mm (0.080 m)
Length (b) of ferrule (a): 50 mm (0.050 m)
TAL STATION”.
30-708 PC210LCI-11
at the edge of GNSS antenna (Main) on L.H. of the ma-
chine. Level it so that the prism (35) faces directly forward
to the total station A.
REMARK
nates.
REMARK
• If the prism (35) of the measurement target B cannot
be collimated accurately due to the handrail, adjust the
height of the prism. At this time, be sure to change the
input height of the prism as well.
PC210LCI-11 30-709
at the diagonal position of the position where the measure-
ment target B is installed in step 70. Level it so that the
prism (35) faces directly forward to the total station A.
REMARK
Adjust the levelness so that bubbles of the level (36) are at
the center in the standard circle.
nates.
REMARK
76. Set the end of the measurement target B to the hole at the
edge of GNSS antenna (Aux) on R.H. of the machine. Lev-
el it so that the prism (35) faces directly forward to the total
station A as accurately as possible.
REMARK
nates.
REMARK
A.
78. Set the end of the measurement target B to the hole at the diagonal position of the position where the
measurement target B is installed in step 74. Level it so that the prism (35) faces directly forward to the total
station A.
REMARK
Adjust the levelness so that bubbles of the level are at the center in the standard circle.
79. An operator of the total station A must measure the coordinates of the GNSS antenna (Aux) position, and
record the coordinates.
REMARK
A.
30-710 PC210LCI-11
80. Input the coordinates of the recorded GNSS antenna

(Main) position.

NOTICE
REMARK
out.
TOTAL STATION”.
PC210LCI-11 30-711

displayed, input the coordinates of recorded GNSS anten-
na (Aux) position.

NOTICE
REMARK
tance between PA1 and PA2 is 0.5m or longer,
out.
TOTAL STATION”.
30-712 PC210LCI-11

displayed, press “Set” (50) for 0.5 second or more.
The horizontal and vertical distances from the GNSS an-
tenna to the boom foot pin are saved in ICT sensor con-
troller.
When the “TS Machine Calibration” menu screen is dis-
played, the calibration is completed.
85. Press “Back” (51) to return to the “Machine Setup” screen.
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITH TOTAL

STATION
To input the measured value in the control box, input the values within the range listed below. The values out of
the range cannot be input.
Monitor display Input range Content
Distance (m) from the mounting pin center of the arm and bucket to
Lbk3 0.00001 to 19.99999
Distance between the side cutters (the widest bucket width if the side
L3 0.00001 to 19.99999
cutters are not installed)
Distance between the root and blade tip of the tooth (the distance of
Lbkw 0.0001 to 5.9999
the blade width if the tooth is not installed).
Distance (m) between the root and blade tip of the tooth (the dis-
Ltooth 0.0001 to 2.9999
tance of the blade width if the tooth is not installed).
A-Angle 0.01 to 179.99 Angle (deg) of shape recognition point A
A-Length 0.0001 to 5.9999 Distance (m) of shape recognition point A
B-Angle 0.01 to 179.99 Angle (deg) of shape recognition point B
PC210LCI-11 30-713

B-Length 0.0001 to 5.9999 Distance (m) of shape recognition point B
C-Angle 0.01 to 179.99 Angle (deg) of shape recognition point C
C-Length 0.0001 to 5.9999 Distance (m) of shape recognition point C
D-Angle 0.01 to 179.99 Angle (deg) of shape recognition point D
D-Length 0.0001 to 5.9999 Distance (m) of shape recognition point D
E-Angle 0.01 to 179.99 Angle (deg) of shape recognition point E
E-Length 0.0001 to 5.9999 Distance (m) of shape recognition point E
PS1-X
Coordinates (m) of the special blade edge measuring jig at PS1 posi-
PS1-Y -99.999 to 99.999
tion
PS1-Z
PS2-X
PS2-Y -99.999 to 99.999
tion
PS2-Z
PS3-X
PS3-Y -99.999 to 99.999
tion
PS3-Z
PB-X
Coordinates (m) of the position of reflector plate (39) pasted to the
PB-Y -99.999 to 99.999
boom foot pin
PB-Z
Distance (m) from the mark at the center of the bucket blade tip to
Loffset2 -5.999 to 8.999
the measuring port
PC1-X
PC1-Y -99.999 to 99.999 Coordinates (m) in PC1 posture
PC1-Z
PC2-X
PC2-Z
PC3-X
PC3-Z
PC4-X
PC4-Z
PC5-X
PC5-Z
Ltgt2 0 to 1.9999 Prism height (m)
30-714 PC210LCI-11

PA1-X
PA1-Y -99.999 to 99.999 Coordinates (m) of GNSS antenna (Main) position
PA1-Z
PA2-X
PA2-Y -99.999 to 99.999 Coordinates (m) of GNSS antenna (Aux) position
PA2-Z
VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL STATION

The control box automatically verifies the coordinates of the inputted bucket blade tip position.
The input error can be found when there is a difference between the coordinate values calculated by the total
station and the coordinate values calculated based on the selected work equipment file and the bucket file is
more than 0.2 (m) in x axial and z axial directions and 0.03 (m) in y axial direction.
If the incorrect values are found as a result of verification, these

values are displayed on the “Check Error” screen, correct the
values based on the following reference information.
(A): Approximately -3 m is displayed for the total station instal-
lation position coordinates in x axis direction.
(B): All the values of y coordinate are negative.
(C): The value of the blade edge position is almost the same as
the value measured by total station.
(D): Approx. 1.9 m
(E): Values at each position is listed below
• “PC1”: 0.1 m
• “PC2”: 0.1 m
• “PC3”: 2.1 m
• “PC4”: 3.6 m
• “PC5”: 3.0 m
(G): The current machine pitch angle is displayed.
(F): The machine pitch angle in the posture PC1 to PC3 is dis-
played.
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITH

TOTAL STATION

WITH TOTAL STATION
Take the following measures if an error occurs.
• If an error has found in the sensor
PC210LCI-11 30-715

ess.
2) When the “Machine Setup” screen is displayed, per-
form troubleshooting for the ongoing error.
REMARK
For the troubleshooting, see corresponding item in
TROUBLESHOOTING.

ess.
2) When the “Machine Setup” screen is displayed, per-
forming troubleshooting for an error in CAN communi-
cation line.
REMARK
For the troubleshooting, see corresponding item in
TROUBLESHOOTING.
CALIBRATION OF GNSS ANTENNA WITHOUT TOTAL STATION

stop the engine.
Calibration of GNSS antenna without total station calibrates the horizontal distance and vertical distance from
GNSS antenna to the boom foot pin manually.
After replacing GNSS antenna with a different model, be sure to perform this work.
This work is not required if the GNSS antenna is replaced with the same model or it is simply removed and in-
stalled.
METHOD FOR CALIBRATING GNSS ANTENNA WITHOUT TOTAL STATION

30-716 PC210LCI-11



PC210LCI-11 30-717


shutdown” (9).

MATSU” logo mark is displayed, press “GPS Antenna Po-
sition Calibration” (10).
10. When the “GPS Antenna Position Calibration [1/3]” screen
is displayed, input the length of the electrical phase center
of the replaced GNSS antenna.
REMARK
The input value range is from -3000 to 3000 m. The values
out of this range cannot be inputted.
• When replacing the antenna with G3-A1 manufactured by TOPCON
30-718 PC210LCI-11
1) Press the input column (11) to display the numer-

ic keypad (12), and then input “0.0303”.
2) Press “OK” (13).
• When replacing with the antennas other than G3-A1
manufactured by TOPCON
1) For the length of the electrical phase center, refer
to the GNSS antenna catalog or contact the man-
ufacturer.

ic keypad (12), and then input “0.0303”.
3) Press “OK” (13).
PC210LCI-11 30-719
11. When the newly input value is displayed, press “Next” (14).

is displayed, press “Next” (15).
REMARK
If the error screen is displayed, take actions by referring to
“ACTION TO BE TAKEN IF AN ERROR OCCURS DUR-
ING CALIBRATION OF GNSS ANTENNA WITHOUT TO-
TAL STATION”.
The parameter of the GNSS antenna is automatically cal-
culated.

is displayed, wait 3 seconds or more, and hold down “Set”
(16) for 0.5 second or more.
14. When the “Machine Setup” screen is displayed, the cali-

bration is completed. Press “Exit” (17) to return to the
standard screen.
16. After checking the control box power supply is turned off,
The result of the calibration is reflected to the control box.
30-720 PC210LCI-11
CALIBRATION OF BUCKET BLADE EDGE POSITION WITHOUT TOTAL STATION

Tools for calibration of bucket blade edge position without total station
Commercially
A L-square 1
available
Commercially
B Convex rule 1
available
Commercially
C Magnet stand 1
available
stop the engine.
Compared with “TS Machine Calibration”, the bucket blade tip position is recognized roughly, and the bucket
CURL accuracy is lowered in this calibration.
Calibration of the bucket blade tip position calibrates the work equipment dimensions by measuring the work
equipment other than the bucket without using the total station.
After completing this calibration, be sure to calibrate the mounted bucket by referring to Operation and Mainte-
nance Manual.
METHOD FOR CALIBRATING BUCKET BLADE EDGE POSITION WITH TOTAL

STATION

PC210LCI-11 30-721



30-722 PC210LCI-11

shutdown” (9).

MATSU” logo mark is displayed, press “Manual Machine
Calibration” (10).
machine.

REMARK

correct
ed to the “Manual Machine Calibration [1/5]”
screen, and the work equipment file values
are displayed.
PC210LCI-11 30-723

REMARK
word.

down menu.
REMARK
changes to yellow.

“Work Equipment Files” screen.
REMARK
changes to yellow.
30-724 PC210LCI-11

correct
ed to the “Manual Machine Calibration [1/5]”
screen, and the work equipment file values
are displayed.
11. Measure the dimensions “L1”, “L2”, and “L3” of the work
equipment.
“L1”: Measure the combined length of the center of the re-
volving frame mounting pin and the boom mounting pin to
the center of the boom mounting pin and the arm mounting
pin
“L2”: Measure the combined length of the center of the

boom mounting pin and the arm mounting pin to the the
center of the arm mounting pin and the bucket mounting
pin
PC210LCI-11 30-725
“L3”: Measure the distance between the center of the arm

mounting pin and the bucket mounting pin to the bucket to
the tooth tip
REMARK
• Measure the dimensions as accurately as possible by
using the square A, convex rule B, and magnet stand
C.
12. Check that the measured values are matched with the val-
ues of the work equipment file.
• When the measured values are not matched with the values in the work equipment file
ic keypad (17), and then input the value.
2) Press “OK” (18).
REMARK
For details of the input range, see “INPUT
RANGE OF THE MEASURED VALUES IN CALI-
BRATION WITHOUT TOTAL STATION”.
The screen is switched to the “Manual Machine Calibration

[2/5]” screen.
30-726 PC210LCI-11
14. Measure the dimensions “Lbm1”, “Lbm3”, “Lam2”, “Lam3”,

and “Lbk1” of the work equipment.
“Lbm1”: Measure the combined length of the center of the
revolving frame mounting pin and the boom mounting pin
to the center of the boom mounting pin to the boom cylin-
der mounting pin
“Lbm3”: Measure the combined length of the center of the

boom mounting pin and the arm cylinder mounting pin to
the center of the boom mounting pin and the arm mounting
pin
“Lam2”: Measure the combined length of the center of the

arm mounting pin and the arm cylinder mounting pin to the
center of the boom mounting pin and the arm mounting pin

arm mounting pin and the bucket cylinder mounting pin to
the center of the arm mounting pin and the link mounting
pin
PC210LCI-11 30-727
“Lbk1”: Measure the combined length of the center of arm

mounting pin and the link mounting pin to the center of the
link mounting pin and the bucket cylinder mounting pin
REMARK
C.
• When the measured values are not matched with the values in the work equipment file
2) Press “OK” (22).
REMARK
The screen is switched to the “Manual Machine Calibration

[3/5]” screen.
30-728 PC210LCI-11
17. Measure the dimensions “Lam4”, “Lbk2”, and “Lbk3” of the

work equipment.
arm mounting pin and the arm cylinder mounting pin to the
center of the boom mounting pin and the arm mounting pin
“Lbk2”: Measure the combined length of the center of the

arm cylinder mounting pin and the link mounting pin to the
center of the link mounting pin and the bucket mounting
pin
“Lbk3”: Measure the combined length of the center of the

arm mounting pin the bucket mounting pin to the center of
the link mounting pin and the bucket mounting pin
REMARK
C.
• When the measured values are not matched with the

values in the work equipment file
2) Press “OK” (26).
REMARK
PC210LCI-11 30-729
20. When the “Manual Machine Calibration [4/5]” screen is dis-

played, press “Next” (28).
REMARK
If the error screen is displayed, take actions by referring to
“ACTION TO BE TAKEN IF AN ERROR OCCURS DUR-
ING CALIBRATION OF BUCKET TIP POSITION WITH-
OUT TOTAL STATION”.
21. When the “Manual Machine Calibration [4/5]” screen is dis-

played, wait 3 seconds or more, and hold down “Set” (29)
for 0.5 seconds or more.
The parameters of each part of the work equipment are
saved in ICT sensor controller.
22. When the “Machine Setup” screen is displayed, the cali-

bration is completed. Press “Exit” (30) to return to the
standard screen.
23. Perform the calibration in accordance with the mounted
bucket.
• When the tilt bucket is mounted
Perform the calibration by referring to the Operation
and Maintenance Manual, “REPLACE TILT BUCKET”.
• When the mounted bucket is not the tilt bucket
Perform the calibration by referring to the Operation
and Maintenance Manual, “REPLACE STANDARD
BUCKET”.
25. After checking the control box power supply is turned off, turn the starting switch to ON position.
The result of the calibration is reflected to the control box.
30-730 PC210LCI-11
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITHOUT TOTAL

STATION
To input the measured value in the control box, input the values within the range listed below. The values out of
the range cannot be input.
Input range table

Distance (m) from the mounting pin center of the revolving frame and
L1
boom to the mounting pin center of the boom and arm
Distance (m) from the mounting pin center of the boom and arm to
L2
the mounting pin center of the arm and bucket
Distance (m) from mounting pin center of arm and bucket to mark (T)
L3
at tooth tip.
Distance (m) from the mounting pin center of the revolving frame and
Lbm1
boom to the mounting pin center of the boom and boom cylinder
Distance (m) from the mounting pin center of the boom and arm cyl-
Lbm3
inder to the mounting pin center of the boom and arm
Distance (m) from the mounting pin center of the arm and arm cylin-
Lbm2 0.00001 to 19.99999
der to the mounting pin center of the boom and arm
Distance (m) from the mounting pin center of the arm and bucket cyl-
Lam3
inder to the mounting pin center of the arm and link
Distance (m) from the mounting pin center of the arm and link to the
Lbk1
mounting pin center of the link and bucket cylinder
Distance (m) from the mounting pin center of the arm and link to the
Lam4
mounting pin center of the arm and bucket
Distance (m) from the mounting pin center of the arm cylinder and
Lbk2
link to the mounting pin center of the link and bucket
Distance (m) from the mounting pin center of the arm and bucket to
Lbk3
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITH-

OUT TOTAL STATION

WITHOUT TOTAL STATION
• If an error code is displayed
1. If the error screen is displayed during the calibration
process, press “Back” (1), and check that the inputted
values are correct.
PC210LCI-11 30-731
1. If the error screen (2) is displayed, press the return

button (3) and stop the calibration process.
2. When the “Machine Setup” screen is displayed, per-
forming troubleshooting for an error in CAN communi-
cation line.
30-732 PC210LCI-11
30 TESTING AND ADJUSTING Pm CLINIC SERVICE
Pm CLINIC
Pm CLINIC SERVICE
Model Serial No. Service meter
□ PC210LCI-11 h
User name Date of inspection Inspector
//
Specifications
Main parts Attachment Shoe width
□ Boom Standard □ (　　　 ) □ Breaker □ 700 mm □ (　　　 )
□ Arm Standard □ (　　　 ) □ (　　　 ) □ 800 mm
□ Bucket Standard □ (　　　 ) □ (　　　 ) □ 900 mm
Check of oil and coolant levels
□ Radiator coolant When necessary
□ Engine oil □ Damper case oil □ Machinery case oil
□ hydraulic oil □ Final drive case oil □ (　　　　　　　　)
Ambient temperature Altitude
°C m
Operator's comment
Result of visual inspection
Mechanical system abnormality record Electrical system abnormality record

A900FR Times/First time h/Latest h Times/First time h/Latest h
A900N6 Times/First time h/Latest h Times/First time h/Latest h
A900NY Times/First time h/Latest h Times/First time h/Latest h
AA10NX Times/First time h/Latest h Times/First time h/Latest h
AB00KE Times/First time h/Latest h Times/First time h/Latest h
AS10KM Times/First time h/Latest h Times/First time h/Latest h
AS10NT Times/First time h/Latest h Times/First time h/Latest h
B@BAZG Times/First time h/Latest h Times/First time h/Latest h
B@BAZK Times/First time h/Latest h Times/First time h/Latest h
B@BCNS Times/First time h/Latest h Times/First time h/Latest h
B@BCZK Times/First time h/Latest h Times/First time h/Latest h
B@hANS Times/First time h/Latest h Times/First time h/Latest h
CA234 Times/First time h/Latest h Times/First time h/Latest h
PC210LCI-11 30-733
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING
Max. range of engine coolant temperature gauge

Coolant temperature Engine coolant tem- Color of monitor
gauge level perature light (a)
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 60 °C
1 30 °C White
Max. range of hydraulic oil temperature gauge

Oil temperature lev- hydraulic oil temper- Color of monitor
el ature light (a)
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 40 °C
1 20 °C White
30-734 PC210LCI-11
Pm CLINIC CHECK SHEET: PC210LCI-11

PC210LCI-11
NOTICE
Perform the checks after sufficient warm-up operation of the engine.
Model Serial No. Service meter User name Date of inspection Inspector
PC210LCI-11 //
Engine
Engine SAA6D107E-3 No
Go
go
Standard val- Meas- od
od
Item Testing conditions Unit ue for new Repair limit ured
machine value
• Engine coolant temperature: 60
to 100 °C
55 °C
Engine high • Working mode: P (Power Mode)

idle speed • Fuel control dial: MAX (High idle) rpm 1780 to 1920 1780 to 1920
(*1) position
• Each control lever and control
pedal: NEUTRAL
to 100 °C
Engine 55 °C
speed at • Working mode: P (Power Mode) rpm 1000 to 1100 1000 to 1100
low idle (*1) • Fuel control dial: MIN (Low idle)
position
pedal: NEUTRAL
to 100 °C
55 °C
Engine
speed at 2- • Working mode: P (Power Mode)
rpm 1600 to 1800 1600 to 1800
pump relief • Fuel control dial: MAX (High idle)
(*1) position
• Work equipment control: Arm IN
relief
PC210LCI-11 30-735

Go
go
od
machine value
to 100 °C
Engine
speed at 2 55 °C
pump relief • Working mode: P (Power Mode)
rpm 1850 to 2050 1850 to 2050
+ one-touch • Fuel control dial: MAX (High idle)
power max-
position
imizing (*1)
relief + One-touch power maxi-
mizing ON
to 100 °C
Engine 55 °C
speed • Working mode: P (Power Mode)
when auto-
• Fuel control dial: MAX (High idle) rpm 950 to 1150 950 to 1150
decelera-
tion is oper-
position
ated (*1) • Swing lock switch: OFF
• Auto-deceleration switch: ON
pedal: NEUTRAL
• Engine coolant tem- Fuel control
perature: 60 to dial: MAX Min. 0.29 Min. 0.25
100 °C (High idle) {Min. 3.0} {Min. 2.5}
position
• Auto-deceleration
switch: OFF MPa
Engine oil
pressure • Engine oil (*2) Fuel control {kg/cm2}
EO10W30-LA dial: MIN Min. 0.10 Min. 0.07
EO15W40-LA (Low idle) {Min. 1.0} {Min. 0.7}
position
EOS5W30-LA
EOS5W40-LA
to 100 °C
55 °C
Blowby kPa Max. 0.98 Max. 1.96
pressure • Fuel control dial: MAX (High idle) {mmH2O} {Max. 100} {Max. 200}
position
relief + One-touch power maxi-
mizing ON
*1: Item that can be checked in monitoring function of machine monitor.
30-736 PC210LCI-11
*2: KES diesel engine oil
PC210LCI-11 30-737
Work equipment speed

Go
go
od
machine value
55 °C
• Fuel control dial: MAX (High idle)
position
• Measurement range: Between
Boom bucket ground point and RAISE sec. 3.2 to 4.0 Max. 4.7
RAISE stroke end
• Measurement posture: Fully ex-
tended boom
See "Standard value table", “Ma-
chine posture and measurement
posture for measuring perform-
ance”, “Work equipment 2”.
• Hydraulic oil temper- Working
ature: 45 to 55 °C mode: P
3.1 to 3.9 Max. 4.5
(Power
• Fuel control dial:
Mode)
MAX (High idle) posi-
tion Digging
(Working
• Measurement range:
mode: E 3.2 to 4.0 Max. 4.5
Between arm OUT
(Economy
stroke end and arm
Mode)
IN stroke end
Arm IN sec.
• Measurement pos-
ture: Boom top face
horizontal Digging
See "Standard value (Working
table", “Machine pos- mode: L
5.8 to 7.2 Max. 7.9
ture and measure- (Lifting Op-
ment posture for eration
measuring perform- Mode)
ance”, “Work equip-
ment 3”.
30-738 PC210LCI-11

Go
go
od
machine value
55 °C
position
• Measurement range: Between arm
Arm OUT IN stroke end and arm OUT stroke sec. 2.4 to 3.0 Max. 3.5
end
• Measurement posture: Boom top
face horizontal
55 °C
position
• Measurement range: Between
Bucket bucket DUMP stroke end and
bucket CURL stroke end sec. 2.2 to 2.6 Max. 3.1
CURL
• Measurement posture: Boom top
face horizontal, fully retracted arm
cylinder
PC210LCI-11 30-739
Swing speed
Go
go
od
machine value
• Hydraulic oil temper- Swing
21.7 to 26.7 Max. 30
ature: 45 to 55 °C RIGHT
tion
• Working mode: P
(Power Mode)
• Measurement range:
Time required to
Swing complete 5 swings sec.
after 1 swing Swing LEFT 21.7 to 26.7 Max. 30
ture: See "Standard
value table", “Lift
truck posture and
measurement pos-
ture for measuring
performance”, “Swing
1”.
30-740 PC210LCI-11
Travel speed
Go
go
od
machine value
• Hydraulic oil temper- For-
48.6 to 59.8 48.6 to 63.8
ature: 45 to 55 °C ward
Lo
• Fuel control dial: Re-
48.6 to 59.8 48.6 to 63.8
MAX (High idle) posi- verse
tion
For-
• Working mode: P 36.7 to 44.9 36.7 to 48.9
ward
(Power Mode) Mi
Re-
• Measurement range: 36.7 to 44.9 36.7 to 48.9
verse
Running Time required to
complete 5 idle turns For-
track idle off sec. 28.9 to 32.1 28.9 to 34.1
with track off ground ward
the ground
after 1 idle turn
ture: See "Standard
value table", “Lift Hi
Re-
truck posture and 28.9 to 32.1 28.9 to 34.1
verse
measurement pos-
ture for measuring
performance”, “Travel
1”.
PC210LCI-11 30-741

Go
go
od
machine value
55 °C
• Engine: Stopped
• Load: Bucket filled up with dirt and
sand, or at the rated load
(0.8 m3:1440 kg)
• Each control lever and control ped-
Hydraulic
drift meas-
al: NEUTRAL
ured at • Measurement posture: Horizontal
mm Max. 600 Max. 900
bucket tip boom top face, fully retracted arm,
(entire work and fully extended bucket cylinder
equipment) on a level and flat ground
• Hydraulic drift for 15 minutes as
measured every 5 minutes starting
immediately after initial setting
30-742 PC210LCI-11
Hydraulic circuit
Go
go
od
machine value
55 °C
Control cir- position MPa
2.93 to 3.43 2.75 to 3.43
cuit oil pres- {kg/
• Working mode: P (Power Mode) {30 to 35} {28 to 35}
sure cm2}
al: NEUTRAL
55 °C
Unload • Fuel control dial: MAX (High idle)
pressure position MPa
2.7 to 4.7 2.7 to 4.7
(pump out- {kg/
• Working mode: P (Power Mode) {28 to 48} {28 to 48}
let pres- cm2}
sure) (*1) • Auto-deceleration switch: OFF
al: NEUTRAL
• Hydraulic oil temper- At normal 33.6 to 36.3 33.1 to 37.2
ature: 45 to 55 °C relief {343 to 370} {338 to 380}
Work equip- tion MPa
ment (arm)
• Working mode: P When one- {kg/
relief pres- 36.1 to 38.8 36.1 to 39.7
(Power Mode) touch power cm2}
sure (*1)
maximizing {368 to 395} {368 to 405}
• Swing lock switch:
is ON
OFF
• Work equipment con-
trol: Arm IN relief
PC210LCI-11 30-743

Go
go
od
machine value
55 °C
Swing relief • Fuel control dial: MAX (High idle) MPa

position 27.9 to 30.9 27.4 to 31.4
pressure {kg/
(*1) • Working mode: P (Power Mode) {285 to 315} {280 to 320}
cm2}
• Swing hydraulic relief
• R.H.
Travel
locked
• Right 36.7 to 39.7 36.2 to 40.2
• Hydraulic oil temper- forward {375 to 405} {370 to 410}
ature: 45 to 55 °C or re-
Travel relief • Fuel control dial: verse MPa
pressure MAX (High idle) posi- relief {kg/
(*1) tion • L.H. cm2}
• Working mode: P Travel
(Power Mode) locked
36.7 to 39.7 36.2 to 40.2
• Left for-
{375 to 405} {370 to 410}
ward or
reverse
relief
55 °C
position
LS differen- MPa
• Working mode: P (Power Mode) 1.7 to 1.85 1.7 to 1.85
tial pressure {kg/
(*1) • Travel speed: Hi {17 to 18.5} {17 to 18.5}
cm2}
• Travel operation: One-side track
idle off the ground at lever half
• LS differential pressure = Pump
discharged pressure - LS pressure
• Hydraulic oil temper- Front pump 36.1 to 38.8 36.1 to 39.7

discharge
ature: 45 to 55 °C {368 to 395} {368 to 405}
pressure
PC valve
MAX (High idle) posi- Servo piston Above value x Above value x
tion inlet pres- approximately approximately
output pres- MPa
sure 0.6 0.6
sure (servo • Working mode: P {kg/
piston inlet (Power Mode) Rear pump
cm2} 36.1 to 38.8 36.1 to 39.7
pressure) discharged
• Swing lock switch: pressure {368 to 395} {368 to 405}
ON
Servo piston Above value x Above value x
• Work equipment con- inlet pres- approximately approximately
trol: Arm IN relief sure 0.6 0.6
30-744 PC210LCI-11

Go
go
od
machine value
• Hydraulic oil temper- Fuel control

Approximately Approximately
ature: 45 to 55 °C dial: MIN
2.6 {Approxi- 2.6 {Approxi-
(Low idle)
• Working mode: P mately 26} mately 26}
position
(Power Mode)
Fuel control
• Each control lever Approximately Approximately
dial: MAX
and control pedal: 1.0 {Approxi- 1.0 {Approxi-
(High idle)
NEUTRAL mately 10} mately 10}
position
Digging
(Working MPa Approximately Approximately
mode: E 1.2 {Approxi- 1.2 {Approxi-
Outlet pres- Pub
(Economy mately 12} mately 12}
sure of PC- Caret 2
• Hydraulic oil temper- Mode)
EPC valve {kg/
ature: 45 to 55 °C
Digging cm2}
• Fuel control dial: (Working
Approximately Approximately
MAX (High idle) posi- mode: L
1.7 {Approxi- 1.7 {Approxi-
tion (Lifting Op-
mately 17} mately 17}
eration
• Each control lever
Mode)
and control pedal:
NEUTRAL Digging
(Working Approximately Approximately
mode: B 1.4 {Approxi- 1.4 {Approxi-
(BREAKER1 mately 14} mately 14}
Mode)
Travel
speed: Lo Approximately Approximately
Travel con- 2.45 {Approxi- 2.45 {Approxi-
trol lever: mately 25} mately 25}
• Hydraulic oil temper- Fine control
ature: 45 to 55 °C Travel
Outlet pres- • Fuel control dial: speed: Mi MPa Approximately Approximately
sure of LS- MAX (High idle) posi- Travel con- {kg/ 1.79 {Approxi- 1.79 {Approxi-
EPC valve tion trol lever: cm2} mately 18.2} mately 18.2}
• Working mode: P Fine control
(Power Mode) Travel
speed: Hi
Travel con- 0 {0} 0 {0}
trol lever:
Fine control
PC210LCI-11 30-745
40 TROUBLESHOOTING
PC210LCI-11 40-1
CONTENTS 40 TROUBLESHOOTING
CONTENTS
ABBREVIATION LIST .................................................................................................................................. 40-15
RELATED INFORMATION ON TROUBLESHOOTING ................................................................................ 40-21
GENERAL TROUBLESHOOTING POINTS .......................................................................................... 40-21
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM................................................................. 40-22
SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................ 40-34
CHECKS BEFORE TROUBLESHOOTING ........................................................................................... 40-36
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ............................................................ 40-38
WALK-AROUND CHECK............................................................................................................... 40-38
TESTING IN ACCORDANCE WITH TESTING PROCEDURE.............................................................. 40-40
CHECK FUEL LEVEL AND TYPE.................................................................................................. 40-40
CHECK IMPURE INGREDIENT IN FUEL ...................................................................................... 40-40
CHECK FUEL PREFILTER ............................................................................................................ 40-41
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.............................................. 40-41
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE...................................................... 40-42
CHECK MAIN FILTER ................................................................................................................... 40-43
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)............................................................. 40-45
CHECK COOLANT LEVEL (RESERVOIR TANK) .......................................................................... 40-46
CHECK CLOGGING OF AIR CLEANER........................................................................................ 40-46
OUTER ELEMENT - CLEAN.......................................................................................................... 40-47
ELEMENTS - REPLACE ................................................................................................................ 40-49
CHECK HYDRAULIC OIL LEVEL .................................................................................................. 40-50
CHECK HYDRAULIC OIL STRAINER ........................................................................................... 40-51
CHECK HYDRAULIC FILTER ........................................................................................................ 40-52
CHECK OIL LEVEL IN SWING MACHINERY CASE ..................................................................... 40-53
CHECK OIL LEVEL IN DAMPER CASE ........................................................................................ 40-54
CHECK OIL LEVEL IN FINAL DRIVE CASE.................................................................................. 40-54
BLEED AIR FROM FUEL SYSTEM .............................................................................................. 40-55
BLEED AIR FROM HYDRAULIC SYSTEM .................................................................................... 40-55
ELECTRICAL EQUIPMENT - CHECK METHOD ........................................................................... 40-55
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM............................................ 40-60
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR ........................................ 40-60
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER ................................... 40-60
PREPARATION FOR TROUBLESHOOTING OF ICT SENSOR CONTROLLER ........................... 40-61
PREPARATION FOR TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER ............... 40-62
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL...................................... 40-63
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER ................................ 40-63
PREPARATION FOR TROUBLESHOOTING OF CONTROL BOX ................................................ 40-64
PREPARATION FOR TROUBLESHOOTING OF GNSS RECIVER .............................................. 40-64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK ... 40-64
PROCEDURE FOR TESTING AND TROUBLESHOOTING ................................................................. 40-69
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS .................................................... 40-72
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 40-77
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM ........................................................................................................................................... 40-79
CONNECTOR LIST AND LAYOUT ....................................................................................................... 40-82
CONNECTOR CONTACT IDENTIFICATION .......................................................................................40-105
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .........................................................................40-145
FUSE LOCATION TABLE ....................................................................................................................40-151
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC).................................40-155
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135]).................................................................................................................................40-159
FAILURE CODES TABLE ....................................................................................................................40-161
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ............................................................40-183
FAILURE CODE [879AKA]...................................................................................................................40-183
FAILURE CODE [879AKB]...................................................................................................................40-184
FAILURE CODE [879BKA]...................................................................................................................40-185
40-2 PC210LCI-11
40 TROUBLESHOOTING CONTENTS
FAILURE CODE [879BKB]...................................................................................................................40-187

FAILURE CODE [879CKA]...................................................................................................................40-189
FAILURE CODE [879CKB]...................................................................................................................40-190
FAILURE CODE [879DKZ]...................................................................................................................40-191
FAILURE CODE [879EMC] ..................................................................................................................40-193
FAILURE CODE [879FMC] ..................................................................................................................40-194
FAILURE CODE [879GKX] ..................................................................................................................40-195
FAILURE CODE [989L00] ....................................................................................................................40-197
FAILURE CODE [989M00] ...................................................................................................................40-198
FAILURE CODE [989N00] ...................................................................................................................40-199
FAILURE CODE [A1U0N3] ..................................................................................................................40-200
FAILURE CODE [A1U0N4] ..................................................................................................................40-202
FAILURE CODE [A900FR]...................................................................................................................40-204
FAILURE CODE [A900N6] ...................................................................................................................40-205
FAILURE CODE [A900NY]...................................................................................................................40-206
FAILURE CODE [AA10NX] ..................................................................................................................40-207
FAILURE CODE [AB00KE] ..................................................................................................................40-209
FAILURE CODE [AQ10N3] ..................................................................................................................40-212
FAILURE CODE [AS00N3]...................................................................................................................40-214
FAILURE CODE [AS00R2]...................................................................................................................40-216
FAILURE CODE [AS00R3]...................................................................................................................40-217
FAILURE CODE [AS00R4]...................................................................................................................40-218
FAILURE CODE [AS00R5]...................................................................................................................40-219
FAILURE CODE [AS00R6]...................................................................................................................40-220
FAILURE CODE [AS00ZK]...................................................................................................................40-221
FAILURE CODE [AS10KM]..................................................................................................................40-222
FAILURE CODE [AS10NR] ..................................................................................................................40-223
FAILURE CODE [AS10NT] ..................................................................................................................40-224
FAILURE CODE [B@BAZG] ................................................................................................................40-225
FAILURE CODE [B@BAZK].................................................................................................................40-226
FAILURE CODE [B@BCNS] ................................................................................................................40-228
FAILURE CODE [B@BCZK] ................................................................................................................40-229
FAILURE CODE [B@HANS] ................................................................................................................40-231
FAILURE CODE [CA115] .....................................................................................................................40-232
FAILURE CODE [CA122] .....................................................................................................................40-233
FAILURE CODE [CA123] .....................................................................................................................40-235
FAILURE CODE [CA131] .....................................................................................................................40-237
FAILURE CODE [CA132] .....................................................................................................................40-239
FAILURE CODE [CA144] .....................................................................................................................40-241
FAILURE CODE [CA145] .....................................................................................................................40-243
FAILURE CODE [CA153] .....................................................................................................................40-245
FAILURE CODE [CA154] .....................................................................................................................40-248
FAILURE CODE [CA187] .....................................................................................................................40-250
FAILURE CODE [CA221] .....................................................................................................................40-252
FAILURE CODE [CA222] .....................................................................................................................40-254
FAILURE CODE [CA227] .....................................................................................................................40-256
FAILURE CODE [CA234] .....................................................................................................................40-257
FAILURE CODE [CA238] .....................................................................................................................40-258
FAILURE CODE [CA239] .....................................................................................................................40-260
FAILURE CODE [CA249] .....................................................................................................................40-262
FAILURE CODE [CA256] .....................................................................................................................40-264
FAILURE CODE [CA271] .....................................................................................................................40-266
FAILURE CODE [CA272] .....................................................................................................................40-268
FAILURE CODE [CA322] .....................................................................................................................40-270
FAILURE CODE [CA323] .....................................................................................................................40-272
FAILURE CODE [CA324] .....................................................................................................................40-274
FAILURE CODE [CA325] .....................................................................................................................40-276
FAILURE CODE [CA331] .....................................................................................................................40-278
PC210LCI-11 40-3
FAILURE CODE [CA332] .....................................................................................................................40-280

FAILURE CODE [CA343] .....................................................................................................................40-282
FAILURE CODE [CA351] .....................................................................................................................40-283
FAILURE CODE [CA352] .....................................................................................................................40-284
FAILURE CODE [CA356] .....................................................................................................................40-287
FAILURE CODE [CA357] .....................................................................................................................40-289
FAILURE CODE [CA386] .....................................................................................................................40-291
FAILURE CODE [CA428] .....................................................................................................................40-292
FAILURE CODE [CA429] .....................................................................................................................40-294
FAILURE CODE [CA435] .....................................................................................................................40-296
FAILURE CODE [CA441] .....................................................................................................................40-298
FAILURE CODE [CA442] .....................................................................................................................40-300
FAILURE CODE [CA449] .....................................................................................................................40-301
FAILURE CODE [CA451] .....................................................................................................................40-302
FAILURE CODE [CA452] .....................................................................................................................40-304
FAILURE CODE [CA488] .....................................................................................................................40-306
FAILURE CODE [CA515] .....................................................................................................................40-307
FAILURE CODE [CA516] .....................................................................................................................40-309
FAILURE CODE [CA553] .....................................................................................................................40-311
FAILURE CODE [CA555] .....................................................................................................................40-312
FAILURE CODE [CA556] .....................................................................................................................40-313
FAILURE CODE [CA559] .....................................................................................................................40-314
FAILURE CODE [CA595] .....................................................................................................................40-317
FAILURE CODE [CA687] .....................................................................................................................40-318
FAILURE CODE [CA689] .....................................................................................................................40-320
FAILURE CODE [CA691] .....................................................................................................................40-323
FAILURE CODE [CA692] .....................................................................................................................40-325
FAILURE CODE [CA697] .....................................................................................................................40-327
FAILURE CODE [CA698] .....................................................................................................................40-328
FAILURE CODE [CA731] .....................................................................................................................40-329
FAILURE CODE [CA778] .....................................................................................................................40-331
FAILURE CODE [CA1117] ...................................................................................................................40-336
FAILURE CODE [CA1664] ...................................................................................................................40-337
FAILURE CODE [CA1669] ...................................................................................................................40-339
FAILURE CODE [CA1673] ...................................................................................................................40-340
FAILURE CODE [CA1677] ...................................................................................................................40-341
FAILURE CODE [CA1678] ...................................................................................................................40-342
FAILURE CODE [CA1682] ...................................................................................................................40-343
FAILURE CODE [CA1683] ...................................................................................................................40-345
FAILURE CODE [CA1684] ...................................................................................................................40-347
FAILURE CODE [CA1686] ...................................................................................................................40-349
FAILURE CODE [CA1691] ...................................................................................................................40-350
FAILURE CODE [CA1694] ...................................................................................................................40-353
FAILURE CODE [CA1695] ...................................................................................................................40-356
FAILURE CODE [CA1696] ...................................................................................................................40-357
FAILURE CODE [CA1712] ...................................................................................................................40-359
FAILURE CODE [CA1713] ...................................................................................................................40-362
FAILURE CODE [CA1714] ...................................................................................................................40-364
FAILURE CODE [CA1715] ...................................................................................................................40-365
FAILURE CODE [CA1776] ...................................................................................................................40-366
FAILURE CODE [CA1777] ...................................................................................................................40-369
FAILURE CODE [CA1843] ...................................................................................................................40-372
FAILURE CODE [CA1844] ...................................................................................................................40-374
FAILURE CODE [CA1879] ...................................................................................................................40-377
FAILURE CODE [CA1881] ...................................................................................................................40-379
FAILURE CODE [CA1883] ...................................................................................................................40-381
FAILURE CODE [CA1885] ...................................................................................................................40-384
FAILURE CODE [CA1887] ...................................................................................................................40-386
40-4 PC210LCI-11
FAILURE CODE [CA1921] ...................................................................................................................40-388

FAILURE CODE [CA1922] ...................................................................................................................40-391
FAILURE CODE [CA1942] ...................................................................................................................40-396
FAILURE CODE [CA1993] ...................................................................................................................40-397
FAILURE CODE [CA2185] ...................................................................................................................40-400
FAILURE CODE [CA2186] ...................................................................................................................40-401
FAILURE CODE [CA2249] ...................................................................................................................40-403
FAILURE CODE [CA2271] ...................................................................................................................40-404
FAILURE CODE [CA2272] ...................................................................................................................40-407
FAILURE CODE [CA2288] ...................................................................................................................40-410
FAILURE CODE [CA2311] ...................................................................................................................40-411
FAILURE CODE [CA2349] ...................................................................................................................40-412
FAILURE CODE [CA2353] ...................................................................................................................40-415
FAILURE CODE [CA2357] ...................................................................................................................40-417
FAILURE CODE [CA2381] ...................................................................................................................40-418
FAILURE CODE [CA2382] ...................................................................................................................40-421
FAILURE CODE [CA2383] ...................................................................................................................40-424
FAILURE CODE [CA2386] ...................................................................................................................40-427
FAILURE CODE [CA2387] ...................................................................................................................40-429
FAILURE CODE [CA2555] ...................................................................................................................40-430
FAILURE CODE [CA2556] ...................................................................................................................40-433
FAILURE CODE [CA2637] ...................................................................................................................40-436
FAILURE CODE [CA2639] ...................................................................................................................40-438
FAILURE CODE [CA2771] ...................................................................................................................40-441
FAILURE CODE [CA2777] ...................................................................................................................40-447
FAILURE CODE [CA2976] ...................................................................................................................40-450
FAILURE CODE [CA3133] ...................................................................................................................40-452
FAILURE CODE [CA3134] ...................................................................................................................40-455
FAILURE CODE [CA3135] ...................................................................................................................40-457
FAILURE CODE [CA3142] ...................................................................................................................40-460
FAILURE CODE [CA3143] ...................................................................................................................40-461
FAILURE CODE [CA3144] ...................................................................................................................40-462
FAILURE CODE [CA3146] ...................................................................................................................40-464
FAILURE CODE [CA3147] ...................................................................................................................40-465
FAILURE CODE [CA3148] ...................................................................................................................40-466
FAILURE CODE [CA3151] ...................................................................................................................40-468
FAILURE CODE [CA3165] ...................................................................................................................40-474
FAILURE CODE [CA3229] ...................................................................................................................40-476
FAILURE CODE [CA3231] ...................................................................................................................40-478
FAILURE CODE [CA3232] ...................................................................................................................40-480
FAILURE CODE [CA3235] ...................................................................................................................40-484
FAILURE CODE [CA3239] ...................................................................................................................40-486
FAILURE CODE [CA3241] ...................................................................................................................40-489
FAILURE CODE [CA3242] ...................................................................................................................40-492
FAILURE CODE [CA3251] ...................................................................................................................40-495
FAILURE CODE [CA3253] ...................................................................................................................40-497
FAILURE CODE [CA3254] ...................................................................................................................40-500
FAILURE CODE [CA3255] ...................................................................................................................40-503
FAILURE CODE [CA3256] ...................................................................................................................40-507
FAILURE CODE [CA3311] ...................................................................................................................40-509
FAILURE CODE [CA3312] ...................................................................................................................40-511
FAILURE CODE [CA3313] ...................................................................................................................40-514
FAILURE CODE [CA3314] ...................................................................................................................40-516
FAILURE CODE [CA3315] ...................................................................................................................40-517
FAILURE CODE [CA3316] ...................................................................................................................40-519
FAILURE CODE [CA3317] ...................................................................................................................40-521
FAILURE CODE [CA3318] ...................................................................................................................40-522
FAILURE CODE [CA3319] ...................................................................................................................40-524
PC210LCI-11 40-5
FAILURE CODE [CA3321] ...................................................................................................................40-525

FAILURE CODE [CA3322] ...................................................................................................................40-527
FAILURE CODE [CA3419] ...................................................................................................................40-529
FAILURE CODE [CA3421] ...................................................................................................................40-531
FAILURE CODE [CA3497] ...................................................................................................................40-533
FAILURE CODE [CA3498] ...................................................................................................................40-534
FAILURE CODE [CA3543] ...................................................................................................................40-535
FAILURE CODE [CA3545] ...................................................................................................................40-541
FAILURE CODE [CA3547] ...................................................................................................................40-543
FAILURE CODE [CA3558] ...................................................................................................................40-544
FAILURE CODE [CA3559] ...................................................................................................................40-546
FAILURE CODE [CA3562] ...................................................................................................................40-548
FAILURE CODE [CA3563] ...................................................................................................................40-550
FAILURE CODE [CA3567] ...................................................................................................................40-553
FAILURE CODE [CA3568] ...................................................................................................................40-556
FAILURE CODE [CA3571] ...................................................................................................................40-560
FAILURE CODE [CA3572] ...................................................................................................................40-562
FAILURE CODE [CA3574] ...................................................................................................................40-564
FAILURE CODE [CA3575] ...................................................................................................................40-566
FAILURE CODE [CA3577] ...................................................................................................................40-568
FAILURE CODE [CA3578] ...................................................................................................................40-570
FAILURE CODE [CA3582] ...................................................................................................................40-572
FAILURE CODE [CA3583] ...................................................................................................................40-578
FAILURE CODE [CA3596] ...................................................................................................................40-580
FAILURE CODE [CA3649] ...................................................................................................................40-582
FAILURE CODE [CA3681] ...................................................................................................................40-584
FAILURE CODE [CA3682] ...................................................................................................................40-589
FAILURE CODE [CA3713] ...................................................................................................................40-595
FAILURE CODE [CA3717] ...................................................................................................................40-598
FAILURE CODE [CA3718] ...................................................................................................................40-599
FAILURE CODE [CA3725] ...................................................................................................................40-600
FAILURE CODE [CA3741] ...................................................................................................................40-603
FAILURE CODE [CA3748] ...................................................................................................................40-604
FAILURE CODE [CA3751] ...................................................................................................................40-606
FAILURE CODE [CA3755] ...................................................................................................................40-608
FAILURE CODE [CA3866] ...................................................................................................................40-610
FAILURE CODE [CA3867] ...................................................................................................................40-613
FAILURE CODE [CA3868] ...................................................................................................................40-616
FAILURE CODE [CA3899] ...................................................................................................................40-620
FAILURE CODE [CA3911] ...................................................................................................................40-622
FAILURE CODE [CA3912] ...................................................................................................................40-626
FAILURE CODE [CA3932] ...................................................................................................................40-628
FAILURE CODE [CA3933] ...................................................................................................................40-630
FAILURE CODE [CA3934] ...................................................................................................................40-632
FAILURE CODE [CA3935] ...................................................................................................................40-635
FAILURE CODE [CA3936] ...................................................................................................................40-637
FAILURE CODE [CA4151] ...................................................................................................................40-639
FAILURE CODE [CA4152] ...................................................................................................................40-643
FAILURE CODE [CA4155] ...................................................................................................................40-647
FAILURE CODE [CA4156] ...................................................................................................................40-650
FAILURE CODE [CA4157] ...................................................................................................................40-653
FAILURE CODE [CA4158] ...................................................................................................................40-655
FAILURE CODE [CA4159] ...................................................................................................................40-656
FAILURE CODE [CA4161] ...................................................................................................................40-657
FAILURE CODE [CA4162] ...................................................................................................................40-660
FAILURE CODE [CA4163] ...................................................................................................................40-663
FAILURE CODE [CA4164] ...................................................................................................................40-664
FAILURE CODE [CA4165] ...................................................................................................................40-666
40-6 PC210LCI-11
FAILURE CODE [CA4166] ...................................................................................................................40-668

FAILURE CODE [CA4168] ...................................................................................................................40-669
FAILURE CODE [CA4169] ...................................................................................................................40-672
FAILURE CODE [CA4171] ...................................................................................................................40-674
FAILURE CODE [CA4249] ...................................................................................................................40-677
FAILURE CODE [CA4251] ...................................................................................................................40-679
FAILURE CODE [CA4259] ...................................................................................................................40-681
FAILURE CODE [CA4261] ...................................................................................................................40-684
FAILURE CODE [CA4277] ...................................................................................................................40-687
FAILURE CODE [CA4281] ...................................................................................................................40-690
FAILURE CODE [CA4459] ...................................................................................................................40-693
FAILURE CODE [CA4461] ...................................................................................................................40-696
FAILURE CODE [CA4658] ...................................................................................................................40-699
FAILURE CODE [CA4731] ...................................................................................................................40-703
FAILURE CODE [CA4732] ...................................................................................................................40-704
FAILURE CODE [CA4739] ...................................................................................................................40-705
FAILURE CODE [CA4768] ...................................................................................................................40-706
FAILURE CODE [CA4769] ...................................................................................................................40-708
FAILURE CODE [CA4842] ...................................................................................................................40-711
FAILURE CODE [CA4952] ...................................................................................................................40-714
FAILURE CODE [CA5115] ...................................................................................................................40-716
FAILURE CODE [CA5179] ...................................................................................................................40-719
FAILURE CODE [CA5181] ...................................................................................................................40-721
FAILURE CODE [CA5383] ...................................................................................................................40-723
FAILURE CODE [D110KB]...................................................................................................................40-725
FAILURE CODE [D19JKZ] ...................................................................................................................40-727
FAILURE CODE [D811MC] ..................................................................................................................40-730
FAILURE CODE [D862KA]...................................................................................................................40-731
FAILURE CODE [D8ALKA] ..................................................................................................................40-732
FAILURE CODE [D8ALKB] ..................................................................................................................40-734
FAILURE CODE [D8AQKR] .................................................................................................................40-736
FAILURE CODE [DA20MC] .................................................................................................................40-738
FAILURE CODE [DA22KK] ..................................................................................................................40-739
FAILURE CODE [DA25KP] ..................................................................................................................40-742
FAILURE CODE [DA26KP] ..................................................................................................................40-745
FAILURE CODE [DA29KQ]..................................................................................................................40-747
FAILURE CODE [DA2LKA] ..................................................................................................................40-750
FAILURE CODE [DA2LKB] ..................................................................................................................40-752
FAILURE CODE [DA2QKR] .................................................................................................................40-754
FAILURE CODE [DA2RKR] .................................................................................................................40-757
FAILURE CODE [DAF0MB] .................................................................................................................40-759
FAILURE CODE [DAF0MC] .................................................................................................................40-760
FAILURE CODE [DAF8KB] ..................................................................................................................40-761
FAILURE CODE [DAF9KQ]..................................................................................................................40-763
FAILURE CODE [DAFGMC] ................................................................................................................40-764
FAILURE CODE [DAFLKA] ..................................................................................................................40-765
FAILURE CODE [DAFLKB] ..................................................................................................................40-767
FAILURE CODE [DAFQKR] .................................................................................................................40-769
FAILURE CODE [DAZ9KQ]..................................................................................................................40-770
FAILURE CODE [DAZQKR] .................................................................................................................40-771
FAILURE CODE [DB2QKR] .................................................................................................................40-776
FAILURE CODE [DB2RKR] .................................................................................................................40-781
FAILURE CODE [DB90MC] .................................................................................................................40-786
FAILURE CODE [DB92KK] ..................................................................................................................40-787
FAILURE CODE [DB95KP] ..................................................................................................................40-789
FAILURE CODE [DB96KP] ..................................................................................................................40-793
FAILURE CODE [DB99KQ]..................................................................................................................40-797
FAILURE CODE [DB9LKA] ..................................................................................................................40-800
PC210LCI-11 40-7
FAILURE CODE [DB9LKB] ..................................................................................................................40-802

FAILURE CODE [DB9QKR] .................................................................................................................40-804
FAILURE CODE [DB9RKR] .................................................................................................................40-811
FAILURE CODE [DBP0KM] .................................................................................................................40-817
FAILURE CODE [DBP0KT] ..................................................................................................................40-818
FAILURE CODE [DBPQKR].................................................................................................................40-819
FAILURE CODE [DBR0MC].................................................................................................................40-824
FAILURE CODE [DBR2KK]..................................................................................................................40-825
FAILURE CODE [DBR5KP]..................................................................................................................40-828
FAILURE CODE [DBR6KP]..................................................................................................................40-830
FAILURE CODE [DBR9KQ] .................................................................................................................40-832
FAILURE CODE [DBRLKA]..................................................................................................................40-835
FAILURE CODE [DBRLKB]..................................................................................................................40-837
FAILURE CODE [DBRQKR].................................................................................................................40-839
FAILURE CODE [DBRRKR].................................................................................................................40-846
FAILURE CODE [DBRSKB] .................................................................................................................40-852
FAILURE CODE [DBRTKB] .................................................................................................................40-854
FAILURE CODE [DBUSKR] .................................................................................................................40-856
FAILURE CODE [DD20MA] .................................................................................................................40-860
FAILURE CODE [DDNRKA].................................................................................................................40-863
FAILURE CODE [DDNRKY].................................................................................................................40-865
FAILURE CODE [DDNS00]..................................................................................................................40-867
FAILURE CODE [DFB1KZ] ..................................................................................................................40-869
FAILURE CODE [DFB3L8]...................................................................................................................40-873
FAILURE CODE [DFB4L8]...................................................................................................................40-875
FAILURE CODE [DGH2KA] .................................................................................................................40-881
FAILURE CODE [DGH2KB] .................................................................................................................40-883
FAILURE CODE [DHA4KA]..................................................................................................................40-885
FAILURE CODE [DHAAMA].................................................................................................................40-887
FAILURE CODE [DHACMA] ................................................................................................................40-889
FAILURE CODE [DHPAMA] .................................................................................................................40-891
FAILURE CODE [DHPBMA].................................................................................................................40-893
FAILURE CODE [DHS3MA] .................................................................................................................40-895
FAILURE CODE [DHSAMA].................................................................................................................40-907
FAILURE CODE [DHSBMA].................................................................................................................40-910
FAILURE CODE [DHSCMA] ................................................................................................................40-913
FAILURE CODE [DHSDMA] ................................................................................................................40-916
FAILURE CODE [DHSFMA].................................................................................................................40-919
FAILURE CODE [DHSGMA] ................................................................................................................40-922
FAILURE CODE [DHSHMA] ................................................................................................................40-925
FAILURE CODE [DHSJMA] .................................................................................................................40-928
FAILURE CODE [DHUXMA] ................................................................................................................40-931
FAILURE CODE [DHUYMA] ................................................................................................................40-933
FAILURE CODE [DK80KM]..................................................................................................................40-935
FAILURE CODE [DK80KR] ..................................................................................................................40-936
FAILURE CODE [DK80KT] ..................................................................................................................40-942
FAILURE CODE [DKG1KM].................................................................................................................40-943
FAILURE CODE [DKG1L8] ..................................................................................................................40-944
FAILURE CODE [DKR0MA] .................................................................................................................40-945
FAILURE CODE [DKR1MA] .................................................................................................................40-947
FAILURE CODE [DKT0KM] .................................................................................................................40-949
FAILURE CODE [DKT0L8]...................................................................................................................40-950
40-8 PC210LCI-11
FAILURE CODE [DKT1KA] ..................................................................................................................40-951

FAILURE CODE [DKT1KB] ..................................................................................................................40-953
FAILURE CODE [DKT4KM] .................................................................................................................40-959
FAILURE CODE [DKT4L8]...................................................................................................................40-960
FAILURE CODE [DKTAKA]..................................................................................................................40-977
FAILURE CODE [DKTAKB]..................................................................................................................40-979
FAILURE CODE [DKTAMB] .................................................................................................................40-981
FAILURE CODE [DKTBKX]..................................................................................................................40-982
FAILURE CODE [DKTBMC].................................................................................................................40-984
FAILURE CODE [DKTEMB] .................................................................................................................40-985
FAILURE CODE [DKTFKX]..................................................................................................................40-987
FAILURE CODE [DKTFMC] .................................................................................................................40-989
FAILURE CODE [DKTJMB]..................................................................................................................40-990
FAILURE CODE [DKTUL8] ..................................................................................................................40-992
FAILURE CODE [DKTVKA]..................................................................................................................40-993
FAILURE CODE [DKTVKB]..................................................................................................................40-995
FAILURE CODE [DKTWKA].................................................................................................................40-996
FAILURE CODE [DKTWKB].................................................................................................................40-998
FAILURE CODE [DKU1MA] .................................................................................................................40-999
FAILURE CODE [DKU2MA] ...............................................................................................................40-1000
FAILURE CODE [DKUGKA]...............................................................................................................40-1001
FAILURE CODE [DKUGKB]...............................................................................................................40-1003
FAILURE CODE [DKUGKY]...............................................................................................................40-1005
FAILURE CODE [DKUHKA] ...............................................................................................................40-1007
FAILURE CODE [DKUHKB] ...............................................................................................................40-1009
FAILURE CODE [DKUHKY] ...............................................................................................................40-1011
FAILURE CODE [DKULKA]................................................................................................................40-1013
FAILURE CODE [DKULKB]................................................................................................................40-1015
FAILURE CODE [DKULKY]................................................................................................................40-1017
FAILURE CODE [DKV0KA]................................................................................................................40-1019
FAILURE CODE [DKV0KY]................................................................................................................40-1022
FAILURE CODE [DKV4MA] ...............................................................................................................40-1036
FAILURE CODE [DKVAMA] ...............................................................................................................40-1054
FAILURE CODE [DKVBKA] ...............................................................................................................40-1057
FAILURE CODE [DKVBKB] ...............................................................................................................40-1059
FAILURE CODE [DKVBKY] ...............................................................................................................40-1061
FAILURE CODE [DKVCKA] ...............................................................................................................40-1063
PC210LCI-11 40-9
FAILURE CODE [DKVCKB] ...............................................................................................................40-1065

FAILURE CODE [DKVCKY] ...............................................................................................................40-1067
FAILURE CODE [DKVDKA] ...............................................................................................................40-1069
FAILURE CODE [DKVDKB] ...............................................................................................................40-1071
FAILURE CODE [DKVDKY] ...............................................................................................................40-1073
FAILURE CODE [DKVDMA]...............................................................................................................40-1075
FAILURE CODE [DLM5KA]................................................................................................................40-1077
FAILURE CODE [DLM5MB] ...............................................................................................................40-1079
FAILURE CODE [DR10KA] ................................................................................................................40-1081
FAILURE CODE [DR21KX] ................................................................................................................40-1084
FAILURE CODE [DR31KX] ................................................................................................................40-1086
FAILURE CODE [DUMBKA]...............................................................................................................40-1088
FAILURE CODE [DUMBKB]...............................................................................................................40-1090
FAILURE CODE [DV20KB] ................................................................................................................40-1092
FAILURE CODE [DW43KA] ...............................................................................................................40-1094
FAILURE CODE [DW43KB] ...............................................................................................................40-1096
FAILURE CODE [DW43KY] ...............................................................................................................40-1098
FAILURE CODE [DW4CKY]...............................................................................................................40-1108
FAILURE CODE [DW4FKA] ............................................................................................................... 40-1110
FAILURE CODE [DW4FKB] ............................................................................................................... 40-1113
FAILURE CODE [DW4FKY] ............................................................................................................... 40-1115
FAILURE CODE [DW4GKA] .............................................................................................................. 40-1117
FAILURE CODE [DW4GKB] ..............................................................................................................40-1120
FAILURE CODE [DW4GKY] ..............................................................................................................40-1122
FAILURE CODE [DW4SKA]...............................................................................................................40-1124
FAILURE CODE [DW4SKB]...............................................................................................................40-1126
FAILURE CODE [DW4SKY]...............................................................................................................40-1128
FAILURE CODE [DWA2KA] ...............................................................................................................40-1136
FAILURE CODE [DWA2KB] ...............................................................................................................40-1138
FAILURE CODE [DWA2KY] ...............................................................................................................40-1140
FAILURE CODE [DWK0KA]...............................................................................................................40-1142
FAILURE CODE [DWK0KB]...............................................................................................................40-1144
FAILURE CODE [DWK0KY]...............................................................................................................40-1146
FAILURE CODE [DWN5KA]...............................................................................................................40-1160
FAILURE CODE [DWN5KB]...............................................................................................................40-1162
FAILURE CODE [DWN5KY]...............................................................................................................40-1164
FAILURE CODE [DXA8KA]................................................................................................................40-1166
FAILURE CODE [DXA8KB]................................................................................................................40-1168
FAILURE CODE [DXA9KA]................................................................................................................40-1170
FAILURE CODE [DXA9KB]................................................................................................................40-1172
FAILURE CODE [DXE0KA]................................................................................................................40-1174
FAILURE CODE [DXE0KB]................................................................................................................40-1175
FAILURE CODE [DXE4KY]................................................................................................................40-1181
40-10 PC210LCI-11

FAILURE CODE [DXEAKA] ...............................................................................................................40-1209
FAILURE CODE [DXEAKB] ...............................................................................................................40-1211
FAILURE CODE [DXEAKY] ...............................................................................................................40-1213
FAILURE CODE [DY20KA] ................................................................................................................40-1215
FAILURE CODE [DY20MA]................................................................................................................40-1217
FAILURE CODE [DY2CKB]................................................................................................................40-1219
FAILURE CODE [DY2DKB]................................................................................................................40-1222
FAILURE CODE [DY2EKB]................................................................................................................40-1224
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................40-1226
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .....................................................40-1226
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...............................................................40-1232
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .........................................................40-1235
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP............40-1237
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTH-
ING.................................................................................................................................................40-1239
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL
LEVEL MONITOR LIGHTS UP IN YELLOW...................................................................................40-1242
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR
COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW.................................................................40-1243
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
.......................................................................................................................................................40-1244
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING ....
.......................................................................................................................................................40-1245
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING..........
.......................................................................................................................................................40-1246
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.....................40-1247
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................40-1248
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .............40-1249
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..
.......................................................................................................................................................40-1250
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......40-1251
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......
.......................................................................................................................................................40-1252
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ........................40-1253
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL......................................40-1255
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM ......................................................................................................................................40-1256
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE.............................................................................................................................40-1257
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAX-
IMUM..............................................................................................................................................40-1258
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERA-
TURE .............................................................................................................................................40-1260
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .............................40-1261
E-24 FUNCTION SWITCH DOES NOT OPERATE ............................................................................40-1262
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER).........................40-1263
PC210LCI-11 40-11
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES

NOT LIGHT UP OR DOES NOT GO OFF ......................................................................................40-1264
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ...........................40-1265
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ...........................................................................................................................40-1266
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT
CHANGED .....................................................................................................................................40-1267
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE
.......................................................................................................................................................40-1268
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE ........................................................................................................................................40-1269
E-32 ALARM BUZZER CANNOT BE CANCELED .............................................................................40-1271
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...40-1272
E-34 SERVICE MODE CANNOT BE SELECTED ..............................................................................40-1273
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ...........40-1274
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK...............40-1277
E-37 BUCKET DOES NOT MOVE WITH AUTO TILT FUNCTION ....................................................40-1279
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ...........................................................................................................................................40-1280
E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE ......................................................................................................40-1283
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICA-
TOR NOT DISPLAYED ON MONITOR...........................................................................................40-1285
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ..................................40-1288
E-42 ALARM DOES NOT SOUND DURING TRAVEL .......................................................................40-1289
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED.................................40-1291
E-44 HORN DOES NOT SOUND.......................................................................................................40-1292
E-45 HORN DOES NOT STOP SOUNDING......................................................................................40-1295
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF ........
.......................................................................................................................................................40-1297
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE..........40-1298
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE .....
.......................................................................................................................................................40-1300
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
.......................................................................................................................................................40-1301
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ........
.......................................................................................................................................................40-1302
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....40-1303
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .......40-1304
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .......
.......................................................................................................................................................40-1305
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ........
.......................................................................................................................................................40-1306
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........40-1307
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ......40-1308
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ....40-1309
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED..............................................40-1311
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ........................................................40-1312
E-60 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connect-
ed !] AND [Slope sensor not connected !] .......................................................................................40-1313
E-61 CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected!] ............................40-1318
E-62 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link...] ......................................40-1322
E-63 CONTROL BOX DISPLAYS THE MESSAGE [Tilt Bucket Sensor Offline!] ................................40-1323
E-64 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites...].......................................40-1324
E-65 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!] ...................40-1325
E-66 CONTROL BOX DISPLAYS THE MESSAGE [Sensors are invalid] ...........................................40-1328
E-67 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize....] ........................................40-1331
E-68 CONTROL BOX DISPLAYS THE MESSAGE [Initializing....]......................................................40-1332
40-12 PC210LCI-11
E-69 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization...]......................................40-1333

E-70 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions...]...............................................40-1334
E-71 CONTROL BOX DISPLAYS [Out of design area...]....................................................................40-1335
E-72 CONTROL BOX DISPLAYS THE MESSAGE [Avoidance Area Breach!] ...................................40-1336
E-73 CONTROL BOX CAN NOT BE TURNED ON ............................................................................40-1337
E-74 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN ..........40-1338
E-75 CONTROL BOX DOES NOT DISPLAY HYDRAULIC EXCAVATOR IMAGE..............................40-1339
E-76 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE .....................................................40-1340
E-77 CONTROL BOX TOUCH PANEL DOES NOT RESPOND.........................................................40-1341
E-78 CONTROL BOX TOUCH PANEL IS INACCURATE...................................................................40-1342
E-79 WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE VALUE IS DIFFERENT
FROM ACTUAL MACHINE ............................................................................................................40-1343
E-80 SEMI-AUTO MODE IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED.......40-1345
E-81 AUTO GRADE ASSIST CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DIS-
PLAYED .........................................................................................................................................40-1346
E-82 AUTO STOP CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED..40-1347
E-83 BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN AUTO GRADE AS-
SIST FUNCTION IS ON .................................................................................................................40-1348
E-84 BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE WHEN AUTO STOP
CONTROL FUNCTION IS ON ........................................................................................................40-1350
E-85 FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TARGET ..............40-1352
E-86 NG OCCURS VERY OFTEN IN IMU CALIBRATION DIAGNOSIS ............................................40-1353
E-87 CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK ....................................40-1354
E-88 CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK ..............................................40-1355
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) ............................40-1358
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)......................................40-1358
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS .................................................40-1359
FAILURE MODE AND CAUSE TABLE...............................................................................................40-1361
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK.............................................40-1373
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .........................40-1374
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR...................................................40-1377
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .........................................40-1378
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .........................................................40-1379
H-6 SPEED OR POWER OF BOOM IS LOW ....................................................................................40-1381
H-7 ARM SPEED OR POWER IS LOW .............................................................................................40-1385
H-8 BUCKET SPEED OR POWER IS LOW.......................................................................................40-1390
H-9 BUCKET DOES NOT MOVE IN SINGLE OPERATION WITH AUTO TILT FUNCTION ...............40-1393
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION ..........................................40-1394
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE ...............................................................................40-1395
H-12 HYDRAULIC DRIFT OF ARM IS LARGE ..................................................................................40-1397
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE............................................................................40-1399
H-14 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT
MOVES ..........................................................................................................................................40-1400
H-15 TIME LAG OF WORK EQUIPMENT IS LARGE ........................................................................40-1401
H-16 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE ................................40-1402
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED...................................................................40-1403
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED ............................................40-1404
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER ..........................................................................................................................40-1405
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 40-1406
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW40-1407
H-22 MACHINE DOES NOT TRAVEL STRAIGHT .............................................................................40-1408
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW....................................40-1410
H-24 TRAVEL SPEED IS LOW ..........................................................................................................40-1413
H-25 ONE OF TRACKS DOES NOT RUN .........................................................................................40-1415
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST .........40-1416
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT ........................40-1417
H-28 SWINGS ONLY IN ONE DIRECTION........................................................................................40-1418
PC210LCI-11 40-13
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) ...
.......................................................................................................................................................40-1419
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE
DIRECTION....................................................................................................................................40-1420
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT
AND LEFT).....................................................................................................................................40-1421
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DI-
RECTION EITHER RIGHT OR LEFT) ............................................................................................40-1422
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING ....................................40-1423
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING.......40-1424
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)......40-1425
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)..40-1426
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ...................................40-1427
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN ................................................................40-1428
TROUBLESHOOTING OF ENGINE (S-MODE) ........................................................................................40-1429
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)......................................40-1429
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.40-1430
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ........................................................40-1431
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT
DOES NOT START) .......................................................................................................................40-1432
S-4 ENGINE STARTABILITY IS POOR..............................................................................................40-1434
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ...............................................................................40-1436
S-6 ENGINE STOPS DURING OPERATION .....................................................................................40-1438
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ...............................................................................40-1440
S-8 ENGINE LACKS POWER............................................................................................................40-1441
S-9 KDPF GETS CLOGGED IN A SHORT TIME ...............................................................................40-1443
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .........................................................................40-1445
S-11 OIL BECOMES CONTAMINATED QUICKLY .............................................................................40-1446
S-12 FUEL CONSUMPTION IS EXCESSIVE ....................................................................................40-1447
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .40-1448
S-14 OIL PRESSURE DROPS ..........................................................................................................40-1449
S-15 FUEL MIXES INTO ENGINE OIL...............................................................................................40-1451
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .............................................................................40-1452
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ...........................................40-1453
S-18 UNUSUAL NOISE IS HEARD....................................................................................................40-1454
S-19 VIBRATION IS EXCESSIVE ......................................................................................................40-1455
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT........................................................................40-1456
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .......................................................40-1457
S-22 ACTIVE REGENERATION TAKES TIME...................................................................................40-1459
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.....................................40-1460
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ..........................................................................40-1461
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .................................................................40-1463
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)................................40-1464
40-14 PC210LCI-11
40 TROUBLESHOOTING ABBREVIATION LIST
ABBREVIATION LIST
the meaning.
Abbrevia-
tion
component/system)
System
AJSS
VERSE).
ARAC
braking force.
Automatic Retarder
Regulator
used independently.
Closed-center Load
Sensing System
injection timing.
PC210LCI-11 40-15
ABBREVIATION LIST 40 TROUBLESHOOTING

Abbrevia-
tion
component/system)
(Same as ECU)
(Same as ECM)
tion
FOPS Cab and canopy
Structure
Forward-Neutral-Re-
verse
tem
Plus) earth.

lite System

HSS
and communication.
IMV)
40-16 PC210LCI-11

Abbrevia-
tion
component/system)
Unit
trol motions.
IMA)
case Ventilation

KCSF Engine
tion Catalyst
fler.
late Filter
KTCS
road.
LIN
sponding to load.
LVDS
as MAF sensor.
Service
ic system
PC210LCI-11 40-17

Abbrevia-
tion
component/system)
ic system
PCCS
and transmission.
Control
oil pressure.
Hydraulic system
(D, PC, etc)
PTP

Structure
ISO 12117-2.
duction
al unit system)
plied.
flow.
TOPS Cab and canopy
40-18 PC210LCI-11

Abbrevia-
tion
component/system)
VGT Engine

D: Bulldozer
HD: Dump truck
WA: Wheel loader
A/C Air Conditioner
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
ENG Engine
F.G. Frame Ground
GND Ground
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
PC210LCI-11 40-19

T/M Transmission
40-20 PC210LCI-11
40 TROUBLESHOOTING GENERAL TROUBLESHOOTING POINTS
RELATED INFORMATION ON TROUBLESHOOTING

GENERAL TROUBLESHOOTING POINTS
k If you remove the radiator cap while the engine is still hot, hot coolant may spout out and can scald
you. Wait until the engine cools down.
k Take extreme care not to touch a hot portion or not to be wound in a turning portion.
k Before removing a plug or a cap of a portion where oil pressure, hydraulic pressure, or air pressure
is applied, release the internal pressure first, then connect the measuring tool securely.
k When disconnecting wiring, remove the key and turn the battery disconnect switch to OFF position.
k Park the machine on a level place and check the frame lock bar, chocks, parking brake, etc.
k When working in a group, make signs and allow only the persons concerned to approach the ma-
chine.
• Troubleshooting means to investigate the root cause of a failure, repair immediately, and prevent recur-
rence of the failure.
• One important thing when you perform troubleshooting is to understand the structure and operation.
• It is important to have an interview with the operator and set up an aim of failure cause for performing a
troubleshooting effectively.
• If you disassembly the machine hastily when it has a failure, you may disassemble unrelated portions and
may not be able to find the cause. As a result, the costs of the man-hours, parts, oil, or grease may in-
crease, and you may lose the confidence of the users and operators. Accordingly, sufficient advance check
and proper procedure are necessary for troubleshooting.
1. Ask users or operators the following questions.
1) Have any other problems occurred apart from the problem that has been reported?
2) Is 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 this?
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?
2. Perform the following checks before troubleshooting.
1) Check the machine for a symptom of abnormality.
2) Perform the Check before starting items.
3) Check the other check items.
4) Check other maintenance matters which can be checked externally and are considered to be necessa-
ry.
3. Check the degree of the trouble by yourself and judge if it is a real failure or it is a problem of handling or
operation.
When reproducing the trouble phenomenon by operating the machine, do not perform check or measure-
ment that can increase the failure.
4. Use the results of the investigation and inspection to narrow down the probable causes of the failure, then
use the troubleshooting flow chart (matrix) to locate the failure exactly.
The basic troubleshooting procedure is as follows.
• Start from the simple points.
• Start from the most likely points.
• Investigate other related parts or information.
5. If the root cause is not corrected, a similar failure may occur again even if the apparent failure has been
repaired. Always find out the cause of a failure first and remove the root cause of each failure.
PC210LCI-11 40-21
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

The followings are troubleshooting related cautions and changes for the newly installed Urea SCR system for
the Tier4 Final specification.
Engine controller shut down
• When the starting switch is turned to the OFF position, the engine controller starts the shutdown process-
ing. After the shutdown processing is completed, the action of turning off the engine controller's power is
referred to as “Engine controller shut down”.
• On machines with the Urea SCR system, the engine controller's shutdown process now includes purging of
AdBlue/DEF from devices or hoses to the tank. This increases average shutdown time from 2 minutes in
former models to maximum 7 minutes in Tier4 Final Specification models. (Described as 2 to 6 minutes in
the description of “Troubleshooting by failure code”).
• If the starting switch is turned OFF and ON before the engine controller is shut down, the information in the
engine controller which should be updated will not be updated, and the troubleshooting of the device may
not function properly. If this happens, it becomes necessary to shut down the engine controller. Completion
of engine controller shut down can be confirmed when the system operating lamp goes out.
Loaded Diagnostics Operation To Confirm Failure Correction and Loaded Diag-
nostics Operation To Clear Failure Code in the troubleshooting procedure
k Since the aftertreatment devices and their temperature sensor, pressure sensor, NOx sensor, ammo-
nia sensor, AdBlue/DEF injector, etc. are heated to a high temperature after “Loaded Diagnostics Op-
eration To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”,
take care not to get burned. Perform troubleshooting or repair after letting the devices cool down.
NOTICE
The operations for “Operation for judging the repair result” and “Machine operation for clearing the fail-
ure code” to apply a load to the engine are special operations to be performed only in a procedure for
trobleshooting.
Peroform stall operatoin, etc . to implement normal check according to the procedure described in
TESTING AND ADJUSTING.
NOTICE
Check the fuel and AdBlue/DEF level before the operation for “Operation for judging the repair result”
or “Machine operation for clearing the failure code”.
For checking the fuel and AdBlue/DEF level, see TESTING AND ADJUSTING, “SET AND OPERATE MA-
CHINE MONITOR”, “SERVICE MODE", "METHOD FOR OPERATING TESTING MENU (SCR SERVICE
TEST)”.
1. Tips
• The engine controller monitors the operation of engine related components (including aftertreatment
devices), and displays a failure code on the monitor when an abnormality is detected, and clears the
failure code after the failure is corrected. The monitored items include: sensors, actuators, electric wir-
ing, catalyzer, etc.
• The engine controller clears the failure code when it performs troubleshooting and the failure is correct-
ed. However, the failure code may be cleared when the engine controller is shut down even if the fail-
ure still exists. It may be necessary to apply load to the engine to activate the troubleshooting. Open
circuits and short circuits can be diagnosed by turning the starting switch to ON position after complet-
ing the repair. The engine controller determines if the failure, and displays a failure code on the monitor
when an abnormality is detected.
• However, the engine controller may not activate troubleshooting of the aftertreatment devices or other
functions if the exhaust gas temperature or flow rate is below the specified value. “Loaded Diagnostics
Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”
should always be performed after the repair. These operations mean to run the engine, and rev up or
load the engine to meet the conditions for activating troubleshooting.
2. Loaded Diagnostics Operation To Confirm Failure Correction
40-22 PC210LCI-11
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
• This operation is performed to confirm if a failure is corrected when the failure code is already cleared
(described later) or has been cleared before the failure was corrected.
• After the repair is completed, run the engine and the machine until the exhaust gas temperature and
flow rate exceed the specified value. Let the engine controller to activate troubleshooting of the after-
treatment devices to determine if the failure is corrected. If the failure is corrected, the failure code will
not be displayed.
REMARK
• For failure codes that require “Loaded Diagnostics Operation To Confirm Failure Correction” or “Loaded
Diagnostics Operation To Clear Failure Code” after repairing, a “Notice” mark is described in the related
information column of each failure code description, and the procedure will be given at the end of each
failure code description.
• When performing “Loaded Diagnostics Operation To Confirm Failure Correction” or “Loaded Diagnostics
Operation To Clear Failure Code”, confirm that the level of AdBlue/DEF and fuel in the tank are enough
to perform. To check the level of AdBlue/DEF and fuel, see to Testing and adjusting chapter, “SETTING
AND OPERATING MACHINE MONITOR”, “SERVICE MODE”, “METHOD FOR OPERATING TESTING
MENU (SCR SERVICE TEST)”.
3. Loaded Diagnostics Operation To Clear Failure Code
• This operation is performed to clear a failure code which is not cleared by turning the starting switch to
ON position after the failure is corrected.
• After the repair is completed, run the engine and the machine until the exhaust gas temperature and
flow rate exceed the specified value. Let the engine controller to activate troubleshooting of the after-
treatment devices to determine if the failure is corrected. If the failure is corrected, the displayed failure
code will go out.
4. SCR Service Test
• This is a function for determining whether there is a failure in the Urea SCR system. Perform this test
from the machine monitor.
REMARK
If instructed to perform a “SCR Service Test” in the troubleshooting procedure or somewhere else, see Test-
ing and adjusting chapter, “SETTING AND OPERATING MACHINE MONITOR”, “SERVICE MODE”,
“METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)” and perform “SCR Service Test”.
Clearing Failure Code
“Clearing failure code” refers to manually deleting an “active” failure code from the engine controller. The follow-
ing two “Clearing Failure Code” functions have been added for Tier4 Final specification.
1. “Engine Controller Active Fault Clear”
• It is now possible to clear the failure code from the machine monitor without using INSITE.
• This function is provided as a means to perform troubleshooting when operating conditions for normally
activating the troubleshooting cannot be met after the cause of the failure is repaired. If the machine
can be operated, always clear failure codes by performing “Loaded Diagnostics Operation To Confirm
Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”.
• For details, refer to Testing and adjusting chapter “SETTING AND OPERATING MACHINE MONITOR”,
“SERVICE MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.However, if a failure code that relates to the “Inducement strategies” is displayed
(see separated list of failure code), failure codes will not be able to be cleared by this function.
• In this case, the failure code is cleared by using the “Engine Controller Active Fault Clear”, described
below, or by using INSITE.
2. “Engine Con Inducement Fault Clear”
• This is a function for clearing failure code caused by the Urea SCR system “Inducement”.
• For the failure code relating to the “Inducement strategy” of the Urea SCR system, which cannot be
cleared by “Engine Controller Active Fault Clear”, these can now be cleared from the machine monitor
by using a one-time password issued by Komatsu. Also, INSITE can be used for clearing.
PC210LCI-11 40-23
In case failure codes cannot be cleared

• The relevant failure code may not be able to clear due to derated engine power caused by “Inducement
strategy”, environmental conditions or other functional restrictions. Details and the measures to be taken
are as shown below.
Case 1 : Derated engine power caused by “Inducement strategy”
• The failure code may not be able to be cleared because it is a failure code caused by an “Inducement strat-
egy”, which derates the engine power. (Detail of “Inducement strategy”, see Structure and function chapter
“UREA SCR SYSTEM”.)
• Failure codes, which are caused by “Inducement strategy”, and be cleared by turning the starting switch to
ON position or operating the engine at low idle, are cleared in the same manner as before.
• However, some failure codes caused by “Inducement strategy” and require “Loaded Diagnostics Operation
To Clear Failure Code” may not let the machine move to activate troubleshooting. (The “Inducement status”
advances to derate engine power.) For the applicable codes, see separate sheet. Applicable codes are also
identified at their descriptions of “Troubleshooting by failure code”.
• Measures to be taken:
When the repair is completed, perform “Engine Con Inducement Fault Clear” and then “Loaded Diagnostics
Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code” to con-
firm that the failure code is cleared.
Case 2 : Environmental conditions
• Depending on environmental conditions (altitude, ambient temperature and etc.) when performing “Loaded
Diagnostics Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure
Code”, or when AdBlue/DEF freeze prevention mode is activated, the failure code may not be able to be
cleared.
(Applicable codes are identified by including the conditions that prevent clearing in “Related information” of
each “Troubleshooting by failure code”.)
1. When the repair is completed, perform “Loaded Diagnostics Operation To Confirm Failure Correction”
or “Loaded Diagnostics Operation To Clear Failure Code” under appropriate environmental conditions.
(See the description of each “Troubleshooting by failure code”.)
2. If the measure mentioned above is difficult to take after the repair is completed, perform “Engine Con-
troller Active Fault Clear”, or “Engine Con Inducement Fault Clear” and then confirm that the failure
code is cleared.
• Examples:
• Some failure codes cannot be cleared under certain environmental conditions (altitude, ambient tem-
perature, etc.)
1. Some failure codes cannot be cleared at high altitudes (ambient pressure 80 kPa or less).
2. Some failure codes cannot be cleared at low temperatures (ambient temperature -7 °C or below).
3. Some failure codes indicate failures only when AdBlue/DEF freeze prevention mode is activated.
4. Some failure codes do not indicate a failure when AdBlue/DEF freeze prevention mode is activat-
ed.
• Code cannot be cleared because AdBlue/DEF pump stops or AdBlue/DEF injection stops
• Condition that stops the AdBlue/DEF pump or AdBlue/DEF injection is shown below.
1. Ambient temperature: -24 °C or below
2. Thaw mode activated
Case 3 : Functional restrictions caused by other failures
• The failure code may not be able to clear due to functional restrictions (Regeneration control stops, Stops
AdBlue/DEF injection, etc.) caused by other failures. Operation and procedure required for clearing the
code are given under “Troubleshooting by each failure code”.
40-24 PC210LCI-11
By following the clearing procedure, clear the failure code.
• Examples:
1. The failure code cannot be cleared because an abnormal high voltage, abnormal low voltage, or com-
munication error (open or short circuit) of failure code is displayed for a related component.
2. The failure code cannot be cleared because correct values are not input from a sensor (a failure code
for a related sensor is displayed).
3. The failure code cannot be cleared because a failure code that disables auto regeneration or manual
stationary regeneration of the aftertreatment devices is displayed.
4. The failure code cannot be cleared because a failure code that stops the AdBlue/DEF pump or disa-
bles AdBlue/DEF injection is displayed.
How to identify the failure code to be repaired
Among failure codes displayed on “Abnormality Record” screen of the machine monitor, identify failure codes
that have following conditions as a code to be repaired
1. Failure codes displayed with “E” (“E” is displayed on the left of failure code. See the following figure.)
• Check the “Abnormality Record” screen and identify all failure codes that “E” is currently displayed as a
code to be repaired.
• The failure codes are displayed in the upper row from the “E” on the “Abnormality Record” screen.
2. Failure codes displayed without “E” and their service meter reading (SMR) at last occurrence (at previous
working time, etc.) become the most recent time.
• The failure codes that have detected records most recently and are displayed without “E” may be in the
state that their abnormalities are not cleared (*1). Due to that, check the description of “Troubleshoot-
ing by failure code” and identify them as a code to be repaired.
• The failure codes are displayed on “Abnormality Record” screen in ascending order. (See the following
figure.)
*1: It corresponds to a failure code that is cleared by turning the starting switch to OFF position, or by stop-
ping the engine though the repair is not completed. Due to this kind of failure code, the failure code to be
repaired is not determined only by the existence of “E”. (Failure C pattern in the following REMARK “Dis-
play of “E” on the “Abnormality Record” screen”.)
1: Area where “E” is displayed
2: Area where the most recent SMR is displayed
REMARK
Display of “E” on the “abnormality record” screen
1. Transition of “E” displayed with failure code has a following pattern.
The table is shown the display of “E” on “Abnormality Record” screen of the machine monitor when turning
the starting switch to O N position after turning the starting switch to OFF position and shutting down the
engine controller.
Occurrence of failure code (with or without “E”)
Transition Before re- Determination of the repair completion
pattern pair (under After repair Remarks
failure)
PC210LCI-11 40-25
The “E” is not displayed To determine if the repair is completed suc-

Failure A “E” No display after the repair is complet- cessfully enables to turn the starting switch to
ed. ON position.
It is necessary to perform “Loaded Diagnos-
The “E” doses not go out
tics Operation To Clear Failure Code” to de-
Failure B “E” “E” only by the repair is com-
termine if the repair is completed successful-
pleted.
ly.
• See the most recent SMR on Abnor-
mality Record screen and determine if
it is to be repaired because only the
Once the engine controller “E” cannot determine if the failure is
shuts down, the “E” goes cleared.
Failure C No display No display
out even if the repair is not
completed. • It is necessary to perform “Loaded Di-
agnostics Operation To Confirm Fail-
ure Correction” to determine if the re-
pair is completed successfully.
2. Unless clearing the “E” of failure code, a number of occurrences increase every time when turning the start-
ing switch to ON position.
40-26 PC210LCI-11
Troubleshooting Flow
PC210LCI-11 40-27
40-28 PC210LCI-11
PC210LCI-11 40-29
List of failure codes related to Inducement

• “●” mark shown in the following list means failure codes related to Inducement in each territory.
• When activating Inducement strategy, the following failure code is displayed with one of “AdBlue/DEF level
Low Error”, or “Urea SCR system devices abnormality” on “Current Abnormality” screen of the machine
monitor.
• “Urea SCR system devices abnormality” is displayed as Urea SCR System Abnormality on the Abnormali-
ty Record screen.
North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
Detail of failure DEF DEF
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
AS00ZK AdBlue/DEF Level Low Error 5 ● - - -
CA249 Ambient Air Temp Sensor High Error - - - ●
CA256 Ambient Air Temp Sensor Low Error - - - ●
CA1669 AdBlue/DEF Level Sensor Voltage High Error - - - ●
CA1673 AdBlue/DEF Level Low Error 3 ● - ● -
CA1677 AdBlue/DEF Temperature Sensor Low Error - - - ●
CA1678 AdBlue/DEF Temperature Sensor High Error - - - ●
CA1682 AdBlue/DEF Pump Priming Error - ● - ●
CA1683 AdBlue/DEF Tank Heating Valve Voltage High Error - ● - ●
CA1684 AdBlue/DEF Tank Heating Valve Voltage Low Error - ● - ●
CA1686 AdBlue/DEF Quality Sensor Voltage High Error - - - ●
CA1714 AdBlue/DEF Quality Sensor Out of Calibration Error - - - ●
CA1715 AdBlue/DEF Quality Sensor Internal Circuit Error - - - ●
CA1885 Turbo Outlet NOx Sensor Circuit Error - - - ●
CA1887 SCR Outlet NOx Sensor Circuit Error - - - ●
CA2271 EGR Valve Position Sensor High Error - - - ●
CA2272 EGR Valve Position Sensor Low Error - - - ●
CA2349 EGR Valve Solenoid Open Circuit Error - - - ●
CA2353 EGR Valve Solenoid Short Circuit Error - - - ●
CA2357 EGR Valve Servo Error - - - ●
CA2771 SCR Outlet NOx Sensor Datalink Timeout Error - ● - ●
CA2976 AdBlue/DEF Pump Temperature Sensor Signal Error - ● - ●
CA3142 SCR Temperature Sensor High Error - ● - ●
CA3143 SCR Temperature Sensor Low Error - ● - ●
CA3144 SCR Temperature Sensor In Range Error - ● - ●
CA3146 SCR Outlet Temperature Sensor High Error - ● - ●
CA3147 SCR Outlet Temperature Sensor Low Error - ● - ●
CA3148 SCR Outlet Temperature Sensor In Range Error - ● - ●
40-30 PC210LCI-11
North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
CA3151 SCR Catalyst Efficiency Low Error 2 - ● - ●
CA3165 SCR Outlet Temperature High Error - ● - ●
CA3229 SCR Temperature High Error - ● - ●
CA3231 SCR Temperature High Error - Non Regeneration - ● - ●
CA3232 Turbo Outlet NOx Sensor Datalink Timeout Error - ● - ●
CA3235 SCR Outlet Temperature High Error - Non Regeneration - ● - ●
CA3319 KDPF Outlet Temperature Sensor High Error - ● - ●
CA3321 KDPF Outlet Temperature Sensor Low Error - ● - ●
CA3322 KDPF Outlet Temperature Sensor In Range Error - ● - ●
CA3543 AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) - ● - -
CA3545 SCR Outlet NOx Sensor Unstable Error - - - ●
CA3558 AdBlue/DEF Pump Voltage High Error - ● - ●
CA3559 AdBlue/DEF Pump Voltage Low Error - ● - ●
CA3563 AdBlue/DEF LineHeater Relay 1 Voltage Low Error - ● - ●
CA3567 AdBlue/DEF Injector Open Circuit Error or Short Circuit Error - ● - ●
CA3568 AdBlue/DEF Injector Malfunction - ● - ●
CA3571 AdBlue/DEF Pump Pressure Sensor High Error - ● - ●
CA3572 AdBlue/DEF Pump Pressure Sensor Low Error - ● - ●
CA3574 AdBlue/DEF Pump Pressure Too Low Error - ● - ●
CA3575 AdBlue/DEF Pump Pressure Too High Error - ● - ●
CA3577 AdBlue/DEF FCV Voltage High Error - ● - ●
CA3578 AdBlue/DEF FCV Voltage Low Error - ● - ●
CA3583 SCR Outlet NOx Sensor Heater Warming up Error - - - ●
CA3596 AdBlue/DEF Pump Pressure Unstable Error - ● - ●
CA3649 Turbo Outlet NOx Sensor Heater Warming up Error - - - ●
CA3681 SCR Outlet NOx Sensor Power Voltage Error - - - ●
CA3682 Turbo Outlet NOx Sensor Power Voltage Error - - - ●
CA3717 SCR Outlet NOx Sensor Voltage Mismatch Error - - - ●
CA3718 Turbo Outlet NOx Sensor Voltage Mismatch Error - - - ●
CA3725 Turbo Outlet NOx Sensor Unstable Error - - - ●
CA3866 AdBlue/DEF Low Concentration Error 2 - - - ●
CA3868 AdBlue/DEF Tank Sensor Datalink Timeout Error - ● - ●
PC210LCI-11 40-31
North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
CA3899 SCR NH3 Sensor Circuit Error - - - ●
CA3911 SCR NH3 Sensor Datalink Timeout Error - ● - ●
CA3912 SCR NH3 Sensor Heater Warming up Error - - - ●
CA3932 SCR NH3 Sensor Heater Voltage High Error - - - ●
CA3933 SCR NH3 Sensor Heater Voltage Low Error - - - ●
CA3934 SCR NH3 Sensor Power Interrupt Error - - - ●
CA3935 SCR NH3 Sensor Trim Resistance Error - - - ●
CA3936 SCR NH3 Sensor Internal Circuit Error - - - ●
CA4151 KDOC and KDPF Temperature Sensor Datalink Timeout Error - ● - ●
CA4152 SCR Temperature Sensor Datalink Timeout Error - ● - ●
CA4155 AdBlue/DEF Pump Heater Relay Voltage High Error - ● - ●
CA4158 KDOC and KDPF Temperature Sensor Internal Circuit Error - ● - ●
CA4159 SCR Temperature Sensor Internal Circuit Error - ● - ●
KDOC and KDPF Temperature Sensor ECU Voltage High Er-
CA4161 - ● - ●
ror
KDOC and KDPF Temperature Sensor ECU Voltage Low Er-
CA4162 - ● - ●
ror
CA4164 SCR Temperature Sensor ECU Voltage High Error - ● - ●
CA4165 SCR Temperature Sensor ECU Voltage Low Error - ● - ●
CA4259 KDOC and KDPF Temperature Sensor Power Interrupt Error - ● - ●
CA4261 SCR Temperature Sensor Power Interrupt Error - ● - ●
CA4461 AdBlue/DEF LineHeater Relay 2 Voltage Low Error - ● - ●
CA4731 AdBlue/DEF Temperature Sensor Transmission Data Error - - - ●
CA4732 AdBlue/DEF Level Sensor Transmission Data Error - - - ●
CA4739 AdBlue/DEF Level Sensor Internal Circuit Error - - - ●
CA4769 AdBlue/DEF Level Measurement Impossible - ● - ●
CA4842 AdBlue/DEF High Concentration Error - - - ●
40-32 PC210LCI-11
List of failure codes that are related to Inducement and cannot be cleared at engine power deration
Failure
Detail of failure North America EU
code
CA1885 Turbo Outlet NOx Sensor Circuit Error - ●
CA1887 SCR Outlet NOx Sensor Circuit Error - ●
CA3144 SCR Temperature Sensor In Range Error ● ●
CA3148 SCR Outlet Temperature Sensor In Range Error ● ●
CA3151 SCR Catalyst Efficiency Low Error 2 ● ●
CA3322 KDPF Outlet Temperature Sensor In Range Error ● ●
CA3543 AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) ● -
CA3545 SCR Outlet NOx Sensor Unstable Error - ●
CA3568 AdBlue/DEF Injector Malfunction ● ●
CA3583 SCR Outlet NOx Sensor Heater Warming up Error - ●
CA3649 Turbo Outlet NOx Sensor Heater Warming up Error - ●
CA3681 SCR Outlet NOx Sensor Power Voltage Error - ●
CA3682 Turbo Outlet NOx Sensor Power Voltage Error - ●
CA3725 Turbo Outlet NOx Sensor Unstable Error - ●
CA3899 SCR NH3 Sensor Circuit Error - ●
CA3912 SCR NH3 Sensor Heater Warming up Error - ●
CA3932 SCR NH3 Sensor Heater Voltage High Error - ●
CA3933 SCR NH3 Sensor Heater Voltage Low Error - ●
CA3934 SCR NH3 Sensor Power Interrupt Error - ●
CA3935 SCR NH3 Sensor Trim Resistance Error - ●
CA3936 SCR NH3 Sensor Internal Circuit Error - ●
List of failure codes is related to Inducement and cannot be cleared when freezing AdBlue/DEF (All terri-
tory)
Failure Detail of failure
code
CA1673 AdBlue/DEF Level Low Error 3
CA1682 AdBlue/DEF Pump Priming Error
CA3567 AdBlue/DEF Injector Open Circuit Error or Short Circuit Error
CA3574 AdBlue/DEF Pump Pressure Too Low Error
CA3575 AdBlue/DEF Pump Pressure Too High Error
CA3578 AdBlue/DEF FCV Voltage Low Error
CA3596 AdBlue/DEF Pump Pressure Unstable Error
CA3866 AdBlue/DEF Low Concentration Error 2
CA4277 AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error
CA4768 Fuel in AdBlue/DEF Tank Error
CA4769 AdBlue/DEF Level Measurement Impossible
CA4842 AdBlue/DEF High Concentration Error
PC210LCI-11 40-33
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40 TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
40-34 PC210LCI-11
40 TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC210LCI-11 40-35
CHECKS BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Engine, lubricating oil, coolant, and AdBlue/AdBlue/DEF
No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check around engine and removal of dirt - Remove
3 Check of engine for water leakage - Repair
4 Check of engine for oil leakage - Repair
5 Check of fuel line for leakage - Repair
6 Check of radiator for clogging - Remove
7 Check of fuel level and type - Add fuel
8 Check of foreign material in fuel - Clean and drain
9 Check of fuel prefilter - Replace
10 Check of fuel main filter - Replace
11 Check of engine oil level (in oil pan) and type Between H and L Add engine oil
12 Check of coolant level (in reservoir tank) Between H and L Add coolant
Air cleaner clogging
caution lamp is not dis- Cleaning or replace-
13 Check of air cleaner for clogging
played on machine ment
monitor
14 Check around aftertreatment devices and dirt removal - Remove
15 Check around aftertreatment devices for gas leakage - Repair
16 Check of AdBlue/DEF line for leakage - Replacement or repair
17 Check of AdBlue/DEF level and type - Add AdBlue/DEF
18 Check of AdBlue/DEF tank breather element - Replace
Hydraulic and mechanical equipment

1 Check for unusual noise and smell - Repair
2 Check for oil leakage - Repair
3 Check of hydraulic oil level Between H and L Refilling with oil
Cleaning or replace-
4 Check of hydraulic oil strainer -
ment
5 Check of hydraulic oil filter - Replace
6 Check of swing machinery case oil level Between H and L Refilling with oil
7 Check of damper case oil level - Refilling with oil
8 Check of final drive case oil level - Refilling with oil
9 Bleeding air from fuel system - Bleeding air
10 Bleeding air from hydraulic circuit - Bleeding air
Electrical equipment
1 Check of battery terminal for looseness and corrosion - Retighten or replace
40-36 PC210LCI-11
40 TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

2 Check of alternator terminal for looseness and corrosion - Retighten or replace
Check of starting motor terminal for looseness and corro-
3 - Retighten or replace
sion
4 Check of battery voltage (with engine stopped) 20 to 30 V Charge or replacement
5 Check of battery electrolyte level Between H and L Refill or replacement
Check of wiring harness for discoloration, burnt areas and
6 - Replacement or repair
cover peeling
Check for coming off of wiring harness clamp and sagging
7 - Repair
of wiring harness
8 Check of grounding - Repair
9 Check for loose connector and damaged lock - Replacement or repair
Check of connector pin for corrosion, bends and AdBlue/
10 - Replacement or repair
DEFormation
Drying, cleaning or re-
11 Check of connector for water and foreign material -
placement
12 Check of wiring harness for open or short circuit - Replacement or repair
13 Check of fuse for blowing out and corrosion - Replacement
Check of alternator voltage (when engine speed is medium 27.5 to 29.5 V after few
14 Replacement
or higher) minutes operation
Check of battery relay operation sound (when starting
15 - Replacement
switch is turned to ON or OFF position)
16 Check and cleaning of camera - Cleaning or repair
Exterior parts
1 Check of undercarriage - Repair
2 Check of handrails and steps - Repair
3 Check of mirrors - Cleaning or repair
Interior parts
Cleaning or replace-
1 Check of gauges and monitors -
ment
2 Check of seat belt - Repair
PC210LCI-11 40-37
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING

WALK-AROUND CHECK
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, wiring harnesses for play, and accumulation of dust in places that reach
high temperatures.
k Accumulated combustibles around hot engine parts such as the engine, after-treatment devices, tur-
bocharger, etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and
repair any failures.
• Check for unusual sounds and smells
Check for unusual sounds or smells.
If the machine is operated under the unusual sounds or smells, the cause of it may damage the machine,
so stop the operation immediately once you recognize it.
• Check around engine and removal of dirt
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the after-treatment devices, turbocharger, etc.
• Check for water leakage around engine
• Check for oil leakage around engine
Check for oil leakage from engine and coolant leakage from cooling system. If any abnormality is found,
repair it.
• Check for leakage from fuel line
Check for fuel leakage, check hoses and pipes for damage. If any abnormality is found, repair it.
• Check of radiator and removal of dirt
Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the radiator.
If any, remove them.
For removal of dirt from the radiator, see the Operation and Maintenance Manual, “Method for checking and
cleaning radiator fins, oil cooler fins, aftercooler fins, and air conditioner condenser fins”.
• Check around aftertreatment devices and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around aftertreatment
devices.
• Check around aftertreatment devices for gas leakage
Check piping between the turbocharger and KDPF and joints of aftertreatment devices for gas leakage
(sticking soot, etc.) If any abnormality is found, repair.
• Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any abnor-
mality is found, repair it.
• Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage
Check for oil leaks. If any abnormality is found, repair it.
• Bleeding air
For the bleeding air from the fuel system, see Testing and adjusting, “BLEEDING AIR FROM FUEL SYS-
TEM”.
For the bleeding air from the hydraulic system, see Testing and adjusting, “BLEED AIR FROM HYDRAULIC
DEVICES”.
• Check and cleaning of rearview camera
Check the rearview camera for abnormality. If any abnormality is found, repair it
• Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers
If any abnormality is found, repair it.
• Check of handrails and steps for abnormality and looseness of bolts
If any abnormality is found, repair it and tighten any loose bolts.
• Check and clean rearview mirrors
40-38 PC210LCI-11
40 TROUBLESHOOTING INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
Check rearview mirror for abnormality. If any, repair it.

Clean the mirror surface and adjust the mirror angle so that the rear of the machine can be seen from the
operator's seat.
• Check of gauges and monitors for abnormality
Check gauges and monitors in the operator's cab for abnormality. If any abnormality is found, replace it with
a new one.
Clean up the surfaces.
• Check of seat belt and mounting hardware
Check the hook, the lock, and hook mounting part for damage. If any abnormality is found, repair it.
PC210LCI-11 40-39
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE

CHECK FUEL LEVEL AND TYPE
k Fuel is highly flammable and dangerous. Never bring open flames near fuel.
k When adding fuel, be careful not to overflow it.
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 starting switch to ON position, and check the fuel
level with fuel level gauge (1) on the monitor panel.
After checking, turn the switch back to OFF position.
2. If the fuel level is low, open fuel filler cap (F) of the fuel
tank and add fuel through the fuel filler port to the neces-
sary level, referring to the position of float gauge (G).
3. After adding fuel, push float gauge (G) straight down with
fuel filler cap (F), and tighten fuel filler cap (F) securely
while taking care the float gauge (G) is not caught in tab
(2) of fuel filler cap (F).
REMARK
If breather hole (3) in the oil filler cap is clogged, the pres-
sure in the tank decreases and fuel may not be supplied.
To prevent this, clean the breather hole.
CHECK IMPURE INGREDIENT IN FUEL

1. Open the side cover on the rear right side of the machine.
40-40 PC210LCI-11
40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE
2. Prepare a container below drain hose (1) to receive the

drained fuel.
3. Turn drain valve (2) to open position (O) to discharge the
sediment and water in the bottom together with the fuel.
4. When only the clean fuel flows out, turn drain valve (2) to
close position (S).
5. Close the side cover.
CHECK FUEL PREFILTER

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running. Stop
the engine and wait at least 30 seconds until the inner pressure is released and then replace the fil-
ter.
k Keep open flame away.
NOTICE
• Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering properties.
Be sure to use Komatsu genuine parts when replacing.
• 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 materials may enter and problem may occur in the injection sys-
tem. Do not use substitute parts.
• During testing or maintenance of the fuel system, be sure that any foreign material does not enter
the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean
fuel.
• Prepare a container to receive the drained fuel.
• Prepare a filter wrench.
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT

1. Open the side cover.
The water separator is integrated with fuel prefilter (1).
2. Through the transparent cup (2), water quantity or sedi-
ments can be visually checked. If they are accumulated,
place a container to receive water under the drain hose
(3).
• This machine is equipped with sensor which detects
water accumulated in transparent cup (2).
• Drain the water when the water separator monitor
lights up in red on machine monitor, since it shows
water accumulated in transparent cup (2).
• If the water in transparent cup (2) is frozen, the water separator monitor may not light up. After the en-
gine is started, when the frozen water is melted because of the increase of the temperature around fuel
prefilter (1), water separator monitor may light up suddenly. Accordingly, drain the water frequently in
the cold weather even if water separator monitor is not lit.
• If water in transparent cup (2) is frozen, drain water only after confirming that it has completely melted.
• If you cannot visually identify the presence of water due to stains on transparent cup (2), clean trans-
parent cup (2) when replacing fuel prefilter cartridge (1).
3. Loosen drain valve (4) and drain the water.
PC210LCI-11 40-41
4. When fuel starts to drain from drain hose (3), tighten drain valve (4) immediately.
REMARK
When you have removed drain valve (4) for the above cleaning process, coat the O-ring with grease and
tighten drain valve until it touches the bottom.
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE

1. Turn valve (1) at the bottom of the fuel tank to close posi-
tion (S).
2. Open the side cover.
3. Place a container under fuel prefilter cartridge (2) to re-

ceive the fuel.
4. Loosen drain valve (3) and drain the water and sediments
from transparent cup (4), and also drain all the fuel from fil-
ter cartridge (2).
5. Remove connector (5). Wrap the disconnected connector
with a plastic bag to protect it from fuel, oil and water.
6. Turn transparent cup (4) by using the filter wrench, and re-
move it.
7. Using the filter wrench, turn filter cartridge (2) to remove.
8. Install currently removed transparent cup (4) to the bottom of the new filter cartridge.
REMARK
At this time, replace O-ring (6) with a new one.
9. When installing the transparent cup, thinly apply oil to the O-ring, set it against the sealing surface of filter
cartridge (2), and then tighten the transparent cup by turning 1/4 to 1/2 turn.
REMARK
If the transparent cup is fastened too much, the O-ring will be damaged and this leads to leakage of fuel. If
it is too loose, fuel will also leak from gaps of the O-ring. Therefore, be sure to observe the fastening angle.
40-42 PC210LCI-11
10. Clean the filter head, fill the new filter cartridge with clean
fuel, apply oil thinly to the packing surface, then install it to
the filter head.
NOTICE
• When adding fuel, do not remove cap (B) at the
center. Always fill the fuel from the dirty side of 8
small holes (A).
• After adding fuel, remove cap (B) at the center and
install the fuel filter.
• Always fill with clean fuel. Be careful to prevent dirt
or dust from entering into the fuel. In particular,
center part is the clean side, so do not remove cap
(B) when adding fuel. Be careful to prevent dirt or
dust from entering into the center clean side part.
11. When installing the cartridge, tighten it until the packing surface contacts the sealing surface of the filter
head, then tighten it 3/4 of a turn.
REMARK
If the filter cartridge is fastened too much, the packing will be damaged and this leads to leakage of fuel. If
the filter cartridge is too loose, fuel will also leak from the packing. Therefore, be sure to observe the fasten-
ing angle.
When using a filter wrench for tightening, take care not to leave flaws or dents on the filter.
12. Check that drain valve (2) is closed securely.
13. Remove the plastic bag wrapping connector (5), then connect connector (5).
14. Turn valve (1) at the bottom of the fuel tank to open position (O).
15. Check for fuel leaks. If the fuel leaks, tighten filter cartridge securely.
REMARK
• 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 that water does not attach to connector.
• If water attaches to connector (5), dry it completely before connecting it.
If the fuel still leaks, repeat steps 1 to 7 to remove the filter cartridge, and if any damage or pinched foreign
material on the packing surface is found, replace the cartridge with a new one, and repeat steps 8 and after.
CHECK MAIN FILTER

k High pressure is generated inside the engine fuel piping system when the engine is running. Stop
the engine and wait at least 30 seconds until the inner pressure is released and then replace the fil-
ter.
k Keep open flame away.
NOTICE
• Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering properties.
Be sure to use Komatsu genuine parts when replacing.
• 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 materials may enter and problem may occur in the injection sys-
tem. Do not use substitute parts.
• During testing or maintenance of the fuel system, be sure that any foreign material does not enter
the fuel system. If any dust or other material sticks to any part, wash the part thoroughly with clean
fuel.
• Prepare a container to receive the drained fuel.
PC210LCI-11 40-43
• Prepare a filter wrench.

1. Turn valve (1) at the bottom of the fuel tank to close posi-
tion (S).
3. Place a container under the filter cartridge to receive the
fuel.
4. Turn filter cartridge (2) by using the filter wrench, and re-
move it.
After removing the filter cartridge, fuel falls in drops from
the filter head.
REMARK
In order to prevent fuel from flowing out, be sure not to
leave the machine without the filter cartridge.
5. Clean the filter head. Thinly apply oil to the packing face of
the new filter cartridge and install the cartridge to the filter
head.
Replace inside seal (3) with a new one.
REMARK
• Do not fill the new filter cartridge with fuel.
• Remove cap (A) at the center, and then install the filter
cartridge.
6. When installing, tighten it by 3/4 turn after the O-ring
comes in contact with the sealing surface of the filter hold-
er.
REMARK
If the filter cartridge is over tightened, fuel will leak be-
cause the O-ring is damaged. If the filter cartridge is not
tightened sufficiently, fuel will also leak through the clear-
ance of the O-ring. Therefore, observe the tightening an-
gle.
7. Set valve (1) at the bottom of fuel tank to open position
(O).
8. Bleed air according to the following procedure.
1) Fill up the fuel tank with fuel (to the level where the
float is at the highest position).
40-44 PC210LCI-11
2) Loosen feed pump knob (4) and draw it out once, then
push and pull several times until its movement be-
comes stiff.
• You do not need to remove the plugs at the head
of the fuel prefilter and fuel main filter.
• If fuel is used up, bleed air by operating feed
pump knob (4) in the same manner.
3) Push in and tighten feed pump knob (4).
9. After replacing the filter cartridge, start the engine and run
it at low idle speed for 10 minutes.
10. Check the filter sealing surface for fuel leakage. If fuel leaks, check the tightening condition of the filter car-
tridges. If fuel still leaks, remove the filter cartridge according to steps 1 to 4 and check for damage of the
O-ring and entry of foreign material. If any trouble is found, replace the cartridge with a new one and per-
form steps 5 and after.
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until all parts have cooled down before starting the work.
REMARK
• When checking the oil level after the engine has been operated, wait at least 15 minutes after stopping the
engine.
• If the machine is inclining, make it level before checking.
• When the ambient temperature is low, water or emulsified matter may stick to the dipstick, oil filler cap, etc.
or the drained oil may be milky white because of water vapor in the blowby gas. However, if the coolant level
is normal, it is not a problem.
1. Stop the engine.
3. Remove dipstick (G) and wipe off oil on it with a cloth.
4. Insert dipstick (G) fully and pull it out.
5. The oil level should be between marks H and L on dipstick

(G).
If the oil level is below mark L, add oil through oil filler port
(F).
PC210LCI-11 40-45
6. If the oil level is above line H, drain the extra engine oil
through drain valve (P) at the bottom of the engine oil pan
and check the oil level again.
7. If the oil is at the correct level, tighten the oil filler cap se-
curely and close the engine hood.
CHECK COOLANT LEVEL (RESERVOIR TANK)

k The radiator cap does not need to be opened for standard checks. When checking the coolant level,
check it in reservoir tank when the engine is cooled down.
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 the radiator
cap, wait until the temperature drops before you do. Then turn the cap slowly to release the pressure
and remove it with care.
1. Open side cover on the rear left of the machine, check the
coolant level is within "FULL - LOW" range at reservoir
tank (1). If coolant is insufficient, add coolant up to FULL
level through water filler port at reservoir tank (1).
2. After refilling with coolant, tighten the cap securely.
3. If the reservoir tank is vacant, coolant may have leaked.
If any abnormality is found in the check for leakage, repair
it immediately. If no abnormality is found, check the level of
the coolant in the radiator. If it is low, add coolant to the ra-
diator and then to the reservoir tank.
4. If reservoir tank (1) is dirty and it is difficult to check the
coolant level, clean it.
CHECK CLOGGING OF AIR CLEANER

k When using compressed air for cleaning, put on personal protective items such as protective eye-
glasses, gloves, dust mask, etc. to protect yourself from dirt that will fly out.
k When removing the outer element from the air cleaner body, do not forcibly pull it out, otherwise it
can be dangerous.
k When working in high places or on poor footing, be careful not to fall because of the reaction when
pulling out the outer element.
40-46 PC210LCI-11
If air cleaner clogging monitor on monitor panel lights up, clean

the air cleaner element.
REMARK
• Do not clean the element until the air cleaner clogging mon-
itor on the monitor panel lights up. If you clean the element
frequently before the air cleaner clogging monitor lights up
on the monitor panel, the true performance of the air clean-
er is not used and the filtration efficiency deteriorates.
• Inspection, cleaning or servicing while the engine is running
allows entry of dusts and can damage the engine since
dusts attached to the element drop into the inner cylinder
element more frequently during the cleaning process. Be
sure to clean after stopping the engine.
OUTER ELEMENT - CLEAN

• Before and after cleaning, be careful not to leave or store the element being exposed to the direct sunlight.
• When the outer element is cleaned 6 times or used for 1 year, replace it. When replacing it, replace the
inner element at the same time.
• Even when the number of cleanings of the outer element is 6 times or less, it must be replaced along with
the inner element if air cleaner clogging monitor lights up prematurely after cleaning.
1. Open side cover on the rear left of the machine, remove
hook (2) (4 places), and remove cover (3).
2. When removing outer element (5), hold it and pull it out

while gently moving it up and down, right and left.
NOTICE
• Never remove inner element (6). If it is removed,
dirt will enter and can cause an engine trouble.
• Do not use tools like a screwdriver.
• After removing outer element (5), check that the in-
ner element is not disengaged or inclined. If it is in-
clined, push it into the end straight with the hand.
3. After removing outer element (5), cover inner element (6)
with a clean cloth or tape to protect from dusts.
4. Wipe off dusts in inside and on cover (3) of air cleaner body (7) by using a clean cloth or brush.
NOTICE
Do not hit the element or bump it against nearby things when cleaning it.
PC210LCI-11 40-47
5. Remove any dirt or dust that is accumulated on vacuator

valve (4) installed to cover (3).
6. Blow dry compressed air (Max. 0.2 MPa {2.1 kg/cm2} )

from the inside of the outer element along the pleats.
7. Then blow it from outside along the pleats, and finally blow it from the inside again.
After clearing the element, throw light on its inside by using
a light bulb to check it. If it has a small hole or thin part, re-
place it.
8. Remove the cover of cloth or tape attached to inner ele-
ment (6).
9. Check the seal of the cleaned or new element for adhesion
of dusts and oil and wipe them off, if any.
REMARK
• Do not use an element or O-ring that has been in serv-
ice for a year since trying to use them after cleaning
most probably induces troubles.
• Do not use the element if its pleats or gasket or seal
are damaged.
10. Push the outer element straight into the air cleaner body
with your hands while moving it up and down, right and
left.
When installing the air cleaner element, direct its bottom
(C) (having no hole) toward cover (3).
REMARK
If they are installed in the opposite direction, serious trou-
bles including damage on the air cleaner elements and en-
gine may occur.
40-48 PC210LCI-11
11. Install cover (3) according to the following procedure.

1) Align cover (3) with the element.
Install cover (3) so that vacuator (4) faces down.
2) Lock the tip of hook (2) on the protrusion of the air

cleaner body.
• Install hooks (2) in the diagonal positions (top and
bottom, or right and left), and lock them.
• After installing cover (3), check that there is no
clearance between the air cleaner body and cover
(3). If any, install the cover again.
12. Peel off a seal after cleaning the element each time.
ELEMENTS - REPLACE
1. Referring to “CLEANING OF OUTER ELEMENT”, remove
outer element (5).
PC210LCI-11 40-49
2. Remove inner element (6), and immediately install new in-

ner element (6) to air cleaner body (7).
REMARK
Do not clean and reuse the inner element. When replacing
the outer element, replace the inner element with new one
at the same time.
When installing the air cleaner element, direct its bottom
(B) (having no hole) toward cover (3).
REMARK
• If they are installed in the opposite direction, serious
troubles including damage on the air cleaner elements
and engine may occur.
• If the outer element and cover are installed when the
inner element is not securely installed, the outer ele-
ment can be damaged. Be sure to install it securely.
3. Push the outer element straight into the air cleaner body with your hands while moving it up and down, right
and left.
When installing the air cleaner element, direct its bottom (C) (having no hole) toward cover (3).
REMARK
If they are installed in the opposite direction, serious troubles including damage on the air cleaner elements
and engine may occur.
4. Replace O-ring (8) of cover (3) with a new one.
5. Referring to “CLEANING OF OUTER ELEMENT”, install
cover (3).
6. Replace seal (9) of cover (3) with a new one.
CHECK HYDRAULIC OIL LEVEL

k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
40-50 PC210LCI-11
1. Set the work equipment in the posture as shown in the fol-

lowing figure and, after stopping the engine, check the oil
level and add new oil if necessary.
If the work equipment posture is not as shown in the fol-
lowing figure, start the engine, fully retract the cylinder
rods for arm and bucket at engine low idle. Then lower the
boom until bucket teeth touch the ground, then stop the
engine.
2. Turn the starting switch to ON position within 15 seconds

from the engine stop and operate control levers (work
equipment and travel) to the travel end in each direction to
release internal pressure.
3. Open the cover on the right side of the machine, and

check the oil level through the sight gauge (G). If it is be-
tween line H and L, it is appropriate.
NOTICE
• If the oil level is below line L, add oil through oil fil-
ter port (F).
• Do not add oil above the H line since it can damage
the hydraulic circuit or allow spurt of oil.
• If oil is added above line H, stop the engine, wait
until the hydraulic oil cools down, discharge ex-
cess oil from drain plug (P) under the suction tube.
Since the oil level varies according to the oil temperature, use the followings as a guide.
• Before operation (oil temperature: 10 to 30 °C), the oil level should be at the medium between lines H
and L.
• During normal operation (oil temperature: 50 to 80 °C), the oil level should be near H mark.
CHECK HYDRAULIC OIL STRAINER

PC210LCI-11 40-51
1. Stop the engine and remove oil filler cap (F) of the hydraul-
ic tank to release the internal pressure.
NOTICE
When removing the cover, it may jump out under the
reaction force of spring. Loosen bolts evenly while
holding cover down, and remove it.
2. Remove the bolts, and remove cover (1).

3. Pull out the top of rod (3) upward and remove spring (2)
and strainer (4).
4. Remove any dirt stuck to strainer (4), then wash it in flush-
ing oil. If strainer (4) is damaged, replace it with a new
one.
5. Insert and set strainer (4) in projected portion (5) of the
tank.
6. Install the bolts while pressing down spring (2) with the
projection at the bottom of cover (1).
Tighten the mounting bolts.
CHECK HYDRAULIC FILTER

1. Set the work equipment in the posture on a level and firm
ground as shown in the following figure, and stop the en-
gine.
2. Remove oil filler cap (F) of the hydraulic tank to release

the internal pressure.
NOTICE
When removing the cover, it may jump out under the
reaction force of spring. Loosen bolts evenly while
holding cover down, and remove it.
40-52 PC210LCI-11
3. Remove the bolts, and remove cover (1).

4. Remove spring (2), valve (3) and strainer (4), and then re-
move element (5).
NOTICE
• Check the bottom of the filter case for dirt or other
material, and remove any if found.
• At this time, take extreme care that the dirt does
not fall into the hydraulic tank.
5. Clean the removed parts by using cleaning oil.
6. Install new element (5).
7. Place strainer (4), valve (3) and spring (2) onto the element.
8. Set cover (1) and install it with the mounting bolts while pressing it by hand.
9. Tighten the mounting bolts.
10. Install oil filler cap (F).
11. To bleed air, run the engine at low idle speed for 10 minutes.
12. Stop the engine.
CHECK OIL LEVEL IN SWING MACHINERY CASE

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn injury.
Accordingly, wait until all parts have cooled down before starting the work.
1. Remove dipstick (G) and wipe off oil on it with a cloth.
2. Insert dipstick (G) fully into guide (F).
3. Pull out dipstick (G) and check the oil level. If the oil level
is between marks (H) and (L) on the dipstick, it is appropri-
ate.
4. If the oil level is below mark (L) on dipstick (G), add oil
through oil filler port (F).
PC210LCI-11 40-53
5. If the oil level is above mark (H) of dipstick (G), loosen

drain valve (P) and drain the excess oil.
When draining the oil, place an oil container under drain
valve (P).
6. After checking the oil level and adding oil, install dipstick
(G) and oil filler cap.
CHECK OIL LEVEL IN DAMPER CASE

k When checking the oil level, place the machine on a level ground, wait at least 30 minutes after stop-
ping the engine, and check.
2. Remove plug (G) and check the oil level. If it is near the
bottom line of the plug hole, it is appropriate.
If it is not, remove plug (F), and add the oil until it reaches
to the bottom of plug (G) through oil filler port (F).
REMARK
If the oil level is too high, it may cause overheating. Drain
oil until it becomes specified level.
3. Install plug (G) and plug (F).
4. Close the side cover.
CHECK OIL LEVEL IN FINAL DRIVE CASE

k Since the oil may spurt out due to internal pressure, rotate the plug gradually from its side to release
the internal pressure and then remove it carefully.
• Refill capacity (each of right and left): 5.0 ℓ
• Prepare a hex wrench for the work.
40-54 PC210LCI-11
1. Set the TOP mark at the top, and the line running on TOP
mark and plug (P) perpendicular to the ground.
2. Place the oil container to receive oil under plug (P).
3. Remove plugs (P) and (F) by using the hex wrench, and
drain oil.
Check for damages on O-ring attached to the plugs. Re-
place it if necessary.
4. Tighten plug (P).
5. Refill oil through plug (F) hole.
6. If oil flows out of the plug (F) hole, install the plug (F).
3 Tightening torque of plugs (P) and (F): :
68.6 ± 9.8 Nm 7 ± 1 kgm
NOTICE
There are 2 plugs (F). For refilling, use the one which
is easier for refilling and inner gear is not seen
through.
BLEED AIR FROM FUEL SYSTEM

For the bleeding air from the fuel system, see “TESTING AND ADJUSTING”, “BLEED AIR FROM FUEL SYS-
TEM”.
BLEED AIR FROM HYDRAULIC SYSTEM

For bleeding air from the hydraulic system, see “TESTING AND ADJUSTING”, “BLEED AIR FROM HYDRAUL-
IC CIRCUIT”.
ELECTRICAL EQUIPMENT - CHECK METHOD

Check of battery terminal for looseness and corrosion
1. Open the battery cover.
2. Check the battery cable terminals for looseness and corrosion.
Check of alternator terminal for looseness and corrosion
3. Check the alternator terminals B, E, and R for open circuit, looseness and corrosion.
Check of starting motor terminal for looseness and corrosion
4. Check the starting motor terminals B and C for open circuit, looseness and corrosion.
Check of battery voltage (with engine stopped)
5. Check the battery voltage by using the battery tester while the engine is stopped.
Check of battery electrolyte level
6. Check before operating the machine.
k Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it
will 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.
PC210LCI-11 40-55
REMARK
• Do not add the electrolyte to the battery exceeding UPPER LEVEL line. If the electrolyte level is too
high, it may leak and cause damage to the paint surface or corrode other parts.
• To avoid freezing, add the purified water (such as a commercial battery fluid) before starting the work in
the next day.
• When checking the electrolyte level through the side face of the battery
1) Clean around the electrolyte level lines with a wet
cloth, and check that the electrolyte level is be-
tween the UPPER LEVEL (U.L.) and LOWER
LEVEL (L.L.) lines.
k Do not clean the battery with a dry cloth
since static electricity may cause an explo-
sion.
2) If the electrolyte level is below the center between
the UPPER LEVEL (U.L.) and LOWER LEVEL
(L.L.) lines, remove cap and add purified water
(example: commercially available battery fluid) to
the UPPER LEVEL (U.L.) line immediately.
3) After adding the purified water, tighten the cap securely.
NOTICE
If purified water is added to above the UPPER LEVEL (U.L.) line, use a syringe to lower the
level to the UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (so-
dium bicarbonate), then flush it away with a large amount of water.
• When electrolyte level cannot be checked through the side face of the battery
1) Remove caps from the top of battery. (described
before)
2) Look into the fluid filler port (3) and check the
electrolyte level. If the electrolyte does not reach
the sleeve (4), always add the purified water (e.g.
commercially available replenishment water for a
battery) so that the level reaches the bottom of
the sleeve (UPPER LEVEL line).
• (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
• (B) Low: Since the electrolyte level does not reach the sleeve bottom, the shape of the elec-
trode plates will appear straight.
3) After adding fluid, tighten cap.
NOTICE
If purified water is added to above the UPPER LEVEL (U.L.) line, use a syringe to lower the
level to the UPPER LEVEL (U.L.) line. Neutralize the removed fluid with baking soda (so-
dium bicarbonate), then flush it away with a large amount of water.
Check of wiring harness for discoloration, burn and cover peeling
7. Check the wiring harness and cables for discoloration and burn.
k 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.
40-56 PC210LCI-11
Check for coming off of wiring harness clamp and sagging of wiring harness
8. Check wiring harness for sagging and looseness due to
coming off of harness clamp
REMARK
In particular, carefully check the wiring harness around the
hot and movable parts. If removed from the clamp, secure
it with the clamp.
Check of grounding
9. Check the connecting state of each ground terminal.
• Check the mounting bolts and nuts for looseness.
• Check the contact face between the ground terminal
(1) and mounting place of machine body for sticking of
the insulator such as foreign material, etc.
Battery ground cable is shown in the figure as an ex-
ample.
• For the position of each ground, see “CONNECTORS
LIST AND LAYOUT”.
Check of connector for looseness and lock for damage

10. Check the connection of male and female connectors by
pulling them by hand.
REMARK
If the connection is loose, secure it.
11. Check the connectors for unlocking, and check the lock
and connector housing for cracking.
12. Check fixing screw (L) of engine controller (1) for loose-
ness.
REMARK
Use a hexagonal wrench with 5 mm width across flats.
Check of connector pin for corrosion, bends and deformation

13. Disconnect the connectors, and check their pins for corrosion, bending, sinking than other pins, and exten-
sion of female pins.
• If pins are defective, repair or replace them.
PC210LCI-11 40-57
• 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)
Check of connector for entering of water and foreign material
14. Disconnect the connectors, and check them for entering of
water or foreign material inside the connector.
NOTICE
If there is entering of water or foreign material inside
connector, 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.
• Wipe and remove any foreign material inside connec-

tor with a cloth or others, and blow the air to clean the
connector.
Check of wiring harness for open or short circuit

15. Check the connection (crimped part) between connector
pins and wiring harness.
If it is open as shown as (A), repair or replace the wiring
harness or connector.
16. Visually check wiring harnesses for peeling of harness
covers and the pins for contact with adjacent pins due to
defective crimping.
40-58 PC210LCI-11
Check of fuse for blowing out and corrosion

17. When replacing a fuse, be sure to turn off the power (turn the starting switch to OFF position) and turn the
battery disconnect switch to OFF position.
• 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.
• For the location of each fuse, see “FUSE LOCATION TABLE”.
Check of alternator voltage (when engine speed is medium or higher)
19. Connect the positive (+) lead of the multimeter to alternator terminal (B) and connect the negative (-) lead to
the chassis ground.
20. Start the engine and warm it up, and measure the voltage while running the engine at a medium or a higher
speed.
REMARK
If the voltage is abnormal, repair or replace the alternator.
Check of battery relay operation sound
21. Open the side cover on the left side of the machine.
22. Turn the starting switch to ON and OFF positions, and check whether the battery relay operation sound is
heard or not.
• If the operation sound is not heard, check the related circuit. For details, see “ENGINE DOES NOT
START (ENGINE DOES NOT CRANK)” in E mode.
• If the relating circuit is normal, replace the battery relay.
PC210LCI-11 40-59
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 40 TROUBLESHOOTING
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM

• When performing troubleshooting of connectors connected to each controller, expose the applicable con-
nector part according to the following procedure.
• For connectors whose lock method is special, perform disconnection and connection.
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR

1. Remove cover (1) mounting screws (3 pieces).
REMARK
One of screws (3 pieces) is covered with cap (2).
2. Disconnect connector P31 of sunlight sensor (3), and re-
move cover (1).
3. Remove bolt (4) and remove duct (5).
4. Insert or connect troubleshooting T-adapters to connectors

CM01 (7), CM02 (8), CM03 (9), and CM04 (10) on ma-
chine monitor (6).
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER

1. Remove the undercover.
2. Remove bolt (1).
3. Insert or connect the T-adapters for troubleshooting to con-
nectors ECM J1 and ECM J2 of the engine controller.
REMARK
• Since the connectors are fixed with the screws, loosen
those screws before disconnecting the connector.
• When returning them, fix them by tightening the screws
to the specified torque.
40-60 PC210LCI-11
40 TROUBLESHOOTING PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
3 Screw:
3±1 Nm {0.3±0.1 kgm}
PREPARATION FOR TROUBLESHOOTING OF ICT SENSOR CONTROLLER

1. Slide the operator's seat and seat stand to the forward end.
2. Remove the bolts (2 pieces) and the plastic bolt (1), and
remove the box (2).
3. Disconnect the connectors M04 (3), M13B (4) and M13A

(5).
4. Remove the bolts (5 pieces), and remove the cover (6).

PC210LCI-11 40-61
7. Connect the T-adapter for troubleshooting to the connec-

tors CS01 (10), CS02 (11) and CS03 (12) of the ICT sen-
sor controller (9).
PREPARATION FOR TROUBLESHOOTING OF WORK EQUIPMENT CONTROL-

LER
2. Remove the bolts (2 pieces) and the plastic bolt (1), and
remove the box (2).
3. Disconnect the connectors M04 (3), M13B (4) and M13A

(5).
40-62 PC210LCI-11

7. Disconnect the connectors CW01 (10), CW02 (11) and

CW03 (12) of the work equipment controller (9), and con-
nect the T-adapter for troubleshooting.
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL

2. Disconnect the connectors CK01 and CK02 from the
KOMTRAX terminal assembly (1) by referring to DISAS-
SEMBLY AND ASSEMBLY, “REMOVE AND INSTALL
KOMTRAX TERMINAL ASSEMBLY”.
3. Connect T-adapter for troubleshooting to connectors CK01
and CK02.
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER

See DISSSEMBLY AND ASSEMBLY, “METHOD FOR REMOV-
ING KomVision CONTROLLER ASSEMBLY”, and connect the
adapter for troubleshooting to connectors CA01 (2) and CA02
(3) of KomVision controller (1).
PC210LCI-11 40-63
PREPARATION FOR TROUBLESHOOTING OF CONTROL BOX

2. Remove the clamp.
3. Insert or connect the T-adapter for troubleshooting to con-
nectors CX01, CX02 and CX03 of the control box (A).
PREPARATION FOR TROUBLESHOOTING OF GNSS RECIVER

4. Remove the bolts (5 pieces), and remove the box (3).
5. Disconnect the hose at the bottom of the box (3).
6. Connect the T-adapter for troubleshooting to connectors

CG01 and CG02 of the GNSS receiver (4).
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPE-

CIAL LOCK
REMARK
For details of each connector type, see “CONNECTORS LIST AND LAYOUT”.
• Precautions for disconnection of connectors
The direction of the lock for connector may be changed to-
ward the difficult direction for unlocking depending on the
position where the sensor is screwed in.
In such a case, use the needle nose pliers with curved tip
(commercially available) [1], then the lock can be canceled
easily.
Since the lock clicks when it is released, listen to the
sound and disconnect the connectors.
• Precautions for connecting connectors
When connecting connectors, pay attention not to connect
the connectors reverse.
40-64 PC210LCI-11
FRAMATOME-3 and FRAMATOME-2 connectors

• Disconnecting and connecting of connectors
Disconnect them in the order of (a) to (c) and connect
them in the order of (d) to (f) as shown in the figure.
Disconnection: (a) Slide the lever, (b) unlock, and (c) dis-
connect the connectors.
Connection: (d) Connect the connectors, (e) engage the
lock, and (f) slide the lever.
SUMITOMO-3 connector
Disconnect them in the order of (a) to (b) and connect
them in the order of (c) to (d) as shown in the figure.
Disconnection: (a) Unlock and (b) disconnect the connec-
tors.
Connection: (c) Connect the connectors, and (d) engage
the lock.
BOSCH connector and BDK connector

them in the order of (c) to (d) as shown in the drawing.
tors.
the lock.
AMP-3 connector
tors.
the lock.
PC210LCI-11 40-65
PACKARD-2 connector
tors.
the lock.
TYCO connector
• Procedure for disconnecting connectors
1. Insert the small flat-head screwdriver [1] to the yellow
lock part (2) of TYCO connector (1).
2. Turn the small minus screwdriver [1] clockwise and
counterclockwise to slowly release the lock part (2).
3. After the yellow lock portion (2) is somewhat released,

lightly hold lock portion (2), and release the lock com-
pletely.
REMARK
Take care not to apply excessive force when releasing
the lock so that yellow lock portion (2) does not comes
off.
4. Remove connector (1) after the lock part (2) is com-

pletely released.
40-66 PC210LCI-11
• Procedure of connecting connectors

1. Connect connector (1) straight as matching the faces
to be engaged when the yellow lock part (2) is com-
pletely unlocked.
2. Connect connector (1) gradually as pushing yellow

lock part (2).
FRAMATOME-24 connector
• Procedure for disconnecting connectors
1. Slide down lock (red) (L1).
2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.
PC210LCI-11 40-67
3. Hold the connector body (black portions on the male

and female sides) and disconnect the connector.
• Procedure of connecting connectors
AMP-81 and DELPHE-96 connectors

Disconnect them in the order of (a) to (c) and connect
them in the order of (d) to (f) as shown in the drawing.
Disconnection: (a) Unlock, (b) slide the lever, and (c) dis-
connect the connectors.
Connection: (d) Position the connectors, (e) slide the lever,
and (f) engage the lock.
40-68 PC210LCI-11
40 TROUBLESHOOTING PROCEDURE FOR TESTING AND TROUBLESHOOTING
PROCEDURE FOR TESTING AND TROUBLESHOOTING

Classification of troubleshooting
Mode Content
Display of code Troubleshooting by failure code
E mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
1. Check whether the action level and failure code are displayed on the machine monitor.
REMARK
If multiple failure codes are displayed simultaneously, all the codes are displayed repeatedly in order. Write
down all the codes.
If action level and failure code are displayed on the standard screen of the machine monitor, perform the
troubleshooting for the corresponding “Display of code” corresponding to the displayed failure code.
2. Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor.
1) Press1, 2, and 3 in this order in the panel switch sec-
tion on the standard screen while pressing numeric
key 4.
2) On the service menu screen, press switch F3 twice in

the panel switch section, and select “03 Abnormality
Record”.
3) Press switch F6 in the panel switch section to enter

the selection, and go to the “Abnormality Record”
screen.
PC210LCI-11 40-69
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING

the selection, and go to the “Mechanical Systems ab-
normality record” screen.
5) Press switch F3 in the panel switch section to see if
the next failure code is displayed and write down all of
the failure codes.
REMARK
A failure code of the mechanical system cannot be de-
leted.
6) Press switch F5 in the panel switch section to return
the screen to the “Troubleshooting Record” screen.
7) On the service menu screen, press switch F3 twice in
the panel switch section, and select “03 Abnormality
Record”.

the selection, and go to the “Abnormality Record”
screen.

the selection, and go to the “Electrical Sys Abnormali-
ty Record” screen.
10) Press switch F3 in the panel switch section to see if
the next failure code is displayed and write down all of
the failure codes.
REMARK
"E" on the left of a failure code indicates that the fail-
ure code is “active” (the failure remains or restoration
to normal has not been checked). A failure code hav-
ing no "E" on its left is a “non-active” one. Since it dis-
appears at the clear step mode, be sure to write it
down.
• When failure code is recorded
Perform the troubleshooting in “Display of code” corresponding to the failure code.
40-70 PC210LCI-11
40 TROUBLESHOOTING PROCEDURE FOR TESTING AND TROUBLESHOOTING
REMARK
• When electrical system failure codes are recorded, delete all of the codes, and then reproduce
them to see if the abnormality still remains.
• The mechanical system failure codes cannot be deleted.
• If abnormality related to the air conditioner is displayed in the electrical system abnormality record,
perform “Check by self-diagnosis function” in “Air conditioner”.
• When no failure code is in abnormality record
• A failure that the machine cannot detect by self-diagnosis may be in the electrical, hydraulic, or
mechanical system. Check the symptom of failure again.
• Select related phenomena from the “Table of symptom of failure and troubleshooting No.”, and
perform troubleshooting corresponding to those phenomena in “E-mode”, “H-mode”, and “S-
mode”.
3. After repairing the failure, clear all the failure codes in the electrical system abnormality record.
1) While pressing numeric key 4 in the panel switch section, press [1], [2] and [3] in this order to go to the
“Clear mode”.
2) Press switch F2 in the panel switch section.
3) Press switch F6 in the panel switch section to clear all of the failure codes.
the screen to the “Electrical Sys Abnormality Record”
screen. Check if failure codes are still displayed and
write down, if any.
the screen to the “Abnormality Record” screen.
6) Note down all of the failure codes.
REMARK
Similarly in the electrical system abnormality record,
"E" on the left of a failure code indicates that the fail-
ure code is “active” (the failure remains or restoration
to normal has not been checked).
7) Press switch F2 in the panel switch section to clear all of the failure codes. Check if “Failure” is still
displayed, and write down all the failures, if any.
8) Press switch F5 in the panel switch section to return the screen to the “Abnormality Record” screen.
PC210LCI-11 40-71
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS

Troubleshooting
No. Symptom of failure
Index
User code, failure code
Action level is displayed on the machine monitor. Press function switch [F5] to
1
display the "Occurred error list".
Perform troubleshooting
2 Failure code is displayed on mechanical system abnormality record. for failure code
3 Failure code is displayed on electrical system abnormality record.
Symptom related to engine
4 Engine does not start. E-1, S-1
5 Engine does not crank when starting switch is turned to “START” position. S-1,E-1
6 Engine cranks but no exhaust smoke comes out. S-2
7 Fuel is being injected but engine does not start. S-3
8 Engine startability is poor. S-4
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 becomes clogged soon). S-9
14 Oil consumption is excessive. S-10
15 Oil becomes contaminated early. 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 mixes into engine oil. S-15
20 Water mixes into engine oil (milky). 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 Air cannot be bled from fuel circuit S-20
25 Automatic regeneration is executed frequently. S-21
26 Active regeneration takes time S-22
27 White smoke is exhausted during active regeneration S-23
28 AdBlue/DEF consumption is excessive S-24
29 There is unusual smell (irritating odor) S-25
30 Foreign materials enter AdBlue/DEF (AdBlue/DEF increases) S-26
31 Manual preheating system does not work. E-2
32 Automatic preheating system does not work. E-3
33 While preheating is working, preheating monitor does not light up. E-4
34 Automatic warm-up system does not operate (in cold season). E-25
40-72 PC210LCI-11
40 TROUBLESHOOTING SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
Troubleshooting
Index
When auto-deceleration switch is operated, auto-deceleration monitor does not
35 E-26
light up or does not go off.
Auto-deceleration function does not operate or is not canceled while lever is oper-
36 E-27
ated.
Symptom related to work equipment, and swing and travel system
37 None of work equipment, swing or travel works. E-35, H-1
38 Any of work equipment, swing, and travel cannot be locked. E-36
39 All of work equipment, swing and travel operation lacks speed and power. H-2
40 Engine speed drops significantly or engine stalls. H-5, S-6
Working mode selection screen is not displayed while working mode selector
41 E-28
switch is operated.
Setting of engine and hydraulic pump is not changed while working mode is
42 E-29
changed.
43 Fine control performance or response is poor. H-3
44 Unusual noise is heard from around hydraulic pump. H-4
Symptom related to work equipment
45 Boom speed or power is low. H-6
46 Arm speed or power is low. H-7
47 Bucket speed or power is low. H-8
48 Bucket does not move with auto tilt function. H-9,E-37
49 Work equipment does not move in single operation. H-10
50 Hydraulic drift of boom is large. H-11
51 Hydraulic drift of arm is large. H-12
52 Hydraulic drift of bucket is large. H-13
When single work equipment is relieved hydraulically, other work equipment
53 H-14
moves.
54 Time lag of work equipment is large. H-15
55 One-touch power maximizing function does not operate. H-16,E-40
56 One-touch power maximizing function cannot be canceled. E-41
57 Attachment hydraulic circuit cannot be changed while attachment is installed. H-17,E-58
58 Oil flow in attachment circuit cannot be changed. H-18
Symptom related to combined operation
In combined operation of work equipment, equipment having heavier load moves
59 H-19
slower.
60 In combined operation of swing and travel, travel speed drops largely. H-20
61 In combined operations of swing and boom RAISE, boom rising speed is low H-21
Symptom related to travel
62 Machine does not travel straight. H-22
63 Machine is not steered well or steering power is low. H-23
64 Travel speed is slow. H-24
PC210LCI-11 40-73
Troubleshooting
Index
65 One of tracks does not run. H-25
66 Travel speed does not change, or travel speed is too slow or fast. H-26,E-31,E-32
67 Alarm does not sound during travel. E-42
68 Alarm does not stop sounding while machine is stopped. E-43
Symptom related to swing
69 Upper structure does not swing to the right or left. H-27
70 Upper structure swing only to the right or left. H-28
71 Swing acceleration or swing speed is low in both directions (right and left). H-29
Swing acceleration performance is poor or swing speed is slow in only one direc-
72 H-30
tion.
73 Upper structure overruns excessively when it stops swinging (both right and left). H-31
74 Upper structure overruns excessively when it stops swinging (either right or left). H-32
75 Shock is large when upper structure stops swinging. H-33
76 Large unusual noise is heard when upper structure stops swinging. H-34
77 Swing drift on a slope is large while swing parking brake is applied. H-35
78 Swing drift on a slope is large while swing parking brake is released. H-36
Upper structure does not swing while swing parking brake cancel switch is set to
79 E-38
CANCEL position.
Swing brake does not operate while swing parking brake cancel switch is set to
80 E-39
NORMAL position.
Symptom related to machine monitor
81 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
82 E-6
level monitor lights up in yellow.
When starting switch is turned to ON position (with engine stopped), radiator cool-
83 E-7
ant level monitor lights up in yellow.
84 Engine coolant temperature monitor lights up in white while engine is running. E-8
85 Hydraulic oil temperature monitor lights up in white while engine is running. E-9
86 Charge level monitor lights up while engine is running. E-11
87 Fuel level monitor lights up in red while engine is running. E-12
88 Air cleaner clogging monitor lights up in yellow while engine is running. E-10
89 Engine coolant temperature monitor lights up in red while engine is running. E-14
90 Engine oil pressure monitor lights up in red while engine is running E-15
91 Hydraulic oil temperature monitor lights up in red while engine is running. E-16
92 Fuel gauge display does not move from minimum or maximum. E-17
93 Fuel gauge indicates incorrect amount (indicates neither full nor empty) E-18
Engine coolant temperature gauge display does not move from minimum or maxi-
94 E-19
mum.
Engine coolant temperature gauge indicates incorrect temperature (indicates nei-
95 E-20
ther full nor empty)
40-74 PC210LCI-11
40 TROUBLESHOOTING SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
Troubleshooting
Index
96 Hydraulic oil temperature gauge does not move from minimum or maximum. E-21
Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither
97 E-22
full nor empty)
98 Some areas of machine monitor screen are not displayed. E-23
99 Function switch does not work. E-24
100 Alarm buzzer does not stop sounding. E-32
101 Service meter is not displayed while starting switch is in OFF position. E-33
102 Service mode cannot be selected. E-34
103 Horn does not sound. E-44
104 Horn does not stop sounding. E-45
Wiper monitor does not light up, or does not go out, while wiper switch is operat-
105 E-46
ed.
106 Wiper does not operate while wiper switch is operated. E-47
107 Window washer does not operate while window washer switch is operated. E-48
“PROCEDURE FOR
Air conditioner does not operate normally (including failure codes related to air TESTING AND TROU-
108
conditioner). BLESHOOTING” in
Chapter 80
109 Lever operation signal is not displayed correctly with monitoring function. E-49 to E-57
Others
110 KOMTRAX system does not operate normally. E-59
111 Fan speed is abnormal (too high or low, or fan does not rotate) H-37
112 Unusual noise is heard from around fan. H-38
Symptom related to ICT
CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES “GPS
113 E-60
receiver not connected!” AND “Slope sensor not connected!”
114 CONTROL BOX DISPLAYS THE MESSAGES“GPS receiver not connected!” E-61
115 CONTROL BOX DISPLAYS THE MESSAGE “Waiting for radio link...” E-62
116 CONTROL BOX DISPLAYS THE MESSAGE “Tilt Bucket Sensor Offline!” E-63
117 CONTROL BOX DISPLAYS THE MESSAGE “Waiting for satellites...” E-64
118 CONTROL BOX DISPLAYS THE MESSAGE “Komatsu controller not connected!” E-65
119 CONTROL BOX DISPLAYS THE MESSAGE “Sensors are invalid” E-66
120 CONTROL BOX DISPLAYS THE MESSAGE “Waiting to initialize....” E-67
121 CONTROL BOX DISPLAYS THE MESSAGE “Initializing...” E-68
122 CONTROL BOX DISPLAYS THE MESSAGE “No GPS Localization...” E-69
123 CONTROL BOX DISPLAYS THE MESSAGE “Low precisions...” E-70
124 CONTROL BOX DISPLAYS “Out of design area...” E-71
125 CONTROL BOX DISPLAYS “Avoidance Area Breach”... E-72
126 CONTROL BOX CAN NOT BE TURNED ON E-73
PC210LCI-11 40-75
Troubleshooting
Index
CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL
127 E-74
SCREEN
128 CONTROL BOX DOES NOT DISPLAY HYDRAULIC EXCAVATOR IMAGE E-75
129 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE E-76
130 CONTROL BOX TOUCH PANEL DOES NOT RESPOND E-77
131 CONTROL BOX TOUCH PANEL IS INACCURATE E-78
WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE
132 E-79
VALUE IS DIFFERENT FROM ACTUAL MACHINE
SEMI-AUTO MODE IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS
133 E-80
PRESSED
AUTO GRADE ASSIST CONTROL DOES NOT OPERATE WHILE SEMI-AUTO
134 E-81
MODE IS DISPLAYED
AUTO STOP CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS
135 E-82
DISPLAYED
BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN
136 E-83
AUTO GRADE ASSIST FUNCTION IS ON
BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE
137 E-84
WHEN AUTO STOP CONTROL FUNCTION IS ON
FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TAR-
138 E-85
GET
139 NG OCCURS VERY OFTEN IN IMU CALIBRATION DIAGNOSIS E-86
140 CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK E-87
141 CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK E-88
40-76 PC210LCI-11
40 TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE

The following types of information are described in the troubleshooting list and related circuit diagram. Fully un-
derstand the description and perform troubleshooting.
Action level Failure code
Display on Display on Failure name displayed on "Abnormality Record" screen of the machine
Failure
machine machine monitor
monitor monitor
Details 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 the ma-
controller chine monitor or controller
Problem on A problem that is displayed as a failure on the lift truck as a result of an action (shown above) that is
machine performed by the machine monitor or controller.
Related in-
Information related to the occurred failure and its troubleshooting
formation
No. Cause Procedure, measuring location, criteria, and remarks

1 Defective --- Contents of description
Open or short circuit • Procedure
2
in wiring harness • Measuring point
Open circuit in wiring "Between A and B" denotes measuring values such as voltage and resistance
harness between A and B.
3 "Between A and ground" means the measurement of voltage, resistance or
(wire breakage or de-
others between place A and the place which has a continuity with chassis
fective contact of con-
nector) frame such as unpainted hexagonal head bolt or bolt hole which has no rust,
etc.
Ground fault in wiring
• Criteria to judge probable causes (standard value), remarks
harness
4 How to use troubleshooting sheet
(contact with ground
circuit) • Perform troubleshooting procedures in following order.
5 Hot short circuit • 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, pro-
ceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been corrected.
Failures in wiring harness
• Open circuit
When the wiring and the internal circuit of the connector are not connected
with each other, and there is no continuity
Short circuit in wiring
6 • Ground fault
harness
A wiring harness not to be connected to the GND (ground) circuit comes into
contact with the GND (ground) circuit or chassis accidentally.
• Hot short circuit
A wiring harness not to be connected to the power circuit comes into contact
with the power circuit accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with one of
another wire. (Defective insulation in connector or others)
PC210LCI-11 40-77
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 TROUBLESHOOTING
No. Cause Procedure, measuring location, criteria, and remarks

Precautions for troubleshooting
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless otherwise speci-
fied.
• When (male) or (female) is not indicated with a connector number, disconnect
the connector, and insert T-adapters to both sides of male and female.
• When (male) or (female) is indicated with a connector number, disconnect the
connector, and connect T-adapter to the indicated side of connector.
7 Defective controller • "Male and female" means male and female of connector pins, not connector
housings.
• Male and female of connector pins and housing in DT series, etc, are opposite
to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wiring harness indicated first.
• Connect the negative (-) lead to a pin or wiring harness indicated second.
Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting
• The circuit diagram contains the connector No., pin No., and connector color related to the failure.
• “/” is used in the connector No. in the following 2 cases.
• Abbreviation (3 letters in many cases)
Example) T/C: Abbreviation for Torque Converter
• Male side and female side have different connector Nos.
Example) BREAK OUT / E24
• The circuit diagram contains the destination or source of the branch line in a wiring harness.
• Arrow (↔): Approximate installation position on the 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.
40-78 PC210LCI-11
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HAR-
40 TROUBLESHOOTING NESS OF PRESSURE SENSOR SYSTEM
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS

OF PRESSURE SENSOR SYSTEM
The pressure sensor consists of not only resistance but also electrical circuit such as amplifier. Accordingly, it
has dispersion and polarity, and care must be taken for measurement.
Object failure code
• CA123: Charge Air Pressure Sensor Low Error
• CA451: Common Rail Pressure Sensor High Error
Procedure
1. Measure the resistance of pressure sensor unit and write down the value.
1) Disconnect connector (1) of the pressure sensor, and connect socket (2) to sensor side.
2) Measure the resistance R1 and R2 between each pins.
• If the polarity of multimeter is reversed, the measurement value may vary. Set the polarity of multi-
meter probe to match with the one of pressure sensor, and measure the resistance.
• If the measured value is infinite, reverse the polarity and measure again. If a value is measured,
take it as a measured value.
• The measured value may vary, so measure several times.
The reason of this may be that the electric charge is stored in the sensor. Measure several times in
step 1 and 2 as well. In step 3, judge if the wiring harness is broken taking this dispersion into con-
sideration.
2. Connect the wiring harness between pressure sensor and engine controller, and measure the resistance of
pressure sensor, and then write down the value.
1) 5V power supply for pressure sensor provides power to other sensors as well. Accordingly, disconnect
connector of other sensors. (*)
2) With target pressure sensor connected, disconnect connector (3) at the engine controller side, and
connect T-adapter (4) to the wiring harness side.
3) Connect T-box (5) to T-adapter (4), and measure the resistance R1' and R2' between each pins.
3. Judgment for open circuit
If there is a difference of 10 times or more between resistance R1 and R2 measured in step 1 and resist-
ance R1' and R2' measured in step 2, you may judge that "the wiring harness has an open circuit".
PC210LCI-11 40-79
NESS OF PRESSURE SENSOR SYSTEM 40 TROUBLESHOOTING
List of pressure sensor measuring locations and reference values

Measured value of resist-
Measuring location at sen-
Sensor ance inside sensor (refer- Remarks
sor pin
ence value)
Charge pressure sen- R2: Between (2) and (4) Approximately 100 Ω Common sensor is used for 107
sor R1: Between (1) and (4) Approximately 200 Ω and 114 engine.
R2: Between (3) and (1) Approximately 23 kΩ

Common rail pres- By reversing polarity, the resistance
sure sensor R1: Between (1) (+) and becomes infinite.
Approximately 10 MΩ
(2) (-)
*: Other sensor connectors to be disconnected when measuring R2' are as follows. (Refer related circuit dia-
gram for each code.)
• When measuring R2' of charge pressure sensor (CA123):
Connectors for ambient pressure sensor, CAM sensor, and crankcase pressure sensor
• When measuring R2' of common rail pressure sensor (CA451)
Since 5V power supply is only for this sensor, there is no connector to be disconnected.
Measurement record (For measuring locations, see related circuit diagram of each code.)
Sensor and wiring harness
Sensor unit
Sensor Measured value (Measuring location at en- Measured value
(Measuring location at
gine controller wiring har-
sensor pin)
ness)
R2': Between (78) and
R2: Between (2) and (4)
Charge pressure sen- (54) (*)
sor R1': Between (45) and
(54)
40-80 PC210LCI-11
40 TROUBLESHOOTING NESS OF PRESSURE SENSOR SYSTEM
R2': Between (82) and

Common rail pres- (58) (*)
sure sensor R1: Between (1) (+) and R1': Between (58) (+) and
(2) (-) (42) (-)
PC210LCI-11 40-81
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING
CONNECTOR LIST AND LAYOUT

Connector No. Connector type Number of pins Location Address
40 SWP 2 Cab rear light (if equipped) AA-9
A13 DT 2 Intermediate connector (boom working lamp) F-9
A13A DT 2 Intermediate connector AU-8
A15 DT 2 Intermediate connector (rear working lamp) H-9
A40 DT 4 Intermediate connector (camera) (rearview cam-
H-9
era)
A41 DT 4 Intermediate connector (camera 2) H-1
A42 DT 4 Intermediate connector (camera 3) I-1
A45 - 4 Camera 1 K-8
A46 DT 4 Camera 2 (if equipped) -
A71 DT-A 8 Intermediate connector I-1
A72 DT-B 8 Intermediate connector I-1
A75 DT 12 Intermediate connector BH-3
A76 DT 4 Camera 2 (if equipped) F-9
A77 DT 4 Camera 3 (if equipped) F-9
A78 DT 4 Camera 4 (if equipped) L-6
A79 DT 8 Intermediate connector G-9
A80 DT 4 Intermediate connector L-4
AA06 DT-A 12 Intermediate connector AS-9
AA12 M 2 Intermediate connector BC-9
AA14 DT-B 12 Intermediate connector AV-6
AA15 S090/187 22 Intermediate connector BH-7
AA16 S090 22 Intermediate connector BG-9
AA17 S090 22 Intermediate connector BC-9
AA18 M/SWP 6 Intermediate connector BH-8
AA19 M 8 Intermediate connector BD-1
AA20 N 1 Intermediate connector AS-2
AA21 N 1 Intermediate connector AT-3
AA22 S090/187 22 Intermediate connector BD-9
AA24 DT 6 Intermediate connector F-9
AA25 TNC 1 Intermediate connector BN-6
AA26 TNC 1 External radio device antenna BN-8
AA27 SUMITOMO 22 Intermediate connector BC-9
AA28 AMPHENOL 39 Intermediate connector AW-4
AA29 DT 6 Bucket tilt cylinder stroke sensor (North America BO-2
specification: Option)
AA30 DT 6 Intermediate connector (North America specifi- BP-2
cation: Option)
40-82 PC210LCI-11
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

AA31 DT 6 Intermediate connector D-2
AA32 DT 6 Intermediate connector AU-2
AA36 TNC 1 Site link BN-7
AA37 TNC 1 Network modem antenna BM-8
AA39 TNC 1 Built-in radio device antenna BN-8
AA45 DT 6 Intermediate connector (North America specifi- BO-6
cation: Option)
AB Terminal 1 Alternator (terminal B) AG-9
AC01 YAZAKI 10 Air conditioner unit X-4
AC02 SUMITOMO 4 Air conditioner unit W-2
AC03 X 1 Air conditioner compressor solenoid clutch L-8
AE Terminal 1 Alternator (terminal E) AH-9
AMB.AIR FRAMATOME 3 Ambient pressure sensor AF-3
PRESSURE
AR Terminal 1 Alternator (terminal R) AI-9
BOOST SUMITOMO 4 Boost pressure and boost temperature sensor AJ-3
PRESS &
TEMPERA-
TURE
CA01 AMP 81 KomVision controller U-1
CA02 AMP 40 KomVision controller U-1
CAM SENSOR FRAMATOME 3 Cam (BKUP) speed sensor AE-1
CG01 DRC 40 GNSS controller BE-9
CG02 DRC 40 GNSS controller BC-9
CK01 70 18 KOMTRAX terminal X-7
CK02 70 12 KOMTRAX terminal X-6
CM01 70 18 Machine monitor M-5
CM02 70 12 Machine monitor M-5
CM04 70 8 Machine monitor (for camera connection) M-6
COOLANT DELPHI 2 Coolant temperature sensor AE-4
TEMP
CP01 AMP 81 Pump controller N-7
CP02 AMP 40 Pump controller O-7
CRANK SEN- FRAMATOME 3 Crankshaft (NE) speed sensor AG-1
SOR
CS01 DRC 24 ICT controller BG-2
CS02 DRC 40 ICT controller BF-2
CS03 DRC 40 ICT controller BE-1
CW01 DRC 24 Work equipment controller BF-2
PC210LCI-11 40-83

CW02 DRC 40 Work equipment controller BE-1
CW03 DRC 40 Work equipment controller BE-1
CX01 TYCO 26 ICT monitor AW-7
CX02 TYCO 26 ICT monitor AW-6
CX03 LTW-RJ45 8 ICT monitor AY-8
D01 SWP 8 Diode array X-8
D02 SWP 8 Diode array W-8
DX01 DT 4 Load dump module BA-1
E01 Terminal 1 Electric intake air heater (ribbon heater) K-8
E08 DT 2 Intermediate connector (alternator) AH-6
E10 DT 1 Intermediate connector (starting motor) AH-5
E25 FRAMATOME 4 KDPF pressure sensor G-9
E26 TYCO 4 KDPF temperature sensor H-9
E31 TYCO 4 Turbocharger outlet NOx sensor G-9
E32 TYCO 4 Ammonia sensor I-9
E34 TYCO 4 SCR temperature sensor I-9
E36 TYCO 4 SCR outlet NOx sensor I-9
ECM-J1 DELPHI 96 Engine controller AI-1
ECM-J2 DELPHI 96 Engine controller L-7
EGR-SOL DT 2 EGR valve solenoid AI-1
F01 - 20 Fuse box V-9
F02 - 20 Fuse box V-9
F04 L 2 Fusible link (65A) B-8
F05 L 2 Fusible link (65A) B-9
F11 Terminal 1 Slow-blow fuse B-9
F12 Terminal 1 Slow-blow fuse B-8
F13 - 10 Fuse box BH-9
FUEL RAIL BOSCH 3 Common rail pressure sensor AJ-4
PRESS
H08 M 4 Intermediate connector (speaker) X-4, AD-4
H09 M 8 Intermediate connector (cab roof) X-5, AD-4
H10 M 6 Intermediate connector (if equipped) -
H14 90 22 Intermediate connector (R.H. console wiring har- S-9
ness)
H15 90 22 Intermediate connector (R.H. console wiring har- S-9
ness)
H16 90 22 Intermediate connector (L.H. console wiring har- X-4
ness)
40-84 PC210LCI-11

H28 DT 6 Intermediate connector BC-1
INJECTOR DT 4 Intermediate connector (injector #1 and #2) AG-4
CYL.1&2
INJECTOR DT 4 Intermediate connector (injector #3 and #4) AI-1
CYL.3&4
INJECTOR DT 4 Intermediate connector (injector #5 and #6) AJ-4
CYL.5&6
INJECTOR#1 - 2 Injector #1 AF-4
INJECTOR #2 - 2 Injector #2 AG-5
INJECTOR #3 - 2 Injector #3 AH-5
INJECTOR #4 - 2 Injector #4 AH-5
INJECTOR #5 - 2 Injector #5 AI-5
INJECTOR #6 - 2 Injector #6 AI-5
INLET ME- BOSCH 2 Supply pump solenoid (IMV) AJ-3
TERING
VALVE
INTER-CON- DT 12 Intermediate connector AH-5
NECT
J01 - 20 Junction connector (black) W-2
J02 - 20 Junction connector (pink) V-1
J03 - 20 Junction connector (orange) V-1
J04 - 20 Junction connector (pink) X-2
J05 - 20 Junction connector (pink) X-3
J06 - 20 Junction connector (orange) X-6
J07 - 20 Junction connector (black) V-2
J08 - 20 Junction connector (gray) BH-5
J09 - 20 Junction connector (orange) BH-4
K01 M 2 Resister for PC-EPC valve X-7
K02 DT 3 CAN terminating resistor L-6
K10 DT 3 CAN terminating resistor E-9
K11 DT 3 CAN terminating resistor L-6
K12 DT 2 Fan clutch resistor A-7
KB01 DT 2 Boom resistor BH-5
KB02 DT 2 LED resistor AY-1
L01 DT 2 Working lamp (boom) B-7
L01A DT 2 Working lamp (boom left) (if equipped) B-6
L01B DT 2 Working lamp (boom right) (if equipped) B-6
L02 DT 2 Working lamp (right) B-4
L03 M 2 Room lamp S-9, AD-7
L05 SWP 2 Revolving lamp (if equipped) AC-9
L09 DT 2 Working lamp (rear) (if equipped) L-7
PC210LCI-11 40-85

L10A DT 2 Working lamp connector (if equipped) D-2
L11A DT 2 Working lamp connector (if equipped) D-3
L14 DT 2 Left headlamp E-1
L19 - 2 System operating lamp A-8
L42 DT 2 Maintenance light F-9
M01 PA 9 Radio T-1
M01A - 3 Radio (AUX jack) U-1
M01B M 3 Intermediate connector (AUX) X-6, AD-4
M01C - 3 AUX (external audio input) jack AD-5
M02 M 2 Speaker (L.H.) AD-8
M03 M 2 Speaker (R.H.) AB-9
M04 YAZAKI 2 Cigarette lighter X-8
M05 M 6 Wiper motor (front window) M-3
M06 YAZAKI 2 Washer motor (front window) B-4
M07 90 2 Horn (high sound) D-3
M08 90 2 Horn (bass tone) D-3
M09 M 2 Optional power supply (1) X-3
M10 M 2 Optional power supply (2) X-4
M11 DT 6 DC/DC converter X-5
M13A M 2 12 V socket X-6
M13B M 2 12 V socket X-6
M14 DT 2 Travel alarm A-1
M15 DT 4 Intermediate connector F-1
M15A DT 4 Lower wiper (if equipped) E-1
M16 DT 6 Fan clutch K-8
M1A M 2 Optional power supply (continuous power sup- X-3
ply)
M22 DTM-A 12 R.H. knob switch N-7
M23 DTM-B 12 L.H. knob switch S-1
M35 DT 2 Heated seat V-1
M36 DT 2 Air suspension seat U-1
M40 X 2 Intermediate connector Z-9
M40A SWP 2 Cab head light (L.H.) (if equipped) Z-9
M40A SWP 2 Cab head light (R.H.) (if equipped) Y-8
M40B SWP 2 Cab head light (L.H.) (if equipped) Z-8
M40B SWP 2 Cab head light (R.H.) (if equipped) Y-8
M41 X 2 Intermediate connector Y-8
M50 AMP 8 Cassette player (if equipped) AC-9
M51 AMP 8 Cassette player (if equipped) AC-9
40-86 PC210LCI-11

M61 DT 16 ROTOTILT relay box X-4
M62 DT 4 ROTOTILT quick coupler switch S-9
M63 DT 6 ROTOTILT D-2
M64 DT 6 Auto-greasing (if equipped) T-9
M65 DT 6 Auto-greasing pump (if equipped) B-5
M66 DT 2 Heated mirror G-1
M86 DT 2 Fuel refill pump B-6
M98 DT 2 Fuel refill pump main power supply B-5
M99 DT 2 Fuel refill pump starting switch B-5
MA06 M 2 Audio guide speaker BH-5
MA07 PA 9 Audio guide amplifier BH-7
MA08 MOLEX 3 Audio guide amplifier BH-8
MA10 DTM 12 Network modem BG-9
MA11 DTM 12 Network modem BF-9
MA12 DT 2 Radio device power supply BG-9
MA13 SUMITOMO 22 Intermediate connector BH-6
MB02 TYCO 12 AdBlue/DEF pump C-7
MB03 BDK 2 AdBlue/DEF injector I-9
MB04 DT 2 AdBlue/DEF line heater (suction and return side) D-8
MB06A DT 2 AdBlue/DEF line heater (force-fed low pressure D-8
side)
MB06B DT 2 AdBlue/DEF line heater (force-fed high pressure C-8
side)
N08 DT 12 Service connector W-8
NA08 DT-B 8 IMU sensor G-1
NA09 - 9 Radio device communication port BF-9
NA11 N 1 GNSS controller BE-9
NA12 N 1 GNSS controller BD-9
NA13 N 1 Main GNSS antenna AT-8
NA14 N 1 AUX GNSS antenna AR-9
NA15 TNC 1 GNSS controller BN-5
NA17 DT 4 Intermediate connector BF-9
OEM CON- FRAMATOME 24 Intermediate connector (engine wiring harness) AH-1
NECTION/E24
OIL PRES- FRAMATOME 2 Engine oil pressure switch (low pressure) AE-2
SURE
SWITCH
P01 AMP 3 Bucket CURL pressure sensor B-3
P01A AMP 3 Bucket CURL pressure sensor C-3
P02 AMP 3 Boom LOWER pressure sensor B-3
PC210LCI-11 40-87

P02A AMP 3 Boom LOWER pressure sensor C-3
P03 AMP 3 Swing (LEFT) pressure sensor A-3
P04 AMP 3 Arm IN pressure sensor C-3
P04A AMP 3 Arm IN pressure sensor C-2
P05 AMP 3 Bucket DUMP pressure sensor B-3
P05A AMP 3 Bucket DUMP pressure sensor C-2
P06 AMP 3 Boom RAISE pressure sensor A-3
P06A AMP 3 Boom RAISE pressure sensor C-2
P07 AMP 3 Swing (RIGHT) pressure sensor C-3
P08 AMP 3 Arm OUT pressure sensor B-3
P08A AMP 3 Arm OUT pressure sensor C-2
P09 AMP 3 Travel forward left pressure sensor E-1
P10 AMP 3 Travel reverse left pressure sensor F-1
P11 AMP 3 Travel forward right pressure sensor E-1
P12 AMP 3 Travel reverse right pressure sensor E-1
P13 X 2 Intermediate connector (attachment PPC oil D-1
pressure switch)
P14 X 2 Right attachment control pedal forward tilt PPC D-1
oil pressure switch
P15 X 2 Right attachment control pedal backward tilt D-1
PPC oil pressure switch
P16 X 2 Left attachment control pedal forward tilt PPC oil F-1
pressure switch
P17 S090 2 Air conditioner Hi/Lo pressure switch J-1
P18 90 2 Air conditioner outside air temperature sensor L-5
P20 M 3 Fuel dial P-8
P21 DT 2 Fuel level sensor D-8
P22 DT 2 Hydraulic oil temperature sensor I-9
P23 DT 2 Air cleaner clogging sensor B-7
P24 X 2 Radiator coolant level sensor J-1
P25 AMP 3 Front pump pressure sensor L-6
P26 AMP 3 Rear pump pressure sensor L-7
P27 DT 3 Front pump swash plate sensor H-9
P28 DT 3 Rear pump swash plate sensor G-9
P30 X 2 Left attachment control pedal backward tilt PPC F-1
oil pressure switch
P31 50 2 Sunlight sensor N-6
P44 DT 2 Engine oil level sensor AH-6
P46 AMP 3 Overload sensor D-2
P47 DT 2 Water-in-fuel sensor G-9
40-88 PC210LCI-11

P49 AMP 3 Service pressure sensor H-9
P50 DT 2 Quick coupler pressure switch E-9
P54 DT 2 Fuel pump limit switch E-9
P55 FRAMATOME 4 MAF sensor L-5
P57 FRAMATOME 3 Crankcase pressure sensor J-9
P63 DT 4 AdBlue/DEF tank sensor D-8
P65 PACKARD 2 Ambient temperature sensor L-4
P66 PACKARD 2 Engine room temperature sensor H-9
PA01 AMP 6 Boom cylinder stroke sensor AQ-1
PA02 AMP 6 Arm cylinder stroke sensor AN-7
PA03 AMP 6 Bucket cylinder stroke sensor AK-4
PA10 AMP 3 PPC pressure sensor C-2
PA14 DT 4 Boom spool stroke sensor L-5
PA15 DT 4 Arm spool stroke sensor L-5
PA18 DT 6 Boom cylinder stroke reset encoder C-8
PA19 DT 6 Arm cylinder stroke reset encoder AU-2
PA20 AMP 3 Attachment R.H. PPC pressure sensor J-9
PA21 AMP 3 Attachment L.H. PPC pressure sensor L-8
R01 Terminal 1 Battery relay (terminal E) A-9
R02 Terminal 1 Battery relay (terminal BR) A-9
R03 Terminal 1 Battery relay (terminal M) A-9
R04 Terminal 1 Battery relay (terminal B) A-9
R05 Relay 5 Deck light relay U-9
R06 Relay 5 Starting motor cut-off relay (PPC lock) X-7
R07 Relay 5 Starting motor cut-off relay (personal code) X-8
R08 Relay 6 Horn relay V-9
R10 Relay 6 Rear light relay U-9
R11 Relay 6 Cab rear light relay (if equipped) U-9
R12 Relay 6 Cab light relay V-9
R15 Terminal 1 Coil circuit (ribbon heater relay) B-9
R16A Terminal 1 Contact circuit (ribbon heater relay) B-8
R16B Terminal 1 Contact circuit (ribbon heater relay) B-9
R17 DT 2 Safety relay (terminals S and R) B-9
R18 Relay 5 Auto preheater relay U-9
R21 Relay 5 Compressor clutch relay X-7
R25 Relay 5 Lower wiper relay T-9
R28 Terminal 1 Starting motor safety relay (terminal C) A-8
R29 Terminal 1 Starting motor safety relay (terminal B) A-8
R35 Relay 5 Additional auto/manual switch relay BC-1
PC210LCI-11 40-89

R40 Relay 5 Quick coupler relay T-9
R43 Relay 5 BR cut-off relay W-8
R47 Relay 5 Fuel refill pump relay T-9
R48 Relay 5 PPC lock relay W-8
R51 Relay 5 Boom RAISE cut-off relay BH-6
R52 DT-D 12 Sensor power supply relay L-3
R53A DT-C 12 AdBlue/DEF line heater relay K-1
R53B DT 6 AdBlue/DEF line heater relay J-1
S01 - 6 Starting switch P-8
S02 SWP 6 Light switch Q-8
S04 SWP 6 Swing lock switch Q-8
S07 SWP 6 Revolving lamp switch (if equipped) Q-9
S08 SWP 6 Lower wiper switch BA-9
S11 Y090 2 L.H. knob switch (one-touch power maximizing) S-1
S14 M 3 PPC oil pressure lock switch T-1
S18 SWP 6 Engine shutdown secondary switch S-1
S19 DT 2 Seat belt monitor switch R-9
S21 - 12 Pump secondary drive switch N-9
S22 - 6 Swing parking brake cancel switch M-9
S23 - 3 Lock lever auto lock release switch M-9
S23 - 12 Boom secondary drive switch BH-7
S25 90 20 Intermediate connector (secondary switch) O-9
S30 S 8 Model selection connector V-9
S31 M 6 Model selection connector BH-3
S41 SWP 6 Additional light switch BA-9
S42 BRITAX 10 Quick coupler drive switch BB-9
S44 SWP 6 Heated mirror switch BB-9
S54 DT 12 Intermediate connector BH-6
S55 - 8 MG-MC switch AX-8
SB Terminal 1 Starting motor (terminal B) AG-5
SC Terminal 1 Starting motor (terminal C) AF-5
SEGR DT 3 EGR stroke sensor AJ-5
SVGT DT 3 VGT stroke sensor AI-5
T01 Terminal 1 Floor frame ground W-2
T02 Terminal 1 Cab ground X-5, AD-3
T04 Terminal 1 Revolving frame ground G-1
T05 Terminal 1 Revolving frame ground G-1
T06 Terminal 1 Revolving frame ground H-1
40-90 PC210LCI-11

T08 Terminal 1 Revolving frame ground K-1
T11 Terminal 1 Engine body ground AI-6
T12 Terminal 1 Engine controller ground L-6
T13 Terminal 1 Revolving frame ground K-2
T14 Terminal 1 Revolving frame ground L-2
TA01 Terminal 1 Revolving frame ground G-1
TA02 Terminal 1 Ground AX-7
TERMINATOR DT 3 CAN terminating resistor AI-1
PORT
TOOL PORT DT 3 CAN terminating resistor AG-1
V01 DT 2 PPC lock solenoid valve B-1
V02 DT 2 2-stage relief solenoid valve A-1
V03 DT 2 Swing parking brake solenoid valve C-1
V04 DT 2 Travel Hi-Lo solenoid valve A-1
V05 DT 2 Travel junction solenoid valve C-1
V06 DT 2 Swing cut off solenoid valve A-1
V07 DT 2 ATT return selector solenoid valve (if equipped) A-2
V11 DT 2 F-PC-EPC valve J-9
V12 DT 2 R-PC-EPC valve H-9
V19 DT 2 LS-EPC valve J-9
V23 DT 2 Merge-divider EPC valve (main) L-7
V24 DT 2 Merge-divider EPC valve (LS) L-7
V25 DT 2 Variable back pressure solenoid valve A-2
V30 DT 2 Attachment flow adjustment EPC valve D-1
V40 DT 2 Quick coupler actuation solenoid valve E-9
V41 DT 2 AdBlue/DEF tank heater valve L-5
V91 DT 2 1st service L.H. EPC valve K-9
V92 DT 2 1st service R.H. EPC valve L-8
V93 DT 2 2nd service L.H. EPC valve (if equipped) K-8
V94 DT 2 2nd service R.H. EPC valve (if equipped) K-8
VA01 DT 2 Arm IN PPC pressure reducing EPC valve A-3
VA03 DT 2 Boom LOWER PPC pressure reducing EPC A-3
valve
VA04 DT 2 Bucket CURL PPC pressure reducing EPC valve A-3
VA05 DT 2 Arm OUT PPC pressure reducing EPC valve A-2
VA07 DT 2 Boom RAISE PPC pressure reducing EPC valve A-2
VA08 DT 2 Bucket DUMP PPC pressure reducing EPC A-2
valve
PC210LCI-11 40-91

VA09 DT 2 Boom RAISE EPC valve A-2
VGT-REV AMP 3 VGT speed sensor AH-5
VGT-SOL DT 2 VGT actuator AJ-2
W03 X 2 Rear limit switch AB-9
40-92 PC210LCI-11
1/12
PC210LCI-11 40-93
2/12
40-94 PC210LCI-11
3/12
PC210LCI-11 40-95
4/12
40-96 PC210LCI-11
5/12
PC210LCI-11 40-97
6/12
40-98 PC210LCI-11
7/12
PC210LCI-11 40-99
8/12
40-100 PC210LCI-11
9/12
PC210LCI-11 40-101
10/12
40-102 PC210LCI-11
11/12
PC210LCI-11 40-103
12/12 (North America specification: Option)
40-104 PC210LCI-11
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION
CONNECTOR CONTACT IDENTIFICATION

(Rev.2014.11)
The male or female is for pin, and the convex or concave is for fitting (housing).
PC210LCI-11 40-105
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING
40-106 PC210LCI-11
PC210LCI-11 40-107
40-108 PC210LCI-11
PC210LCI-11 40-109
40-110 PC210LCI-11
PC210LCI-11 40-111
40-112 PC210LCI-11
PC210LCI-11 40-113
40-114 PC210LCI-11
PC210LCI-11 40-115
40-116 PC210LCI-11
PC210LCI-11 40-117
40-118 PC210LCI-11
PC210LCI-11 40-119
40-120 PC210LCI-11
PC210LCI-11 40-121
40-122 PC210LCI-11
PC210LCI-11 40-123
40-124 PC210LCI-11
PC210LCI-11 40-125
40-126 PC210LCI-11
PC210LCI-11 40-127
40-128 PC210LCI-11
PC210LCI-11 40-129
40-130 PC210LCI-11
PC210LCI-11 40-131
40-132 PC210LCI-11
PC210LCI-11 40-133
40-134 PC210LCI-11
PC210LCI-11 40-135
40-136 PC210LCI-11
PC210LCI-11 40-137
40-138 PC210LCI-11
PC210LCI-11 40-139
40-140 PC210LCI-11
PC210LCI-11 40-141
40-142 PC210LCI-11
*:No.1 and 7 pin in male pin side do not exist.
PC210LCI-11 40-143
40-144 PC210LCI-11
40 TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

(Rev.2014.11)
The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of har-
ness checker assemblies are listed in the horizontal line.
T-adapter kit
Number of pins
Non-kit part
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 No. Part name ID marking
799-601-2600 T-box (for ECONO) 21 ● ● ● ● ●

799-601-3100 T-box (for MS) 37 ●
799-601-3200 T-box (for MS) 37 ●
799-601-3380 Plate for MS (14 pins) ●
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P ●
799-601-3470 Case ●
799-601-2710 Adapter for MIC 5 MIC-5P ● ● ●
799-601-2720 Adapter for MIC 13 MIC-13P ● ● ●
799-601-2730 Adapter for MIC 17 MIC-17P ● ● ● ● ● ●
799-601-2740 Adapter for MIC 21 MIC-21P ● ● ● ● ● ●
799-601-2950 Adapter for MIC 9 MIC-9P ● ● ● ●
ECONO
799-601-2750 Adapter for ECONO 2 ● ●
2P
ECONO
3P
ECONO
4P
ECONO
8P
ECONO
12P
799-601-2810 Adapter for DLI 8 DLI-8P ● ●
PC210LCI-11 40-145
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40 TROUBLESHOOTING
T-adapter kit
Number of pins
Non-kit part
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
Extension cable (ECONO ECONO

799-601-2840 12 ● ● ●
type) 12P
799-601-2850 Case ●
799-601-4350 T-box (for DRC60, ECONO) 60 ●
799-601-4360 Case ●
799-601-7010 Adapter for X (T-adapter) 1 ● ●
799-601-7020 Adapter for X 2 X2P ● ● ● ●
799-601-7030 Adapter for X 3 X3P ● ● ● ●
799-601-7040 Adapter for X 4 X4P ● ● ● ●
799-601-7050 Adapter for SWP 6 SW6P ● ● ●
799-601-7060 Adapter for SWP 8 SW8P ● ● ●
799-601-7310 Adapter for SWP 12 SW12P ●
799-601-7070 Adapter for SWP 14 SW14P ● ●
799-601-7320 Adapter for SWP 16 SW16P ●
799-601-7080 Adapter for M (T-adapter) 1 ● ●
799-601-7090 Adapter for M 2 M2P ● ● ● ●
799-601-7110 Adapter for M 3 M3P ● ● ● ●
799-601-7120 Adapter for M 4 M4P ● ● ● ●
799-601-7130 Adapter for M 6 M6P ● ● ● ●
799-601-7340 Adapter for M 8 M8P ●
799-601-7140 Adapter for S 8 S8P ● ● ● ●
799-601-7150 Adapter for S (white) 10 S10P ● ● ● ●
799-601-7160 Adapter for S (blue) 12 S12P ● ● ●
799-601-7170 Adapter for S (blue) 16 S16P ● ● ● ●
799-601-7330 Adapter for S (white) 16 S16PW ●
799-601-7350 Adapter for S (white) 12 S12PW ●
799-601-7180 Adapter for AMP040 8 A8P ●
799-601-7190 Adapter for AMP040 12 A12P ● ●
799-601-7210 Adapter for AMP040 16 A16P ● ● ● ●
799-601-7220 Adapter for AMP040 20 A20P ● ● ● ●
799-601-7230 Short socket adapter for X 2 ● ● ● ●
799-601-7240 Case ● ●
799-601-7270 Case ●
799-601-7510 Adapter for 070 10 07-10 ●
799-601-7520 Adapter for 070 12 07-12 ●
40-146 PC210LCI-11
T-adapter kit
Number of pins
Non-kit part
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
799-601-7530 Adapter for 070 14 07-14 ●

799-601-7540 Adapter for 070 18 07-18 ●
799-601-7550 Adapter for 070 20 07-20 ●
799-601-7360 Adapter for relay 5 REL-5P ●
799-601-7370 Adapter for relay 6 REL-6P ●
799-601-7380 Adapter for JFC 2 ●
799-601-9010 Adapter for DTM 2 DTM2 ● ●
799-601-9020 Adapter for DT 2 DT2 ● ● ● ●
799-601-9030 Adapter for DT 3 DT3 ● ●
799-601-9040 Adapter for DT 4 DT4 ● ● ● ●
799-601-9050 Adapter for DT 6 DT6 ● ●
799-601-9060 Adapter for DT (gray) 8 DT8GR ● ●
799-601-9070 Adapter for DT (black) 8 DT8B ● ●
799-601-9080 Adapter for DT (green) 8 DT8G ● ●
799-601-9090 Adapter for DT (brown) 8 DT8BR ● ●
799-601-9110 Adapter for DT (gray) 12 DT12GR ● ●
799-601-9120 Adapter for DT (black) 12 DT12B ● ●
799-601-9130 Adapter for DT (green) 12 DT12G ● ●
799-601-9140 Adapter for DT (brown) 12 DT12BR ● ●
799-601-9210 Adapter for HD30-18 8 D18-8 ● ●
799-601-9220 Adapter for HD30-18 14 D18-14 ● ●
799-601-9230 Adapter for HD30-18 20 D18-20 ● ●
799-601-9240 Adapter for HD30-18 21 D18-21 ● ●
799-601-9250 Adapter for HD30-24 9 D24-9 ● ●
799-601-9260 Adapter for HD30-24 16 D24-16 ● ●
799-601-9270 Adapter for HD30-24 21 D24-21 ● ●
799-601-9280 Adapter for HD30-24 23 D24-23 ● ●
799-601-9290 Adapter for HD30-24 31 D24-31 ● ●
799-601-9310 Plate for HD30 (24 pins) ● ● ●
799-601-9320 T-box (for ECONO) 24 ● ● ●
799-601-9330 Case ●
799-601-9340 Case ●
799-601-9350 Adapter for DRC 40 DRC-40 ●
799-601-9360 Adapter for DRC 24 DRC-24 ●
799-601-9410* Socket for engine (CRI-T2) 2 G ●
PC210LCI-11 40-147
T-adapter kit
Number of pins
Non-kit part
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
Adapter for engine (CRI-T2)

Adapter PFUEL for engine
799-601-9420 3 A3 ● ●
(CRI-T3)
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* Socket PCV for engine (CRI- 2 P ● ●
T3)
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 ●
795-799-5520* Socket for engine (HPI-T2) 2 S ●
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C ● ●
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* Socket TIM for engine (CRI- 2 A ● ●
T3)
795-799-5460 Cable for engine (HPI-T2) 3 ●
Adapter PIM for engine (140-
799-601-4110 4 ITT3N ● ●
T3)
Adapter NE, CAM for engine
799-601-4130 3 FCIN ● ●
(CRI-T3)
799-601-4140 3 FCIG ● ●
Ambient pressure
Adapter POIL for engine
799-601-4150 3 FCIB ● ●
(CRI-T3)
799-601-4160 2 4160 ● ●
Oil pressure switch
Adapter PEVA for engine
799-601-4180 3 4180 ● ●
(CRI-T3)
799-601-4190* 3 1, 2, 3L ● ●
Common rail pressure
799-601-4230* 4 1, 2, 3, 4C ● ●
Intake pressure/temperature
Socket PAMB for engine
799-601-4240* 3 1, 2, 3A ● ●
(CRI-T3)
Socket PIM for engine (CRI-
799-601-4250* 3 1, 2, 3B ● ●
T3)
Socket G for engine (CRI-
799-601-4330* 3 1, 2, 3G ● ●
T3)
40-148 PC210LCI-11
T-adapter kit
Number of pins
Non-kit part
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

799-601-4340* 2 2, PA ● ●
Pump actuator
799-601-4380* (95) 4 1, 2, 3, 4T ●
Intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 ● ●
799-601-4211 Adapter for controller (ENG) 50 DRC50 ●
799-601-4220 Adapter for controller (ENG) 60 DRC60 ●
Socket for controller
799-601-4390* 60 ●
(95ENG)
799-601-4280* Box for controller (PUMP) 121 ●
799-601-9720 Adapter for controller (HST) 16 HST16A ●
799-601-9710 Adapter for controller (HST) 16 HST16B ●
799-601-9730 Adapter for controller (HST) 26 HST26A ●
Multi-adapter for DT 2 to 4, 2, 3,
799-601-9890 ●
DTM 2 pins 4
799-902-9600 T-adapter for ICT control box 26 ●
799-902-9700 T-box 26 ●
*: These are not T-adapters but sockets.
PC210LCI-11 40-149
T-adapter kit
Number of pins
Non-kit part
799-A65-4600
799-902-9300
799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 ●

799-902-9310 Adapter for control box 19 799-902-9310 ●
799-902-9320 Adapter for IMU 10 799-902-9320 ●
799-902-9330 Adapter for MS cylinder 6 799-902-9330 ●
KDPF differential pressure sensor
799T-601-4611 4 799T-601-4611 ●
short socket adapter
KDPF outlet pressure sensor short
799T-601-4670 4 799T-601-4670 ●
socket adapter
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 ●
40-150 PC210LCI-11
40 TROUBLESHOOTING FUSE LOCATION TABLE
FUSE LOCATION TABLE

• This connection table shows the devices which receive the power from the fuse box. (A switched power
supply is the power which is supplied while the starting switch is in ON position and a continuous power
supply is the power which is supplied while the starting switch is in ON and OFF positions.)
• When performing troubleshooting related to the electrical system, at first, check the fuses and fusible links
to see if the power is supplied properly.
Fuse box F01

Type of pow- Power supply Fuse Fuse ca-
Destination of power
er supply to fuse No. pacity
1 5 A Pump secondary drive switch, working lamp relay
2 30 A Solenoid valve
3 5 A PPC hydraulic lock solenoid
4 10 A Window washer, cigarette lighter
5 10 A Horn, R.H. knob switch
6 5 A Auto preheater
Fusible link
F04 (65 A) 7 10 A Revolving lamp
8 10 A Radio, speaker, and L.H. knob switch
Switched
power supply 9 10 A Rear working lamp
10 20 A Air conditioner unit
11 10 A Optional power supply (1)
Optional power supply (2), 12 A power supply, air suspension
12 30 A
seat with heater
Starting switch 13 5 A Air conditioner ECU power supply

ACC 14 5 A Key ACC signal
Fusible link
15 20 A Working lamp
F04 (65 A)
16 10 A Radio backup, room lamp, system operating lamp
17 20 A Machine monitor and pump controller
Continuous Fusible link
18 30 A Engine controller
power supply F05 (65 A)
19 5 A Air conditioner ECU backup
20 10 A Optional power supply (continuous power supply)
PC210LCI-11 40-151
FUSE LOCATION TABLE 40 TROUBLESHOOTING
Fuse box F02

1 10 A CAB front lamp (1)
2 10 A CAB rear lamp
3 10 A Lower windshield wiper
4 10 A Quick coupling
Switched Fusible link 5 15 A Refueling pump

power supply F04 (65 A) 6 10 A CAB front lamp (2)
7 10 A Optional lamp
8 20 A Auto-greasing
9 30 A OPT heater
10 10 A Spare
11 20 A Sensor power supply relay (1)
12 10 A Sensor power supply relay (2)
Continuous Fusible link
13 10 A AdBlue/DEF line heater relay (1)
power supply F05 (65 A)
14 20 A AdBlue/DEF line heater relay (2)
15 10 A KomVision controller
Fuse box F13

Continuous Fusible link 1 5 A ICT devices (1)

power supply F05 (65 A) 2 20 A ICT devices (2)
6 5 A ICT sensor (1)
Switched Fusible link 7 5 A Solenoid valve

power supply F04 (65 A) 8 20 A Solenoid valve
9 20 A Secondary drive switch
Fusible link
Connector No. Capacity Name of circuit
F04 65 A Standard power supply
F05 65 A Continuous power supply
Electric intake air heater (ribbon heater)
F11 120 A
Electric intake air heater relay (ribbon heater relay)
40-152 PC210LCI-11
40 TROUBLESHOOTING FUSE LOCATION TABLE
Fuse box F01 and F02 positions
Fuse No. of fuse box F01
Fuse box F13 position
PC210LCI-11 40-153
FUSE LOCATION TABLE 40 TROUBLESHOOTING
Locations of fusible links
When the battery cover is raised, fusible links F04, F05, and F11 are seen.
40-154 PC210LCI-11
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and
40 TROUBLESHOOTING KDOC)

KDOC)
k Since KDPF and KDOC are heated to 500 °C or above, take care not to get burn injury.
Related information
Soot accumulation amount of KCSF in KDPF is classified in 8 levels. From “Service menu” of machine monitor,
display “Diagnostic Tests” screen, and current level of accumulated soot can be checked on “Active Regenera-
tion for Service” screen.
Following failure codes are displayed corresponding to the soot accumulation level.
• If the soot accumulation level is 4 or 5, the failure code [CA2639] is displayed.
• If the soot accumulation level is 6 or 7, the failure code [CA1921] is displayed.
• If the soot accumulation level is 8, the failure code [CA1922] is displayed.
• If the soot accumulation level is 8, you need to check, clean or replace because KDPF is completely
clogged with soot.
• Manual stationary regeneration can be performed up to soot accumulation level 7, and soot in KCSF
can be burnt and removed.
• If the soot accumulation level is 4 to 7, perform the manual stationary regeneration.
Manual stationary regeneration can be performed from Active Regeneration for Service (see below) or from
operator mode.
Method of manual stationary regeneration from “Active Regeneration for Service”.
• When the soot accumulation level is 3 or below, manual stationary regeneration can be performed only
from “Active Regeneration for Service” according to the following procedure.
2. Secure the safety of the machine.
3. From “Service menu” of machine monitor, display “Diagnostic Tests” screen, open “Active Regenera-
tion for Service”, and then perform “Manual Stationary Regeneration”.
• Time required for manual stationary regeneration varies depending on soot accumulation amount in KCSF.
Rough guide is described below.
Soot accumulation level 4: Approximately 40 minutes to 1 hour
Soot accumulation level 5: Approximately 1 hour to 2 hours
• How to reset KDPF (KCSF) cleaning.
From “Service menu” of machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory Re-
set”, and perform “KDPF Cleaning” (Reset KDPF cleaning).
• How to reset KDPF (KCSF) replacing.
From “Service menu” of machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory Re-
set”, and perform “KDPF Change” (Reset KDPF change).
• If KCSF in KDPF is replaced, perform reset of “KDPF Cleaning” and reset of “KDPF Change”, and perform
Manual Stationary Regeneration from always “Active Regeneration for Service” to remove moisture from
KCSF.
• How to reset after KDOC change
From “Service menu” of the machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory
Reset”, and perform “KDOC Change” (Reset after KDOC change).
• If KDOC in KDPF is replaced, perform reset of “KDOC Change” but it is not necessary to perform manual
stationary regeneration.
In case of KCSF cleaning or change
• At 4500 h period periodical cleaning
1. Check the soot accumulation level, if it is displayed, perform “Active Regeneration for Service” until it
becomes zero.
PC210LCI-11 40-155
KDOC) 40 TROUBLESHOOTING
2. Stop the engine, wait for the piping around the engine to be cooled down, and then remove KDPF. Fur-
thermore, remove KCSF.
3. Perform cleaning of KCSF at the specified repair shop, etc. (In case of reusing removed KCSF after
cleaning)
4. Install cleaned up KCSF to the machine. (In case of reusing removed KCSF after cleaning)
5. Install alternative KCSF to the machine. (In case of changing to a new KCSF)
6. Turn the starting switch to ON position. From “Service menu” of machine monitor, display “Diagnostic
Tests” screen, open “KDPF Memory Reset”, and perform reset of “KDPF Cleaning”.
7. On “KDPF Memory Reset” screen, perform reset of “KDPF Change”.
After resetting “KDPF Change”, the changes in the parentheses are reflected. (“Soot Correction by Ash
Influence” is changed to 0 g/ℓ.)
8. Start the engine, and run it at low idle to warm up.
9. Perform “Active Regeneration for Service”.
• When breakage or damage is found in check.
1. Stop the engine, wait for the piping around the engine to be cooled down, and then remove KDPF. Fur-
thermore, remove KCSF.
2. Install alternative KCSF (new or used).
3. Turn the starting switch to ON position. From “Service menu” of machine monitor, display “Diagnostic
Tests” screen, open “KDPF Memory Reset”, and perform reset of “KDPF Cleaning”.
4. On “KDPF Memory Reset” screen, perform reset of “KDPF Change”.
5. Start the engine, and run it at low idle to warm up.
6. Perform “Active Regeneration for Service”.
• When KDPF Soot Accumulation High Error 2 [CA1922] is displayed
1. Stop the machine, and check that failure code [CA1922] is displayed on the machine monitor.
2. Check the display record of “[CA2639]: Manual Stationary Regeneration Request”, “[CA1921]: KDPF
Soot Accumulation High Error 1”, and “[CA1922]: KDPF Soot Accumulation High Error 2” on the ma-
chine monitor
3. Calculate the time between displays [CA2639] and [CA1921], and time between displays [CA1921] and
[CA1922].
• In the case that time between displays [CA2639] and [CA1921] ≧ 0.1 h, and time between dis-
plays [CA1921] and [CA1922] ≧ 0.1 h, perform item 4, replacing KCSF.
REMARK
Since the soot accumulation exceeds the limit which the regeneration can be performed, KCSF
must be replaced by removing KDPF.
• In the case that either time between displays [CA2639] and [CA1921] < 0.1 h, or time between dis-
plays [CA1921] and [CA1922] < 0.1 h, proceed to item 5, performing “Active Regeneration for
Service”.
REMARK
Actually, soot is not sedimented (equivalent to 9 g/ℓ), but accumulation condition of soot is uneven
and it makes clogging and causes increase of differential pressure. With this level of soot accumu-
lation, even if active regeneration is performed, abnormal combustion does not occur. Accordingly,
do not replace KCSF, perform “Active Regeneration for Service” to reduce soot, and continue to
use KCSF.
4. In case of KCSF change
1) Stop the engine, wait for the piping around the engine to be cooled down, and then remove KCSF.
2) Install alternative KCSF (new or used).
3) Turn the starting switch to ON position. From “Service menu” of machine monitor, display “Diag-
nostic Tests” screen, and perform reset of “KDPF Cleaning” from “KDPF Memory Reset”screen.
40-156 PC210LCI-11
40 TROUBLESHOOTING KDOC)
After resetting “KDPF Cleaning”, the changes in the parentheses is reflected. (Soot accumulation:
9 g/ℓ → 8.1 g/ℓ, action level: L04 → L03, failure code: [CA1922] → [CA1921])
4) From “Service menu” of machine monitor, display “Diagnostic Tests” screen, and perform reset of
“KDPF Change” from “KDPF Memory Reset” screen.
After resetting “KDPF Change”, the changes in the parentheses are reflected. (“Soot Correction by
Ash Influence” is changed to 0 g/ℓ.)
5) Start the engine, and run it at low idle to warm up.
6) Perform “Active Regeneration for Service”. (Active regeneration for service may continue for ap-
proximately 2 hours.)
7) Check that failure codes [CA1922], [CA1921], and [CA2639] are not displayed after finishing “Ac-
tive Regeneration for Service”.
5. In case of performing “Active Regeneration for Service”
NOTICE
When performing “Active Regeneration for Service” (KDPF does not need to be removed), do
not reset “KDPF Change”.
If “KDPF Change” is reset, “Soot Correction by Ash Influence” calculated in engine controller
becomes 0 g/ℓ, and it differs from actual ash accumulation value in KDPF.
When resetting “KDPF Change” by any chance, and “Soot Correction by Ash Influence” be-
comes 0 g/ℓ, perform TESTING AND ADJUSTING, “SET AND OPERATE MACHINE MONITOR”,
“SERVICE MODE”, “METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULA-
TION CORRECTION)”.
Check that there is no abnormality of sensor system by troubleshooting, and then perform it.
1) Start the engine and run it at low idle to warm up the engine. From “Service menu” of machine
monitor, display “Diagnostic Tests” screen, and perform reset of “KDPF Cleaning” from “KDPF
Memory Reset”screen.
After resetting “KDPF Cleaning”, the changes in the parentheses is reflected. (Soot accumulation:
9 g/ℓ → 8.1 g/ℓ, action level: L04 → L03, failure code: [CA1922] → [CA1921])
2) Perform “Active Regeneration for Service”. (Active regeneration for service may continue for ap-
proximately 2 hours.)
3) Check that failure codes [CA1922], [CA1921], and [CA2639] are not displayed after finishing “Ac-
tive Regeneration for Service”.
6. When Ash Accumulation High Error [CA5383] is displayed
If the expected cause as the results of investigation referring to failure code [CA5383] is “Ash Accumu-
lation High”, perform same contents of “At the 4500 H period periodical cleaning” in “In case of KCSF
cleaning or change” described in precautions of this chapter.
In case of KDOC cleaning or change
• When breakage or damage is found in check.
1. When damage or crack is found in KDOC, change KDOC.
2. From “Service menu” of machine monitor, display “Diagnostic Tests” screen, and perform reset of
“KDOC Change” from “KDPF Memory Reset” screen.
• When Defective Regeneration [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 exhaust gas color of the engine.
3. Stop the engine, wait for the piping around the engine to be cooled down, and remove KDOC, and then
check it for damage or crack.
4. When crack or damage is found in KDOC
1) Replace KDOC.
PC210LCI-11 40-157
KDOC) 40 TROUBLESHOOTING
5. When crack or damage is not found in KDOC

1) Clean KDOC and install it again.
3) Perform “Active Regeneration for Service” twice. (The fuel is injected during regeneration.)
REMARK
When “Active Regeneration for Service” is performed continuously, stop the engine once.
Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is retracted
(for up to 6 minutes). So when you restart engine, wait for the system operating lamp to go out
after starting switch is turned OFF, and then turn the starting switch to ON position.
4) If “[CA2637]: KDOC Face Plugging” is displayed after performing “Active Regeneration for Serv-
ice”, KDOC efficiency is decreased, so replace KDOC.
40-158 PC210LCI-11
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR
40 TROUBLESHOOTING (FOR FAILURE CODES [CA1883] AND [CA3135])
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR

FAILURE CODES [CA1883] AND [CA3135])
NOTICE
The KDPF differential pressure sensor and the KDPF outlet pressure sensor use the same connector.
Contained in kit part No. 799-A65-4600.
Short socket adapter for KDPF differential pressure used in failure code [CA1883]
PC210LCI-11 40-159
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR
(FOR FAILURE CODES [CA1883] AND [CA3135]) 40 TROUBLESHOOTING
Short socket adapter for KDPF outlet pressure used in failure code [CA3135]
40-160 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODES TABLE
FAILURE CODES TABLE

Failure Applicable Action History cate-
Failure (Displayed on screen) Remarks
code component level gory
A/C Recirculation Air Temperature Sensor Open Electrical
879AKA MON -
Circuit system
A/C Recirculation Air Temperature Sensor Short Electrical
879AKB MON -
Circuit system
Electrical
879BKA A/C Fresh Air Temperature Sensor Open Circuit MON -
system
Electrical
879BKB A/C Fresh Air Temperature Sensor Short Circuit MON -
system
Electrical
879CKA Ventilating Sensor Open Circuit MON -
system
Electrical
879CKB Ventilating Sensor Short Circuit MON -
system
Electrical
879DKZ Sunlight Sensor Open Circuit or Short Circuit MON -
system
Electrical
879EMC Ventilation Damper Malfunction MON L01
system
Electrical
879FMC Air Mix Damper Malfunction MON L01
system
Electrical
879GKX Refrigerant Pressure Input Signal Out of Range MON L01
system
Electrical
989L00 Engine Controller Lock Caution 1 MON -
system
Electrical
989M00 Engine Controller Lock Caution 2 MON -
system
Electrical
989N00 Engine Controller Lock Caution 3 MON -
system
Electrical
A1U0N3 HC Desorb Request 1 ENG L01
system
Electrical
A1U0N4 HC Desorb Request 2 ENG L03
system
Mechanical
A900FR Abrupt Engine Stop by Auto Idling Stop 3 MON L03
system
Mechanical
A900N6 Abrupt Engine Stop by Auto Idling Stop 1 MON -
system
Mechanical
A900NY Abrupt Engine Stop by Auto Idling Stop 2 MON L01
system
Mechanical
AA10NX Air Cleaner Clogging MON L01
system
Mechanical
AB00KE Charge Voltage Low MON L03
system
Manual Stationary Regeneration Request (KDOC Electrical
AQ10N3 ENG L01
Face Plugging) system
Electrical
AS00N3 Manual Stationary Regeneration Request (SCR) ENG L01
system
PC210LCI-11 40-161
FAILURE CODES TABLE 40 TROUBLESHOOTING

Electrical
AS00R2 Warning 2 (SCR Device Abnormality) ENG L01
system
Electrical
AS00R3 Inducement 1 (SCR Device Abnormality) ENG L03
system
Electrical
system
Electrical
system
Electrical
AS00R6 Temporary Recovery of Inducement ENG -
system
Electrical
AS00ZK AdBlue/DEF Level Low Error 5 ENG L04
system
Mechanical
AS10KM AdBlue/DEF Injector Overheat Warning MON L01
system
Mechanical
AS10NR AdBlue/DEF Injector High Temperature Warning ENG —
system
Mechanical
AS10NT AdBlue/DEF Injector Overheat Caution MON -
system
Mechanical
B@BAZG Engine Oil Pressure Low ENG L03
system
Mechanical
B@BAZK Eng Oil Level Low MON L01
system
Mechanical
B@BCNS Eng Water Overheat ENG L02
system
Mechanical
B@BCZK Eng Water Level Low MON L01
system
Mechanical
B@HANS Hyd Oil Overheat ENG L02
system
Electrical
CA115 Engine NE and Backup Speed Sensor Error ENG L04
system
Electrical
CA122 Charge Air Pressure Sensor High Error ENG L03
system
Electrical
CA123 Charge Air Pressure Sensor Low Error ENG L03
system
Electrical
CA131 Throttle Sensor High Error ENG L03
system
Electrical
CA132 Throttle Sensor Low Error ENG L03
system
Electrical
CA144 Coolant Temperature Sensor High Error ENG L01
system
Electrical
CA145 Coolant Temperature Sensor Low Error ENG L01
system
Electrical
CA153 Charge Air Temperature Sensor High Error ENG L03
system
Electrical
CA154 Charge Air Temperature Sensor Low Error ENG L03
system
40-162 PC210LCI-11

Electrical
CA187 Sensor 2 Supply Voltage Low Error ENG L03
system
Electrical
CA221 Ambient Pressure Sensor High Error ENG L03
system
Electrical
CA222 Ambient Pressure Sensor Low Error ENG L03
system
Electrical
CA227 Sensor 2 Supply Voltage High Error ENG L03
system
Mechanical
CA234 Engine Overspeed ENG L02
system
Electrical
CA238 NE Speed Sensor Supply Voltage Error ENG L01
system
Electrical
CA239 NE Speed Sensor Supply Voltage High Error ENG L01
system
Electrical
CA249 Ambient Air Temp Sensor High Error ENG L01
system
Electrical
CA256 Ambient Air Temp Sensor Low Error ENG L01
system
Electrical
CA271 IMV or PCV 1 Short Circuit Error ENG L03
system
Electrical
CA272 IMV or PCV 1 Open Circuit Error ENG L03
system
Injector #1 (L#1) Open Circuit Error or Short Circuit Electrical
CA322 ENG L03
Error system
CA323 ENG L03
Error system
CA324 ENG L03
Error system
CA325 ENG L03
Error system
CA331 ENG L03
Error system
CA332 ENG L03
Error system
Electrical
CA343 Engine Controller Internal Failure ENG L04
system
Electrical
CA351 Injectors Drive Circuit Error ENG L03
system
Electrical
system
Electrical
CA356 MAF Sensor High Error ENG L03
system
Electrical
CA357 MAF Sensor Low Error ENG L03
system
Electrical
system
PC210LCI-11 40-163

Electrical
CA428 Water in Fuel Sensor High Error ENG L01
system
Electrical
CA429 Water in Fuel Sensor Low Error ENG L01
system
Electrical
CA435 Engine Oil Pressure SW Error ENG L01
system
Electrical
CA441 Battery Voltage Low Error ENG L04
system
Electrical
CA442 Battery Voltage High Error ENG L04
system
Electrical
CA449 Common Rail Pressure High Error 2 ENG L03
system
Electrical
CA451 Common Rail Pressure Sensor High Error ENG L03
system
Electrical
CA452 Common Rail Pressure Sensor Low Error ENG L03
system
Electrical
CA488 Charge Air Temperature High Torque Derate ENG L03
system
Common Rail Pressure Sensor Supply Voltage High Electrical
CA515 ENG L03
Error system
Common Rail Pressure Sensor Supply Voltage Low Electrical
CA516 ENG L03
Error system
Electrical
CA553 Common Rail Pressure High Error 1 ENG L01
system
Electrical
CA555 Crankcase Pressure High Error 1 ENG L01
system
Electrical
CA556 Crankcase Pressure High Error 2 ENG L03
system
Electrical
CA559 Common Rail Pressure Low Error 1 ENG L01
system
Electrical
CA595 Turbocharger Speed High Error 2 ENG L01
system
Electrical
CA687 Turbocharger Speed Low Error ENG L01
system
Electrical
CA689 Engine NE Speed Sensor Error ENG L01
system
Electrical
CA691 Intake Air Temperature Sensor High Error ENG L01
system
Electrical
CA692 Intake Air Temperature Sensor Low Error ENG L01
system
Engine Controller Internal Temperature Sensor High Electrical
CA697 ENG L01
Error system
Engine Controller Internal Temperature Sensor Low Electrical
CA698 ENG L01
Error system
Electrical
CA731 Engine Backup Speed Sensor Phase Error ENG L01
system
40-164 PC210LCI-11

Electrical
CA778 Engine Backup Speed Sensor Error ENG L01
system
Electrical
CA1117 Engine Controller Partial Data Lost Error ENG L04
system
Electrical
CA1664 KDOC Abnormality ENG L03
system
Electrical
CA1669 AdBlue/DEF Level Sensor Voltage High Error ENG L01
system
Electrical
CA1673 AdBlue/DEF Level Low Error 3 ENG L03
system
Electrical
CA1677 AdBlue/DEF Temperature Sensor Low Error ENG L01
system
Electrical
CA1678 AdBlue/DEF Temperature Sensor High Error ENG L01
system
Electrical
CA1682 AdBlue/DEF Pump Priming Error ENG L01
system
Electrical
CA1683 AdBlue/DEF Tank Heating Valve Voltage High Error ENG L01
system
Electrical
CA1684 AdBlue/DEF Tank Heating Valve Voltage Low Error ENG L01
system
Electrical
CA1686 AdBlue/DEF Quality Sensor Voltage High Error ENG L01
system
Electrical
CA1691 Defective Regeneration ENG L03
system
Electrical
CA1694 SCR Outlet NOx Sensor In Range Error ENG L01
system
Electrical
system
Electrical
system
Electrical
CA1712 AdBlue/DEF Tank Thawing Error ENG L01
system
Electrical
CA1713 AdBlue/DEF Tank Heater Valve Open Stuck Error ENG L01
system
Electrical
CA1714 AdBlue/DEF Quality Sensor Out of Calibration Error ENG L01
system
Electrical
CA1715 AdBlue/DEF Quality Sensor Internal Circuit Error ENG L01
system
Electrical
CA1776 Sensor Supply Relay Voltage High Error ENG L01
system
Electrical
CA1777 Sensor Supply Relay Voltage Low Error ENG L01
system
Electrical
CA1843 Crankcase Pressure Sensor High Error ENG L01
system
Electrical
CA1844 Crankcase Pressure Sensor Low Error ENG L01
system
PC210LCI-11 40-165

Electrical
CA1879 KDPF Differential Pressure Sensor High Error ENG L03
system
Electrical
CA1881 KDPF Differential Pressure Sensor Low Error ENG L03
system
Electrical
CA1883 KDPF Differential Pressure Sensor In Range Error ENG L03
system
Electrical
CA1885 Turbo Outlet NOx Sensor Circuit Error ENG L01
system
Electrical
CA1887 SCR Outlet NOx Sensor Circuit Error ENG L01
system
Electrical
CA1921 KDPF Soot Accumulation High Error 1 ENG L03
system
Electrical
CA1922 KDPF Soot Accumulation High Error 2 ENG L04
system
Electrical
CA1942 Crankcase Pressure Sensor In Range Error ENG L01
system
Electrical
CA1993 KDPF Differential Pressure Low Error ENG L03
system
Electrical
CA2185 Throttle Sensor Supply Voltage High Error ENG L03
system
Electrical
CA2186 Throttle Sensor Supply Voltage Low Error ENG L03
system
Electrical
CA2249 Common Rail Pressure Low Error 2 ENG L03
system
Electrical
CA2271 EGR Valve Position Sensor High Error ENG L03
system
Electrical
CA2272 EGR Valve Position Sensor Low Error ENG L03
system
Electrical
CA2288 Turbocharger Speed High Error 1 ENG L01
system
Electrical
CA2311 lMV Solenoid Error ENG L03
system
Electrical
CA2349 EGR Valve Solenoid Open Circuit Error ENG L03
system
Electrical
CA2353 EGR Valve Solenoid Short Circuit Error ENG L03
system
Electrical
CA2357 EGR Valve Servo Error ENG L03
system
Electrical
CA2381 KVGT Position Sensor High Error ENG L03
system
Electrical
CA2382 KVGT Position Sensor Low Error ENG L03
system
Electrical
CA2383 KVGT Solenoid Open Circuit Error ENG L03
system
Electrical
CA2386 KVGT Solenoid Short Circuit Error ENG L03
system
40-166 PC210LCI-11

Electrical
CA2387 KVGT Servo Error ENG L03
system
Electrical
CA2555 Intake Air Heater Relay Open Circuit Error ENG L01
system
Electrical
CA2556 Intake Air Heater Relay Short Circuit Error ENG L01
system
Electrical
CA2637 KDOC Face Plugging ENG L01
system
Electrical
CA2639 Manual Stationary Regeneration Request ENG L01
system
Electrical
CA2771 SCR Outlet NOx Sensor Datalink Timeout Error ENG L01
system
Manual Stationary Regeneration Request but KDPF Electrical
CA2777 ENG -
Regeneration Disable system
AdBlue/DEF Pump Temperature Sensor Signal Er- Electrical
CA2976 ENG L01
ror system
Electrical
CA3133 KDPF Outlet Pressure Sensor High Error ENG L03
system
Electrical
CA3134 KDPF Outlet Pressure Sensor Low Error ENG L03
system
Electrical
CA3135 KDPF Outlet Pressure Sensor In Range Error ENG L03
system
Electrical
CA3142 SCR Temperature Sensor High Error ENG L01
system
Electrical
CA3143 SCR Temperature Sensor Low Error ENG L01
system
Electrical
CA3144 SCR Temperature Sensor In Range Error ENG L01
system
Electrical
CA3146 SCR Outlet Temperature Sensor High Error ENG L01
system
Electrical
CA3147 SCR Outlet Temperature Sensor Low Error ENG L01
system
Electrical
CA3148 SCR Outlet Temperature Sensor In Range Error ENG L01
system
Electrical
CA3151 SCR Catalyst Efficiency Low Error 2 ENG L01
system
Electrical
CA3165 SCR Outlet Temperature High Error ENG L03
system
Electrical
CA3229 SCR Temperature High Error ENG L03
system
Electrical
CA3231 SCR Temperature High Error - Non Regeneration ENG L03
system
Electrical
CA3232 Turbo Outlet NOx Sensor Datalink Timeout Error ENG L01
system
SCR Outlet Temperature High Error - Non Regener- Electrical
CA3235 ENG L03
ation system
PC210LCI-11 40-167

Electrical
CA3239 AdBlue/DEF Line Heater 2 Voltage High Error ENG L01
system
Electrical
CA3241 AdBlue/DEF Line Heater 2 Voltage Low Error ENG L01
system
Electrical
CA3242 AdBlue/DEF Tank Heating Error ENG L01
system
Electrical
CA3251 KDOC Inlet Temperature High Error ENG L03
system
Electrical
CA3253 KDOC Temperature Error - Non Regeneration ENG L03
system
Electrical
CA3254 KDOC Outlet Temperature High Error 1 ENG L01
system
Electrical
CA3255 KDPF Temperature Error - Non Regeneration ENG L03
system
Electrical
CA3256 KDPF Outlet Temperature High Error 1 ENG L01
system
Electrical
CA3311 KDOC Outlet Temperature High Error 2 ENG L03
system
Electrical
CA3312 KDPF Outlet Temperature High Error 2 ENG L03
system
Electrical
CA3313 KDOC Inlet Temperature Sensor Low Error ENG L03
system
Electrical
CA3314 KDOC Inlet Temperature Sensor High Error ENG L03
system
Electrical
CA3315 KDOC Inlet Temperature Sensor In Range Error ENG L03
system
Electrical
CA3316 KDOC Outlet Temperature Sensor Low Error ENG L03
system
Electrical
CA3317 KDOC Outlet Temperature Sensor High Error ENG L03
system
Electrical
CA3318 KDOC Outlet Temperature Sensor In Range Error ENG L03
system
Electrical
CA3319 KDPF Outlet Temperature Sensor High Error ENG L03
system
Electrical
CA3321 KDPF Outlet Temperature Sensor Low Error ENG L03
system
Electrical
CA3322 KDPF Outlet Temperature Sensor In Range Error ENG L03
system
Electrical
CA3419 MAF Sensor Supply Voltage High Error ENG L03
system
Electrical
CA3421 MAF Sensor Supply Voltage Low Error ENG L03
system
Electrical
CA3497 AdBlue/DEF Level Low Error 1 ENG -
system
Electrical
CA3498 AdBlue/DEF Level Low Error 2 ENG -
system
40-168 PC210LCI-11

AdBlue/DEF Quality Error (SCR Catalyst Efficiency Electrical
CA3543 ENG L01
Low) system
Electrical
CA3545 SCR Outlet NOx Sensor Unstable Error ENG L01
system
Electrical
CA3547 AdBlue/DEF Level Low Error 4 ENG L04
system
Electrical
CA3558 AdBlue/DEF Pump Voltage High Error ENG L01
system
Electrical
CA3559 AdBlue/DEF Pump Voltage Low Error ENG L01
system
Electrical
CA3562 AdBlue/DEF LineHeater Relay 1 Voltage High Error ENG L01
system
Electrical
CA3563 AdBlue/DEF LineHeater Relay 1 Voltage Low Error ENG L01
system
AdBlue/DEF Injector Open Circuit Error or Short Electrical
CA3567 ENG L01
Circuit Error system
Electrical
CA3568 AdBlue/DEF Injector Malfunction ENG L01
system
Electrical
CA3571 AdBlue/DEF Pump Pressure Sensor High Error ENG L01
system
Electrical
CA3572 AdBlue/DEF Pump Pressure Sensor Low Error ENG L01
system
Electrical
CA3574 AdBlue/DEF Pump Pressure Too Low Error ENG L01
system
Electrical
CA3575 AdBlue/DEF Pump Pressure Too High Error ENG L01
system
Electrical
CA3577 AdBlue/DEF FCV Voltage High Error ENG L01
system
Electrical
CA3578 AdBlue/DEF FCV Voltage Low Error ENG L01
system
Electrical
CA3582 SCR Catalyst Efficiency Low Error 1 ENG -
system
Electrical
CA3583 SCR Outlet NOx Sensor Heater Warming up Error ENG L01
system
Electrical
CA3596 AdBlue/DEF Pump Pressure Unstable Error ENG L01
system
Electrical
CA3649 Turbo Outlet NOx Sensor Heater Warming up Error ENG L01
system
Electrical
CA3681 SCR Outlet NOx Sensor Power Voltage Error ENG L01
system
Electrical
CA3682 Turbo Outlet NOx Sensor Power Voltage Error ENG L01
system
Electrical
CA3713 AdBlue/DEF Line Heater 1 Voltage High Error ENG L01
system
Electrical
CA3717 SCR Outlet NOx Sensor Voltage Mismatch Error ENG L01
system
PC210LCI-11 40-169

Electrical
CA3718 Turbo Outlet NOx Sensor Voltage Mismatch Error ENG L01
system
Electrical
CA3725 Turbo Outlet NOx Sensor Unstable Error ENG L01
system
Electrical
CA3741 Rail Press Valve Trip Error ENG L03
system
Electrical
CA3748 Turbo Outlet NOx Sensor Stuck In Range Error ENG L01
system
Electrical
CA3751 SCR Catalyst Degradation Error ENG L03
system
AdBlue/DEF Dosing Performance Degradation Er- Electrical
CA3755 ENG L03
ror system
Electrical
CA3866 AdBlue/DEF Low Concentration Error 2 ENG L01
system
Electrical
CA3867 AdBlue/DEF Low Concentration Error 1 ENG ―
system
Electrical
CA3868 AdBlue/DEF Tank Sensor Datalink Timeout Error ENG L01
system
Electrical
CA3899 SCR NH3 Sensor Circuit Error ENG L01
system
Electrical
CA3911 SCR NH3 Sensor Datalink Timeout Error ENG L01
system
Electrical
CA3912 SCR NH3 Sensor Heater Warming up Error ENG L01
system
Electrical
CA3932 SCR NH3 Sensor Heater Voltage High Error ENG L01
system
Electrical
CA3933 SCR NH3 Sensor Heater Voltage Low Error ENG L01
system
Electrical
CA3934 SCR NH3 Sensor Power Interrupt Error ENG L01
system
Electrical
CA3935 SCR NH3 Sensor Trim Resistance Error ENG L01
system
Electrical
CA3936 SCR NH3 Sensor Internal Circuit Error ENG L01
system
KDOC and KDPF Temperature Sensor Datalink Electrical
CA4151 ENG L03
Timeout Error system
Electrical
CA4152 SCR Temperature Sensor Datalink Timeout Error ENG L01
system
Electrical
CA4155 AdBlue/DEF Pump Heater Relay Voltage High Error ENG L01
system
Electrical
CA4156 AdBlue/DEF Pump Heater Relay Voltage Low Error ENG L01
system
Electrical
CA4157 AdBlue/DEF FCV Malfunction ENG L01
system
KDOC and KDPF Temperature Sensor Internal Cir- Electrical
CA4158 ENG L03
cuit Error system
40-170 PC210LCI-11

Electrical
CA4159 SCR Temperature Sensor Internal Circuit Error ENG L01
system
KDOC and KDPF Temperature Sensor ECU Volt- Electrical
CA4161 ENG L03
age High Error system
KDOC and KDPF Temperature Sensor ECU Volt- Electrical
CA4162 ENG L03
age Low Error system
KDOC and KDPF Temperature Sensor ECU Over Electrical
CA4163 ENG L01
Temperature Error system
Electrical
CA4164 SCR Temperature Sensor ECU Voltage High Error ENG L01
system
Electrical
CA4165 SCR Temperature Sensor ECU Voltage Low Error ENG L01
system
SCR Temperature Sensor ECU High Temperature Electrical
CA4166 ENG L01
Error system
Electrical
CA4168 AdBlue/DEF Pump Heater ON Stuck Error ENG L01
system
Electrical
CA4169 AdBlue/DEF Pump Heater OFF Stuck Error ENG L01
system
Electrical
CA4171 AdBlue/DEF Pump Thawing Error ENG L01
system
AdBlue/DEF Pump Temperature Sensor 1 In Range Electrical
CA4249 ENG L01
Error system
AdBlue/DEF Pump Temperature Sensor 2 In Range Electrical
CA4251 ENG L01
Error system
KDOC and KDPF Temperature Sensor Power Inter- Electrical
CA4259 ENG L03
rupt Error system
Electrical
CA4261 SCR Temperature Sensor Power Interrupt Error ENG L01
system
AdBlue/DEF Quality Sensor Liquid Distinction Im- Electrical
CA4277 ENG L01
possible Error system
Electrical
CA4281 SCR NH3 Sensor Stuck Response Error ENG L01
system
Electrical
CA4459 AdBlue/DEF LineHeater Relay 2 Voltage High Error ENG L01
system
Electrical
CA4461 AdBlue/DEF LineHeater Relay 2 Voltage Low Error ENG L01
system
Electrical
CA4658 AdBlue/DEF Flow Low Error ENG -
system
AdBlue/DEF Temperature Sensor Transmission Da- Electrical
CA4731 ENG L01
ta Error system
Electrical
CA4732 AdBlue/DEF Level Sensor Transmission Data Error ENG L01
system
Electrical
CA4739 AdBlue/DEF Level Sensor Internal Circuit Error ENG L01
system
Electrical
CA4768 Fuel in AdBlue/DEF Tank Error ENG L03
system
PC210LCI-11 40-171

Electrical
CA4769 AdBlue/DEF Level Measurement Impossible ENG L01
system
Electrical
CA4842 AdBlue/DEF High Concentration Error ENG L01
system
Electrical
CA4952 System Operating Lamp Short Circuit ENG) ENG ―
system
Electrical
CA5115 AdBlue/DEF Line Heater 1 Voltage Low Error ENG L01
system
Electrical
CA5179 Engine Room Temperature Sensor High Error ENG L01
system
Electrical
CA5181 Engine Room Temperature Sensor Low Error ENG L01
system
Electrical
CA5383 Ash Accumulation High Error ENG —
system
Electrical
D110KB Battery Relay Output Short Circuit PUMP L01
system
Electrical
D19JKZ Personal Code Relay Open Circuit or Short Circuit MON L03
system
Electrical
D811MC KOMTRAX Malfunction KOMTRAX -
system
Electrical
D862KA GPS Antenna Open Circuit KOMTRAX -
system
Electrical
D8ALKA System Operating Lamp Open Circuit (KOMTRAX) KOMTRAX -
system
Electrical
D8ALKB System Operating Lamp Short Circuit (KOMTRAX) KOMTRAX -
system
Electrical
D8AQKR CAN 2 Defective Communication (KOMTRAX) MON -
system
Electrical
DA20MC Pump Controller Malfunction PUMP ―
system
Electrical
DA22KK Pump Controller Solenoid Power Voltage Low Error PUMP L03
system
Electrical
DA25KP 5V Sensor 1 Power Voltage Low Error PUMP ―
system
Electrical
DA26KP 5V Sensor 2 Power Voltage Low Error PUMP ―
system
Electrical
DA29KQ Model Selection Signal Mismatch (Pump Controller) PUMP L01
system
System Operating Lamp Open Circuit (Pump Con- Electrical
DA2LKA PUMP ―
troller) system
System Operating Lamp Short Circuit (Pump Con- Electrical
DA2LKB PUMP ―
troller) system
Controller Area Network 2 Defective Communica- Electrical
DA2QKR MON L03
tion (Pump Controller) system
Controller Area Network 1 Defective Communica- Electrical
DA2RKR MON L04
tion (Pump Controller) system
40-172 PC210LCI-11

Electrical
DAF0MB Monitor ROM Abnormality MON -
system
Electrical
DAF0MC Monitor Malfunction MON -
system
Electrical
DAF8KB Camera Power Supply Short Circuit MON L03
system
Electrical
DAF9KQ Model Selection Signal Mismatch (Monitor) MON L03
system
Electrical
DAFGMC GPS Module Malfunction KOMTRAX -
system
Electrical
DAFLKA System Operating Lamp Open Circuit (Monitor) MON -
system
Electrical
DAFLKB System Operating Lamp Short Circuit (Monitor) MON -
system
Electrical
DAFQKR CAN 2 Defective Communication (Monitor) KOMTRAX -
system
Electrical
DAZ9KQ Model Selection Signal Mismatch (A/C) MON -
system
Electrical
DAZQKR CAN 2 Defective Communication (A/C ECU) MON L01
system
Electrical
DB2QKR CAN 2 Defective Communication ENG) MON L03
system
Electrical
DB2RKR CAN 1 Defective Communication ENG) MON L04
system
Electrical
DB90MC W/E Controller Reset WE -
system
Electrical
DB92KK W/E Controller Solenoid Power Voltage Low Error WE L03
system
Electrical
DB95KP W/E Con 5V Sensor 0 Power Volt Low Error WE L01
system
Electrical
DB96KP W/E Con 5V Sensor 1 Power Volt Low Error WE L01
system
Electrical
DB99KQ Model Selection Signal Mismatch (W/E Con) WE L04
system
System Operating Lamp Open Circuit (W/E Control- Electrical
DB9LKA WE -
ler) system
Electrical
DB9LKB Operating Lamp Hot Short Circuit (W/E Con) WE -
system
Electrical
DB9QKR CAN 2 Defective Communication (W/E Con) MON L03
system
Electrical
DB9RKR CAN 1 Defective Communication (W/E Con) MON L03
system
Electrical
DBP0KM KomVision Setting Error KomVision L01
system
Electrical
DBP0KT KomVision Controller Abnormality KomVision L01
system
PC210LCI-11 40-173

Electrical
DBPQKR CAN 2 Defective Communication (KomVision) MON L01
system
Electrical
DBR0MC ICT Sensor Controller Reset ICT -
system
Electrical
DBR2KK ICT Sensor Con Solenoid Power Low Error ICT L01
system
Electrical
DBR5KP ICT Sensor Con 5V Sensor 0 Power Low Error ICT L01
system
Electrical
DBR6KP ICT Sensor Con 5V Sensor 1 Power Low Error ICT L01
system
Electrical
DBR9KQ Model Selection Signal Mismatch (ICT Sens) ICT L04
system
Electrical
DBRLKA Operating Lamp Open Circuit(ICT Con) ICT -
system
Electrical
DBRLKB Operating Lamp Open Circuit (ICT Sens Con) ICT -
system
Electrical
DBRQKR CAN2 Discon (ICT Con) MON L01
system
Electrical
DBRRKR CAN1 Discon (ICT Con) MON L01
system
Electrical
DBRSKB Battery Relay Short Circuit (ICT Sensor) ICT L01
system
Electrical
DBRTKB Control Box Power Short Circuit(ICT Sensor) ICT L01
system
Electrical
DBUSKR Ethernet 0 Discon (GNSS Controller) ICT L01
system
Electrical
DD20MA Auto/Manual Selector Switch Error WE L01
system
Electrical
DDNRKA W/E Lever Lock SW Open Circuit PUMP L03
system
Electrical
DDNRKY W/E Lever Lock SW Short Circuit PUMP L03
system
Electrical
DDNS00 Lock Lever Auto Lock Release SW On PUMP -
system
Service Lever Potentiometer 1 Open Circuit or Electrical
DFB1KZ PUMP L01
Short Circuit system
Service Lever Potentiometer 2 Open Circuit or Electrical
DFB2KZ PUMP L01
Service Lever 1 Potentiometer Signal Incompatibili- Electrical
DFB3L8 PUMP L01
ty system
Service Lever 2 Potentiometer Signal Incompatibili- Electrical
DFB4L8 PUMP L01
ty system
Service Lever sub-Potentiometer 1 Open Circuit or Electrical
DFB5KZ PUMP L01
Service Lever sub-Potentiometer 2 Open Circuit or Electrical
DFB6KZ PUMP L01
40-174 PC210LCI-11

Electrical
DGH2KA Hydraulic Oil Temperature Sensor Open Circuit PUMP L01
system
Electrical
DGH2KB Hydraulic Oil Temperature Sensor Ground Fault PUMP L01
system
Electrical
DHA4KA Air Cleaner Clog Sensor Open Circuit MON L01
system
Electrical
DHAAMA KDPF Differential Pressure Sensor Frozen ENG -
system
Electrical
DHACMA KDPF Outlet Pressure Sensor Frozen ENG -
system
Electrical
DHPAMA Front Pump Pressure Sensor Defective Function PUMP L01
system
Electrical
DHPBMA Rear Pump Pressure Sensor Defective Function PUMP L01
system
Electrical
DHS3MA Arm IN PPC Pressure Sensor Defective Function WE L01
system
Bucket CURL PPC Pressure Sensor Defective Electrical
DHS4MA WE L01
Function system
Boom RAISE PPC Pressure Sensor Defective Electrical
DHS8MA WE L01
Function system
Boom LOWER PPC Pressure Sensor Defective Electrical
DHS9MA WE L01
Function system
Swing Right PPC Pressure Sensor Defective Func- Electrical
DHSAMA WE L01
tion system
Swing Left PPC Pressure Sensor Defective Func- Electrical
DHSBMA WE L01
tion system
Electrical
DHSCMA Arm OUT PPC Pressure Sensor Defective Function WE L01
system
Bucket DUMP PPC Pressure Sensor Defective Electrical
DHSDMA WE L01
Function system
Travel Forward Left PPC Pressure Sensor Defec- Electrical
DHSFMA PUMP L01
tive Function system
Travel Forward Right PPC Pressure Sensor Defec- Electrical
DHSGMA PUMP L01
Travel Reverse Left PPC Pressure Sensor Defec- Electrical
DHSHMA PUMP L01
Travel Reverse Right PPC Pressure Sensor Defec- Electrical
DHSJMA PUMP L01
Electrical
DHUXMA ATT1 LH PPC Press Sens Def Function PUMP L01
system
Electrical
DHUYMA ATT1 RH PPC Press Sens Def Function PUMP L01
system
Electrical
DK80KM IMU Calibration Not Completed ICT L01
system
Electrical
DK80KR IMU Defective Communication ICT L01
system
PC210LCI-11 40-175

Electrical
DK80KT IMU Internal Failure ICT L01
system
Electrical
DKG1KM Bucket Cylinder Calibration Not Completed ICT L01
system
Electrical
DKG1L8 Bucket Cyl Stroke Sensor In Range Error ICT L01
system
Electrical
DKR0MA Front Pump Swash Plate Sensor Defective Function PUMP L01
system
Electrical
DKR1MA Rear Pump Swash Plate Sensor Defective Function PUMP L01
system
Electrical
DKT0KM Boom Cylinder Calibration Not Completed ICT L01
system
Electrical
DKT0L8 Boom Cylinder Stroke Sensor In Range Error ICT L01
system
Electrical
DKT1KA Boom Cyl Stroke Sens A Phase Open Circuit ICT L01
system
Electrical
DKT1KB Boom Cyl Stroke Sens A Phase Hot Short ICT L01
system
Electrical
DKT2KA Boom Cyl Stroke Sens B Phase Open Circuit ICT L01
system
Electrical
DKT2KB Boom Cyl Stroke Sensor B Phase Hot Short ICT L01
system
Electrical
DKT4KM Arm Cylinder Calibration Not Completed ICT L01
system
Electrical
DKT4L8 Arm Cylinder Stroke Sensor In Range Error ICT L01
system
Electrical
DKT5KA Arm Cyl Stroke Sensor A Phase Open Circuit ICT L01
system
Electrical
DKT5KB Arm Cyl Stroke Sensor A Phase Hot Short ICT L01
system
Electrical
DKT6KA Arm Cyl Stroke Sensor B Phase Open Circuit ICT L01
system
Electrical
DKT6KB Arm Cyl Stroke Sensor B Phase Hot Short ICT L01
system
Electrical
DKT8KA Bucket Cyl Stroke Sensor A Open Circuit ICT L01
system
Electrical
DKT8KB Bucket Cyl Stroke Sensor A Phase Hot Short ICT L01
system
Electrical
DKT9KA Bucket Cyl Stroke Sensor B Open Circuit ICT L01
system
Electrical
DKT9KB Bucket Cyl Stroke Sensor B Phase Hot Short ICT L01
system
Electrical
DKTAKA Bucket Cyl Stroke Reset Sens Open Circuit ICT L01
system
Electrical
DKTAKB Bucket Cyl Stroke Reset Sensor Hot Short ICT L01
system
40-176 PC210LCI-11

Electrical
DKTAMB Bucket Cyl Stroke Reset Sens InRange Error ICT -
system
Electrical
DKTBKX Boom Cyl Stroke Reset Encoder A,B Error ICT -
system
Electrical
DKTBMC Boom Cylinder Stroke Reset Encoder Error ICT L01
system
Electrical
DKTEMB Boom Cylinder Stroke Reset Encoder Z Error ICT L01
system
Electrical
DKTFKX Arm Cyl Stroke Reset Encoder A,B Error ICT -
system
Electrical
DKTFMC Arm Cylinder Stroke Reset Encoder Error ICT L01
system
Electrical
DKTJMB Arm Cyl Stroke Reset Encoder Z Phase Error ICT L01
system
Electrical
DKTUL8 Bucket Tilt Cyl Stroke Sensor In Range Error ICT L01
system
Electrical
DKTVKA Bucket Tilt Cyl Stroke Sensor A Open Circuit ICT L01
system
Electrical
DKTVKB Bucket Tilt Cyl Stroke Sensor A Phase Hot Short ICT L01
system
Electrical
DKTWKA Bucket Tilt Cyl Stroke Sensor B Open Circuit ICT L01
system
Electrical
DKTWKB Bucket Tilt Cyl Stroke Sensor B Phase Hot Short ICT L01
system
Electrical
DKU1MA Boom Spool Storke Sensor In Range Error WE L01
system
Electrical
DKU2MA Arm Spool Storke Sensor In Range Error WE L01
system
Electrical
DKUGKA Arm IN PPC Reduce Press EPC Open Circuit WE L03
system
Electrical
DKUGKB Arm IN PPC Reduce Press EPC Ground Fault WE L03
system
Electrical
DKUGKY Arm IN PPC Reduce Pressure EPC Hot Short WE L01
system
Electrical
DKUHKA Arm OUT PPC Reduce Press EPC Open Circuit WE L03
system
Electrical
DKUHKB Arm OUT PPC Reduce Press EPC Ground Fault WE L03
system
Electrical
DKUHKY Arm OUT PPC Reduce Pressure EPC Hot Short WE L01
system
Electrical
DKULKA PPC Lock Relay Open Circuit PUMP L03
system
Electrical
DKULKB PPC Lock Relay Short Circuit PUMP L03
system
Electrical
DKULKY PPC Lock Relay Hot Short Circuit PUMP L03
system
PC210LCI-11 40-177

Electrical
DKV0KA Boom Spool Stroke Sensor 1 Open Circuit WE L01
system
Electrical
DKV0KY Boom Spool Stroke Sensor 1 Hot Short Cir WE L01
system
Electrical
DKV1KA Arm Spool Stroke Sensor 1 Open Circuit WE L01
system
Electrical
DKV1KY Arm Spool Stroke Sensor 1 Hot Short Cir WE L01
system
Electrical
DKV2KA Boom Spool Stroke Sensor 2 Open Circuit WE L01
system
Electrical
DKV2KY Boom Spool Stroke Sensor 2 Hot Short Cir WE L01
system
Electrical
DKV3KA Arm Spool Stroke Sensor 2 Open Circuit WE L01
system
Electrical
DKV3KY Arm Spool Stroke Sensor 2 Hot Short Cir WE L01
system
Electrical
DKV4MA Boom RAISE PPC Press Sensor 2 Def Function WE L01
system
Electrical
DKV5MA Boom LOWER PPC Press Sensor 2 Def Function WE L01
system
Electrical
DKV6MA Arm OUT PPC Press Sensor 2 Def Function WE L01
system
Electrical
DKV7MA Arm IN PPC Press Sens 2 Defective Function WE L01
system
Electrical
DKV8MA Bucket DUMP PPC Press Sens 2 Def Function WE L01
system
Electrical
DKV9MA Bucket CURL PPC Press Sens 2 Def Function WE L01
system
Electrical
DKVAMA PPC Source Press Sensor Error WE -
system
Electrical
DKVBKA Bucket CURL PPC Reduce Press EPC Open Cir WE L03
system
Electrical
DKVBKB Bucket CURL PPC Reduce Press EPC Grd Fault WE L03
system
Electrical
DKVBKY Bucket CURL PPC Reduce Press EPC Hot Short WE L01
system
Electrical
DKVCKA Boom RAISE PPC Intervention EPC Open Cir WE L04
system
Electrical
DKVCKB Boom RAISE PPC Intervention EPC Grnd Fault WE L04
system
Electrical
DKVCKY Boom RAISE PPC Intervention EPC Hot Short WE L04
system
Electrical
DKVDKA Boom RAISE EPC Cut Relay Open Circuit WE L01
system
Electrical
DKVDKB Boom RAISE EPC Cut Relay Ground Fault WE L01
system
40-178 PC210LCI-11

Electrical
DKVDKY Boom RAISE EPC Cut Relay Hot Short Circuit WE L01
system
Electrical
DKVDMA Boom RAISE EPC Cut Relay Error WE L01
system
Electrical
DLM5KA Fan Speed Sensor Open Circuit PUMP L01
system
Electrical
DLM5MB Fan control:Mismatch PUMP L01
system
Electrical
DR10KA KomVision Camera Open Circuit KomVision L01
system
Camera 2 Picture Reverse Drive Input Out of Electrical
DR21KX MON L01
Range system
Camera 3 Picture Reverse Drive Input Out of Electrical
DR31KX MON L01
Range system
Electrical
DUMBKA Operating Lamp Open Circuit(KomVision) KomVision L01
system
Electrical
DUMBKB Operating Lamp Short Circuit(KomVision) KomVision L01
system
Electrical
DV20KB Travel Alarm Short Circuit PUMP L01
system
Electrical
DW43KA Travel Speed Solenoid Open Circuit PUMP L01
system
Electrical
DW43KB Travel Speed Solenoid Short Circuit PUMP L01
system
Electrical
DW43KY Travel Speed Solenoid Hot Short Circuit PUMP L01
system
Electrical
DW45KA Swing Parking Brake Solenoid Open Circuit PUMP L03
system
Electrical
DW45KB Swing Parking Brake Solenoid Short Circuit PUMP L03
system
Electrical
DW45KY Swing Parking Brake Solenoid Hot Short Circuit PUMP L03
system
Electrical
DW4CKY PPC Lock Solenoid Hot Short Circuit PUMP L03
system
Electrical
DW4FKA Boom LOWER PPC Reduce Press EPC Open Cir WE L03
system
Electrical
DW4FKB Boom LOWER PPC Reduce Press EPC Grnd Fault WE L03
system
Electrical
DW4FKY Boom LOWER PPC Reduce Press EPC Hot Short WE L01
system
Boom RAISE PPC Reduce Pressure EPC Open Electrical
DW4GKA WE L03
Circuit system
Electrical
DW4GKB Boom RAISE PPC Reduce Press EPC Grnd Fault WE L03
system
Boom RAISE PPC Reduce Pressure EPC HOT Electrical
DW4GKY WE L01
PC210LCI-11 40-179

Electrical
DW4SKA Bucket DUMP PPC Reduce Press EPC Open Cir WE L03
system
Electrical
DW4SKB Bucket DUMP PPC Reduce Press EPC Grd Fault WE L03
system
Electrical
DW4SKY Bucket DUMP PPC Reduce Press EPC Hot Short WE L01
system
Electrical
DW91KA Travel Junction Solenoid Open Circuit PUMP L01
system
Electrical
DW91KB Travel Junction Solenoid Short Circuit PUMP L01
system
Electrical
DW91KY Travel Junction Solenoid Hot Short Circuit PUMP L01
system
Attachment Single or 2-Way Change Solenoid Electrical
DWA2KA PUMP L03
Open Circuit system
Attachment Single or 2-Way Change Solenoid Short Electrical
DWA2KB PUMP L03
Circuit system
Attachment Single or 2-Way Change Solenoid Hot Electrical
DWA2KY PUMP L03
Electrical
DWK0KA 2-Stage Relief Solenoid Open Circuit PUMP L01
system
Electrical
DWK0KB 2-Stage Relief Solenoid Open Circuit PUMP L01
system
Electrical
DWK0KY 2-Stage Relief Solenoid Hot Short Circuit PUMP L01
system
Electrical
DWK2KA Variable Back Pressure Solenoid Open Circuit PUMP L01
system
Electrical
DWK2KB Variable Back Pressure Solenoid Short Circuit PUMP L01
system
Electrical
DWK2KY Variable Back Pressure Solenoid Hot Short Circuit PUMP L01
system
Electrical
DWK8KA Swing Pressure Cutoff Solenoid Open Circuit PUMP L01
system
Electrical
DWK8KB Swing Pressure Cutoff Solenoid Short Circuit PUMP L01
system
Electrical
DWK8KY Swing Pressure Cutoff Solenoid Hot Short Circuit PUMP L01
system
Electrical
DWN5KA Fan Clutch Solenoid Open Circuit PUMP L03
system
Electrical
DWN5KB Fan Clutch Solenoid short Circuit PUMP L03
system
Electrical
DWN5KY Fan Clutch Solenoid Hot Short Circuit PUMP L03
system
Electrical
DXA8KA Front Pump PC-EPC Solenoid Open Circuit PUMP L03
system
Electrical
DXA8KB Front Pump PC-EPC Solenoid Short Circuit PUMP L03
system
40-180 PC210LCI-11

Electrical
DXA9KA Rear Pump PC-EPC Solenoid Open Circuit PUMP L03
system
Electrical
DXA9KB Rear Pump PC-EPC Solenoid Short Circuit PUMP L03
system
Electrical
DXE0KA LS-EPC Solenoid Open Circuit PUMP L01
system
Electrical
DXE0KB LS-EPC Solenoid Short Circuit PUMP L01
system
Attachment Flow Regulating EPC Solenoid Open Electrical
DXE4KA PUMP ―
Circuit system
Attachment Flow Regulating EPC Solenoid Short Electrical
DXE4KB PUMP ―
Circuit system
Electrical
DXE4KY Attachment Flow EPC Hot Short Circuit PUMP ―
system
Electrical
DXE5KA Merge-divider Main Solenoid Open Circuit PUMP L01
system
Electrical
DXE5KB Merge-divider Main Solenoid Short Circuit PUMP L01
system
Electrical
DXE6KA Merge-divider LS Solenoid Open Circuit PUMP L01
system
Electrical
DXE6KB Merge-divider LS Solenoid Short Circuit PUMP L01
system
Attachment Flow Regulating EPC 2 Solenoid Open Electrical
DXE7KA PUMP -
Circuit system
Attachment Flow Regulating EPC 2 Solenoid Short Electrical
DXE7KB PUMP -
Circuit system
Attachment Flow Regulating EPC 2 Hot Short Cir- Electrical
DXE7KY PUMP -
cuit system
DXE8KA PUMP -
Circuit system
DXE8KB PUMP -
Circuit system
DXE8KY PUMP -
cuit system
DXE9KA PUMP -
Circuit system
DXE9KB PUMP -
Circuit system
DXE9KY PUMP -
cuit system
DXEAKA PUMP -
Circuit system
DXEAKB PUMP -
Circuit system
DXEAKY PUMP -
cuit system
PC210LCI-11 40-181

Electrical
DY20KA Wiper Motor Open Circuit PUMP ―
system
Electrical
DY20MA Wiper Motor Defective Function PUMP ―
system
Electrical
DY2CKB Washer Motor Short Circuit PUMP ―
system
Electrical
DY2DKB Wiper Motor (Normal Rotation) Short Circuit PUMP ―
system
Electrical
DY2EKB Wiper Motor (Reverse Rotation) Short Circuit PUMP ―
system
• In this table, failure codes are arranged in alphabetical order.

• Applicable component is the controller which checks the system.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
WE: Work equipment controller
KOMTRAX: KOMTRAX terminal
ICT: ICT sensor controller
KomVision: KomVision controller
• 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.
• 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.
40-182 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [879AKA]
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF

CODE)
FAILURE CODE [879AKA]
Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Open Circuit
Failure
- 879AKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in recirculation air temperature sensor.
failure
Air conditioner controller transmits open circuit information of recirculation air temperature sensor to
Action of
machine monitor by CAN communication.
controller
Stops air conditioner when in automatic air conditioner mode.
Since air conditioner recirculation air temperature sensor has open circuit, automatic air conditioner
Phenomenon
does not operate.
on machine
(Air conditioner can be operated in manual mode.)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in “SERV-
information ICE MODE” of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.
No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)
PC210LCI-11 40-183
FAILURE CODE [879AKB] 40 TROUBLESHOOTING
FAILURE CODE [879AKB]

Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Short Circuit
Failure
- 879AKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in recirculation air temperature sensor.
failure
• Air conditioner controller transmits short circuit information of recirculation air temperature
Action of
sensor to machine monitor by CAN communication.
controller
• Stops air conditioner when in automatic air conditioner mode.
Phenomenon Since air conditioner recirculation air temperature sensor has short circuit, automatic air conditioner
does not operate.
on machine (Air conditioner can be operated in manual mode)
Related • Check if this failure code is displayed on electrical system failure record screen in SERV-
information ICE MODE of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.

controller
2
40-184 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [879BKA]
FAILURE CODE [879BKA]

Action level Failure code Air Conditioner Fresh Air Temperature Sensor Open Circuit
Failure
- 879BKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in outside air temperature sensor.
failure
Air conditioner controller transmits open circuit information of outside air temperature sensor to ma-
Action of chine monitor by CAN communication.
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has open circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
(Air conditioner is not affected in manual mode.)
• Check if this failure code is displayed on electrical system failure record screen in service
mode of machine monitor.
Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information
• Since air conditioner controller connector ACECU has no T-adapter and has small pins,
perform troubleshooting by using intermediate connector (although intermediate connector
has no T-adapter either, it has large pins).
• When replacing air conditioner harness between air conditioner controller connector ACE-
CU and intermediate connector, replace air conditioner unit.

Defective fresh air tem- 2. Disconnect connector P18.
1
perature sensor
Between P18 (male) (1) Approx.
Resistance 25 °C
and (2) 1.7 kΩ
Open or short circuit in 2. Disconnect connector AC01.
2
wiring harness
Between AC01 (female) Approx.
Resistance 25 °C
(7) and (8) 1.7 kΩ
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or
3 2. Disconnect connectors P18 and AC01.
defective contact of con-
nector) Between AC01 (female) (7) and P18 (female) (1) Max. 1 Ω
Resistance
Between AC01 (female) (8) and P18 (female) (2) Max. 1 Ω
If failure code is still displayed after above checks, air conditioner controller is de-
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
controller
Replace whole assembly.)
If failure code is still displayed after above checks, air conditioner unit may be de-
unit
PC210LCI-11 40-185
FAILURE CODE [879BKA] 40 TROUBLESHOOTING
Circuit diagram related to air conditioner fresh air temperature sensor
40-186 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [879BKB]
FAILURE CODE [879BKB]

Action level Failure code Air Conditioner Fresh Air Temperature Sensor Short Circuit
Failure
- 879BKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in outside air temperature sensor.
failure
Air conditioner controller transmits short circuit information of outside air temperature sensor to ma-
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has short circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
(Air conditioner is not affected in manual mode.)
Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information

Defective fresh air tem- 2. Disconnect connector P18.
1
perature sensor
Between P18 (male) (1) Approx.
Resistance 25 °C
and (2) 1.7 kΩ
Open or short circuit in 2. Disconnect connector AC01.
2
wiring harness
Between AC01 (female) Approx.
Resistance 25 °C
(7) and (8) 1.7 kΩ
quired.
Short circuit in wiring har- 1. Turn starting switch to OFF position.
3
ness 2. Disconnect connectors P18 and AC01.
Between AC01 (female) (7) and (8), or between P18

Resistance Min. 1 MΩ
(female) (1) and (2)
Ground fault in wiring 2. Disconnect connectors P18 and AC01.
4
harness
Between ground and AC01 (female) (8) or P18 (fe-
male) (2)
controller
PC210LCI-11 40-187
FAILURE CODE [879BKB] 40 TROUBLESHOOTING

unit
Circuit diagram related to air conditioner fresh air temperature sensor
40-188 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [879CKA]
FAILURE CODE [879CKA]

Action level Failure code Ventilating sensor Open Circuit
Failure
- 879CKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in evaporator temperature (frost) sensor.
failure
• Air conditioner controller transmits open circuit information of evaporator temperature
Action of
(frost) sensor to machine monitor by CAN communication.
controller
• Stops air conditioner.
Phenomenon
Air conditioner does not operate because of open circuit in evaporator temperature (frost) sensor.
on machine
Related • Check if this failure code is displayed on electrical system failure record screen in service
information mode of machine monitor.
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

controller
2
PC210LCI-11 40-189
FAILURE CODE [879CKB] 40 TROUBLESHOOTING
FAILURE CODE [879CKB]

Action level Failure code Ventilating sensor Short Circuit
Failure
- 879CKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in evaporator temperature (frost) sensor.
failure
• Air conditioner controller transmits short circuit information of evaporator temperature
Action of
(frost) sensor to machine monitor by CAN communication.
controller
• Stops air conditioner.
Phenomenon
Air conditioner does not operate because of short circuit in evaporator temperature (frost) sensor.
on machine
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

controller
2
40-190 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [879DKZ]
FAILURE CODE [879DKZ]

Action level Failure code Sunlight Sensor Open Circuit or Short Circuit
Failure
- 879DKZ (Machine monitor system)
Details of
Air conditioner controller detects open or short circuit in sunlight sensor.
failure
• Air conditioner controller transmits open or short circuit information of sunlight sensor to
Action of machine monitor by CAN communication.
controller • Ignores data of sunlight sensor and continues control of air conditioner in automatic air
conditioner mode.
Phenomenon Since air conditioner sunlight sensor has open or short circuit, sunlight intensity is not considered in
on machine automatic air conditioner mode.(Air conditioner is not affected in manual mode.)
• For each connector, see 80 APPENDIX, “Installation locations of air conditioner parts and
Related arrangement of connectors”.
information • Since air conditioner controller connector ACECU has no T-adapter and has small pins,
• T-adapter is not provided for connectors of sunlight sensor.

See 80 APPENDIX, “Testing sunlight sensor”.
Approx.
Direct sunlight
0.55 V
1 Defective sunlight sensor Between sunlight sensor Approx.
Voltage Cloudy
terminals 0.45 V
Approx.
Indoor
0.4 V
See “Testing sunlight sensor”.
ness (wire breakage or 2. Disconnect connector P31 and AC01.
2
nector) Between P31 (female) (1) and AC01 (female) (10) Max. 1 Ω
Resistance
Between P31 (female) (2) and AC01 (female) (9) Max. 1 Ω
controller
unit
PC210LCI-11 40-191
FAILURE CODE [879DKZ] 40 TROUBLESHOOTING
Circuit diagram related to sunlight sensor
40-192 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [879EMC]
FAILURE CODE [879EMC]

Action level Failure code Ventilation Damper Malfunction
Failure
L01 879EMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of vent selector (mode) damper servomotor, judging
failure from potentiometer voltage of servomotor.
Action of Air conditioner controller transmits abnormality of vent selector (mode) damper to machine monitor
controller by CAN communication.
Phenomenon
Vent (mode) cannot be selected, but air conditioner operates.
on machine
• Since connector of vent selector (mode) damper servomotor cannot be checked when it is
mounted on machine, troubleshooting cannot be performed.

controller
2
PC210LCI-11 40-193
FAILURE CODE [879FMC] 40 TROUBLESHOOTING
FAILURE CODE [879FMC]

Action level Failure code Air Mix Damper Malfunction
Failure
L01 879FMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of air mix (temperature regulator) damper servomotor,
failure judging from potentiometer voltage of servomotor.
Action of Air conditioner controller transmits abnormality of air mix damper to machine monitor by CAN com-
controller munication.
Phenomenon
Air conditioner does not operate since temperature cannot be regulated.
on machine
• Since connector of air mix damper servomotor cannot be checked when it is mounted on
machine, troubleshooting cannot be performed.

controller
2
40-194 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [879GKX]
FAILURE CODE [879GKX]

Action level Failure code Refrigerant Pressure Input Signal Out of Range
Failure
L01 879GKX (Machine monitor system)
Details of
Air conditioner controller detected that dual pressure switch is OFF (abnormal).
failure
• Air conditioner controller transmits abnormality information of refrigerant pressure to ma-
controller • Air conditioner controller turns OFF compressor clutch relay since refrigerant pressure is
abnormal.(Air conditioner compressor stops)
Phenomenon
Air conditioner does not function (in cooling mode).
on machine
• For each connector, see 80 APPENDIX, “Installation locations of air conditioner parts and
arrangement of connectors”.
Related perform troubleshooting by using intermediate connector (although intermediate connector
information has no T-adapter either, it has large pins).
• T-adapter is not provided for connectors of dual pressure switch.

See 80 APPENDIX, “TEST (DUSL) PRESSURE SWITCH FOR REFRIGERANT”.
Defective refrigerant (du-
1
al) pressure switch k Before replacing dual pressure switch, collect refrigerant. See 80 AP-
PENDIX, “PRECAUTIONS FOR REFRIGERANT”.
Open circuit in wiring har-
2. Disconnect connectors AC01 and P17.
2
defective contact of con- Between P17 (female) (1) and AC01 (female) (6) Max. 1 Ω
nector) Resistance
Between P17 (female) (2) and ground Max. 1 Ω
controller
unit
PC210LCI-11 40-195
FAILURE CODE [879GKX] 40 TROUBLESHOOTING
Circuit diagram related to refrigerant (dual) pressure switch
40-196 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [989L00]
FAILURE CODE [989L00]

Action level Failure code Engine Controller Lock Caution 1
Failure
- 989L00 (Machine monitor system)
Details of
Engine controller lock up is detected (Factor 1).
failure
Action of ma- • None in particular

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Engine does not start.
on machine
• If the failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.
information • After repairing, check if the failure code is cleared by the following procedure.

Machine monitor re- This failure may occur due to machine monitor replacement.
1
placed
PC210LCI-11 40-197
FAILURE CODE [989M00] 40 TROUBLESHOOTING
FAILURE CODE [989M00]

Failure
- 989M00 (Machine monitor system)
Details of
Machine monitor detects engine controller lock (Factor 2).
failure
Action of ma- • None in particular

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
on machine
• If the failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.

Machine monitor re- This failure may occur due to machine monitor replacement.
1
placed
If this failure code is displayed even when machine monitor is not replaced, failure
Defective machine moni-
2 in machine monitor may occur. (Because this is an internal defect, troubleshooting
tor
cannot be performed.)
40-198 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [989N00]
FAILURE CODE [989N00]

Failure
- 989N00 (Machine monitor system)
Details of
Machine monitor detects engine controller lock (Factor 3).
failure
Action of • Tries automatic recovery.
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
Procedure: Failure code cannot be reproduced since machine recovers when cause of failure disap-
information pears.

Defective engine control- If this repeatedly occurs, engine controller may be defective. (In case of an internal
1
ler defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
PC210LCI-11 40-199
FAILURE CODE [A1U0N3] 40 TROUBLESHOOTING
FAILURE CODE [A1U0N3]

Action level Failure code Hydrocarbon Desorb Request 1
Failure
L01 A1U0N3 (Engine controller system)
Details of Unburned fuel remains in KDPF because engine has been running at low idle speed or low load for
failure a long time.
Action of Requests an operator to perform manual stationary regeneration (fuel drying). Or informs manual
controller stationary regeneration (fuel drying) is in progress.
Phenomenon Same phenomenon as automatic regeneration occurs. (When the machine is in a safe condition,
on machine machine controls the engine speed to stay up around 1000 rpm.)
k KDPF and KDOC become hot (Min. 500 °C). Be careful not to get burned.
• Temperature detected by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
ing function. (Code: 47400 (°C))
• Temperature detected by KDPF outlet temperature sensor can be checked with monitoring
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is performed due to the guidance of monitor display-
ing failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled. Accordingly, each temper-
Related ature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to approximately 250 to
information 400 °C.
• When manual stationary regeneration except above is in progress, KDOC inlet tempera-
ture is approximately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet tem-
perature are 450 to 600 °C.
• If there is a significant difference between KDOC inlet temperature and KDOC outlet tem-
perature when KDPF is completely cooled or engine is running at engine low idle speed
(without regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet
temperature sensor, whichever is suspected to be defective, judging from KDPF outlet
temperature.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.

Manual stationary regen- Follow the instruction on the monitor to perform manual stationary regeneration.
1 eration performed (to dry
If this failure code is cleared after this, repair work is complete.
KDPF)
1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
2
connector
If this failure code is cleared, wiring harness connector is defective.
NOTICE
If this failure code is displayed, perform the following checks:
40-200 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [A1U0N3]

Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform troubleshoot-
3
temperature sensor ing for [CA3313], [CA3314] or [CA3315].
After temperature is cooled down sufficiently, run engine at low idle speed and
Defective KDOC inlet check if temperature differences between the KDOC inlet temperature and the
4
temperature sensor KDOC outlet temperature, or KDPF outlet temperature is not large. If it is large dif-
ference, try to change KDOC inlet temperature sensor.
If the KDOC inlet temperature is approximately 250 °C or below during manual sta-
tionary regeneration and if the VGT solenoid current remains approximately
5 Defective VGT
1000 mA even when several hours have passed and the manual stationary regen-
eration does not complete, the VGT is defective.
Turn starting switch to ON position.
Defective engine control- If this failure code is still displayed and no failure is found by preceding checks, en-
6
ler gine controller is defective. (In case of an internal defect, troubleshooting is impos-
sible as an assembly. Replace whole assembly.)
PC210LCI-11 40-201
FAILURE CODE [A1U0N4] 40 TROUBLESHOOTING
FAILURE CODE [A1U0N4]

Action level Failure code Hydrocarbon Desorb Request 2
Failure
L03 A1U0N4 (Engine controller system)
Details of Unburned fuel remains in KDPF because engine has been running at low idle speed or low load for
failure a long time.
Action of Requests an operator to perform manual stationary regeneration (fuel drying). Or informs manual
controller stationary regeneration (fuel drying) is in progress.
Phenomenon Same phenomenon as automatic regeneration occurs. (When the machine is in a safe condition,
on machine machine controls the engine speed to stay up around 1000 rpm.)
difference between these temperatures are approximately 10 °C. (KDOC inlet temperature
> KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is performed due to the guidance of monitor display-
ing failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled. Accordingly, each temper-
Related ature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to approximately 250 to
400 °C.
information
• When manual stationary regeneration except above is in progress, KDOC inlet tempera-
ture is approximately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet tem-
perature are approximately 450 to 600 °C.
• If there is a significant difference between KDOC inlet temperature and KDOC outlet tem-
perature when KDPF is completely cooled or engine is running at engine low idle speed
(without regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet
temperature sensor, whichever is suspected to be defective, judging from KDPF outlet
temperature.
• After completion of repair, check that this failure code and failure code [A1U0N3] are
cleared by the following procedure.

Manual stationary regen- Follow the instruction on the monitor to perform manual stationary regeneration.
1 eration performed (to dry
If this failure code is cleared after this, repair work is complete.
KDPF)
40-202 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [A1U0N4]

2
connector
NOTICE
If this failure code is displayed, perform the following checks:
3
4
5 Defective VGT
6
PC210LCI-11 40-203
FAILURE CODE [A900FR] 40 TROUBLESHOOTING
FAILURE CODE [A900FR]

Action level Failure code Abrupt Engine Stop by Auto Idle Stop 3
Failure
L03 A900FR (Machine monitor system)
Detail of fail- Durability of turbocharger is degraded due to high engine speed before the engine is stopped by
ure auto idle stop function and frequent engine stops.
• Turn the auto-deceleration setting ON.
Action of
• Auto idle stop sudden stop monitor is displayed in red on machine monitor.
controller
• Resets when next auto idle stop countdown starts or starting switch is turned OFF.
Phenomenon
Turbocharger may get damaged.
on machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 2000
times.
• This failure code will be cleared after replacing the turbocharger assembly and resetting
Related the auto idle stop sudden engine stop counter.
Procedure: Before resetting the auto idle stop sudden engine stop counter, let the engine
stop by auto idle stop function with auto-deceleration turned OFF and fuel dial set at maxi-
mum.

If this repeatedly occurs even when the auto idle stop function is OFF, machine
1 monitor may be defective. (In case of an internal defect, troubleshooting is impossi-
tor
ble as an assembly. Replace whole assembly.)
40-204 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [A900N6]
FAILURE CODE [A900N6]

Action level Failure code Abrupt Engine Stop by Auto Idle Stop 1
Failure
- A900N6 (Machine monitor system)
Detail of fail-
Engine speed just before the engine is stopped by auto idle stop function is high.
ure
Action of
Turn the auto-deceleration setting ON.
controller
Phenomenon
None in particular
on machine
• This failure code is displayed if auto-deceleration is not OFF and fuel dial is not at mini-
mum when auto idle stop function commands engine stop.
• Engine speed can be checked with monitoring function. (Code: 01002)
Related
• Accumulated counts can be checked with auto idle stop sudden stops counter reset menu.
information
Procedure: Let the engine stop by auto idle stop function with auto-deceleration turned
OFF and fuel dial set at maximum.

tor
PC210LCI-11 40-205
FAILURE CODE [A900NY] 40 TROUBLESHOOTING
FAILURE CODE [A900NY]

Action level Failure code Abrupt Engine Stop by Auto Idling Stop 2
Failure
L01 A900NY (Machine monitor system)
Detail of fail- Accumulated count of abrupt engine stops is high because engine speed just before the engine is
ure stopped by auto idle stop function is high.
• Turn the auto-deceleration setting ON.
Action of
• Auto idle stop sudden stop monitor is displayed in red on machine monitor.
controller
• Resets when next auto idle stop countdown starts or starting switch is turned OFF.
Phenomenon
Turbocharger may get damaged.
on machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 1000
times.
• This failure code is not detected after replacing the turbocharger assembly and performing
Related “Reset Number of Abrupt Engine Stop by AIS”.
Procedure: Before resetting the auto idle stop sudden engine stop counter, let the engine
stop by auto idle stop function with auto-deceleration turned OFF and fuel dial set at maxi-
mum.

tor
40-206 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AA10NX]
FAILURE CODE [AA10NX]

Action level Failure code Air Cleaner Clogging
Failure
L01 AA10NX (Machine monitor system)
Detail of fail- Air cleaner clogging switch signal voltage is not 1 V and below while engine is running, and machine
ure monitor detects clogging of air cleaner (open of sensor contacts).
Action of ma-
Displays air cleaner clogging monitor in yellow on machine monitor.
chine monitor
Phenomenon
If machine is used as it is, engine may be damaged.
on machine
• Input (ON/OFF) from air cleaner clogging switch can be checked with monitoring function.
(Code: 04501)
Related
• After completion of repair, check that the failure code is cleared by the following proce-
information
dure.
Procedure: Start the engine.

Clogged air cleaner Air cleaner may be clogged. Check it for clogging and then clean or replace if clog-
1 (when system works ged.
properly)
Defective air cleaner
2 clogging switch (internal 2. Disconnect connector P23, and connect T-adapter to male side.
open circuit)
Resistance Between P23 (male) (1) and (2) Max. 1 Ω
Open circuit in wiring har- 2. Disconnect connectors CM02 and P23, and insert T-adapters to each fe-
ness (wire breakage or male side.
3
nector) Between CM02 (female) (4) and P23 (female) (1) Max. 1 Ω
Resistance
If failure code is still displayed after above checks, machine monitor is defective. (In
case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
Reference
4 1. Turn starting switch to OFF position.
tor
2. Insert T-adapters into connectors CM01 and CM02.
3. Start engine.
Voltage Between CM02 (4) and CM01 (3) Max. 1 V
PC210LCI-11 40-207
FAILURE CODE [AA10NX] 40 TROUBLESHOOTING
CIRCUIT DIAGRAM (AIR CLEANER CLOGGING SENSOR)
40-208 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AB00KE]
FAILURE CODE [AB00KE]

Failure Charge Voltage Low (Machine monitor system)
L03 AB00KE
Details of While engine is running, voltage from alternator drops, and machine monitor detects charge voltage
failure low.
Action of ma-
Displays the charge level monitor in red on machine monitor.
chine monitor
Phenomenon
If machine continues to be operated, battery may not be charged.
on machine
• Battery power supply can be checked with monitoring function. (Code: 04300 battery
Related charge voltage)
Procedure: Start engine.
Loose alternator terminal 1. Turn starting switch to OFF position.

1
or open circuit at terminal 2. Check terminal.
Defective charging by al- 2. Insert T-adapter into connector E08.
2 ternator (when system 3. Start engine.
works properly)
Between E08(1) and Engine speed: Medium or 27.5 to
Voltage
ground above 29.5 V
2. Disconnect diode D01 and connect T-adapter to male side.
REMARK
3 Defective diode Measure it in diode range.
No continui-
Between D01 (male) (2) (+) and (6) (-)
Continuity ty
Between D01 (male) (6) (+) and (2) (-) Continuity
Defective wiring harness 2. Insert T-adapter into connector CM01.
4
or machine monitor 3. Start engine.
Voltage Between CM01 (16) and ground 20 to 30 V
REMARK
If failure code is still displayed after above checks on cause 2, this check is not
Open circuit in wiring har- required.
nector) 2. Disconnect connectors CM01 and E08, and connect T-adapter to each fe-
male side.
Resistance Between CM01 (female) (16) and E08 (female) (1) Max. 1 Ω
PC210LCI-11 40-209
FAILURE CODE [AB00KE] 40 TROUBLESHOOTING

Ground fault in wiring 2. Disconnect connectors CM01 and E08, and connect T-adapter to either fe-
6 harness (contact with male side.
ground circuit)
Between CM01 (female) (16) and ground, or between
E08 (female) (1) and ground
Defective machine moni- If failure code is still displayed after above checks, machine monitor is defective.
7
tor (Because this is an internal defect, troubleshooting cannot be performed.)
40-210 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AB00KE]
CIRCUIT DIAGRAM (BATTERY CHARGE)
PC210LCI-11 40-211
FAILURE CODE [AQ10N3] 40 TROUBLESHOOTING
FAILURE CODE [AQ10N3]

Action level Failure code Manual Stationary Regeneration Request
Failure (KDOC Face Plugging)
L01 AQ10N3
(Engine controller system)
The Manual Stationary Regeneration Request (KDOC) requires the user to perform “manual station-
ary regeneration” to recover the efficiency effectively because the efficiency of KDOC (catalyst ac-
Detail of fail-
tion) (The soot in KCSF does not burn normally because the KDOC inlet temperature in regenera-
ure
tion is normally approximately 250 to 400 °C and the KDOC outlet temperature is normally approxi-
mately 450 to 600 °C but the KDOC outlet temperature does not rise).
Action of • EGR valve closed.
controller • Fuel dosing stops.
Phenomenon
• None
on machine
k KDOC and KDPF become hot (Min. 500 °C). Be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked with monitoring function
(Code: 47300(°C))
• Temperature in KDOC outlet temperature sensor can be checked with monitoring function
(Code: 47400(°C))
• Temperature in KDPF outlet temperature sensor can be checked with monitoring function
(Code: 47200(°C))
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
ON position.
Related • All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
information during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
ence is approximately 10 °C (KDOC inlet temperature > KDOC outlet temperature > KDPF
outlet temperature).
• During manual stationary regeneration, KDOC inlet temperature is approximately 250 to
400 °C, and both KDOC outlet temperature and KDPF outlet temperature are approxi-
mately 450 to 600 °C.
• The manual stationary regeneration (KDOC Face Plugging) does not perform fuel dozing
to recover the KDOC efficiently, so all of KDOC inlet temperature, KDOC outlet tempera-
ture, and KDPF outlet temperature become approximately 250 to 400 °C.
• The failure code [CA2637] is displayed while this failure code is displayed.
How to perform manual stationary regeneration
2. From service menu of machine monitor, display “Diagnostic Tests” screen, open “02 Active
Regeneration for Service”, and then perform “Manual Stationary Regeneration”.
REMARK
The manual stationary regeneration time of the Manual Stationary Regeneration Request (KDOC
Face Plugging) is approximately one and a half hours.
40-212 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AQ10N3]

If this failure code is displayed on the machine monitor for several hours after man-
Defective engine control- ual stationary regeneration has been performed, engine controller is defective. (In
1
ler case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
PC210LCI-11 40-213
FAILURE CODE [AS00N3] 40 TROUBLESHOOTING
FAILURE CODE [AS00N3]

Action level Failure code Manual Stationary Regeneration Request (SCR)
Failure
L01 AS00N3 (Engine controller systems)
Manual Stationary Regeneration Request (SCR) requires the user to perform “manual stationary re-
Detail of fail-
generation” to clear urea deposit effectively when the efficiency (catalyst action) of KDOC decreas-
ure
es or the KDOC outlet temperature in regeneration does not rise.
Action of
• Normal operation
controller
Phenomenon
None
on machine
k Since KDPF and KDOC are heated to 500 °C or above, be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked with monitoring function
(Code: 47300(°C))
• Temperature in KDOC outlet temperature sensor can be checked with monitoring function
(Code: 47400(°C))
• Temperature in KDPF outlet temperature sensor can be checked with monitoring function
(Code: 47200(°C))
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY”.
ON position.
• All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
Related during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
information
• During manual stationary regeneration, KDOC inlet temperature is approximately 280 to
400 °C, and both KDOC outlet temperature and KDPF outlet temperature are approxi-
mately 450 to 600 °C.
• During manual stationary regeneration (SCR), KDOC inlet temperature is approximately
250 to 400 °C, and both KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 350 to 600 °C to clear urea deposit.
• Even if regeneration is not implemented normally, the failure code [AS00N3] may disap-
pear.
• The failure code [CA3568], [CA3582] may be displayed while this failure code is displayed.
How to perform manual stationary regeneration
2. From service menu of machine monitor, display “Diagnostic Tests” screen, open “02 Active
Regeneration for Service”, and then perform “Manual Stationary Regeneration”.
REMARK
The manual stationary regeneration time of the Manual Stationary Regeneration Request (SCR) is
approximately an hour.
40-214 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AS00N3]

1
2 Defective VGT
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)
PC210LCI-11 40-215
FAILURE CODE [AS00R2] 40 TROUBLESHOOTING
FAILURE CODE [AS00R2]

Action level Failure code Warning 2 (SCR Device Abnormality)
Failure
L01 AS00R2 (Engine controller system)
• A certain time has passed since an abnormality of SCR System occurs.

Detail of fail-
ure • An abnormality of SCR system has occurred again within a certain time since abnormality
repair of SCR system. (EU specification)
Action of • The information related to this failure code is displayed on the monitor screen.
controller • [AS00R3] occurs and operates with restricted output after a certain time.
Phenomenon
The engine power deration after a certain time.
on machine
Related
This failure code is detected during engine operation.
information

Failure codes of SCR system abnormality are displayed. Perform troubleshooting
1 SCR system abnormality
for them.
Engine system abnormal- If any other failure codes than SCR system abnormality are displayed, perform
2
ity troubleshooting for them.
40-216 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AS00R3]

Action level Failure code Inducement 1 (SCR Device Abnormality)
Failure
• A certain time has passed since AS00R2 occurs.

Detail of fail-
repair of SCR system. (EU Specification)
• The information related to this failure code is displayed on the monitor screen.
Action of
• Engine power deration
controller
• [AS00R4] occurs and operates with largely restricted output after a certain time.
Phenomenon • Engine power deration
on machine • The engine output reduces heavily after a certain time.
• This failure code is detected during engine operation.
Related • If this failure code displays after SCR system abnormality is repaired and the engine con-
troller is shut down, run the engine for 1 minute to clear the failure code.
information
• After this failure code is cleared, engine power deration continues until the starting switch
is turned to OFF position.

for them.
2
PC210LCI-11 40-217

Failure
• A certain time has passed since AS00R3 occurs.

Detail of fail-
repair of SCR system. (EU Specification)
Action of • Controls engine output significantly for operation.
controller • [AS00R5] occurs and operates with engine speed is fixed at low idle speed after a certain
time.
Phenomenon • Engine output reduces heavily.
on machine • Engine speed is fixed at low idle speed.
• From the machine monitor, it is possible to perform a temporary restoration from induce-
ment to clear engine output low temporarily.
Related
• If this failure code displays after SCR system abnormality is repaired and the engine con-
information

for them.
2
40-218 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AS00R5]

Failure
Detail of fail-
Engine power deration.
ure
Action of • Engine power is restricted to low idle.
controller • Neither Manual Stationary Regeneration nor Active Regeneration for Service can be per-
formed.
Phenomenon
• Engine speed is fixed at low idle speed.
on machine
Related • If this failure code displays after SCR system abnormality is repaired and the engine con-
information

for them.
2
Repair completion re-judgment operation

Check if the repair has been completed with the following procedure:
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Start the engine, and run it at low idle.
3. Monitor the KDOC inlet temperature and drive until it becomes approximately 200 °C.
4. Make sure that this failure code is cleared.
PC210LCI-11 40-219

Action level Failure code Temporary Recovery of Inducement
Failure
- AS00R6 (Engine controller system)
Detail of fail- • Temporary recovery of inducement is implemented from the machine monitor while engine
ure deration.
Action of • Restore engine power temporarily
controller • The information related to this failure code is displayed on the monitor screen.
Phenomenon
• Engine power recovered temporarily.
on machine
• This failure code is not failure but caution to display that temporary restoration from in-
ducement has been performed on Abnormality Record screen and KOMTRAX on the ma-
Related
chine monitor.
information
• After performing “Temporary restoration from inducement”, “E” of this failure code that is
active currently is displayed for 20 second on the “Abnormality record” screen.
40-220 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AS00ZK]
FAILURE CODE [AS00ZK]

Action level Failure code AdBlue/DEF Level Low Error 5
Failure
L04 AS00ZK (Engine controller system)
Detail of fail-
AdBlue/DEF tank level lowers and a certain time has passed since failure code [CA3574] occurs.
ure
Action of • Engine power deration for operation.
controller • Neither Manual Stationary Regeneration nor Active Regeneration for Service can be per-
formed.
Phenomenon
Engine speed is fixed at low idle.
on machine
• The AdBlue/DEF level has been equivalent to or lower than 0.0 % for an hour.
Related • After repairing, check if the failure code is cleared by the following procedure.
information

2. Check the sight gauge to confirm that there is sufficient amount of
1 Low AdBlue/DEF level 3. Refill AdBlue/DEF if the level is low.
If this failure code is cleared, AdBlue/DEF has been insufficient.
1. Check the sensor connector for contamination and damage.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
3
PC210LCI-11 40-221
FAILURE CODE [AS10KM] 40 TROUBLESHOOTING
FAILURE CODE [AS10KM]

Action level Failure code AdBlue/DEF Injector Overheat Warning
Failure
L01 AS10KM (Machine monitor system)
Detail of fail- Engine stops over 150 times under the condition of engine and aftertreatment devices with high
ure temperature
Action of Displays the caution symbol of Engine Stop at AdBlue/DEF system Overheat on the machine moni-
controller tor.
Phenomenon
Defective injection of AdBlue/DEF may occur when engine starts operation again
on machine
• On the Pre-defined Monitoring screen, troubleshooting for the engine aftertreatment relat-
ed items is used (the figures below denote monitoring codes).
47000 KDPF Outlet Pressure
Related
47100 KDPF Differential Pressure
information
47200 KDPF 1 Outlet Temperature
47300 KDOC 1 Inlet Temperature
47400 KDOC 1 Outlet Temperature

Instruct an operator about performing running at low idle approximately 5 minutes
1 Defective operation
before stopping the engine.
40-222 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [AS10NR]
FAILURE CODE [AS10NR]

Action level Failure code AdBlue/DEF Injector High Temperature Warning
Failure
— AS10NR (Engine controller system)
Detail of fail- The temperature of the AdBlue/DEF injector may become so high that it is damaged, so the output
ure is limited.
Action of
• Changes to output limitation
controller
Phenomenon
on machine
• This may occur if a heavy load operation is performed for a long time during AdBlue/DEF
thawing.
• This may occur if a heavy load operation is performed for a long time when an error relat-
ed to SCR system occurs.
• If the engine coolant temperature is high, the cooling capability of the AdBlue/DEF injector
Related is degraded and a warning may appear.
information • If the ambient temperature sensor and engine room temperature sensor shows different
values (values much lower than the actual temperature), unnecessary thawing control is
applied and a warning may appear.
• This failure code is a warning for equipment protection and does not indicate any failures.
• Both failure code and output limitation are cleared by turning OFF and ON the starting
switch.

Occurrence of an error Confirm if an error that stops AdBlue/DEF injection is displayed.
related to SCR compo- If displayed, perform a cancellation process.
1
nents (error that stops
AdBlue/DEF injection)
Rising coolant tempera- Check the radiator condition if the radiator shutter prevents the coolant from work-
ture ing properly, or the radiator is clogged. Correct so that the radiator cooling capabili-
2 ty works sufficiently.
(degraded radiator capa-
bility)
Turn the starting switch to ON position.
Defective ambient tem-
3 If the temperature sensed by ambient temperature sensor is significantly low com-
perature sensor
pared to the actual temperature, the ambient temperature sensor is defective.
2. Open the pump side cover and wait for 5 minutes.
Defective engine room
4
temperature sensor If the temperature sensed by engine room temperature sensor is significantly low
compared to the actual temperature, the engine room temperature sensor is defec-
tive.
5
PC210LCI-11 40-223
FAILURE CODE [AS10NT] 40 TROUBLESHOOTING
FAILURE CODE [AS10NT]

Action level Failure code AdBlue/DEF Injector Overheat Caution
Failure
- AS10NT (Machine monitor system)
• Engine stops over 150 times under the condition of engine aftertreatment devices with
Details of high temperature. Engine may have been stopped without sufficient running at low idle
speed. Failure does not occur at once, but if it is repeated, it slowly damages AdBlue/DEF
failure injector. AdBlue/DEF injector will be damaged eventually, and it may cause defective injec-
tion or leakage of AdBlue/DEF.
Action of
None in particular (No error is displayed on the machine monitor.)
controller
Phenomenon
Defective injection of AdBlue/DEF may occur when engine starts operation again.
on machine
• On the Pre-defined Monitoring screen, aftertreatment devices related for engine are used
(the numbers below denote monitoring codes).
47000 KDPF Outlet Pressure
Related
47200 KDPF 1 Outlet Temperature
information
47300 KDOC 1 Inlet Temperature
47400 KDOC 1 Outlet Temperature
• Failure code [AS10KM] is displayed after this failure code has been detected 150 times or
more.

Instruct an operator about performing running at low idle approximately 5 minutes
1 Defective operation
before stopping the engine.
40-224 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [B@BAZG]
FAILURE CODE [B@BAZG]

Action level Failure code Engine Oil Pressure Low
Failure
L03 B@BAZG (Engine controller system)
Detail of fail- Signal voltage from engine oil pressure switch becomes GND while engine is running, and engine
ure controller detects engine oil pressure abnormality.
Action of • Lights up engine oil pressure monitor in red on machine monitor.
controller • Engine power deration.
Phenomenon • Engine power deration.
on machine • If machine is used as it is, engine may be seized.
• Signal voltage of engine oil pressure switch is input to engine controller that transmits the
information to machine monitor through CAN communication system.
Related • See failure code [CA435] for troubleshooting of engine oil pressure switch while engine is
information stopped.

1. Since engine oil pressure drop is sensed, check engine oil pressure.
Low engine oil pressure 2. Perform troubleshooting “Oil pressure drops”.
1 (when system works
properly) 3. In the case of excessive consumption of engine oil, perform troubleshoot-
ing “Engine oil consumption is excessive”.
Defective engine oil pres- If failure code is still displayed after above checks on cause 1, engine oil pressure
2
sure system switch system may be defective. Perform troubleshooting for failure code [CA435].
PC210LCI-11 40-225
FAILURE CODE [B@BAZK] 40 TROUBLESHOOTING
FAILURE CODE [B@BAZK]

Action level Failure code Eng Oil Level Low
Failure
L01 B@BAZK (machine monitor system)
Detail of fail- When the starting switch is turned ON, the signal voltage from the engine oil level switch becomes
ure higher than 1 V and the machine monitor detected engine oil level low (oil level switch OPEN).
Action of
Lights up engine oil level in yellow on machine monitor.
controller
Phenomenon
If machine is used as it is, engine may be seized.
on machine
• Input (ON/OFF) from engine oil level switch can be checked with monitoring function
Related (Code: 04501 Monitor input 2).

1. Since engine oil level drop is sensed, check engine oil level.
Low engine oil level 2. Perform troubleshooting “Oil pressure drops”.
1 (when system works
properly) 3. In the case of excessive consumption of engine oil, perform troubleshoot-
ing “Engine oil consumption is excessive”.
Defective engine oil level 2.
2 Disconnect connector P44, and connect T-adapter to male side.
sensor (internal defect)
Resistance Between P44 (male) (1) and ground Max. 1 Ω
ness (wire breakage or 2. Disconnect connectors CM02 and P44 and connect T-adapters to each fe-
3
defective contact of con- male side.
nector)
Resistance Between CM02 (female) (2) and P44 (female) (1) Max. 1 Ω
If failure code is still displayed after above checks, machine monitor is defective.
• Reference
4 2.
tor Insert T-adapters into connectors CM01 and CM02.
Voltage Between CM02 (female) (2) and CM01 (female) (3) Max. 1 V
40-226 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [B@BAZK]
Circuit diagram related to engine oil level
PC210LCI-11 40-227
FAILURE CODE [B@BCNS] 40 TROUBLESHOOTING
FAILURE CODE [B@BCNS]

Action level Failure code Engine Coolant Overheat
Failure
L02 B@BCNS (Engine controller system)
Details of Engine controller determines engine coolant temperature overheat when voltage from engine cool-
failure ant temperature sensor drops while engine is running.
Action of • Lights up engine coolant temperature monitor in red on machine monitor.

on machine • If machine is used as it is, engine may be seized.
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related
• Engine coolant temperature can be checked with monitoring function (Code: 04107)
information

Overheat of engine cool- Engine coolant may overheat. Check coolant temperature and remove cause of
1 ant (when system works failure if engine coolant overheats.
properly)
Defective engine coolant If failure code is still displayed after above checks on cause 1, engine coolant tem-
2 temperature sensor sys- perature sensor system may be defective. Perform troubleshooting for failure codes
tem [CA144] and [CA145].
40-228 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [B@BCZK]
FAILURE CODE [B@BCZK]

Action level Failure code Eng Water Level Low
Failure
L01 B@BCZK (Machine monitor system)
Details of Signal circuit of radiator coolant level switch is "OPEN" (disconnected from GND) when the engine
failure is stopped.
Action of ma-
None in particular
chine monitor
Phenomenon
Machine is used when coolant level is low, engine may overheat.
on machine
• Operation of radiator coolant level switch can be becked with (Code: 04500).
Related
information

Check whether radiator coolant level is normal.
1 Low radiator coolant level

NOTICE
If radiator coolant level is lowered, check periphery of engine and radia-
tor for leakage before refilling.
Defective radiator coolant
2 Radiator coolant level is
level sensor Max. 1 Ω
Between P24 (male) (1) normal.
Resistance
and ground
Low radiator coolant level Min. 1 MΩ
2. Disconnect connectors CM02 and P24 and connect T-adapters to each fe-
3 ness (wire breakage or male side.
defective contact) Between CM02 (female) (3) and P24 (female) (1) Max. 1 Ω
Resistance
2. Connect T-adapter to connector CM01,CM02.
Defective machine moni- 3. Turn starting switch to ON position.
4
tor Radiator coolant level is
CM02 (female) (3) to Max. 1 V
Voltage normal.
CM01 (female) (3)
Low radiator coolant level Min. 10 V
PC210LCI-11 40-229
FAILURE CODE [B@BCZK] 40 TROUBLESHOOTING
Circuit diagram related to radiator coolant level switch
40-230 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [B@HANS]
FAILURE CODE [B@HANS]

Action level Failure code Hydraulic Oil Overheat
Failure
L02 B@HANS (Engine controller system)
Detail of fail- Pump controller detects overheating of hydraulic oil temperature (approximately 102 °C or above)
ure by signal voltage of hydraulic oil temperature sensor while engine is running.
Action of • Displays hydraulic oil temperature monitor on machine monitor in red.
Phenomenon
If machine is used as it is, hydraulic component may be damaged.
on machine
• Signal from 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 "Hy-
draulic Oil Temperature")
Related
• See troubleshooting for “HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES
information
NOT MOVE FROM MINIMUM OR MAXIMUM” and “DISPLAY OF HYDRAULIC OIL TEM-
PERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE” in E mode.

Overheating of hydraulic Hydraulic oil may overheat. Check hydraulic oil temperature, and remove cause of
1 oil (when system is nor- failure if hydraulic oil overheats.
mal)
Defective hydraulic oil If failure code still displays after above checks on cause 1, hydraulic oil tempera-
2 temperature gauge sys- ture system may be defective. Perform troubleshooting for failure code [DGH2KB].
tem
PC210LCI-11 40-231
FAILURE CODE [CA115] 40 TROUBLESHOOTING
FAILURE CODE [CA115]

Action level Failure code Engine NE and Backup Speed Sensor Error (Engine controller sys-
Failure
L04 CA115 tem)
Details of
Errors occur simultaneously in signal circuits of Ne speed sensor and Bkup speed sensor.
failure
Action of
Stops engine.
controller
Phenomenon • Stopped engine cannot be started.
on machine • Running engine stops.
information Procedure: Start engine.

Defective connection of Since connection of connector between NE speed sensor and Bkup speed sensor
1
sensor connector may be defective (incorrect connection), check it.
Defective Ne speed sen- Perform troubleshooting for failure code [CA689].
2
sor system
Defective Bkup speed Perform troubleshooting for failure code [CA778].
3
sensor system
4
40-232 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [CA122]

Failure Charge Air Pressure Sensor High Error (Engine controller system)
L03 CA122
Details of
High voltage occurs in signal circuit of charge pressure sensor (boost pressure sensor).
failure
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2} ) for operation.
Action of • EGR valve closes and fully opens VGT.
controller • Engine power deration
• Regeneration control stops.
Phenomenon • Engine acceleration performance is poor.
on machine • Engine power deration
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
monitoring function. (Code: 36501 (V))
• Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
checked by monitoring function. (Code: 36500 (kPa))
Related
information
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
Defective sensor power If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
2
supply system first.
2. Disconnect connector BOOST PRESS & IMT.
If failure code changes from [CA122] to [CA123], charge pressure (boost pressure)
sensor is defective.
Defective charge (boost) Reference
3
pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ECM J1 or BOOST PRESS & IMT.
Between ECM J1 (45) and
Voltage (54), or between BOOST Sensor output 0.3 to 4.7 V
PRESS & IMT (1) and (4)
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
ness (ground line break-
4 T-adapters to each female side.
age or defective contact
of connector) Between ECM J1 (female) (54) and BOOST PRESS &
Resistance Max. 10 Ω
IMT (female) (4)
PC210LCI-11 40-233

Short circuit in wiring har- 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
5
ness T-adapter to female side of ECM J1.
Resistance Between ECM J1 (female) (45) and (78) Min. 100 kΩ
2. Disconnect connector BOOST PRESS & IMT and connect T-adapter to fe-
male side, or insert T-adapter into connector ECM J1.
Hot short circuit in wiring
6 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
harness
disconnected).
Between BOOST PRESS & IMT (1) and (4), or be-
Voltage Max. 1 V
tween ECM J1 (female) (45) and (54)
7
Circuit diagram related to charge air pressure sensor
40-234 PC210LCI-11

Failure Charge Air Pressure Sensor Low Error (Engine controller system)
L03 CA123
Details of
Low voltage occurs in signal circuit of charge pressure sensor (boost pressure sensor).
failure
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2} ) for operation.
Phenomenon • Engine acceleration performance is poor.
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
monitoring function. (Code: 36501 (V))
• Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
information Procedure: Turn starting switch to ON position.
• This failure code is displayed if sensor connector is disconnected.
code is cleared).

1
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
first.
Defective power supply
system of charge pres- 2. Disconnect connector BOOST PRESS & IMT and connect T-adapter to fe-
2
sure sensor (boost pres- male side.
sure sensor) 3. Switch ON
Between BOOST PRESS 4.75 to
Voltage Power supply
& IMT (female) (1) and (2) 5.25 V
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
T-adapters to each female side.
Between ECM J1 (female) (45) and BOOST PRESS &
ness (wire breakage or Max. 10 Ω
3 IMT (female) (1)
nector) Between ECM J1 (female) (62) and BOOST PRESS &
IMT (female) (3)
Between ECM J1 (female) (78) and BOOST PRESS &
Max. 10 Ω
IMT (female) (2)
PC210LCI-11 40-235

Short circuit in wiring har-
4 T-adapter to either female side.
ness
Between ECM J1 (female) (45) and (54), or between
Resistance Min. 100 kΩ
BOOST PRESS & IMT (female) (1) and (4)
1. Turn starting switch to OFF position to perform troubleshooting.
Ground fault in wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
5 harness (contact with T-adapter to either female side.
ground circuit)
Between ground and ECM J1 (female) (45) or BOOST
PRESS & IMT (female) (1)
If failure code is still displayed after above checks on causes 1 to 5 and any failure
is found by checks on cause 6, sensor is defective.
Defective charge (boost) 2. Insert T-adapter into connector ECM J1 or BOOST PRESS & IMT.
6
Voltage (54), or between BOOST Sensor output 0.3 to 4.7 V
PRESS & IMT (1) and (4)
7
Circuit diagram related to charge air pressure sensor
40-236 PC210LCI-11

Action level Failure code Throttle sensor high error
Failure
L03 CA131 (Engine controller system)
Detail of fail-
High voltage occurs in signal circuit of fuel dial sensor.
ure
• If error occurs while starting switch is ON, controller sets to fixed value used before the
Action of error has been detected and runs engine.
controller • If starting switch is turned to ON position after the error has occurred, controller uses a
value of 100%.
Phenomenon
Engine speed cannot be controlled by using fuel control dial.
on machine
• Signal voltage from fuel control dial can be checked with monitoring function. (Code:
Related 03000)

1
Defective throttle sensor If failure code [CA2185] or [CA2186] are displayed at the same time, perform trou-
2
power supply system bleshooting these first.
4.0 to
Between P20 (male) (1) and (3)
Defective fuel dial (throt- 6.0 kΩ
3
tle sensor)
0.25 to
Resistance Between P20 (male) (2) and (3)
5.0 kΩ
0.25 to
5.0 kΩ
1. Starting switch: OFF
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in 4.0 to
4 Between ECM J2 (female) (9) and (33)
wiring harness 6.0 kΩ
Resistance
0.25 to
Between ECM J2 (female) (9) and (10)
5.0 kΩ
quired.
5 2. Disconnect connectors ECM J2 and P20, and connect T-adapter to either
ness
female side.
P20 (female) (1) and (2)
PC210LCI-11 40-237

Hot short circuit in wiring 2. Disconnect connector P20 and connect T-adapter to female side.
6 harness (contact with
24 V 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.)
Defective engine control- 3. Starting switch: ON
7
ler 4. Operate fuel dial and perform troubleshooting.
Between ECM J2 (9) and 4.75 to
Power supply
(33) 5.25 V
Voltage
Sensor output 0.5 to 4.5 V
(33)
Circuit diagram related to throttle sensor
40-238 PC210LCI-11

Action level Failure code Throttle Sensor Low Error
Failure
Detail of fail-
Low voltage occurs in signal circuit of fuel dial sensor.
ure
• If error occurs while starting switch is ON, controller sets to fixed value used before the
Action of error has been detected and runs engine.
controller • If starting switch is turned to ON position after the error has occurred, controller uses a
value of 100%.
Phenomenon
Engine speed cannot be controlled by using fuel control dial.
on machine
• Signal voltage from fuel control dial can be checked with monitoring function. (Code:
Related 03000)

1
Defective throttle sensor If failure code [CA2185] or [CA2186] are displayed at the same time, perform trou-
2
power supply system bleshooting these first.
4.0 to
Defective fuel dial (throt- 6.0 kΩ
3
tle sensor)
0.25 to
5.0 kΩ
0.25 to
5.0 kΩ
Open or short circuit in 4.0 to
4 Between ECM J2 (female) (9) and (33)
wiring harness 6.0 kΩ
Resistance
0.25 to
5.0 kΩ
quired.
Open circuit in wiring har- 2.
Disconnect connectors ECM J2 and P20, and connect T-adapter to each
5 female side.
nector) Between ECM J2 (female) (9) and P20 (female) (1) Max. 10 Ω
Resistance Between ECM J2 (female) (10) and P20 (female) (2) Max. 10 Ω
Between ECM J2 (female) (33) and P20 (female) (3) Max. 10 Ω
PC210LCI-11 40-239

quired.
6 2. Disconnect connectors ECM J2 and P20, and connect T-adapter to either
ness
female side.
Ground fault in wiring 2. Disconnect connectors ECM J2 and P20, and connect T-adapter to either
7 harness (contact with female side.
ground circuit)
Between ground and ECM J2 (female) (10) or P20 (fe-
male) (2)
Defective engine control- 3. Starting switch: ON
8
ler 4. Operate fuel dial and perform troubleshooting.
Between ECM J2 (9) and 4.75 to
Power supply
(33) 5.25 V
Voltage
Sensor output 0.5 to 4.5 V
(33)
40-240 PC210LCI-11

Failure Coolant Temperature Sensor High Error (Engine controller system)
L01 CA144
Details of
High voltage occurs in signal circuit of engine coolant temperature sensor.
failure
Action of
Sets coolant temperature to fixed value for operation.
controller
Phenomenon • Engine startability becomes poor in low temperature.
on machine • Overheat prevention function does not operate.
• Signal voltage from engine coolant temperature sensor can be checked by monitoring
function. (Code: 04105 (V))
• Temperature in engine oil coolant sensor can be checked by monitoring function. (Code:
04107 (°C))
Related Procedure: Turn starting switch to ON position.
information • This failure code is displayed when temperature sensor connector is disconnected.
• Because female connector alone is provided in “Socket” for troubleshooting for this sen-
sor, socket cannot be connected to female connector on wiring harness side of sensor and
check for wire breakage cannot be performed (T-adapter is not provided).
k Do not work at high coolant temperature, when testing and replacing coolant temper-
ature sensor.

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
1
REMARK
Regard coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ
when coolant temperature is min. 0 °C.
0 °C 30 to 37 kΩ
9.3 to
25 °C
Defective coolant tem- 10.7 kΩ
2 Between COOLANT
perature sensor 3.2 to
TEMP (male) (A) and (B) 50 °C
3.8 kΩ
Coolant temperature char-
Resistance acteristics 1.0 to
80 °C
1.3 kΩ
700 to
95 °C
800 Ω
Between COOLANT
All coolant temperature
TEMP (male) (B) and Min. 100 kΩ
range
ground
PC210LCI-11 40-241

REMARK
Open or short circuit in
3 Use coolant temperature sensor resistance charac-
wiring harness
Resistance teristics table for check on cause 2 as criteria for re- 700 Ω to
sistance 37 kΩ
between ECM J1 (female) (83) and (54) (coolant tem-
perature: Min. 0 °C).
2. Disconnect connector COOLANT TEMP.
Hot short circuit in wiring 3.
4 Insert T-adapter into connector ECM J1.
harness
Voltage Between ECM J1 (83) and (54) Max. 5.25 V
2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect T-
5 adapter to female side of ECM J1.
ness
Between ECM J1 (female) (83) and each pin other No continui-
Continuity
than pin (83) ty
6
Electrical circuit diagram related to coolant temperature sensor
40-242 PC210LCI-11

Failure Coolant Temperature Sensor Low Error (Engine controller system)
L01 CA145
Details of
Low voltage occurs in signal circuit of engine coolant temperature sensor.
failure
Action of
Sets coolant temperature to fixed value for operation.
controller
on machine • Overheat prevention function does not operate.
• Signal voltage from engine coolant temperature sensor can be checked by monitoring
function. (Code: 04105 (V))
• Temperature in engine oil coolant sensor can be checked by monitoring function. (Code:
04107 (°C))
• When temperature sensor connector is removed, failure code for High Error [CA144] is
displayed instead of this failure code.
k Do not work at high coolant temperature, when testing and replacing coolant temper-
ature sensor.

1
REMARK
Regard coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ
when coolant temperature is min. 0 °C.
0 °C 30 to 37 kΩ
9.3 to
25 °C
Defective coolant tem- 10.7 kΩ
2 Between COOLANT
perature sensor 3.2 to
TEMP (male) (A) and (B) 50 °C
3.8 kΩ
Coolant temperature char-
Resistance acteristics 1.0 to
80 °C
1.3 kΩ
700 to
95 °C
800 Ω
Between COOLANT
All coolant temperature
TEMP (male) (B) and Min. 100 kΩ
range
ground
PC210LCI-11 40-243

REMARK
3 Use coolant temperature sensor resistance charac-
ness
Resistance teristics table for check on cause 2 as criteria for re- 700 Ω to
sistance 37 kΩ
between ECM J1 (female) (83) and (54) (coolant tem-
perature: Min. 0 °C).
Ground fault in wiring 2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect T-
adapter to female side of ECM J1.
ground circuit)
Resistance Between ECM J1 (female) (83) and ground Min. 100 kΩ
5
Electrical circuit diagram related to coolant temperature sensor
40-244 PC210LCI-11

Action level Failure code Charge Air Temperature Sensor High Error (Engine controller sys-
Failure
L03 CA153 tem)
Details of
High voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70 °C) for operation.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked by monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
Related
• Because female connector alone is provided in “Socket” for troubleshooting for this sen-
information
sor, socket cannot be connected to female connector on wiring harness side of sensor and
• This failure code is displayed when temperature sensor connector is disconnected.
code is cleared).

1
PC210LCI-11 40-245

2. Disconnect connector BOOST PRESS & IMT and connect socket to male
side.
REMARK
Regard charge temperature sensor as normal if its resistance is 80 Ω to 48 kΩ.
-40 °C 41 to 48 kΩ
-20 °C 14 to 16 kΩ
Defective charge temper-
2 5.4 to
ature sensor 0 °C
6.1 kΩ
Between BOOST PRESS
& IMT (male) (3) and (4) 1.6 to
30 °C
Resistance 1.8 kΩ
Charge thermal character-
istics 500 to
60 °C
600 Ω
230 to
90 °C
250 Ω
130 °C 80 to 90 Ω
Open or short circuit in REMARK

3
wiring harness Use charge temperature sensor resistance charac- 80 Ω to
Resistance teristics table for check on cause 2 as criteria for re- 48 kΩ
sistance
between ECM J1 (female) (62) and (54).
Hot short circuit in wiring 2. Disconnect connector BOOST PRESS & IMT.
4
harness 3. Insert T-adapter into connector ECM J1.
5 T-adapter to female side of ECM J1.
ness
Continuity
than pin (62) ty
6
40-246 PC210LCI-11
Circuit diagram related to charge temperature sensor
PC210LCI-11 40-247

Failure Charge Air Temperature Sensor Low Error (Engine controller system)
L03 CA154
Details of
Low voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70 °C) for operation.
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked by monitoring function. (Code: 18501 (V))
information
• When temperature sensor connector is removed, failure code for High Error [CA153] is
displayed instead of this failure code.
code is cleared).

1
2. Disconnect connector BOOST PRESS & IMT and connect socket to male
side.
REMARK
Regard charge temperature sensor as normal if its resistance is 80 Ω to 48 kΩ.
-40 °C 41 to 48 kΩ
-20 °C 14 to 16 kΩ
Defective charge temper-
2 5.4 to
ature sensor 0 °C
6.1 kΩ
Between BOOST PRESS
& IMT (male) (3) and (4) 1.6 to
30 °C
Resistance 1.8 kΩ
Charge thermal character-
istics 500 to
60 °C
600 Ω
230 to
90 °C
250 Ω
130 °C 80 to 90 Ω
40-248 PC210LCI-11

Short circuit in wiring har- REMARK

3
ness Use charge temperature sensor resistance charac- 80 Ω to
Resistance teristics table for check on cause 2 as criteria for re- 48 kΩ
sistance
between ECM J1 (female) (62) and (54).
4 harness (contact with 2. Disconnect connector ECM J1, and connect T-adapter to female side.
ground circuit)
5
Circuit diagram related to charge temperature sensor
PC210LCI-11 40-249

Action level Failure code Sensor 2 Supply Voltage Low Error
Failure
Details of
Low voltage occurs in sensor 2 supply (5 V) circuit.
failure
• Ignores signals from EGR valve lift sensor and VGT position sensor, and fixes values be-
Action of
fore detecting error for operation.
controller
Phenomenon
on machine
Related
information
code is cleared).

1
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 cleared, disconnected sensor or engine wiring harness is de-
fective.
Defective sensor or wir-
2 REMARK
ing harness
Other failure codes are also displayed. This is because connector is discon-
nected. Ignore all failure codes except for [CA187].
EGR valve lift sensor SEGR
Connector VGT position sensor SVGT
Engine wiring harness ECM J1
2. Disconnect connector ECM J1, and connect T-adapter to male side.
3. Turn starting switch ON with connector ECM J1 disconnected.
4. If no failure is found by this check, perform troubleshooting again from
Defective engine control-
3 cause 1 before replacing the engine controller.
ler
4.75 to
Voltage Between ECM J1 (male) (81) and (57)
5.25 V
40-250 PC210LCI-11
Circuit diagram related to sensor 2 supply circuit
PC210LCI-11 40-251

Action level Failure code Ambient Pressure Sensor High Error
Failure
Detail of fail-
High voltage occurs in signal circuit of ambient pressure sensor.
ure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
• Stops KDPF regeneration control.
Phenomenon
Engine power deration
on machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
Related function. (Code: 37400 (kPa))
• Engine power deration is canceled when this failure code is cleared and the starting switch
is turned to OFF position (not canceled only by deactivation of the failure code).

1
Defective ambient pres- If failure code [CA352] or [CA386] is displayed, perform troubleshooting these first.
2 sure sensor power sup-
ply system
2. Disconnect connector AMB.AIR PRESSURE.
If failure code [CA221] changes to [CA222], sensor is defective.
Defective ambient pres- Reference

sure sensor
2. Insert T-adapter into connector ECM J1 and AMB.AIR PRESSURE.
Between (54) and ECM J1
Voltage (44), or between (2) and Sensor output 0.3 to 4.7 V
AMB.AIR PRESSURE (3)
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and AMB.AIR PRESSURE and connect T-
ness (wire breakage of
4 adapters to each female side.
ground line or defective
contact of connector) Between ECM J1 (female) (54) and AMB.AIR PRES-
SURE (female) (2)
40-252 PC210LCI-11

2. Disconnect connectors ECM J1 and AMB.AIR PRESSURE, and connect
ness
AMB.AIR PRESSURE (female) (1) and (3)
2. Disconnect connector AMB.AIR PRESSURE, and connect T-adapter to fe-
Hot short circuit in wiring male side.
6
harness
Voltage Between (2) and AMB.AIR PRESSURE (female) (3) Max. 1 V
7
CIRCUIT DIAGRAM (AMBIENT PRESSURE SENSOR)
PC210LCI-11 40-253

Action level Failure code Ambient Pressure Sensor Low Error
Failure
Details of
Low voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa) for operation.
Phenomenon
on machine
• Signal voltage sensed by ambient pressure sensor can be checked with monitoring func-
tion. (Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
code is cleared).

1
If failure code [CA352] or [CA386] is displayed, perform troubleshooting these first.
Defective ambient pres- 2. Disconnect connector AMB.AIR PRESSURE, and connect T-adapter to fe-
2 sure sensor power sup- male side.
ply system 3. Switch ON
Between (2) and AMB.AIR 4.75 to
Voltage Turn power supply ON.
PRESSURE (female) (1) 5.25 V
2. Disconnect connectors AMB.AIR PRESSURE and ECM J1, and connect
ness
Between (54) and ECM J1 (female) (44), or between
(2) and AMB.AIR PRESSURE (female) (3)
Ground fault in wiring 2. Disconnect connectors AMB.AIR PRESSURE and ECM J1, and connect
ground circuit)
Between ground and ECM J1 (female) (44) or
AMB.AIR PRESSURE (female) (3)
40-254 PC210LCI-11

2. Disconnect connectors AMB.AIR PRESSURE and ECM J1 and connect T-
adapters to each female side.
Between ECM J1 (female) (44) and AMB.AIR PRES-
Open circuit in wiring har- Max. 10 Ω
5 SURE (female) (3)
ness
SURE (female) (2)
Max. 10 Ω
SURE (female) (1)
2. Insert T-adapter into connector ECM J1 or AMB.AIR PRESSURE.
Defective ambient pres- 3. Turn starting switch to ON position.
6
sure sensor
Between (54) and ECM J1
Voltage (44), or between (2) and Sensor output 0.3 to 4.7 V
AMB.AIR PRESSURE (3)
7
CIRCUIT DIAGRAM (AMBIENT PRESSURE SENSOR)
PC210LCI-11 40-255

Failure Sensor 2 Supply Voltage High Error (Engine controller system)
L03 CA227
Detail of fail-
High voltage occurs in sensor power supply 2 (5 V) circuit.
ure
• Ignores signals from EGR valve lift sensor and VGT position sensor, and fixes values be-
Action of
fore detecting error for operation.
controller
Phenomenon
on machine
Related Procedure: Turn starting switch to ON position.
information • Engine power deration is canceled when this failure code is cleared and the starting switch
is turned to OFF position (not canceled only by deactivation of the failure code).

Defective sensor 2 sup- Perform troubleshooting for failure code [CA187].
1
ply system
40-256 PC210LCI-11

Action level Failure code Engine Overspeed
Failure
Details of
Engine speed exceeds operating range.
failure
Action of
Restricts fuel injection rate until speed is lowered within operating range.
controller
Phenomenon
Engine speed varies.
on machine
• Engine speed can be checked with monitoring function. (Code: 01002 (rpm))
Related
information
Procedure: Start engine and run at high idle speed.

1 Improper fuel is used. Fuel used may be improper. Check it.
Defective relevant sys- If other failure codes are also displayed, perform troubleshooting for them.
2
tem
Method of using machine may be improper, so instruct operator on how to use ma-
3 Improper machine usage
chine properly.
If failure code is still displayed after above checks on causes 1 to 2, engine control-
4 ler is defective. (In case of an internal defect, troubleshooting is impossible as an
ler
assembly. Replace whole assembly.)
PC210LCI-11 40-257

Action level Failure code NE Speed Sensor Supply Voltage Error
Failure
Details of
Error occurs in NE speed sensor power supply (5 V) circuit.
failure
Action of
Controls by Bkup speed sensor signal.
controller
Phenomenon • Running engine stops (when Bkup (G) speed sensor is also defective).
on machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).

1
connector 2. Start the engine.
2. Disconnect following connectors one by one and turn starting switch to ON po-
sition each time.
3. Each time troubleshooting is finished at one connector , return to step 1.
and troubleshoot next connector.
If this code is not displayed, disconnected sensor or engine wiring harness is de-
fective.
2
ing harness REMARK
Many of other failure codes are displayed at the same time. This is because of
connector being disconnected. So ignore other codes than this failure code
[CA238].
CRANK
NE speed sensor
Connector SENSOR
3. Turn starting switch ON with engine wiring harness disconnected.
3 4.75 to
ler Voltage Between ECM J1 (male) (79) and (55)
5.25 V
40-258 PC210LCI-11
CIRCUIT DIAGRAM (Ne SPEED SENSOR)
PC210LCI-11 40-259

Action level Failure code NE Speed Sensor Supply Voltage High Error (Engine controller sys-
Failure
L01 CA239 tem)
Details of
High voltage occurs in power supply (5 V) circuit of Ne speed sensor.
failure
Action of
Controls by Bkup speed sensor signal.
controller
Phenomenon • Running engine stops (when Bkup (G) speed sensor is also defective).
on machine • Stopped engine cannot be started (when Bkup (G) speed sensor is also defective).

1
2. Disconnect connector CRANK SENSOR.
Defective NE speed sen-
sor
If this code is not displayed, disconnected sensor or engine wiring harness is de-
fective.
2. Disconnect connector ECM J1.
3 Defective wiring harness If this failure code is cleared, wiring harness is defective.
REMARK
Many of other failure codes are displayed at the same time. This is because of
connector being disconnected. So ignore other codes than this failure code
[CA239].
3. Turn starting switch ON with engine wiring harness disconnected.
4 4.75 to
ler Voltage Between ECM J1 (male) (79) and (55)
5.25 V
40-260 PC210LCI-11
PC210LCI-11 40-261

Action level Failure code Ambient Air Temp Sensor High Error
Failure
Detail of fail-
High voltage occurs in signal circuit of ambient temperature sensor.
ure
• Operates substituting the ambient temperature with the intake temperature.
Action of (If there are any abnormalities in the intake air temperature sensor, operates with the am-
controller bient temperature set to the default value (25 °C))
• Advances to Inducement strategy. (EU Specification)
• AdBlue/DEF line stops thawing.
Phenomenon • The NOx emission increases because the AdBlue/DEF injection becomes improper, or the
on machine AdBlue/DEF line cannot be thawed at low temperature.
• Engine power deration according to inducement strategy. (EU Specification)
• This failure code is displayed when ambient temperature sensor connector is disconnect-
Related ed.

Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check them.
1
connector 2. Turn the starting switch to ON position.
If this failure code is not displayed, the wiring harness connector is defective.
REMARK
If a resistance value of the ambient temperature sensor ranges from 280 Ω to
382 kΩ, the ambient temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
Defective ambient tem- 109 kΩ
2
perature sensor
0 °C 29 to 36 kΩ
7.3 to
Between P65 (male) (A) 30 °C
Resistance 8.8 kΩ
and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
40-262 PC210LCI-11

REMARK
3 Use ambient temperature sensor resistance characteristics table for check on
wiring harness
cause 2 as a resistance value.
280 Ω to
Resistance Between ECM J2 (female) (56) and (32)
382 kΩ
REMARK
harness
280 Ω to
382 kΩ
5
Circuit diagram related to ambient air temperature sensor
PC210LCI-11 40-263

Action level Failure code Ambient Air Temp Sensor Low Error
Failure
Detail of fail-
Low voltage occurs in signal circuit of ambient temperature sensor.
ure
• Operates substituting the ambient temperature with the intake temperature.
Action of (If there are any abnormalities in the intake air temperature sensor, operates with the am-
controller bient temperature set to the default value (25 °C))
Phenomenon • The NOx emission increases because the AdBlue/DEF injection becomes improper, or the
on machine AdBlue/DEF line cannot be thawed at low temperature.

1
REMARK
If a resistance value of the ambient temperature sensor ranges from 280 Ω to
382 kΩ, the ambient temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
Defective ambient tem-
2 0 °C 29 to 36 kΩ
perature sensor
7.3 to
Between P65 (male) (A) 30 °C
8.8 kΩ
Resistance and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
Between P65 (male) (B) and ground Min. 100 kΩ
40-264 PC210LCI-11

REMARK
wiring harness
280 Ω to
382 kΩ
Ground fault in wiring 2. Disconnect connectors ECM J2 and P65, and connect T-adapter to female
4
harness side of ECM J2.
5
Circuit diagram related to ambient air temperature sensor
PC210LCI-11 40-265

Action level Failure code IMV or PCV 1 Short Circuit Error
Failure
Details of
Short circuit is detected in supply pump actuator (IMV) drive circuit.
failure
Action of • Engine power deration.
controller • Close EGR valve.
• Engine speed does not increase from low idle speed.
on machine • Engine startability is poor.
• Common rail fuel pressure rises above command value.
• While engine is running normally, approximately 24 V of pulse voltage is supplied to PCV1
(1). Because it is pulse voltage, it cannot be measured by using multimeter.
information
ure code is cleared (note that the engine power deration is not canceled right after failure
code is cleared).

1. Check according to sections related to wiring harnesses and connectors in
“TROUBLESHOOTING-RELATED INFORMATION”, “CHECKS BEFORE
Defective wiring harness TROUBLESHOOTING”, “c Electrical equipment”.
1
connector 2. Start engine.
If this failure code goes out, wiring harness connector is defective.
2. Disconnect connector INLET METERING VALVE, and connect socket to
Defective supply pump male side.
2 PCV1 (internal short cir-
cuit) Resistance Between INLET METERING VALVE (male) (1) and (2) 2.3 to 5.3 Ω
Between INLET METERING VALVE (male) (1) and
ground
Short circuit in wiring har- 2. Disconnect connector ECM J1, and connect T-adapter to female side.
3
ness
Between ECM J1 (female) (10) and (11) (INLET ME-
Resistance 2.3 to 5.3 Ω
TERING VALVE resistance)
2. Disconnect connectors ECM J1 and INLET METERING VALVE, and con-
4 harness (contact with nect T-adapter to female side of ECM J1.
ground circuit) Between ECM J1 (female) (10) and ground Min. 100 kΩ
Resistance
Between ECM J1 (female) (11) and ground Min. 100 kΩ
Hot short circuit in wiring 2. Insert T-adapter into connector ECM J1.
5
harness 3. Turn starting switch to ON position.
Voltage Between ECM J1 (10) and ground Max. 1 V
40-266 PC210LCI-11

6
Circuit diagram related to IMV/PCV1
PC210LCI-11 40-267

Action level Failure code IMV or PCV 1 Open Circuit Error
Failure
L03 CA272 (Engine controller systems)
Details of
Open circuit is detected in supply pump actuator (IMV) drive circuit.
failure
controller • Close EGR valve.
Phenomenon • Engine startability is poor.
on machine • Engine runs but its speed does not stabilize.
• Common rail fuel pressure rises above command value.
• While engine is running normally, approximately 24 V of pulse voltage is supplied to PCV
(1). Because it is pulse voltage, it cannot be measured by using multimeter.
Related • Because female connector alone is provided in “Socket” for troubleshooting for this sen-
information sor, socket cannot be connected to female connector on wiring harness side of sensor and
ure code is cleared (note that the engine power deration is not canceled right after failure
code is cleared).

1. Check according to sections related to wiring harnesses and connectors in
“TROUBLESHOOTING-RELATED INFORMATION”, “CHECKS BEFORE
Defective wiring harness TROUBLESHOOTING”, “c Electrical equipment”.
1
connector 2. Start engine.
If this failure code goes out, wiring harness connector is defective.
Defective supply pump 2. Disconnect connector INLET METERING VALVE, and connect socket to
2 PCV1 (internal short cir-
male side.
cuit)
Resistance Between INLET METERING VALVE (male) (1) and (2) 2.3 to 5.3 Ω
Open or short circuit in 2. Disconnect connector ECM J1, and connect T-adapter to female side.
3
wiring harness
Between ECM J1 (female) (10) and (11) (INLET ME-
Resistance 2.3 to 5.3 Ω
TERING VALVE resistance)
4
40-268 PC210LCI-11
Circuit diagram related to IMV/PCV1
PC210LCI-11 40-269

Action level Failure code Injector #1 (L#1) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA322 controller system)
Details of
Open or short circuit is detected in #1 injector circuit.
failure
Action of
None in particular
controller
on machine • Engine does not run stably.
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
information tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
• If ground fault or hot short circuit is detected, failure codes [CA322], [CA331] and [CA324]
appear simultaneously.

1. See “RELATED INFORMATION ON TROUBLESHOOTING”, “CHECKS
BEFORE TROUBLESHOOTING”, “Electrical equipment”, and check them
Defective wiring harness according to the descriptions of wiring harness and connectors.
1
2. Disconnect connector INJECTOR CYL 1 & 2, and connect T-adapter to
2 Defective injector #1 male side.
Between INJECTOR CYL 1 & 2 (male) (3) and (4) Max. 2 Ω
Resistance
Between INJECTOR CYL 1 & 2 (male) (3) and ground Min. 100 kΩ
Open circuit or ground
3
fault in wiring harness Between ECM J1 (female) (25) and (1) Max. 2 Ω
Resistance
quired.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
ness (wire breakage or T-adapter to each female side.
4
nector) Between ECM J1 (female) (25) and INJECTOR CYL 1
Max. 2 Ω
& 2 (female) (3)
Resistance
Between ECM J1 (female) (1) and INJECTOR CYL 1 &
Max. 2 Ω
2 (female) (4)
40-270 PC210LCI-11

quired.
Ground fault in wiring 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
5 harness (contact with T-adapter to each female side.
ground circuit) Between ground and ECM J1 (female) (25) or INJEC-
Min. 100 kΩ
TOR CYL 1 & 2 (female) (3)
Resistance
Between ground and ECM J1 (female) (1) or INJEC-
Min. 100 kΩ
2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
T-adapter to female side of ECM J1.
Short circuit in wiring har- No continui-

6 Between ECM J1 (female) (25) and each pin other
ness ty (no sound
than pin (25)
is heard)
Continuity
No continui-
Between ECM J1 (female) (1) and each pin other than
ty (no sound
pin (1)
is heard)
2. Insert T-adapter to connector ECM J1.
Hot short circuit in wiring Voltage Between ECM J1 (25) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector INJECTOR CYL 1 & 2 and
measure the voltage at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
9
Circuit diagram related to injector #1
PC210LCI-11 40-271

Failure
Details of
failure
Action of
None in particular
controller
Related • If ground fault or hot short circuit is detected, failure codes [CA323], [CA325] and [CA332]
information appear simultaneously.
• While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.

1
Resistance
3
Resistance
quired.
4
Max. 2 Ω
& 6 (female) (3)
Resistance
Between ECM J1 (female) (74) and INJECTOR CYL 5
Max. 2 Ω
& 6 (female) (4)
40-272 PC210LCI-11

quired.
5 harness (contact with T-adapter to each female side.
Min. 100 kΩ
Resistance
Min. 100 kΩ

ness ty (no sound
than pin (50)
is heard)
Continuity
No continui-
Between ECM J1 (female) (74) and each pin other
ty (no sound
than pin (74)
is heard)
7
harness
harness
9
PC210LCI-11 40-273

Failure
Details of
failure
Action of
None in particular
controller
Procedure: Start engine

1
Resistance
3
Resistance
quired.
4
Max. 2 Ω
& 4 (female) (3)
Resistance
Max. 2 Ω
4 (female) (4)
40-274 PC210LCI-11

quired.
Min. 100 kΩ
Resistance
Min. 100 kΩ

ness ty (no sound
than pin (27)
is heard)
Continuity
No continui-
ty (no sound
pin (3)
is heard)
7
harness
harness
9
PC210LCI-11 40-275

Failure
Details of
failure
Action of
None in particular
controller

1
Resistance
3
Resistance
quired.
4
Max. 2 Ω
& 6 (female) (2)
Resistance
Max. 2 Ω
& 6 (female) (1)
40-276 PC210LCI-11

quired.
Min. 100 kΩ
Resistance
Min. 100 kΩ

ness ty (no sound
than pin (51)
is heard)
Continuity
No continui-
ty (no sound
than pin (75)
is heard)
7
harness
harness
9
PC210LCI-11 40-277

Failure
Details of
failure
Action of
None in particular
controller

1
Resistance
3
Resistance
quired.
4
Max. 2 Ω
& 2 (female) (2)
Resistance
Max. 2 Ω
2 (female) (1)
40-278 PC210LCI-11

quired.
Min. 100 kΩ
Resistance
Min. 100 kΩ

ness ty (no sound
than pin (26)
is heard)
Continuity
No continui-
ty (no sound
pin (2)
is heard)
7
harness
harness
9
PC210LCI-11 40-279

Failure
Details of
failure
Action of
None in particular
controller
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
information tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
• If ground fault or hot short circuit is detected, failure codes [CA323], [CA325] and [CA332]
appear simultaneously.

1
Resistance
3
Resistance
quired.
4
Max. 2 Ω
& 4 (female) (2)
Resistance
Max. 2 Ω
& 4 (female) (1)
40-280 PC210LCI-11

quired.
Min. 100 kΩ
Resistance
Min. 100 kΩ

ness ty (no sound
than pin (49)
is heard)
Continuity
No continui-
ty (no sound
than pin (73)
is heard)
7
harness
harness
9
PC210LCI-11 40-281

Failure Engine Controller Internal Failure (Engine controller system)
L04 CA343
Details of
Internal defect is detected in engine controller.
failure
Action of
None in particular
controller
Phenomenon Engine runs normally. However, engine may be stopped during operation or stopped engine may
on machine not be started.
• Battery voltage of engine controller can be checked by monitoring function. (Code: 03203)
Related
information

Defective engine control- Perform troubleshooting for failure code [CA441].
1
ler system
40-282 PC210LCI-11

Failure Injectors Drive Circuit Error (Engine controller system)
L03 CA351
Details of
Error occurs in injector drive circuit
failure
Action of
Restricts engine output for operation (restricts common rail pressure).
controller
Phenomenon
on machine

Defective relevant sys- If other failure codes (for injector system) are also displayed, perform troubleshoot-
1
tem ing for them.
2
ler system
PC210LCI-11 40-283

Failure Sensor 1 Supply Voltage Low Error (Engine controller system)
L03 CA352
Details of
Low voltage occurs in sensor power supply 1 (5 V) circuit.
failure
• Ignores signal from Bkup speed sensor, and operates by NE speed sensor signal.
• Ignores signal from ambient pressure sensor, and fixes ambient pressure value to
(52.44 kPa {0.53 kg/cm2} ) for operation.
• Ignores signal from charge (boost) pressure sensor, and fixes charge (boost) pressure val-
Action of ue to (400 kPa {4.1 kg/cm2} ) for operation.
controller • Ignores signal from crankcase pressure sensor, and fixes crankcase pressure value to
(0 kPa {0 kg/cm2} ) for operation.
• EGR valve closes and fully opens VGT.
Phenomenon
on machine
Related
information
code is cleared).

1
40-284 PC210LCI-11

position each time.
If this failure code is cleared, disconnected sensor or engine wiring harness is de-
fective.
REMARK
Other failure codes are also displayed. This is because connector is discon-
nected. Ignore all failure codes except for [CA352].
2 CAM SEN-
ing harness Bkup speed sensor
SOR
BOOST
PRESS &
Charge (Boost) pressure sensor
TEMPERA-
Connector TURE
AMB.AIR
Ambient pressure sensor
PRESSURE
Crank case pressure sensor P57
3. Turn starting switch ON with connector ECM J1 disconnected.
4. If no failure is found by this check, perform troubleshooting again from
3 cause 1 before replacing the engine controller.
ler
4.75 to
Voltage Between ECM J1 (male) (78) and (54)
5.25 V
PC210LCI-11 40-285
Circuit diagram related to sensor 1 supply circuit
40-286 PC210LCI-11

Failure MAF Sensor High Error (Engine controller system)
L03 CA356
Details of
High frequency input error is detected in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) for operation.
Phenomenon
on machine
• Because sensor output is approximately 5 V of pulse waveform, it is not measured by us-
ing multimeter.
• Mass air flow sensor and intake air temperature sensor are provided as a unit.
code is cleared).

1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
Defective wiring harness ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
1
Defective sensor power If failure code [CA3419] or [CA3421] are displayed at the same time, perform trou-
2
supply system bleshooting these first.
2. Disconnect connector P55.
Defective mass air flow
If this failure code changes to failure code [CA357], mass air flow sensor is defec-
tive.
1. Perform preparation when starting switch is in OFF position.
2. Disconnect connector P55 and connect T-adapter to female side.
Defective sensor power
supply system
Between P55 (female) (2) Approx.
and (3) 12 V
PC210LCI-11 40-287

quired.
2. Disconnect connectors ECM J1 and P55, and connect T-adapters to each
5 female side.
contact of connector) REMARK
Open circuit in GND line
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to female
Short circuit in wiring har- side of ECM J1.
6
ness Check by using multimeter in continuity mode.
Continuity
than (32) pin. ty
7
CIRCUIT DIAGRAM (MASS AIR FLOW SENSOR)
40-288 PC210LCI-11

Failure Mass Air Flow Sensor Low Error (Engine controller system)
L03 CA357
Details of
Low frequency input error is detected in signal circuit of mass air flow sensor.
failure
• Sets mass air flow sensor to fixed value (10 kg/min) for operation.
Phenomenon
on machine
• Because sensor output is approximately. 5 V of pulse waveform, it is not measured by us-
ing multimeter.
• This failure code and failure code [CA691] are displayed simultaneously if sensor connec-
Related tor is removed.
code is cleared).

1
Defective sensor power If failure code [CA3419] or [CA3421] are displayed at the same time, perform trou-
2
supply system bleshooting these first.
Defective mass air flow 2. Replace mass air flow sensor.
3
sensor (internal defect) 3. Turn starting switch to ON position.
If this failure code is cleared, originally-provided mass air flow sensor is defective.
2. Disconnect connector P55 and connect T-adapter to female side.
supply system
Between P55 (female) (2) Approx.
and (3) 12 V
PC210LCI-11 40-289

2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
female side.
Open circuit in wiring har- If failure code is still displayed after above checks on
ness (wire breakage or cause 4, this check is not required. Max. 10 Ω
5
defective contact of con- Between ECM J1 (female) (80) and P55 (female) (2)
nector)
Resistance If failure code is still displayed after above checks on
cause 4, this check is not required. Max. 10 Ω
Between ECM J1 (female) (56) and P55 (female) (3)
ground circuit)
male) (1)
7
Continuity
than (32) pin. ty
8
Voltage Between P55 (female) (1) and (3) Max. 1 V
9
40-290 PC210LCI-11

Failure Sensor 1 Supply Voltage High Error (Engine controller system)
L03 CA386
Details of
High voltage occurs in sensor power supply 1 (5 V) circuit.
failure
• Ignores signal from Bkup speed sensor, and operates by NE speed sensor signal.
• Ignores signal from ambient pressure sensor, and fixes ambient pressure value to
(52.44 kPa {0.53 kg/cm2} ) for operation.
• Ignores signal from charge (boost) pressure sensor, and fixes charge (boost) pressure val-
Action of ue to (400 kPa {4.1 kg/cm2} ) for operation.
controller • Ignores signal from crankcase pressure sensor, and fixes crankcase pressure value to
(0 kPa {0 kg/cm2} ) for operation.
• EGR valve closed.
Phenomenon
on machine
Related
• Engine power deration is canceled by turning starting switch to OFF position after this the
information
failure code is cleared (note that the engine power deration is not canceled right after the
failure code is cleared).

Defective sensor 1 sup- Perform troubleshooting for failure code [CA352].
1
ply system
PC210LCI-11 40-291

Action level Failure code Water in Fuel Sensor High Error
Failure
L01 CA428 (Engine Controller System)
Detail of fail-
High voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
ure
Action of
None in particular
controller
Phenomenon
Water separator monitor is not displayed properly
on machine
• State (ON/OFF) of water-in-fuel sensor signal can be checked with monitoring function.
Related (Code: 18800 State of WIF sensor)

1
connector
REMARK
If this failure code is displayed, perform following.
Defective water-in-fuel
REMARK
2 sensor installed to fuel
prefilter If water is in fuel prefilter, drain it.
10 to
100 kΩ
Short circuit or ground 2. Disconnect connector ECM J2 and connect T-adapter to female side.
3
fault in wiring harness
Between ECM J2 (female) (13) and (32) (Water sensor 10 to
Resistance
resistance) 100 kΩ
REMARK
required.
ness (wire breakage or 1. Perform preparation when starting switch is in OFF position.
4
defective contact of con- 2. Disconnect connectors ECM J2 and P47, and connect T-adapter to female
nector) side of ECM J2 and female side of P47.
Resistance
40-292 PC210LCI-11

5
ness
No continui-
Continuity ty (no
than pin (13)
sound)
6
Circuit diagram related to water-in-fuel sensor
PC210LCI-11 40-293

Failure Water in Fuel Sensor Low Error (Engine Controller System)
L01 CA429
Detail of fail-
Low voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
ure
Action of
None in particular
controller
Phenomenon
Water separator monitor is not displayed properly
on machine
• State (ON/OFF) of water-in-fuel sensor signal can be checked with monitoring function.
Related (Code: 18800 State of WIF sensor)

1
connector
REMARK
Defective water-in-fuel REMARK

2 sensor installed to fuel If water is in fuel prefilter, drain it.
prefilter
10 to
Resistance 100 kΩ
Between P47 (male) (1) and ground Min. 100 kΩ
2. Disconnect connector ECM J2 and connect T-adapter to female side of
Short circuit or ground connector.
3
fault in wiring harness Between ECM J2 (female) (13) and (32) (water-in-fuel 10 to
Resistance sensor resistance) 100 kΩ
Between ECM J2 (female) (13) and ground Min. 1 Ω
4
ness
No continui-
Continuity ty (no
than pin (13)
sound)
40-294 PC210LCI-11
REMARK
required.
ground circuit) 2. Disconnect connectors ECM J2 and P47, and connect T-adapter to either
of female side of ECM J2 or female side of P47
male) (2)
6
Circuit diagram related to water-in-fuel sensor
PC210LCI-11 40-295

Action level Failure code Engine Oil Pressure SW Error
Failure
Details of
Failure occurs in engine oil pressure switch signal circuit.
failure
Action of
None in particular.
controller
Phenomenon • Protection function based on engine oil pressure does not work.
on machine • Engine oil pressure monitor is not displayed normally.
Procedure: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is
stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running).
• To generate this failure code, engine controller checks whether engine oil pressure switch
Related is in CLOSED (ON) only when engine is stopped, that is, whether signal voltage is zero or
information not.
• Failure of engine oil pressure switch when engine is running is indicated by failure code
[B@BAZG].
REMARK
When performing checking and replacement of engine oil pressure switch, open oil filler port,
and check that engine oil temperature cools down enough not to get scalded.

Defective harness con- 2. Turn starting switch to ON position.
1
nector
REMARK
2. Disconnect connector OIL PRESSURE SWITCH and connect Tadapters to
Defective engine oil pres-
2 male side.
sure switch
Between OIL PRESSURE SWITCH (male) (1) and
ground
Open circuit or ground 2.
3 Disconnect connector ECM J1 and connect T-adapters to female side.
Resistance Between ECM J1 (female) (52) and ground Max. 10 Ω
4
40-296 PC210LCI-11
Circuit diagram related to engine oil pressure switch
PC210LCI-11 40-297

Action level Failure code Power Voltage Low Error
Failure
Detail of fail-
Low voltage occurs in power supply circuit of controller.
ure
Action of
Operates at fixed value (approximately 6.0 V) of battery voltage.
controller
Related
information
Procedure: Turn engine starting switch to ON position.

Loose or corroded bat- Battery terminal may be loose or corroded. Check it directly.
1
tery terminal
Loose terminal or partial 1. Turn starting switch to OFF position.

2
open circuit at terminal Check terminals of the alternator, battery, ground terminal (T12), etc.
3
1. Perform troubleshooting with starting switch at OFF position and when starting
4 Improper battery voltage engine.
Voltage Between battery (+) and (-). 20 to 30 V
5 Defective alternator 2. Start engine. (Engine speed: Medium or higher)
Voltage alternator terminal R and ground 26 to 30.5 V
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
3. Turn battery disconnect switch to ON position.
Defective engine control- 4. Measure voltage with starting switch at OFF position and when starting en-
6
ler gine.
40-298 PC210LCI-11
CIRCUIT DIAGRAM (ENGINE CONTROLLER POWER SUPPLY)
PC210LCI-11 40-299

Action level Failure code Battery voltage high error
Failure
Detail of fail-
High voltage (Min. 36 V) occurs in power supply circuit of controller.
ure
Action of
Operates at fixed value (approximately 36 V) of battery voltage.
controller
Related
information

1
ler power supply system
40-300 PC210LCI-11

Action level Failure code Common Rail Pressure High Error 2
Failure
Details of
High pressure error (exceeding specified maximum level) has occurred in common rail pressure.
failure
Action of
• Restricts engine output for operation.
controller
Phenomenon
on machine
• Signal voltage from common rail pressure sensor can be checked by monitoring function.
(Code: 36401 (V))
Related • Common rail pressure in common rail pressure sensor can be checked by monitoring
information function. (Code: 36400 (MPa))

1
tem
Air may be in low-pressure circuit. Check it according to the following procedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel prefilter.
2 Air in low-pressure circuit 3. Check pressure pickup plug for leakage of fuel and air.
If this error occurs during air bleeding after fuel filter is replaced, air may remain in
fuel circuit. Keep running engine at low idle speed for approximately 3 minutes. As
air is bled from fuel circuit, engine speed is stabilized, and error display disappears.
For the test of the fuel return piping, see “TEST FUEL PRESSURE” of TESTING
AND ADJUSTING.
Defective fuel return pip- Max.
3 Fuel return
ing 18.6 kPa
piping pres- At low idle or at cranking
sure {Max.
0.19 kg/cm2}
Defective common rail Perform troubleshooting for failure code [CA451] and [CA452].
4
pressure sensor system
For details of testing pressure limiter leakage amount, see TESTING AND AD-
JUSTING, “TEST FUEL RETURN RATE AND LEAKAGE”.
5 Defective pressure limiter Leakage
Max.
from pres- At low idle (for 30 seconds)
8 cc/30 sec
sure limiter
6 Defective supply pump If failure code is still displayed after above checks, supply pump may be defective.
PC210LCI-11 40-301

Action level Failure code Common Rail Pressure Sensor High Error
Failure
Details of
High voltage occurs in signal circuit of common rail pressure sensor.
failure
Action of
• Restricts common rail pressure.
controller
• Close EGR valve.
Phenomenon
on machine
(Code: 36401 (V))
• Common rail pressure in common rail pressure sensor can be checked by monitoring
function. (Code: 36400 (MPa))
Related • This failure code is displayed if connector of common rail pressure sensor is disconnected.
information • Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after failure code
is cleared).

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
If this failure code is cleared, harness connector is defective.
Defective common rail If failure code [CA515] or [CA516] is also displayed, perform troubleshooting these
2 pressure sensor power first.
supply system
Open circuit in wiring har- If failure code is still displayed after above checks, wiring harness may have open
ness (wire breakage or circuit.
3
defective contact of con- See “Troubleshooting method for open circuit in wiring harness of pressure sensor
nector) system” of “RELATED INFORMATION ON TROUBLESHOOTING”
Short circuit in wiring har- 2. Disconnect connectors FUEL RAIL PRESS and ECM J1, and connect T-
4
ness adapter to female side of ECM J1.
2. Disconnect connector FUEL RAIL PRESS.
Hot short circuit in wiring 4. Starting switch: ON
5
harness
REMARK
Voltage of 5 V is connected to ECM J1 pin (42) through resistor in engine controller.
Approxi-
Voltage Between ECM J1 (42) and (58)
mately 5 V
40-302 PC210LCI-11

If no failure is found by checks on causes 1 to 5 and any failure is found by checks
on cause 6, sensor is defective.
Defective common rail 2. Insert T-adapter into connector ECM J1.
6
pressure sensor
3. Starting switch: ON
(58)
7
Circuit diagram related to common rail pressure sensor
PC210LCI-11 40-303

Action level Failure code Common Rail Pressure Sensor Low Error
Failure
Details of
Low voltage occurs in signal circuit of common rail pressure sensor.
failure
Action of
• Restricts common rail pressure.
controller
Phenomenon
on machine
(Code: 36401 (V))
Related • If temperature sensor connector is removed even in normal condition, failure code for High
Error [CA451] is displayed instead of this failure code.
information
is cleared).

1
Defective common rail If failure code [CA515] or [CA516] is also displayed, perform troubleshooting these
2 pressure sensor power first.
supply system
If failure code [CA452] changes to [CA451], sensor is defective.
Defective common rail Reference
3
pressure sensor 1. Starting switch: OFF
(58)
Open circuit in wiring har- If failure code is still displayed after above checks, wiring harness may have open
ness (5 V line breakage circuit.
4
or defective contact of See “Troubleshooting method for open circuit in wiring harness of pressure sensor
connector) system” of “RELATED INFORMATION ON TROUBLESHOOTING”
40-304 PC210LCI-11

Ground fault in wiring 2. Disconnect connectors ECM J1 and FUEL RAIL PRESS, and connect T-
ground circuit)
Short circuit in wiring har- 2. Disconnect connectors ECM J1 and FUEL RAIL PRESS, and connect T-
6
ness adapter to female side of ECM J1.
7
PC210LCI-11 40-305

Action level Failure code Charge Air Temperature High Torque Derate
Failure
Details of Temperature signal from boost pressure & temperature sensor exceeds upper limit of control tem-
failure perature.
Action of
Restricts engine output and allows engine to run.
controller
Phenomenon
on machine
• Boost temperature can be checked with monitoring function. (Code: 18500)
Related
information

Aftercooler cooling performance may be degraded. Check for following points:
Drop of cooling perform- • Defective fan rotation
1
ance of aftercooler • Insufficient cooling air
• Clogged aftercooler fins
Unusual rise of turbo- Outlet temperature of turbocharger may be unusually high. Check related parts.
2 charger outlet tempera-
ture
Defective boost tempera- Perform troubleshooting for failure codes [CA153] and [CA154].
3
ture sensor system
40-306 PC210LCI-11

Action level Failure code Common Rail Pressure Sensor Supply Voltage High Error (Engine
Failure
Detail of fail-
High voltage occurs in power supply (5 V) of common rail pressure sensor.
ure
controller • Restricts common rail pressure.
Phenomenon
on machine
Procedure: Turn the starting switch to ON position.
Related
• Because female connector alone is provided in "Socket" for troubleshooting for this sen-
information
sor, check for open circuit in wiring harness and voltage check cannot be performed (T-
adapter is not provided).

1
Defective common rail
2 pressure sensor (internal If this failure code is cleared any more, sensor is defective.
defect)
REMARK
Other failure codes are displayed at the same time. This happens because the
connector is disconnected. So ignore other codes than this failure code.
3 Defective wiring harness If this failure code is cleared, wiring harness system may be defective. perform fol-
lowing diagnosis.
REMARK
Many other failure codes appear at same time because of disconnected con-
nector. Ignore failure codes other than this.
quired.
Hot short circuit in wiring 2. Disconnect connector FUEL RAIL PRESS.

4
harness 3. Insert T-adapter into connector ECM J1.
4.75 to
Voltage Between ECM J1 (82) and (58)
5.25 V
PC210LCI-11 40-307

Defective engine control- 4.7 to
5 Voltage Between ECM J1 (male) (82) and (58)
ler 5.25 V
If failure code is still displayed after above checks, engine controller is defective.
Replace engine controller. (Troubleshooting will be impossible, because this is an
internal defect.)
40-308 PC210LCI-11

Action level Failure code Common Rail Pressure Sensor Supply Voltage Low Error (Engine
Failure
Detail of fail-
Low voltage occurs in power supply (5 V) of common rail pressure sensor.
ure
controller • Restricts common rail pressure.
Phenomenon
on machine
Related
• Because female connector alone is provided in "Socket" for troubleshooting for this sen-
information
sor, check for open circuit in wiring harness and voltage check cannot be performed (T-
adapter is not provided).

1
Defective common rail
2 pressure sensor (internal If this failure code is cleared any more, sensor is defective.
defect)
REMARK
Other failure codes are displayed at the same time. This happens because the
connector is disconnected. So ignore other codes than this failure code.
3 Defective wiring harness If this failure code is cleared, wiring harness system may be defective. perform fol-
lowing diagnosis.
REMARK
Many other failure codes appear at same time because of disconnected con-
nector. Ignore failure codes other than this.
quired.
Ground fault in wiring 1. Starting switch: OFF
2. Disconnect connectors ECM J1, and connect T-adapter to female side of
ground circuit)
ECM J1.
PC210LCI-11 40-309

quired.
5
ness 2. Disconnect connectors ECM J1, FUEL RAIL PRESS, and connect T-
Defective engine control- 4.7 to
ler 5.25 V
internal defect.)
40-310 PC210LCI-11

Failure Common Rail Pressure High Error 1 (Engine controller system)
L01 CA553
Details of
Common rail pressure high error 1 (indicated pressure is higher than that which is assumed)
failure
Action of
None in particular
controller
Phenomenon
on machine
(Code: 36401 (V))

1
tem
Ground terminal may be connected defectively. Check following terminals directly.
• Ground terminal of machine ((-) terminal of battery)
Defective connection of • Ground terminal of engine
3
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
Defective electrical sys- Since common rail pressure sensor may have electrical defect, perform trouble-
4 tem of common rail pres- shooting for following failure codes. [CA451], [CA452]
sure sensor
Defective mechanical Common rail pressure sensor may have mechanical trouble. Check it.
5 system of common rail
pressure sensor
Overflow valve spring may be broken, seat may be worn, and ball may be stuck.
6 Defective overflow valve
Check them.
7 Clogged overflow piping Overflow piping may be clogged. Check it.
8 Defective pressure limiter Pressure limiter may be defective mechanically. Check it.
PC210LCI-11 40-311

Action level Failure code Crankcase Pressure High Error 2
Failure
Details of
High pressure error (level 1) in crankcase pressure is detected.
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Signal voltage from crankcase pressure sensor can be checked by monitoring function.
(Code: 48401 (V))
• Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
Related
48400 (kPa))
information
• This failure code is cleared when failure code [CA1942] is displayed.

1 Clogged KCCV filter Replace the KCCV filter.
If an error persists after replacement of the KCCV filter and emulsions are detected
Blocked KCCV gas pip-
2 inside KCCV, blocked emulsions may be suspected in KCCV blow by gas piping.
ing
Check that there is no coolant leakage.
Defective crankcase Crankcase pressure sensor system may be defective. Perform troubleshooting for
3
pressure sensor failure codes [CA1843] and [CA1844].
The error does not disappear after replacing KCCV filter, and “Crankcase Pressure
High Error 1” or “Crankcase Pressure High Error 2” is also displayed, piston ring
4 Increase of blowby gas may be worn or broken, or oil from VGT may be leaked, valve guide and stem seal
may be worn or damaged. Perform troubleshooting “TROUBLESHOOTING OF EN-
GINE (S MODE)”, “Engine oil consumption is excessive”.
40-312 PC210LCI-11

Failure Crankcase Pressure High Error 3 (Engine controller system)
L03 CA556
Details of
High pressure error (level 2) in crankcase is detected.
failure
Action of
controller
on machine • Oil may leak from seals or gauge.
(Code: 48401 (V))
Related
48400 (kPa))
information
• This failure code is cleared when failure code [CA1942] is displayed.

ing
3
PC210LCI-11 40-313

Action level Failure code Common Rail Pressure Low Error 1
Failure
Details of
No-pressure error (level 1) is detected in supply pump.
failure
• Engine power deration.
Action of
controller
• Stop regeneration control.
Phenomenon
on machine
Related • Engine power deration is canceled by turning starting switch to OFF position after this fail-
information is cleared).

1 Non-fuel Check the remaining quantity of fuel
Defective fuel tank Fuel tank breather may be clogged. Check it directly
3
breather
Fuel may be leaking to outside. Check it directly (Check visually while running en-
4 Fuel leakage to outside
gine at low idle)
For the test of the fuel low-tension circuit pressure, see “TEST FUEL PRESSURE”
of TESTING AND ADJUSTING.
Max.
Inlet negative pressure of -40.7 kPa
fuel supply pump (fuel pre- At high idle speed {Max.
filter outlet pressure) -305 mmHg}

Defective low-pressure 207 to
5
circuit component 500 kPa
Pressure At cranking
{2.11 to
5.1 kg/cm2}
Fuel main filter inlet pres-
sure 207 to
650 kPa
At high idle speed {2.11 to
6.63 kg/cm2
}
For check of return rate from injector, see TESTING AND ADJUSTING, “TEST
Fuel leakage from inlet FUEL RETURN RATE AND LEAKAGE”.
6 connector (inside head)
(note 2) If fuel return rate is excessive, check the tightening of high-pressure pipe connect-
ing part referring to "Note 2".
40-314 PC210LCI-11

For check of return rate from injector, see TESTING AND ADJUSTING, “TEST
FUEL RETURN RATE AND LEAKAGE”.
At cranking Max.
7 Defective injector (Min. 150 rpm, for 30 seconds) 45 cc/30 sec
Return rate
from injector At low idle Max.
125 cc/30
(For 30 seconds) sec
For details of testing return rate from supply pump, see TESTING AND ADJUST-
ING, “TEST FUEL RETURN RATE AND LEAKAGE”.
At cranking Max.
575 cc/30
8 Defective supply pump Return rate (Min. 150 rpm, for 30 seconds) sec
from supply
pump At low idle Max.
575 cc/30
(For 30 seconds) sec
For details of testing pressure limiter leakage amount, see TESTING AND AD-
JUSTING, “TEST FUEL RETURN RATE AND LEAKAGE”.
9 Defective pressure limiter Leakage
Max.
from pres- At low idle (for 30 seconds)
8 cc/30 sec
sure limiter
Air may be in low-pressure circuit. Check it according to the following procedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel prefilter.
10 Air in low-pressure circuit 3. Check pressure pickup plug for leakage of fuel and air.
If this error occurs during air bleeding after fuel filter is replaced, air may remain in
fuel circuit. Keep running engine at low idle speed for approximately 3 minutes. As
air is bled from fuel circuit, engine speed is stabilized, and error display disappears.
Defective common rail Perform troubleshooting for failure code [CA451] and [CA452].
11
pressure sensor system
Note 1: Investigate low-pressure fuel circuit parts for following items.

1. Clogging of fuel tank breather
2. Leakage from or clogging of low-pressure fuel piping
3. Clogging of fuel prefilter
4. Clogging of fuel main filter
5. Replace fuel filter when problem is not removed even if no clogging is found.
Note 2
PC210LCI-11 40-315
High-pressure pipe from common rail is connected to the injector via inlet connection (11) inside of the cylinder
head.
Since inlet connection (11) is tightened with retainer (10), retighten retainer (10).
3 Retainer:
50 ± 4 Nm {5 ± 0.4 kgm}
40-316 PC210LCI-11

Action level Failure code Turbocharger Speed High Error 2
Failure
Details of
Turbocharger rotates at abnormally high speed.
failure
Action of
Runs turbocharger speed at fixed value of 125000 rpm.
controller
Phenomenon
None in particular
on machine
• Turbocharger speed in turbocharger speed sensor can be checked by monitoring function.
(Code: 48100 (rpm))
Related
• Because sensor output is pulse waveform, it is not measured by using multimeter.
information

Increase of turbocharger Since turbocharger speed may increase, check it.
1
speed
2 Defective turbocharger Turbocharger may have a failure. Check it.
Defective turbocharger If no failure is found in cause 1, the turbocharger speed sensor system may be de-
3
speed sensor fective. Perform troubleshooting for failure code [CA687].
PC210LCI-11 40-317

Action level Failure code Turbocharger Speed Low Error
Failure
Details of
Turbocharger turbine blade rotates at abnormal low speed.
failure
Action of
controller
Phenomenon
on machine
k VGT is heated to 500 °C and above. Be careful not to get burn injury.
• Because sensor output is pulse waveform, it is not measured by using multimeter.
• Turbocharger speed in turbocharger speed sensor can be checked by monitoring function.
(Code: 48100 (rpm))
Related • Engine speed can be checked by monitoring function. (Code: 01002 (rpm))
information • Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
• This failure code is displayed if VGT speed sensor connector is disconnected.
Procedure: Start engine and sets engine speed to 1200 rpm or higher, and set charge
pressure sensor (boost pressure sensor) to approximately 120 kPa or higher.

1 Defective turbocharger Turbocharger may have a failure. Check it.
2
connector 2. Run engine at high idle speed.
Defective VGT speed 2. Disconnect connector VGT REV. and connect T-adapter to female side.
3
600 to
Resistance Between VGT REV. (female) (1) and (2)
1600 Ω
Open circuit and short 1. Turn starting switch to OFF position.
circuit in wiring harness 2. Disconnect connector ECM J1, and connect T-adapter to female side.
4 (short circuit, wire break-
age or defective contact 600 to
of connector) 1600 Ω
If failure code is still displayed after above checks on open circuit and short circuit
in wiring harness, this check is not required.
2. Disconnect connectors ECM J1 and VGT REV., and connect T-adapters to
Open circuit in wiring har- each female side.
5
ness
Between ECM J1 (female) (17) and VGT REV. (fe-
Max. 10 Ω
male) (1)
Resistance
Between ECM J1 (female) (16) and VGT REV. (fe-
Max. 10 Ω
male) (2)
40-318 PC210LCI-11

2. Disconnect connectors ECM J1 and VGT REV., and connect T-adapter to
6 either female side.
ness
VGT REV. (female) (1) and (2)
2. Disconnect connectors ECM J1 and VGT REV., and connect T-adapter to
Ground fault in wiring either female side.
7 harness (contact with Between ground and ECM J1 (female) (17) or VGT
ground circuit) Resistance Min. 100 kΩ
REV. (female) (1)
Between ground and ECM J1 (female) (16) or VGT
REV. (female) (2)
Hot short circuit in wiring 2. Disconnect connector ECM J1, and connect T-adapter to female side.
8
Voltage Between ECM J1 (female) (17) and ground Max. 1 V
Defective sensor installa- Defective VGT speed sensor (looseness) or defective parts for speed detection
9 tion or defective parts for (VGT internal parts) (including deformation by heat) may be suspected. Check it.
speed detection
10
CIRCUIT DIAGRAM (TURBO SPEED SENSOR)
PC210LCI-11 40-319

Failure Engine NE Speed Sensor Error (Engine controller system)
L01 CA689
Detail of fail-
Error occurs in the signal from engine NE speed sensor.
ure
Action of
Operates by Bkup speed sensor signal.
controller
• Running engine stops (when Bkup (CAM) speed sensor is also defective).
Phenomenon • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
on machine • Engine hunts.
• Engine startability is poor.
• Because internal speed sensor consists of hole sensor and electronic circuit instead of
coil, whether speed sensor is normal or not cannot be determined even if resistance of
Related
speed sensor is measured by using multimeter.
information
• Because speed sensor output is 5 V of pulse voltage, it cannot be measured by using mul-
timeter.
• Speed sensor senses the passes of speed sensing wheel oblong hole installed to inside of
crankshaft vibration damper rotated with crankshaft.

1
Defective NE speed sen- If failure code [CA238] or [CA239] is displayed, perform troubleshooting for the
2
sor power supply system code first.
Engine NE speed sensor Engine NE speed sensor may be broken or installed improperly (loosened). Check
3 broken or installed im- it.
properly (loosened)
2. Disconnect connector CRANK SENSOR, and connect T-adapter to female
Defective NE speed sen- side.
4
sor power supply system 3. Starting switch: ON
Between CRANK SEN- 4.75 to
SOR (female) (1) and (2) 5.25 V
40-320 PC210LCI-11

2. Disconnect connectors ECM J1 and NE, and connect T-adapters to each
female side.
If failure code is still displayed after above checks on
cause 4, this check is not required.
Between ECM J1 (female) (79) and CRANK SENSOR
5 (female) (1)
nector) If failure code is still displayed after above checks on
Resistance
Max. 10 Ω
(female) (2)
Max. 10 Ω
(female) (3)
2. Disconnect connectors ECM J1 and NE, and connect T-adapter to either
female side.
6 Between ECM J1 (female) (79) and (31), or between
ness Min. 100 kΩ
CRANK SENSOR (female) (1) and (3)
Resistance
Min. 100 kΩ
CRANK SENSOR (female) (2) and (3)
Ground fault in wiring 2. Disconnect connectors ECM J1 and NE, and connect T-adapter to either
ground circuit)
Between ground and ECM J1 (female) (31) or CRANK
SENSOR (female) (3)
Hot short circuit in wiring 2. Disconnect connector NE, and connect T-adapter to female side.
8
Voltage Between CRANK SENSOR (female) (3) and ground Max. 1 V
Breakage or looseness of Check speed sensing wheel.
9 rotation speed sensed (See cause 3 for failure code [CA731].)
wheel
If failure code is still displayed after above checks, the engine Ne speed sensor
Defective engine NE
10 may be defective. (In case of an internal defect, troubleshooting is impossible as an
speed sensor
11
PC210LCI-11 40-321
40-322 PC210LCI-11

Failure Intake Air Temperature Sensor High Error (Engine controller system)
L01 CA691
Details of
High voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of
Sets intake air temperature to fixed value (25 °C) for operation.
controller
Phenomenon
None in particular
on machine
Related • This failure code and failure code [CA357] are displayed simultaneously if sensor connec-
tor is removed.
information

1
-30 °C 25 to 28 kΩ
5.5 to
0 °C
Between P55 (male) (3) 6.1 kΩ
Defective intake air tem- and (4) 1.9 to
2 perature sensor (internal 25 °C
Characteristic of intake 2.1 kΩ
defect) temperature - resistance
Resistance 1.1 to
value 40 °C
1.2 kΩ
180 to
100 °C
185 Ω
Between P55 (male) (3)
Entire area Min. 100 kΩ
and ground (sensor body)
Open circuit and short
circuit in wiring harness REMARK
3 (short circuit, wire break- Use intake temperature sensor resistance characteristics table for check on
age or defective contact
cause 2 as an air intake temperature resistance value.
of connector)
180 Ω to
28 kΩ
PC210LCI-11 40-323

Hot short circuit in wiring 3. Insert T-adapter into connector ECM J1, or connect T-adapter to female
4
harness side of P55.
Between ECM J1 (32) and (56) or P55 (female) (1) and
Voltage Max. 5.25 V
(3)
5
than pin (61)
6
40-324 PC210LCI-11

Failure Intake Air Temperature Sensor Low Error (Engine controller system)
L01 CA692
Details of
Low voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of
Sets intake air temperature to fixed value (25 °C) for operation.
controller
Phenomenon
None in particular
on machine
Related
information

1
If this failure code changes to failure code [CA691]. intake air temperature sensor is
defective.
Defective intake air tem- -30 °C 25 to 28 kΩ

2 perature sensor (internal 5.5 to
defect) 0 °C
Between P55 (male) (3) 6.1 kΩ
and (4) 1.9 to
25 °C
Characteristic of intake 2.1 kΩ
Resistance temperature - resistance 1.1 to
value 40 °C
1.2 kΩ
180 to
100 °C
185 Ω
Between P55 (male) (3)
Entire area Min. 100 kΩ
and ground (sensor body)
ground circuit)
male) (4)
PC210LCI-11 40-325

4
than pin (61)
5
40-326 PC210LCI-11

Action level Failure code Engine Controller Internal Temperature Sensor High Error
Failure
Details of
High voltage error occurs in signal circuit of engine controller internal temperature sensor.
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Temperature detected by engine controller internal temperature sensor can be checked
Related with monitoring function. (Code: 18900 (°C))

Improper use of control- Check that controller is not used in high temperature environment.
1
ler
2
PC210LCI-11 40-327

Action level Failure code Engine Controller Internal Temperature Sensor Low Error
Failure
Details of
Low voltage error occurs in signal circuit of engine controller internal temperature sensor.
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Temperature detected by engine controller internal temperature sensor can be checked
Related with monitoring function. (Code: 18900 (°C))

Improper use of control- Check that controller is not used in low temperature environment.
1
ler
2
40-328 PC210LCI-11

Action level Failure code Engine Backup Speed Sensor Phase Error
Failure
Detail of fail- Engine controller detects phase error by signal from engine Bkup speed sensor. (Compared with
ure signal from NE speed sensor, phase does not fit.)
Action of
Controls by NE speed sensor signal.
controller
• Running engine stops (when NE speed sensor is also defective).
Phenomenon
• Engine cannot start or engine is hard to start.
on machine
• Engine idling speed is unstable.

Breakage of engine NE Engine NE speed sensor (CRANK sensor) may be broken. Check it.
1
speed (CRANK) sensor
Breakage of engine Bkup Engine Bkup speed sensor (CAM sensor) may be broken. Check it.
2
speed (CAM) sensor
1. Align painted mark (M1) of damper with damper mounting bolt (M2).
REMARK
Installation error or dam-
3 age of speed sensing No. 1 cylinder is not at its compression top dead center.(before top dead cen-
wheel on crankshaft side ter (B.T.D.C), approximately 76 to 80 °)
2. Installation is correct if the center of speed sensing wheel oblong hole (WS) is
on the top face of NE speed sensor (M3).
Speed ring on camshaft side may be installed improperly or damaged. Check it ac-
cording to the following procedure.
Improper installation or 1. Set No. 1 cylinder to compression top dead center (align stamping mark).
4 damage of speed sens-
ing ring on camshaft side 2. Remove Bkup speed sensor.
3. Installation is correct if twin groove (single rib) (B) of speed sensing ring is visi-
ble through sensor mounting hole (H).
• Timing of crankshaft and camshaft may be defective. Check it directly.
Defective timing of crank-
5 • Remove engine front cover, and check that matchmarks of crank gear and
shaft and camshaft
cam gear are matched.
Ground terminal may be connected defectively. Check following terminals directly.
• Ground terminal of machine ((-) terminal of battery)
Defective connection of • Ground terminal of engine
6
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
PC210LCI-11 40-329
Engine NE speed (CRANK) sensor
Engine Bkup speed (CAM) sensor
40-330 PC210LCI-11

Action level Failure code Engine Backup Speed Sensor Error
Failure
Detail of fail-
Error is detected in engine Backup speed sensor circuit.
ure
Action of
Operates by NE speed sensor signal.
controller
• Running engine stops (when NE speed sensor is also defective).
Phenomenon
• Stopped engine cannot be started (when NE speed sensor is also defective).
on machine
• Engine startability is deteriorated (when NE speed sensor is normal).
• Because internal speed sensor consists of electronic circuit instead of coil, whether speed
sensor is normal or not cannot be determined even if resistance of speed sensor is meas-
Related
ured by using multimeter.
information
• Because speed sensor output is 5 V of pulse voltage, it cannot be measured by using mul-
timeter.
• Speed sensor senses the speed by groove of speed sensing ring installed to the cam-
shaft.

1
2
Breakage or defective in- Engine Bkup speed (CAM) sensor may be broken or installed improperly (loos-
stallation (looseness) of ened). Check it.
3
engine Bkup speed
(CAM) sensor
2. Disconnect connector CAM SENSOR and connect T-adapters to female
Defective engine Bkup side.
4 speed sensor power sup-
ply system
Between CAM SENSOR 4.75 to
(female) (1) and (2) 5.25 V
PC210LCI-11 40-331

2. Disconnect connectors ECM J1 ,CAM SENSOR, and connect T-adapters
to each female side.
If power supply voltage in check on cause 5 is normal,
this check is not required.
Open circuit in wiring har- Max.10 Ω
ness Between ECM J1 (female) (78) and CAM SENSOR
5 (female) (1)
(wire breakage or defec-
tive contact of connector) Resistance If power supply voltage in check on cause 5 is normal,
Max.10 Ω
Between ECM J1 (female) (54) and CAM SENSOR
(female) (2)
Between ECM J1 (female) (18) and CAM SENSOR
Max.10 Ω
(female) (3)
2. Disconnect connectors ECM J1, CAM SENSOR, and connect T-adapters
to female side of ECM J1 or CAM SENSOR.
ness Min.100 kΩ
CAM SENSOR (female) (1) and (3)
Resistance
Min.100 kΩ
CAM SENSOR (female) (2) and (3)
2. Disconnect connectors ECM J1 and G, and connect T-adapters to either
harness
7 female side.
(contact with ground cir-
cuit) Between ground and ECM J1 (female) (18) or CAM
Resistance Min.100 kΩ
SENSOR (female) (3)
2. Disconnect connectors CAM SENSOR and connect T-adapters to female
Hot short circuit in wiring side of CAM SENSOR.
8
harness 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
disconnected).
Voltage Between CAM SENSOR (female) (3) and ground Max.1 V
Remove e Bkup speed (CAM) sensor, and check through hole (H).
Looseness of speed
9 sensing ring on camshaft REMARK
side
If camshaft speed sensing ring (B) is loose, see “Reference”.
If failure code is still displayed after above checks, engine Bkup speed sensor is
Defective engine Bkup
10 defective. (In case of an internal defect, troubleshooting is impossible as an assem-
speed sensor
bly. Replace whole assembly.)
11
40-332 PC210LCI-11
CIRCUIT DIAGRAM (Bkup (CAMSHAFT) SPEED SENSOR)
Reference: Check of camshaft gear for looseness (107 Engine)

Remove pulley, damper, front seal, front cover, and housing, and check camshaft ring for looseness.
REMARK
Prepare front seal, gasket, liquid gasket LG-7, and front seal tool (795-799-6400).
Removal
1. Remove cooling assembly.
2. Remove compressor belt. For details, see DISASSEMBLY AND ASSEMBLY, “REMOVE AND INSTALL EN-
GINE FRONT OIL SEAL”.
3. Remove damper assembly (1).
PC210LCI-11 40-333
(DP): Dowel pin
4. Remove front cover (2).

5. Remove front seal (3).
(RING): Ring
6. Check mounting bolt (4) of camshaft ring (5) for looseness.

10±2 Nm {0.98±0.2 kgm}
Installation
REMARK
For the figure, see Removal.
1. Install front cover (2).
2 Housing:
Liquid gasket LG-7
2. See DISASSEMBLY AND ASSEMBLY, “REMOVE AND INSTALL ENGINE FRONT OIL SEAL” and,.
1) Install front seal (3).
40-334 PC210LCI-11
2) Install dowel pin (DP), and install damper assembly (1).

3) Install compressor belt.
4) Install cooling assembly.
PC210LCI-11 40-335

Action level Failure code Engine Controller Partial Data Lost Error
Failure
Details of
Internal defect is detected in controller.
failure
Action of
None in particular
controller
• Engine runs normally. However, engine may be stopped during operation or stopped en-
Phenomenon
gine may not be started.
on machine
• Engine controller cannot memorize internal data correctly.
• Engine controller internal data (related to KDPF, AdBlue/DEF Level, etc.) may be lost. Ap-
propriate remedy must be performed after resetting error.
Related • This error code is displayed when power supply is disconnected by battery disconnect
switch, etc. before engine controller is normally exited.
information
NOTICE
Remedy after resetting error
See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SETTING TESTING
(ACTIVE REGENERATION FOR SERVICE)” in “SETTING AND OPERATION OF MACHINE
MONITOR” to perform “Active Regeneration for Service”.

Defective power supply Since the power supply circuit may be defective, perform troubleshooting for failure
1
circuit system code [CA441].
Improper operation of Battery disconnect switch may be operated improperly.
2
battery disconnect switch
3
40-336 PC210LCI-11

Action level Failure code KDOC Abnormality
Failure
Details of During regeneration, KDOC inlet temperature sensor and KDOC outlet temperature sensor indicate
failure similar values (temperature difference is approximately within 10°C).

Action of • Engine power deration
controller • Regeneration control stops.
• Fuel dosing stops.
Phenomenon
on machine
k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
low idle speed (KDPF regeneration is not executed) are 100 to 250 °C, and difference be-
tween these temperatures is approximately 10 °C. (KDOC inlet temperature > KDOC out-
let temperature > KDPF outlet temperature)
• When manual stationary regeneration is in progress, KDOC inlet temperature is 250 to
400 °C, and KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
Related • As to procedure for accessing KDPF temperature sensor, see “50 Disassembly and as-
information sembly”, “Removal and installation of KDPF assembly” and “Disassembly and assembly of
KDPF assembly”.
• Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
retracted (for up to 6 minutes). So when you restart engine, wait until the system operating
lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• Before performing “Loaded Diagnostics Operation To Confirm Failure Correction”,
firstly “Setting and operating machine monitor”, Service mode, Testing menu (En-
gine Controller Active Fault Clear) to be performed to clearer this failure code.
PC210LCI-11 40-337

1
Defective KDOC outlet If failure code [CA3316], [CA3317] or [CA3318] is displayed, perform troubleshoot-
2
1. Check if KDPF is correctly attached to the exhaust system.
3 Defective KDOC
2. Check if KDOC is correctly attached to KDPF.
4
Loaded Diagnostics Operation To Clear Failure Code

(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch from OFF to ON.
2. Start the engine and keep the engine running for approximately 1 minute at low idle speed.
3. Display KDOC inlet and outlet temperatures with monitoring function.
REMARK
KDOC inlet temperature of 280 °C or more is a requirement for clearing the failure code.
4. Raise one side by work equipment.
5. Set the swing lock to ON and the working mode to P.
6. Set the fuel control dial to MAX position and travel to Hi and drive for 15 minutes in succession with one
side idle running.
7. If the failure code is cleared after steps 1 to 6 are implemented, repair work is complete.
40-338 PC210LCI-11

Action level Failure code AdBlue/DEF Level Sensor Voltage High Error
Failure
Detail of fail-
Failure of AdBlue/DEF level sensor (Piezoelectric element for level measurement is open)
ure
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • Failure to measure AdBlue/DEF level.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF level sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF temperature sensor and AdBlue/DEF quality sensor performs CAN communi-
cation with the engine controller.
Related
• If the engine controller receives open-circuit information of Piezoelectric element for level
information measurement, this failure code is displayed.

1
tank sensor
3
PC210LCI-11 40-339

Failure
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank level becomes 2.5 % or less)
ure
Action of
controller
Phenomenon
on machine
• The failure codes of AdBlue/DEF level low are as follows:
When AdBlue/DEF level is 10 % or less [CA3497]
When AdBlue/DEF level is 2.5 % or less [CA1673]
Related When AdBlue/DEF level is 0.0 %or less [CA3547]
information • CA3547 is displayed and engine output is limited significantly if usage is continued without
refilling AdBlue/DEF and the AdBlue/DEF level becomes 0.0 %.
• After this failure code is cleared, Engine power deration continues until the starting switch

tank sensor
3
40-340 PC210LCI-11

Action level Failure code AdBlue/DEF Temperature Sensor Low Error
Failure
Detail of fail- Failure of AdBlue/DEF temperature sensor (Short circuit of thermistor for temperature measure-
ure ment)
Action of
controller
• The AdBlue/DEF temperature sensor is one of the AdBlue/DEF tank sensors integrated
with the AdBlue/DEF level sensor and AdBlue/DEF quality sensor performs CAN commu-
nication with the engine controller.
Related
• If the thermistor for temperature measurement shorts, this failure code is sent to the en-
information gine controller via CAN communication and displayed.

1
tank sensor
3
PC210LCI-11 40-341

Action level Failure code AdBlue/DEF Temperature Sensor High Error
Failure
Detail of fail- Failure of AdBlue/DEF temperature sensor (Open circuit of thermistor for temperature measure-
ure ment)
Action of
controller
• The AdBlue/DEF temperature sensor is one of the AdBlue/DEF tank sensors integrated
with the AdBlue/DEF level sensor and AdBlue/DEF quality sensor performs CAN commu-
nication with the engine controller.
Related
• If the thermistor for temperature measurement is open, this failure code is sent to the en-
information gine controller via CAN communication and displayed.

1
tank sensor
3
40-342 PC210LCI-11

Action level Failure code AdBlue/DEF Pump Priming Error
Failure
Detail of fail- The pressure cannot be raised for preparation of AdBlue/DEF injection due to damage, clogging,
ure etc. of the AdBlue/DEF pump or hose.
Action of • AdBlue/DEF pump stop
controller • Advances to Inducement strategy.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine power deration according to inducement strategy.
• The engine controller does not display this failure code during thawing control of the AdBl-
ue/DEF supply system (AdBlue/DEF injection is disabled, which disables judgment).
• Make sure that the value of the following 4 states are other than 1 (thawing) 3 minutes af-
ter the engine is started. (It is not possible to troubleshoot this failure until thawing control
is completed.)
• The state of each heater is 1: Thawing, 2: Warming, or 0: OFF.
Enter the following numbers directly and confirm the values on the monitoring code
screen.
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF suction and purge line heater state
19307 AdBlue/DEF pressure line heater state
19308 AdBlue/DEF pump heater state
• This failure code is cleared on the AdBlue/DEF pump “Pre-defined Monitoring” screen if
Related the AdBlue/DEF pump pressure rises to around 900 kPa.
information • The associated values can be confirmed on the following screen. (The values can also be
confirmed on the monitoring code screen by entering the numbers directly.)
• The “Pre-defined Monitoring” screen. (The following numbers are the monitoring codes)
AdBlue/DEF pump diagnosis
19304 AdBlue/DEF pump state
19108 AdBlue/DEF Pump Pressure
19136 AdBlue/DEF Pump Temperature
19109 AdBlue/DEF Pump Pressure Sensor Voltage
19120 AdBlue/DEF Injection Quantity
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by only turning ON the starting switch again.)

Defective AdBlue/DEF If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] is displayed on the
1
pump system abnormality record screen, perform troubleshooting these first.
Open circuit or short cir- If failure code [CA3713] or [CA5115] is displayed on the abnormality record screen,
2 cuit in AdBlue/DEF line perform troubleshooting these first.
heater 1
Defective AdBlue/DEF If failure code [CA2976] is also displayed, perform checks on causes 2 and after in
3 pump temperature sen- troubleshooting for this failure code.
sor system
PC210LCI-11 40-343

Defective AdBlue/DEF If failure code [CA1669] or [CA3868] or [CA4732] or [CA4739] or [CA4769] is dis-
4
level sensor system played, perform troubleshooting these first.
If failure code [CA1673] or [CA3497] or [CA3498] or [CA3547] is displayed, trouble-
shoot for those codes first.
5 Low AdBlue/DEF level
If the level is low, replenish AdBlue/DEF until it can be seen in the sight gauge, and
then “Loaded Diagnostics Operation To Clear Failure Code”.
If crystallized AdBlue/DEF is adhered to the surrounding of hose, tank, pump, or
engine compartment, it shows AdBlue/DEF may be leaking. Refer to “TESTING
Damaged AdBlue/DEF AND ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”,
6 hose, AdBlue/DEF leak- “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” to per-
age at connection form AdBlue/DEF Pump Pressure Up Test and find the location of the AdBlue/DEF
leak.
Replace parts as necessary.
Check the AdBlue/DEF suction hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
7 frozen AdBlue/DEF. Blow air or send AdBlue/DEF through each AdBlue/DEF hose,
suction hose
and repair or replace the hose if clogged.
Check the AdBlue/DEF tank for entry of foreign material. Check the AdBlue/DEF
Clogged AdBlue/DEF
8 tank strainer for clogging. Repair or replace the part if any abnormality is found.
tank strainer
Use AdBlue/DEF for cleaning.
1. Remove the flange from the AdBlue/DEF tank.
2. Check if a suction tube in the AdBlue/DEF tank is torn apart.
Suction tube clogged or 3. see “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
9 torn apart in the CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
AdBlue/DEF tank TESTING MENU (SCR SERVICE TEST)” to perform “AdBlue/DEF Pump
Pressure Up Test” to check if AdBlue/DEF is not leaking from the suction tube
in the AdBlue/DEF tank visually.
If the interval specified in the Operation and Maintenance Manual has elapsed
since the last time the AdBlue/DEF pump filter was replaced, or foreign material
Clogged AdBlue/DEF
10 was found in the check for AdBlue/DEF tank strainer, replace the AdBlue/DEF
pump filter
pump filter. (Refer to “METHOD FOR REPLACING AdBlue/DEF FILTER” in the Op-
eration and Maintenance Manual)
Defective AdBlue/DEF If the cause is not determined by above checks, replace the AdBlue/DEF pump.
11
pump
12
Loaded Diagnostics Operation to Clear Failure Code

2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at low idle speed.
4. Check if monitoring code 19108 “AdBlue/DEF Pump Pressure” rises up 900 ± 100 kPa within 5 minutes.
5. After ensuring the above 4., and after 3 minutes, check if this failure code is cleared after 3 minutes.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.
40-344 PC210LCI-11

Action level Failure code AdBlue/DEF Tank Heating Valve Voltage High Error
Failure
Detail of fail-
High voltage error is detected in signal circuit of AdBlue/DEF tank heating valve.
ure
Action of
Advances to Inducement strategy.
controller
Phenomenon • Failure to thaw AdBlue/DEF.
• This failure code is displayed when AdBlue/DEF tank heating valve connector is discon-
nected.
• AdBlue/DEF tank heating valve is driven when AdBlue/DEF is thawed and engine starts
Related with the temperature of engine coolant 45 °C or below.
information • AdBlue/DEF tank heating value can also be driven at “AdBlue/DEF tank heater valve test”.
• This failure code is detected only when AdBlue/DEF tank heating value stops.

1
Defective AdBlue/DEF 2.
2 Disconnect connector V41, and connect T-adapter to male side.
tank heating valve
Open or short circuit in Between ECM J2 (female) (82) and (57)
3
wiring harness
Resistance REMARK 15 to 30 Ω
The resistance value is the same as the value for an
AdBlue/DEF tank heating valve
1. If failure code is still displayed after above checks on cause 3, this check is not
required.
ness (wire breakage or 3. Disconnect connectors ECM J2 and V41 and connect T-adapters to each
4
defective contact of con- female side.
nector)
Between ECM J2 (female) (82) and V41 (female) (1) Max. 10 Ω
Resistance
Between ECM J2 (female) (57) and V41 (female) (2) Max. 10 Ω
Hot short circuit in wiring 2. Disconnect connector V41, and connect T-adapter to female side.
5
harness 3. Turn starting switch to ON position (with the valve disconnected).
Voltage Between V41 (female) (1) and (2) Max. 4.5 V
PC210LCI-11 40-345

2. Disconnect connectors ECM J2 and V41, and connect T-adapter to female
6
ness
No continui-
Continuity ty (no
than pin (82)
sound)
7
Circuit diagram related to AdBlue/DEF tank heating valve
40-346 PC210LCI-11

Action level Failure code AdBlue/DEF Tank Heating Valve Voltage Low Error
Failure
Detail of fail-
Low voltage error is detected in signal circuit of AdBlue/DEF tank heating valve.
ure
Action of
controller
Phenomenon • Failure to thaw AdBlue/DEF.
• The AdBlue/DEF tank heating valve operates when thawing the AdBlue/DEF and when
starting the engine while the temperature of the engine coolant is 45 °C or below.
• The AdBlue/DEF tank heating valve also operates when an “AdBlue/DEF Tank Heater
Valve Test” is implemented.
Related
• This failure code is detected only when the AdBlue/DEF tank heating valve is driven.
information
Procedure: Start engine (Engine coolant temperature: 45 °C or below), “Service mode”
and “Testing menu (SCR service test) - Operate” of “Setting and operating machine moni-
tor” to perform “AdBlue/DEF tank heater valve test”.

Defective wiring harness
1 2.
connector Start engine (engine coolant temperature: Max. 45 °C) or perform
“AdBlue/DEF tank heater valve test”.
2 Disconnect connector V41, and connect T-adapter to male side.
tank heating valve
Open or short circuit in Between ECM J2 (female) (82) and (57)
3
wiring harness
Resistance REMARK 15 to 30 Ω
The resistance value is the same as the value for an
AdBlue/DEF tank heating valve
Ground fault in wiring 2. Disconnect connectors ECM J2 and V41, and connect T-adapter to either
ground circuit)
Between ECM J2 (female) (82) or V41 (female) (1) and
ground
2. Disconnect connectors ECM J2 and V41, and connect T-adapter to female
5
ness
No continui-
Continuity ty (no
than pin (82)
sound)
PC210LCI-11 40-347

6
Circuit diagram related to AdBlue/DEF tank heating valve
40-348 PC210LCI-11

Action level Failure code AdBlue/DEF Quality Sensor Voltage High Error
Failure
Detail of fail-
Failure of AdBlue/DEF quality sensor (Piezoelectric element for quality measurement is open)
ure
Action of
controller
Phenomenon • The AdBlue/DEF quality cannot be measured.
• The AdBlue/DEF quality sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF level sensor and AdBlue/DEF temperature sensor performs CAN communi-
Related
• If the engine controller receives open-circuit information of Piezoelectric element for quali-
information ty measurement, this failure code is displayed.

1
tank sensor
3
PC210LCI-11 40-349

Action level Failure code Defective Regeneration
Failure
L03 CA1691 (Engine controller systems)
Details of KDOC efficiency (catalyzer function) is lowered. (Because KDOC outlet temperature does not rise
compared with KDOC inlet temperature: 250 to 400 °C as normal, KDOC outlet temperature: 450 to
failure 600 °C as normal during regeneration.)
Action of
controller
Phenomenon
on machine
40-350 PC210LCI-11
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
low idle speed (KDPF regeneration is not executed) are 100 to 250 °C, and difference be-
tween these temperatures is approximately 10 °C. (KDOC inlet temperature > KDOC out-
let temperature > KDPF outlet temperature)
• During manual stationary regeneration (normal), KDOC inlet temperature is 250 to 400 °C,
and both KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
• When dosing fuel does not blow out (KDOC drying) during manual stationary regenera-
tion, all of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet tempera-
ture are 250 to 400 °C.
Related
• Test exhaust gas color. For details, see “TESTING AND ADJUSTING”, “TEST EXHAUST
information
GAS COLOR”.
• Failure code [CA2637] may be also displayed. However, perform troubleshooting for this
failure code.
• When soot accumulation is at level 3 or lower, manual stationary regeneration can be per-
formed only from active regeneration for service.
• Procedure of performing the manual stationary regeneration from the "active regeneration
for service".
1. Start engine.
2. Make sure that machine is in safe condition.
3. Display Testing screen from Service Menu screen of machine monitor, open Active
Regeneration for Service, and perform Manual Stationary Regeneration (manual sta-
tionary regeneration finishes in approximately 40 minutes).
• Confirmation method of repair completion: For checking repair completion, start engine
and perform manual stationary regeneration if KDOC is not replaced. (See cause 5.)
NOTICE
• Confirmation of repair completion is not necessary if KDOC is replacecd.
• When KDOC in KDPF is changed, perform reset procedure for KDOC change and
then finish repair.

When KDPF cooled down sufficiently or there are significant differences between
Defective KDOC outlet
1 the KDOC outlet temperature and the KDOC inlet temperature or KDPF outlet tem-
temperature sensor
perature at idle (non-regeneration), change the KDPF temperature sensor.
Suddenly accelerate the engine from low idle to high idle two times, and then keep
the engine running at high idle speed for 5 seconds.
NOTICE
Defective exhaust gas
2 • If an excess black smoke is seen at high idle speed during accelera-
color
tion, perform “S-9 KDPF GETS CLOGGED IN A SHORT TIME”.
• Even excessive black smoke is exhausted during engine acceleration,
if it is not at engine high idle, it is not defective.
PC210LCI-11 40-351
k Perform after KDPF and KDOC cooled down sufficiently.

1. Remove KDPF.
2. Remove KDOC.
Defective KDOC (stain, 3. Blow air from KDOC outlet and remove stains on ceramic surface inside
3 crack, damage on KDOC KDOC.
surface) 4. Check if the ceramic inside KDOC has cracks.
KDOC is defective if any cracks are found in KDOC (change KDOC).
NOTICE
Perform the following whether or not KDOC is changed:
1. Attach KDOC and KDPF.
3. On the Service screen of the machine monitor, display “Diagnostic Tests”
screen, open 03 “KDPF Memory Reset”, and perform 03 “KDOC Change”
(Reset after KDOC change).
NOTICE
Reset after KDOC
4 • Failure codes [CA1691] and [CA2637] are cleared when reset after
change
KDOC change is performed. At this point, a corrective action which is
effective when the failure code is displayed and is taken for dozing
fuel which is not injected is reset.
• Check that reset after KDOC change is complete successfully (by re-
set count). If not, perform troubleshooting again.
• If KDOC is changed, troubleshooting is complete without performing
manual stationary regeneration.
NOTICE
Perform if KDOC is not changed:
2. Take notes on the temperature in initial state and during manual stationary
regeneration from the KDOC inlet temperature sensor and the KDPF outlet
temperature sensor to check if the KDOC outlet temperature sensor is nor-
mal (see Related information).
3. Perform manual stationary regeneration (see Related information).
Defective KDOC (de- 4. Turn starting switch to OFF position.
5 graded catalyst action of
KDOC) 5. Start the engine and perform manual stationary regeneration (to check if
failure code [CA2637] is displayed).
NOTICE
• Troubleshooting is complete after making sure that the failure code is
cleared.
• If failure code [CA2637] is displayed after manual stationary regenera-
tion is complete, KDOC is defective (catalyst action of KDOC is de-
graded. Change KDOC).
• Perform cause 4 again when KDOC is changed.
40-352 PC210LCI-11

Action level Failure code SCR Outlet NOx Sensor In Range Error
Failure
Detail of fail- The value of the NOx sensor of the SCR outlet is abnormal compared with the turbocharger outlet
ure NOx emission value
Action of
None in particular
controller
Phenomenon NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injection works
on machine inappropriately.
k SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
ambient temperature is not high.
• If the SCR outlet NOx sensor probe is disconnected from the exhaust pipe or loosened,
this failure code may appear.
• The SCR outlet NOx sensor and turbocharger outlet NOx sensor are not serviceable,
Related therefore, replace the sensor if it is defective.
information NOTICE
• For this failure code, after investigating the cause of the problem and completing the
repair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
make sure repair is completed. (This failure code is not cleared by only turning ON
the starting switch.)
• If the failure code of active regeneration prohibition or that of AdBlue/DEF injection
prohibition is displayed, the failure cannot be cleared. Clear the corresponding fail-
ure codes first.

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], [CA3718], [CA3725], or
outlet NOx sensor sys- [CA3748] is displayed, perform troubleshooting for these failure codes failure codes
tem first.
1
(Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR outlet If failure code [CA1887], [CA2771], [CA3545], [CA3583], [CA3681], or [CA3717] is
NOx sensor system displayed, perform troubleshooting for these failure codes first.
2 (Open circuit, internal de-
heater)
Urea deposit is accumu- 1. Perform “Loaded Diagnostics Operation To Clear Failure Code” to sublime
lated in the AdBlue/DEF urea deposit.
3 mixing tube but it is re- 2. Repair is completed if the failure code is cleared after performing “Loaded
movable by application of Diagnostics Operation To Clear Failure Code” (urea deposit has been re-
the thermal load. moved by sublimation).
Defective connection be- Check if the SCR outlet NOx sensor probe is installed securely.
tween the SCR outlet
4
NOx sensor probe and
an exhaust pipe
PC210LCI-11 40-353

1. Check if urea deposits are accumulated in the AdBlue/DEF mixing tube and
the AdBlue/DEF injector mount.
Accumulation of urea de- 2.
If deposits are accumulated, remove the AdBlue/DEF mixing tube to remove
5 posits in AdBlue/DEF
deposits and clean the tube.
mixing tube
3. Check if urea deposits are accumulated in the SCR inlet case. If accumulated,
perform the next item.
1. If urea deposit is accumulated inside the SCR inlet case, remove the urea
Accumulated urea de- deposit as much as possible.
6
posit in SCR assembly
2. Repair AdBlue/DEF mixing tube back to normal.
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF
MACHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING
WITH TESTING MENU (SCR SERVICE TEST)” to perform an
“AdBlue/DEF INJECTOR INJECTION AMOUNT TEST” to judge the injec-
tor.
2. If the AdBlue/DEF injection amount test results are within the values speci-
Abnormal injection from fied in “TESTING AND ADJUSTING”, it is OK. Proceed to step 4.
7
AdBlue/DEF injector
3. If the AdBlue/DEF injection amount is out of the range specified in “Testing
and adjusting”, replace the AdBlue/DEF injector.
4. When the repair is completed, repeat “Loaded Diagnostics Operation To
Clear Failure Code” the system two times (repeat the operation two times
to ensure AdBlue/DEF to be sublimed, in case it has flown into the catalyst
(Required time: approximately 2 hours)).
If no failure is found by preceding checks, the turbocharger outlet NOx sensor may
Defective turbocharger
8 be defective. (Abnormality in the turbocharger outlet NOx sensor due to adverse ef-
outlet NOx sensor
fects of sulfur content)
Defective SCR outlet If no failure is found by the above checks, the SCR outlet NOx sensor is defective
9
NOx sensor (NOx sensor measurement probe is clogged with urea deposit)
10

2. Disconnect connector P55(To activate automatic regeneration).
3. Turn starting switch to ON position, and start the engine.
REMARK
Ignore other failure codes displayed.
4. Run the engine at low idle speed until the aftertreatment devices regeneration pilot lamp lights up (for ap-
proximately 10 minutes).
5. Stop the engine.
6. Connect connector P55.
8. When “Turn the key to OFF position.” is displayed on the machine monitor, turn the starting switch to OFF
position once, and re-start the engine.
9. After checking the aftertreatment devices regeneration pilot lamp lights up (automatic regeneration), per-
form the following operation.Set the swing lock to ON, and the operation mode to P, and run the engine with
40-354 PC210LCI-11
one-side track idle off the ground (set the fuel dial to FULL and travel to Hi) until the failure code disappears
(for approximately 20 minutes).
10. After checking that the failure code is cleared, run the engine at low idle speed till the aftertreatment devi-
ces regeneration pilot lamp goes off.
REMARK
PC210LCI-11 40-355

Action level Failure code Sensor 5 Supply Voltage High Error
Failure
Details of High voltage error is detected in 5 V power supply of the KDPF differential pressure sensor, KDPF
failure outlet pressure sensor and, AdBlue/DEF pump pressure sensor.
• Operates at estimated value of KDPF outlet pressure sensor. (Operation may be per-
formed at 0 kPa {0 kg/cm2} .)
• Operates at estimated value of KDPF differential pressure sensor. (Operation may be per-
Action of formed at 0 kPa.)
controller • Operates at fixed value (1300 kPa) of AdBlue/DEF pump pressure.
Phenomenon
on machine
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).

Defective sensor 5 power Perform troubleshooting for failure code [CA1696].
1
supply system
40-356 PC210LCI-11

Action level Failure code Sensor 5 Supply Voltage Low Error
Failure
Detail of fail- Low voltage error is detected in 5 V power supply of the KDPF differential pressure sensor, KDPF
ure outlet pressure sensor and, AdBlue/DEF pump pressure sensor.
• Operates at estimated value of KDPF outlet pressure sensor. (Operation may be per-
formed at 0 kPa {0 kg/cm2} .)
• Operates at estimated value of KDPF differential pressure sensor. (Operation may be per-
Action of formed at 0 kPa {0 kg/cm2} .)
controller • Operates at fixed value (-100 kPa) of AdBlue/DEF pump pressure.
• Closes EGR valve.
• Controls engine output for operation.
• Stops regeneration control.
Phenomenon
on machine
unit.
information
code is cleared).

1
position each time.
If this failure code goes out, disconnected sensor is defective.
2
ing harness REMARK
Other failure codes are also displayed. This is because the connector is dis-
connected. Ignore all failure codes except for [CA1695].
KDPF differential pressure (outlet pressure) sensor E25
Connector
AdBlue/DEF pump pressure sensor MB02
Ground fault in wiring 2. Disconnect connectors ECM J2, E25, and MB02, and connect T-adapter to
3 harness (contact with either female side.
ground circuit)
Between ECM J2 (female) (8) and ground, or between
E25 (female) (4) and ground
PC210LCI-11 40-357

2. Disconnect connectors ECM J2, E25, and MB02, and connect T-adapter to
4 female side of ECM J2.
ness
pin (8)
REMARK
If the fuse is not blown out, this check is not required.
2. Disconnect connector E25.
3. Insert T-adapter into connector ECM J2, or connect T-adapter to female
side of connector E25.
5 4. Turn the starting switch to ON position.
ler
5. If no failure is found by this check, repeat from procedures of cause 1
again.
Between ECM J2 (8) and (32), or between E25 (fe- 4.75 to
Voltage
male) (4) and (1) 5.25 V
Circuit diagram related to KDPF differential pressure and KDPF outlet pressure
sensor
40-358 PC210LCI-11

Action level Failure code AdBlue/DEF Tank Thawing Error
Failure
Detail of fail- Thawing of the AdBlue/DEF tank cannot be completed due to failure of the AdBlue/DEF tank heat-
ure ing valve, failure of the engine coolant circuit, etc.
Action of
None in particular
controller
Phenomenon
NOx emission increases because AdBlue/DEF injection is disabled.
on machine
• The engine controller judges whether this failure code is displayed only during thawing
control of the AdBlue/DEF tank (The value of 19305 AdBlue/DEF Tank Heating State is
“1”).
• 19305 AdBlue/DEF Tank Heating State, 1: Thawing, 2: Warming, or 0: OFF.
• The Pre-defined Monitoring screen uses the AdBlue/DEF tank thawing control diagnosis.
(The following numbers are the monitoring codes)
• AdBlue/DEF injector diagnosis
Related 19102 AdBlue/DEF Tank HtrValve Command
information 19115 AdBlue/DEF Temperature in Tank
4107 Coolant Temperature
19400 Ambient Temperature
19133 Engine Room Temperature
NOTICE
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure this failure code is not re-
displayed. (Turning the starting switch to ON position does not confirm the completion of re-
pair.)

Defective AdBlue/DEF If failure code [CA1683] or [CA1684] is displayed on the abnormality record screen,
1 tank heating valve sys- perform troubleshooting these first.
tem
2 tank temperature sensor perform troubleshooting these first.
system
PC210LCI-11 40-359

See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OPERA-
TION MACHINE MONITOR”, “METHOD FOR SETTING WITH TESTING MENU
(SCR SERVICE TEST)” to perform an “AdBlue/DEF TANK HEATER RELAY TEST”
and check if the AdBlue/DEF tank heater valve is driven normally.
Confirm that the AdBlue/DEF tank heating valve operates in response to 19102
“AdBlue/DEF Tank HtrValve Command” (switches between 0 and 1).
1. Remove the coolant hose from the outlet side of the AdBlue/DEF tank heating
valve, and plug the removed hose.
3. Perform an “AdBlue/DEF TANK HEATER RELAY TEST” to drive the
AdBlue/DEF tank heating valve.
Mechanical failure of
4. Make sure that coolant flows out in response to valve open and close com-
3 AdBlue/DEF tank heating
valve mands.
REMARK
If coolant flows out in response to valve operation, the AdBlue/DEF tank
heating valve is normal.
If coolant does not flow out:
Increase the temperature of the inlet side coolant hose to make sure that the cool-
ant flows out.
1. If coolant flows out from the inlet side coolant hose, replace the AdBlue/DEF
tank heating valve.
2. If coolant does not flow out from the inlet side coolant hose, clogging of the
coolant circuit is suspected.
Check if the engine coolant circuit in the engine or AdBlue/DEF tank is leaking or
Clogged engine coolant clogged. In addition check if the engine coolant level is appropriate. If there are
4
circuit and trapped air some problems, repair the relevant portions. Bleed air from the engine coolant
again.
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If the AdBl-
5 ue/DEF tank temperature does not rise correctly, replace the AdBlue/DEF tank sen-
tank temperature sensor
sor.
6
Loaded Diagnostics Operation to Confirm Failure Correction

(Make sure this failure code is not displayed after this procedure.)
3. Check monitoring code 19115 “AdBlue/DEF Temperature in Tank” on the “Pre-defined Monitoring” screen.
1) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is less than 1 °C.
1] Check if monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued (from 0 to
1) ,and perform warm-up operation.
When monitoring code 04107 “Coolant Temperature” becomes 0 °C or more during warm-up oper-
ation, monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued (from 0 to 1).
2] Keep warm-up operation and that monitoring code 04107 “Coolant Temperature” is 20 °C or more.
3] Confirmation will be completed if the AdBlue/DEF tank temperature becomes 4 °C or more within
an hour after the “AdBlue/DEF Tank HtrValve Command” is issued. If it becomes 4 °C or less, re-
turn to troubleshooting.
2) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 1 °C or more.
40-360 PC210LCI-11
1] Perform warm-up operation, and raise the monitoring code 04107 “Coolant Temperature” to the
degree over 20 °C added to the ambient temperature.
2] See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR OPERATING TEST-
ING MENU (SCR SERVICE TEST)” in “SETTING AND OPERATION OF MACHINE MONITOR” to
perform “AdBlue/DEF Tank Heater Valve Test”.
3] When monitoring code 04107 “Coolant Temperature” is less than the ambient temperature added
to 20 °C during “AdBlue/DEF tank heater relay test”, perform warm-up operation together with
“AdBlue/DEF Tank Heater Valve Test” again.
4] Confirmation will be completed if the AdBlue/DEF temperature in Tank becomes 5 °C or above
within an hour after starting the “AdBlue/DEF Tank Heater Valve Test”. If it becomes 5 °C or less,
return to troubleshooting.
4. After the repair is completed, see “PROCEDURE FOR TESTING AND TROUBLESHOOTING” to clear the
failure code and make sure that the failure code has been cleared from the Abnormality Record screen.
PC210LCI-11 40-361

Action level Failure code AdBlue/DEF Tank Heater Valve Open Stuck Error
Failure
Detail of fail-
The AdBlue/DEF tank heating valve is open at all times.
ure
Action of
None in particular
controller
Phenomenon
AdBlue/DEF in the AdBlue/DEF tank may deteriorate quickly because the temperature is high.
on machine
ue/DEF tank.
• The Pre-defined Monitoring screen uses the AdBlue/DEF tank thawing control diagnosis.
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure repair
is completed. (This failure code is not cleared by only turning ON the starting switch.)

tem
system
40-362 PC210LCI-11

See Testing and adjusting, “service modes” of “setting and operating machine mon-
itor”, “operating method of testing menu (SCR service test)” to perform an
“AdBlue/DEF tank heater relay test” and check if the AdBlue/DEF tank heater valve
is driven normally.
Mechanical failure of 2. Start the engine.
3 AdBlue/DEF tank heating 3.
Perform an “AdBlue/DEF tank heater relay test” to drive the AdBlue/DEF tank
valve
heating valve.
mands.
If coolant flows out regardless of valve open and close commands, replace the
REMARK
sor.
5

3. Check if monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is not issued (0) on “Pre-defined
Monitoring” screen.
4. Start the engine and check the monitoring code 19115 “AdBlue/DEF Temperature in Tank”.
5. Raise monitoring code 04107 “Coolant Temperature” to the degree 10 °C or more than AdBlue/DEF tank
temperature.
6. Check again if the monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is not issued (0) on the
“Pre-defined Monitoring” screen.
7. Check if monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 1 °C or less after a lapse of 5 mi-
nutes after starting the engine.
8. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the Abnormality Record
screen.
REMARK
If the monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 2 °C or more, return to troubleshooting.
PC210LCI-11 40-363

Action level Failure code AdBlue/DEF Quality Sensor Out of Calibration Error
Failure
Detail of fail-
AdBlue/DEF quality sensor transmission data is abnormal
ure
Action of
controller
Phenomenon • The AdBlue/DEF quality data cannot be measured.
Related
• If the AdBlue/DEF tank sensor is changed without installing genuine spare parts, this fail-
information ure code is displayed.

1
tank sensor
3
40-364 PC210LCI-11

Action level Failure code AdBlue/DEF Quality Sensor Internal Circuit Error
Failure
Detail of fail-
Failure of AdBlue/DEF quality sensor (Abnormality in the circuit for quality measurement)
ure
Action of
controller
Phenomenon • The AdBlue/DEF quality data cannot be measured.
Related
• If the engine controller receives information that the circuit for quality measurement is ab-
information normal, this failure code is displayed.

1
tank sensor
3
PC210LCI-11 40-365

Action level Failure code Sensor Supply Relay Voltage High Error
Failure
Detail of fail-
A high voltage error occurs in sensor power supply relay circuit.
ure
Action of
None in particular
controller
• Inoperative KDPF temperature sensor, turbocharger outlet NOx sensor, SCR outlet NOx
Phenomenon
sensor, ammonia sensor, SCR temperature sensor and AdBlue/DEF tank sensor.
on machine
• NOx emission increases because AdBlue/DEF injection is disabled.
• This failure code is displayed if the connector is removed when the sensor power supply
relay is turned OFF.
• Note that sensor power supply relay connector is energized even if starting switch is
turned to OFF position.
• This failure code is detected until the sensor power supply relay is turned OFF, during
which the engine controller shuts down since starting switch is turned to OFF position.
• This failure code is not detected when starting switch is at ON position and not displayed
Related on the monitor standard screen. Check the detection on "Abnormality Record" screen.
information • Troubleshooting of this failure code covers circuits from engine controller through sensor
power supply relay to ground.
NOTICE
• If the failure code is displayed, perform investigation of the cause, perform repair,
clear “Electrical Sys Abnormality Record”, turn starting switch off, and shut down
the engine controller. (See “PROCEDURE FOR TROUBLESHOOTING” in this chap-
ter.) Turn starting switch to ON position again and check "Abnormality Record"
screen. If this failure code is not logged, the repair is completed.

3. Perform deletion of “Electrical Sys Abnormality Record” in “SERVICE
Defective wiring harness MODE” of machine monitor.
1
connector
4. Turn the starting switch to OFF position, and shut down the engine control-
ler.
If this failure code is not logged on Abnormality Record screen, wiring harness con-
nector is defective.
2. Check that system operating lamp does not light up, and then turn battery
Open circuit in wiring har- disconnect switch to OFF position.
ness (wire breakage or 3. Disconnect connectors ECM J1 and R52 and connect T-adapters to each
2
defective contact of con- female side.
nector)
Between ECM J1 (female) (9) and R52 (female) (5) Max. 10 Ω
Resistance
Between R52 (female) (4) and ground Max. 10 Ω
40-366 PC210LCI-11

2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective sensor power 3. Disconnect connector R52, and replace sensor power supply relay.
3
supply relay
If this failure code is cleared, the original sensor power supply relay is defective.
4
PC210LCI-11 40-367
Circuit diagram related to sensor power supply relay circuit
40-368 PC210LCI-11

Action level Failure code Sensor Supply Relay Voltage Low Error
Failure
Detail of fail-
Low voltage error occurs in sensor power supply relay circuit.
ure
Action of
None in particular
controller
• Inoperative KDPF temperature sensor, turbocharger outlet NOx sensor, SCR outlet NOx
Phenomenon
sensor, ammonia sensor, SCR temperature sensor and AdBlue/DEF tank sensor.
on machine
• Be careful that voltage is applied to the connector of the sensor power supply relay even if
the starting switch is OFF.
Related • Troubleshooting of this failure code covers circuits from engine controller through sensor
information power supply relay to ground.

3. Perform deletion of “Electrical Sys Abnormality Record” in “SERVICE
Defective wiring harness MODE” of machine monitor.
1
connector
4. Turn the starting switch to OFF position, and shut down the engine control-
ler.
If this failure code is not logged on Abnormality Record screen, wiring harness con-
nector is defective.
Check if fuses No. 11 and 12 in fuse box F02 are blown.
2 Defective fuse REMARK
If blown, perform troubleshooting for ground fault in wiring harness for it first.
3
supply relay
PC210LCI-11 40-369
REMARK
If failure code is still displayed after above checks, this check is not required.
disconnect switch to OFF position.
Open circuit in wiring har- 3. Disconnect connectors ECM J1 and R52 and connect T-adapters to each
ness (wire breakage or female side.
4
defective contact of con- 4. Remove fuses No. 11 and 12 from fuse box F02.
nector)
Between ECM J1 (female) (9) and R52 (female) (5) Max. 10 Ω
Between R52 (female) (4) and ground Max. 10 Ω
Resistance Between fuse box F02-11 and R52 (female) (1) Max. 10 Ω
Between fuse box F02-11 and R52 (female) (2) Max. 10 Ω
Between fuse box F02-12 and R52 (female) (3) Max. 10 Ω
Ground fault in wiring 2. Disconnect connectors ECM J1 and R52 and connect T-adapters to each
GND circuit)
Between ECM J1 (female) (9) or R52 (female) (5) and
ground
6
40-370 PC210LCI-11
Circuit diagram related to sensor power supply relay circuit
PC210LCI-11 40-371

Failure Crankcase Pressure Sensor High Error (Engine controller system)
L01 CA1843
Details of
High voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of
Sets crankcase pressure to fixed value. (approximately 0 kPa)
controller
Phenomenon
None in particular
on machine
(Code: 48401 (V))
Related • Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
information 48400 (MPa))

1
first.
Defective sensor power 2.
2 Disconnect connector P57 and connect T-adapter to female side.
supply system
Between P57 (female) (1) 4.75 to
and (2) 5.25 V
Defective crankcase 2. Disconnect connector P57.
3 pressure sensor (internal 3. Turn starting switch to ON position.
defect)
If failure code changes from [CA1843] to [CA1844], crankcase pressure sensor is
defective.
female side.
ness (ground line break-
4
age or defective contact NOTICE
of connector)
Open circuit in GND line
5 female side.
ness
40-372 PC210LCI-11

6
Voltage Between P57 (female) (3) and (2) Max. 1 V
Reference
Defective engine control- 1. Turn starting switch to OFF position.
7
ler 2. Insert T-adapter into connector ECM J1.
(54)
Circuit diagram related to crankcase pressure sensor
PC210LCI-11 40-373

Action level Failure code Crankcase pressure sensor low error
Failure
Detail of fail-
Low voltage error is detected in signal circuit of crankcase pressure sensor.
ure
Action of
Sets crankcase pressure to fixed value (approximately 0 kPa) for operation.
controller
Phenomenon
None in particular
on machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401 (V))
Related • Pressure by crankcase pressure sensor can be checked with monitoring function. (Code:
information 48400 (MPa))
• After completion of repair, check that the failure code is cleared by the following operation.

1
first.
2 Disconnect connector P57 and connect T-adapter to female side.
supply system
Between P57 (female) (1) 4.75 to
and (2) 5.25 V
female side.
NOTICE
If there is any abnormality in wiring harness, disconnect connector OEM
CONNECTION and check similarly to see if abnormality is in engine harness
or in chassis harness.
ness (wire breakage or REMARK
3
defective contact of con- If failure code is still displayed after above checks on Max. 10 Ω
nector) cause 2, this check is not required.
Resistance REMARK
If failure code is still displayed after above checks on Max. 10 Ω
40-374 PC210LCI-11

female side.
Ground fault in wiring NOTICE
If there is any abnormality in wiring harness, disconnect connector OEM
ground circuit)
CONNECTION and check similarly to see if abnormality is in engine harness
or in chassis harness.
male) (3)
5 female side.
ness
Defective crankcase 2. Insert T-adapter to connector P57.
6 pressure sensor (internal 3. Turn starting switch to ON position.
defect)
Between P57 (female) (3)
and (2)
Reference
7
ler 2. Insert T-adapter into connector ECM J1.
(54)
PC210LCI-11 40-375
Circuit diagram related to crankcase pressure sensor
40-376 PC210LCI-11

Action level Failure code KDPF Differential Pressure Sensor High Error (Engine controller sys-
Failure
L03 CA1879 tem)
Details of
High voltage error is detected in signal circuit of KDPF differential pressure sensor.
failure
• Operates at estimated value of KDPF differential pressure sensor. (If other failure code al-
so is displayed, operation may be performed at 0 kPa.)
Action of
• EGR valve closes and VGT opens fully.
controller
Phenomenon
on machine
k KDPF becomes hot (Min. 500 °C). Be careful not to get burned.

unit.
• If failure code [CA3133] is displayed instead of failure code [CA1695], wire breakage (de-
fective contact of connector) of GND line is highly possible.
Related • Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
information
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring

1
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
2 Disconnect connector E25, and connect T-adapter to female side.
supply system
4.75 to
Voltage Between E25 (female) (4) and (1)
5.25 V
PC210LCI-11 40-377

If this failure code is changed to [CA1881], the KDPF differential pressure sensor is
Defective KDPF differen-
3 defective.
tial pressure sensor
NOTICE
• If this failure code is displayed, the wiring harness or engine control-
ler is defective.
• Ignore other failure codes displayed.
quired.
Starting switch: OFF
4 2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
GND line or defective
contact of connector) female side.
Resistance Between ECM J2 (female) (32) and E25 (female) (1) Max. 10 Ω
2. Disconnect connectors ECM J2 and E25, and connect T-adapter to female
5
ness
No continui-
Continuity ty (no sound
than pin (41)
is heard)
3. Connect T-adapter to female side of connector E25, or insert T-adapter to
6 connector ECM J2.
harness
4. Turn starting switch to ON position (with connector E25 disconnected).
Voltage Max. 1 V
E25 (female) (2) and (1)
7
Circuit diagram related to KDPF differential pressure sensor
40-378 PC210LCI-11

Action level Failure code KDPF Differential Pressure Sensor Low Error
Failure
Details of
Low voltage error is detected in signal circuit of KDPF differential pressure sensor.
failure
Action of
• EGR valve closes and VGT opens fully.
controller
Phenomenon
on machine

unit.
• If failure code [CA3134] is also displayed instead of failure code [CA1696], it is highly pos-
sible that sensor connector is removed or wire breakage (defective contact of connector)
occurs in 5 V line.
Related
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
information
tion. (Code: 47101 (V))

1
supply system
4.75 to
5.25 V
PC210LCI-11 40-379

2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
female side.
3
defective contact of con- Between ECM J2 (female) (32) and E25 (female) (1)
nector)
Between ECM J2 (female) (8) and E25 (female) (4)
Between ECM J2 (female) (41) and E25 (female) (2) Max. 10 Ω
Ground fault in wiring 2. Disconnect connectors ECM J2 and E25, and connect T-adapter to either
ground circuit)
Between ECM J2 (female) (41) and ground, or be-
tween E25 (female) (2) and ground
5
ness
No continui-
than pin (41)
is heard)
Defective KDPF differen- 2. Insert T-adapter into connector E25.
6
tial pressure sensor 3. Turn starting switch to ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
7
40-380 PC210LCI-11

Action level Failure code KDPF Differential Pressure Sensor In Range Error
Failure
Details of Signal voltage from KDPF differential pressure sensor does not show correct value. (Signal voltage
failure is within use range.)
Action of • EGR valve closes and fully opens KVGT.
Phenomenon
on machine

• KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
tion. (Code: 47101 (V))
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Use “Short socket adapter: 799T-601-4611”.
• For details of access to KDPF differential pressure sensor, wiring harness and tube, see
Related “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
information BLY” and “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
ON position.
• “Loaded Diagnostics Operation To Clear Failure Code”.
NOTICE
again.)
• This failure code is cleared by performing operations indicated in TESTING AND AD-
JUSTING, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE MODE”,
“METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER ACTIVE
FAULT CLEAR)”.
PC210LCI-11 40-381

1. Remove KDPF differential pressure sensor tube.
2. Clean and unclog the KDPF differential pressure sensor tube.
3. Check the KDPF differential pressure sensor tube for cracks or damages.
4. Securely connect both ends of the tube and install the KDPF differential
pressure sensor tube.
1 Reference
tial pressure sensor tube
How to check clogged KDPF differential pressure sensor tube
2. Monitor the differential pressure by using KDPF differential pressure sen-
sor on Self-define Monitoring screen of the machine monitor.
Code 47100(kPa) 0 ± 3( kPa)
See “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEMBLE AND AS-
Improper installation of
2 SEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND ASSEMBLY
KDPF
for repair.
supply system
4.75 to
5.25 V
Defective wiring harness ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
4
connector FORMATION ON TROUBLESHOOTING”, and check and repair defects, if
any.
If failure code [CA1881] is cleared, the wiring harness or engine controller is defec-
tive.
Check cause 4 again.
5 2. Disconnect connector E25 and connect short socket adapter to female
or engine controller
side.
REMARK
Connect 5 V to the signal line. (Short-circuit pins (4) and (3) of connector E25.)
tive.
Defective KDPF differen- If failure codes [CA1881] and [CA1879] are displayed after checks on cause 5, the
6
tial pressure sensor KDPF differential pressure sensor is defective.
40-382 PC210LCI-11

If failure code is still displayed after above checks, any internal parts in the engine
7 controller is defective. (In case of an internal defect, troubleshooting is impossible
ler
as an assembly. Replace whole assembly.)

k Place the machine on a level ground.
1. Turn starting switch to ON position and leave it for 1 minute.
REMARK
It is required that the engine controller recognizes the dispersion of sensor.
4. After warm-up operation, set the swing lock to ON, working mode to P, and fuel control dial to MAX position.
5. Operate for 40 seconds with Arm IN relief.
NOTICE
Be careful care not to overheat hydraulic oil temperature.
7. If failure code is not cleared, repeat above operation 5 for 3 times.
8. If the failure code is cleared, repair is complete.
PC210LCI-11 40-383

Action level Failure code Turbocharger Outlet NOx Sensor Circuit Error
Failure
Detail of fail- The turbocharger outlet NOx sensor does not display any values due to an internal circuit error of
ure the turbocharger outlet NOx sensor.
Action of • Operate using the NOx value in the memory.
controller • Advances to Inducement strategy (EU Specification)
Phenomenon • The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
on machine • Engine power deration (EU Specification)
k The turbo outlet, KDPF, sensor fitting piping, and sensor probe become hot (Min.
500 °C). Be careful not to get burn injury.
• The turbocharger outlet NOx sensor performs CAN communication with the engine con-
troller.
• The turbocharger outlet NOx sensor operates when KDOC inlet temperature is 150 °C or
more (19203 turbocharger outlet NOx sensor measurement state is "1").
• The turbocharger outlet NOx sensor does not operate when KDOC inlet temperature is
150 °C or lower, and correct value is not displayed.
• “Pre-defined” screen uses the engine operation state diagnosis, SCR catalyst, NOx sen-
sor, and ammonia sensor diagnosis.
• Engine operation state diagnosis
01002 Engine speed
19200 Exhaust gas flow rate
Related
47300 KDOC Inlet Temperature
information
19300 SCR Temperature
19302 SCR Outlet Temperature
• SCR catalyst, NOx sensor, ammonia sensor diagnosis.
19203 Turbo Outlet NOx Sensor State
19210 SCR Outlet NOx Sensor State
19202 Turbo Outlet Concentration Corrected
19209 SCR Outlet NOx Corrected
19205 Ammonia Concentration Corrected
NOTICE
For this failure code, after investigating the cause of the problem and completing the re-
pair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make
sure repair is completed. (This failure code is not cleared by only turning ON the start-
ing switch.)

CAN communication sys- If failure code [CA3232] is displayed, perform troubleshooting for [CA3232] first.
1
tem error
Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.
40-384 PC210LCI-11

If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
Defective turbocharger 2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3
outlet NOx sensor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
4

Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
3. Run the engine at high idle speed safely to raise the exhaust temperature. (Keep the engine speed so that
monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or higher. Check that monitoring code
19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1).
4. Repair is completed if failure code is cleared after 3 minutes has passed.
REMARK
If the turbocharger outlet NOx sensor does not activate (that is, 19203 “Turbo Outlet NOx Sensor State” remains
as 0), return to troubleshooting.
PC210LCI-11 40-385

Action level Failure code SCR Outlet NOx Sensor Circuit Error
Failure
Detail of fail- The SCR outlet NOx sensor does not display any values due to an internal circuit error of the SCR
ure outlet NOx sensor.
Action of • Drive at the default NOx emission value (0 ppm)
controller • Advances to Inducement strategy. (EU Specification)
on machine • The engine power deration according to inducement strategy. (EU Specification)
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min.
400 °C). Be careful not to get burned.
• The SCR outlet NOx sensor is a smart sensor which performs CAN communication with
the engine controller together with the other sensors.
• The SCR outlet NOx sensor operates when SCR outlet temperature is 150 °C or more
(19210 SCR outlet NOx sensor measurement state is "1").
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or
lower, and correct value is not displayed.
• “Pre-defined Monitoring” screen uses the engine operation state diagnosis, SCR catalyst,
NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
Related 19200 Exhaust gas flow rate
information 47300 KDOC Inlet Temperature
NOTICE
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure repair
is completed. (This failure code is not cleared by only turning ON the starting switch.)

Defective CAN communi- If failure code [CA2771] is displayed, perform troubleshooting for [CA2771] first.
1
cation system
2
40-386 PC210LCI-11

If no failure is found by preceding checks, the SCR outlet NOx sensor is defective.
2. Replace the SCR outlet NOx sensor.
Defective SCR outlet
NOx sensor
4

monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or higher. Check that monitoring code
19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
If the SCR outlet NOx sensor does not activate (that is, 19210 “SCR Outlet NOx Sensor State” remains as 0),
PC210LCI-11 40-387

Action level Failure code KDPF Soot Accumulation High Error 1
Failure
Details of This failure code requests users to perform “Manual stationary regeneration” immediately, because
KDPF soot accumulation level is 6 or 7 and it means a large amount of soot is accumulated in
failure KCSF (If soot accumulation level is 8, KDPF must be replaced.)
Action of
• Controls output for operation.
controller
• Disables automatic regeneration but enables manual stationary regeneration.
Phenomenon
on machine
40-388 PC210LCI-11
k Since KDOC and KDPF are heated to 500 °C or above, be careful not to get burned.
tion. (Code: 47101 (V))
• When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 450 to 550 °C.
Related GAS COLOR”.
information • Soot accumulation amount in KDPF is classified into 8 levels. Current soot accumulation
level can be checked in 02 Active Regeneration for Service screen of machine monitor.
• Manual stationary regeneration downs soot accumulation level 7 from level 8 by removing
soot.
• If soot accumulation level is 8, failure code [CA1922] is displayed. At this time, KDPF is
completely clogged with soot and inspection, cleaning or replacement is required.
• If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for these failure codes first.
• If failure code [CA1922] is originally displayed, failure code changes from [CA1922] to
[CA1921] in troubleshooting process. In this case, see failure code [CA1922].
code is cleared).
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: Approximately 40 minutes to 1 hour
• If soot accumulation is level 5: Approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: Approximately 2 to 3 hours
• If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
Cause for excessive soot accumulation
PC210LCI-11 40-389
1. Engine runs in light load area where exhaust gas temperature is high enough to burn soot
in KDPF.
• Low gas temperature at entering into KDPF cause a large amount of soot to be accu-
mulated.
• To protect KDPF from soot accumulation, it is necessary to run the engine under high
load.
2. There is an engine failure generating excessive black smoke.
Related
3. The function of disable regeneration is set from monitor.
information
• Regeneration is set not to perform automatically even if soot is accumulated. It is re-
quired to cancel regeneration disable and perform regeneration at safe place.
Method of canceling regeneration disable
• Select Cancel of Regeneration Disable from Aftertreatment Devices Regeneration screen
of user menu, and perform it. (For details, see “PROCEDURE FOR CANCEL OF AFTER-
TREATMENT DEVICES REGENERATION DISABLE SETTING” of “HANDLE Komatsu
Diesel Particulate Filter (KDPF)” of “Handling” in Operation and Maintenance Manual.)

1. Check that regeneration disable is not set on machine monitor. (Cancel the
regeneration disable if it is set.)
4. Perform “manual stationary regeneration” in user mode.
Defective accumulation When the manual stationary regeneration is completed successfully, the repair
1 is completed.
of soot in KDPF (KCSF)
If the regeneration is not completed after 3 hours, perform troubleshooting for
[CA2639].
5. Check that the failure code is cleared after manual stationary regeneration
is complete.
6. If failure code [CA1921] or [CA2639] is displayed after manual stationary
regeneration is complete, perform check on cause 2.
• If failure code [CA1921], or [CA2639] is displayed after manual stationary
regeneration is complete, perform the following:
• See “TEST EXHAUST GAS COLOR” section in “Chapter 30 TESTING
AND ADJUSTING” for checking the exhaust gas color.
• Perform regeneration disable on the machine monitor to check the exhaust
gas color.
Defective exhaust gas 1. Suddenly accelerate the engine from low idle to high idle two times, and then
2
color keep the engine running at high idle speed for 5 seconds.
If an excess black smoke is seen at high idle speed during acceleration, per-
form “KDPF GETS CLOGGED IN A SHORT TIME” of S mode.
Even excessive black smoke is exhausted during engine acceleration, if it is
not at engine high idle, it is not defective.
2. To finish the exhaust gas color check, cancel the regeneration disable.
3. Make sure that the failure code is cleared.
40-390 PC210LCI-11

Action level Failure code KDPF Soot Accumulation High Error 2
Failure
Details of • If soot accumulation is level 8 : Manual stationary regeneration cannot be performed.

failure • Engine must be stopped immediately and perform diagnostic test and maintenance.
Action of
• Controls output for operation.
controller
• Disables automatic regeneration and manual stationary regeneration.
Phenomenon
on machine
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
tion. (Code: 47101 (V))
Related • When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
information mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
GAS COLOR”.
code is cleared).
• Soot accumulation amount in KDPF is classified into 8 levels. Current soot accumulation
level can be checked in 02 Active Regeneration for Service screen of machine monitor.
• Manual stationary regeneration downs soot accumulation level 7 from level 8 by removing
soot.
• If soot accumulation level is 8, failure code [CA1922] is displayed. At this time, KDPF is
completely clogged with soot and inspection, cleaning or replacement is required.
PC210LCI-11 40-391
Cause for excessive soot accumulation
1. Engine runs in light load area where exhaust gas temperature is high enough to burn soot
in KDPF.
• Low gas temperature at entering into KDPF cause a large amount of soot to be accu-
mulated.
• To protect KDPF from soot accumulation, it is necessary to run the engine under high
load.
2. There is an engine failure generating excessive black smoke.
3. The function of disable regeneration is set from monitor.
• Regeneration is set not to perform automatically even if soot is accumulated. Cancel
regeneration disable at safe place.
Method of canceling regeneration disable
Select Cancel of Regeneration Disable from Aftertreatment devices regeneration screen of user
Related menu, and perform it. (For details, see “PROCEDURE FOR CANCEL OF AFTERTREATMENT DE-
information VICES REGENERATION DISABLE SETTING” of “HANDLE Komatsu Diesel Particulate Filter
(KDPF)” of “Handling” in Operation and Maintenance Manual.)
Method of performing active regeneration for service
When soot accumulation is at level 3 or lower, manual stationary regeneration can be performed on-
ly from Active Regeneration for Service.
1. Start engine.
2. Make sure that machine is in a safe condition.
3. From service menu of machine monitor, display Diagnostic Tests screen, open Active Re-
generation for Service, and then perform Manual Stationary Regeneration.
Method of resetting KDPF cleaning
Display Testing screen from service menu of machine monitor, open KDPF Memory Reset, and per-
form KDPF cleaning (resetting KDPF cleaning).
Method of resetting KDPF change
Display Testing screen from service menu of machine monitor, open KDPF Memory Reset, and per-
form KDPF change (resetting KDPF change).
Removing humidity in KCSF
When KCSF of KDPF has been replaced, be sure to perform Manual Stationary Regeneration from
Active Regeneration for Service and remove humidity, etc. in KCSF after resetting KDPF cleaning
and KDPF change.
40-392 PC210LCI-11

1. Check if the Disable Regeneration button is pressed from the machine
monitor.
Increased accumulation REMARK
1 of soot due to regenera-
If pressed, cancel the function of Disable regeneration first.
tion disable
REMARK
Cancel regeneration disable and perform cause 2 and subsequent causes.
Check records for appeared failure codes.
2. ON the Abnormality Record screen of the machine monitor, check records
for appeared failure codes CA2639, CA1921, and CA1922.
Period between CA2639 and CA1921 ≧ 360sec. (KOMTRAX Record) or ≧ 0.1h
(Monitor Record screen) and period between CA1921 and CA1922 ≧ 360sec.
(KOMTRAX Record) or ≧ 0.1h (Monitor Record screen)
[When the above condition is met]
REMARK
Because accumulated soot amount is high, KDPF regeneration cannot be per-
formed.
1. Change KCSF or KDPF.
2. Turn the starting switch to ON and perform “KDPF Cleaning” reset (see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”).
Make sure that failure code [CA1922] changed to [CA1921].
If failure code [CA1922] persists, check the operation procedure for “KDPF
Defective KDPF (KCSF)
2 Memory Reset”, then perform “KDPF Cleaning” Reset again.
(change KCSF)
3. Perform Reset after “KDPF Change” (see “PRECAUTIONS FOR KDPF
(KCSF, KDOC) CLEANING AND CHANGE”).
4. Perform checks on causes 4 to 7.
7. Perform “Active Regeneration for Service” to remove humidity, etc. in KCSF.
When the manual stationary regeneration is finished correctly, the repair is
completed.
[CA2639].
Check that the failure code is cleared after manual stationary regeneration is
complete.
If failure code [CA1922], [CA1921] or [CA2639] is displayed after manual sta-
tionary regeneration is complete, perform checks on cause 8.
[When the above condition is NOT met]
Actual accumulation of soot is less than the indicated value. Perform checks on
cause 3.
PC210LCI-11 40-393

If the actual accumulation of soot is less than the the indicated value on the ma-
chine monitor:
1. Perform checks on causes 4 to 7.
2. Turn the starting switch to ON and perform “KDPF Cleaning” reset (see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”).
Make sure that failure code [CA1922] changed to [CA1921].
If failure code [CA1922] persists, check the operation procedure for “KDPF
Memory Reset” Reset, then perform “KDPF Cleaning” Reset again.(see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”)
NOTICE
Do not perform “KDOC Change”(resetting KDOC Change) if KCSF or
Defective KDPF (KCSF) KDOC is not changed.
3 (abnormal accumulation
of soot) 3. Start the engine.
5. Perform “manual stationary regeneration” in user mode.
When the manual stationary regeneration is finished correctly, the repair is
completed.
If failure code [CA1922] is displayed again within 1 hour after starting the man-
ual stationary regeneration, perform steps 2 and 3 again.
[CA2639].
Check that the failure code is cleared after manual stationary regeneration is
complete.
If failure code [CA1922], [CA1921] or [CA2639] is displayed after manual sta-
tionary regeneration is complete, perform checks on cause 8.
4
5
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform troubleshoot-
6
2. Monitor the differential pressure by using KDPF differential pressure sensor on
Self-define Monitoring screen of the machine monitor.
Code 47100 ( kPa) 0±3 kPa
NOTICE
Perform the following when differential pressure is not within the above
7 tial pressure sensor (in-
range:
cluding the sensor tube)
Perform this when the KDPF differential pressure sensor tube is not clogged.
3. Check “Short circuit in wiring harness” for failure code [CA1881] or
[CA1879] (change the KDPF differential pressure sensor if no short circuit
is found).
40-394 PC210LCI-11

gas color.
8
PC210LCI-11 40-395

Action level Failure code Crankcase Pressure Sensor In Range Error
Failure
Details of
For output from crankcase pressure sensor, value out of normal range is displayed.
failure
Action of
None in particular
controller
Phenomenon
on machine
(Code: 48401 (V))
Related 48400 (MPa))
• This code is displayed if sensor value is not abnormal when turning starting switch to ON
position.

1
ing
40-396 PC210LCI-11

Action level Failure code KDPF Differential Pressure Low Error
Failure
Details of
Sensor voltage from KDPF differential pressure sensor is lower than threshold value.
failure
• EGR valve closes.
Phenomenon
on machine

tion. (Code: 47101 (V))
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• For details of access to KDPF differential pressure sensor, wiring harness and tube, see
“Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
Related BLY” and “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
information • After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ON position.
code is cleared).
NOTICE
• This failure code requires “ Loaded Diagnostics Operation To Confirm Failure Cor-
rection”. After investigating the cause of the problem and completing the repair, per-
form “ Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared.
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

Defective KDPF differen- If failure code [CA1879], [CA1881] or [CA1883] is displayed, perform troubleshoot-
1 tial pressure sensor sys- ing for [CA1879], [CA1881] or [CA1883].
tem
PC210LCI-11 40-397

1. Turn the starting switch to OFF position, then turn the starting switch to ON
again.
2. Check if a failure code other than [CA1993] is displayed.
3. Start the engine and suddenly accelerate it from low idle to high idle two
times, then keep the engine running at high idle speed for 5 seconds. At
this point, check the color of exhaust gas at the exhaust pipe section dur-
2 KCSF failure 1 ing sudden acceleration and high idle.
4. If black smoke comes out of the exhaust pipe after performing 3., KCSF is
defective. Check KCSF for existence, damages or contamination by for-
eign materials. Repair it if necessary.
NOTICE
Perform checks on cause 3 and subsequent causes if no black smoke is de-
tected.
Check if:
1. the KDPF differential pressure sensor tube is present,
2. the KDPF differential pressure sensor tube is not connected improperly,
3 3. the removed KDPF differential pressure sensor tube for clogging, cracks,
or damages, or
4. the both ends of the KDPF differential pressure sensor tube is not loose.
1. If this failure code is displayed again after preceding procedures are imple-
mented, remove KDPF, then remove KCSF, and check filters for existence,
damages or contamination by foreign materials. Repair it if necessary.
4 KCSF failure 2 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
3. Perform repair again from cause 1 if this failure code is displayed again af-
ter “Loaded Diagnostics Operation To Confirm Failure Correction” has
been performed.
5
Loaded Diagnostics Operation To Confirm Failure Correction

k Place the machine on a level place.
2. Perform “Engine Controller Active Fault Clear” from the “Service mode” of the machine monitor, and clear
this failure code.
5. After warm-up operation, set the swing lock to ON, working mode to P, and fuel control dial to MAX position.
6. Operate for 1 minute in succession with Arm IN relief.
NOTICE
7. If the failure code is not displayed after steps 1 to 6 are performed, repair is complete.
40-398 PC210LCI-11
PC210LCI-11 40-399

Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
Detail of fail-
A high voltage occurs in throttle sensor power supply (5 V) circuit.
ure
• If this failure code is displayed when starting switch is in ON position, set value to that be-
Action of fore detecting abnormality and fix it for operation.
controller • If turning starting switch to ON in abnormal condition, operation is performed at 100% val-
ue.
Phenomenon
Engine speed cannot be controlled by fuel dial.
on machine

1
2. Disconnect connector P20, and turn starting switch to ON position.
Defective fuel dial (throt-
2 If this failure code is cleared, throttle sensor is defective.
tle sensor)
Other failure codes are displayed as well. This is because connector is disconnect-
ed. Ignore failure codes other than this failure code.
2. Disconnect connector P20, and connect T-adapter to female side of ECM
3 J2.
ness
Between ECM J2 (female) (9) and each pin other than No continui-
Continuity
ECM J2 (female) (9) pin ty
4
40-400 PC210LCI-11

Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
Detail of fail-
A low voltage occurs in throttle sensor power supply (5 V) circuit.
ure
• If this failure code is displayed when starting switch is in ON position, set value to that be-
Action of fore detecting abnormality and fix it for operation.
controller • If turning starting switch to ON in abnormal condition, operation is performed at 100% val-
ue.
Phenomenon
Engine speed cannot be controlled by fuel dial.
on machine

1
2. Disconnect connector P20, and turn starting switch to ON position.
Defective fuel dial (throt-
2 If this failure code is cleared, throttle sensor is defective.
tle sensor)
Other failure codes are displayed as well. This is because connector is disconnect-
ed. Ignore failure codes other than this failure code.
ground circuit)
male) (1)
Defective engine control- 2. Insert T-adapter to connector ECM J2 or disconnect connector P20, and
4
ler connect T-adapter to female side.
Between ECM J2 (9) and (33), or between P20 (fe- 4.75 to
Voltage
male) (1) and (3) 5.25 V
PC210LCI-11 40-401
40-402 PC210LCI-11

Failure Common Rail Pressure Low Error 2 (Engine controller system)
L03 CA2249
Details of No-pressure error is detected in supply pump. (Pressure lower than specified pressure continues for
failure a long time: Level 2.)
Action of
Restricts engine output for operation.
controller
Phenomenon
on machine
(Code: 36401 (V))

Supply pump pressure Perform troubleshooting for failure code [CA559].
1
low error
PC210LCI-11 40-403

Action level Failure code EGR Valve Position Sensor High Error
Failure
Detail of fail-
High voltage occurs in signal circuit of EGR valve position sensor.
ure
on machine • Engine power deration according to inducement strategy. (EU Specification).
• Signal voltage from EGR valve position sensor can be checked with monitoring function.
(Code: 18101 (V))
• EGR valve position (mm) sensed by EGR valve position sensor can be checked with mon-
Related itoring function. (Code: 18100 (mm))
information • Engine power deration is canceled when the failure code is cleared and the starting switch

1
Defective sensor power If failure code [CA187] or [CA227] is displayed, perform troubleshooting for those
2
supply system codes first.
Defective EGR valve lift 2. Disconnect connector SEGR.
3
sensor (internal defect) 3. Turn starting switch ON (with connector SEGR disconnected).
If failure code [CA2271] changes to [CA2272], the sensor is defective.
2. Disconnect connector INTER-CONNECT.
Defective connector box 3. Turn starting switch to ON position.
4
(internal short circuit) If failure code [CA2271] changes to [CA2272], the connector box is defective.
REMARK
Open circuit of connector 2.
Disconnect connectors INTER-CONNECT and SEGR, and connect T-adapter
box (wire breakage of
5 to male side of INTER-CONNECT or female side of SEGR.
contact of connector) Between INTER-CONNECT (male) (4) and SEGR (fe-
male) (B)
40-404 PC210LCI-11

2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-adapter
Short circuit of connector
box (internal short circuit)
Between INTER-CONNECT (male) (3) and (5), or be-
tween SEGR (female) (A) and (C)
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
contact of connector) Between ECM J1 (female) (57) and INTER-CONNECT
(female) (4)
2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
8 adapter to either female side.
ness
INTER-CONNECT (female) (3) and (5)
2. Disconnect connector INTER-CONNECT, and connect T-adapter to female
Hot short circuit in wiring side.
9
harness
Voltage Between INTER-CONNECT (female) (5) and ground Max. 1 V
Reference
10
ler
Voltage Between ECM J1 (88) and (57) 1.0 to 4.0 V
PC210LCI-11 40-405
CIRCUIT DIAGRAM (EGR VALVE LIFT SENSOR)
40-406 PC210LCI-11

Action level Failure code EGR Valve Position Sensor Low Error
Failure
Detail of fail-
Low voltage occurs in signal circuit of EGR valve position sensor.
ure
on machine • Engine power deration according to inducement strategy. (EU Specification).
• Signal voltage from EGR valve position sensor can be checked with monitoring function.
(Code: 18101 (V))
• EGR valve position (mm) sensed by EGR valve position sensor can be checked with mon-
itoring function. (Code: 18100 (mm))
Related
information

1
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for those
codes first.
2 Disconnect connector SEGR and connect T-adapter to female side.
supply system
Between SEGR (female) 4.75 to
(A) and (B) 5.25 V
PC210LCI-11 40-407

2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-
adapter to male side of INTER-CONNECT and female side of SEGR.
Open circuit of connector Max. 10 Ω
Between INTER-CONNECT (male) (3) and SEGR (fe-
box (wire breakage or
3 male) (A)
nector) If power supply voltage in check on cause 2 is normal,
Resistance
Max. 10 Ω
male) (B)
Max. 10 Ω
male) (C)
2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-
Ground fault of connector adapter to male side of INTER-CONNECT and female side of SEGR.
4 box (contact with ground Between ground and INTER-CONNECT (male) (5) or
circuit) Min. 100 kΩ
SEGR (female) (C)
Resistance
Between ground and INTER-CONNECT (male) (3) or
Min. 100 kΩ
SEGR (female) (A)
2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-adapter
box (internal short circuit)
tween SEGR (female) (B) and (C)
2. Disconnect connectors INTER-CONNECT and ECM J1, and connect T-
Between ECM J1 (female) (81) and INTER-CONNECT
6 (female) (3)
nector) If power supply voltage in check on cause 2 is normal,
Resistance
Max. 10 Ω
(female) (4)
Max. 10 Ω
(female) (5) (sensor output)
Ground fault in wiring 2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
7 harness (contact with adapter to either female side.
ground circuit)
tween INTER-CONNECT (female) (5) and ground
40-408 PC210LCI-11

ness
If no failure is found in causes 1 through 8 but found in cause 9, the sensor is de-
fective.
Defective EGR valve lift 2.
9 Insert T-adapter into connector ECM J1 or SEGR.
sensor
Between ECM J1 (88) and (57), or between SEGR (C)
and (B)
10
CIRCUIT DIAGRAM (EGR VALVE LIFT SENSOR)
PC210LCI-11 40-409

Failure Turbocharger Speed High Error 1 (Engine controller system)
L01 CA2288
Details of
Turbocharger runs at abnormally high speed.
failure
Action of
controller
Phenomenon
Engine output decreases.
on machine
• Speed sensed by turbocharger speed sensor can be checked with monitoring function.
Related (Code: 48100 (rpm))

Increased turbocharger Turbocharger speed may increase abnormally high. Check it.
1
speed
2 Defective turbocharger Turbocharger may be defective. Check it.
Defective turbocharger If failure code is still displayed after above checks on cause 1, turbocharger speed
3
speed sensor sensor system may be defective. Perform troubleshooting for failure code [CA687].
40-410 PC210LCI-11

Action level Failure code lMV Solenoid Error
Failure
Details of Resistance value of supply pump actuator circuit is unusually high or low. Or common rail pressure
failure error.
Action of
None in particular
controller
Phenomenon
on machine

1 Defective IMV solenoid Perform troubleshooting for failure codes [CA271] and [CA272].
2 Rail pressure error Perform troubleshooting for failure code [CA449].
PC210LCI-11 40-411

Failure EGR Valve Solenoid Open Circuit Error (Engine controller system)
L03 CA2349
Detail of fail-
Open circuit occurs in EGR valve solenoid drive circuit.
ure
on machine • Engine output is reduced based on inducement strategy. (EU Specification).
• Signal current to EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))
Related • Engine power deration is canceled when the failure code is cleared and the starting switch
information is turned OFF (not canceled only by deactivation of the failure code).

1
Defective EGR valve sol-
2 enoid (internal open cir- 2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
cuit)
Resistance Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
2. Disconnect connector ECM J1 and connect T-adapter to female side.
3
wiring harness system
If resistance is 100 kΩ or higher, wiring harness has open circuit. If resistance is
10 Ω or below, wiring harness has short circuit.
Resistance Between ECM J1 (female) (13) and (76) 5 to 10 Ω
2. Disconnect connectors ECM J1 and EGR-SOL, and connect T-adapter to
4 harness system (contact Between ground and ECM J1 (female) (13) or EGR-
with ground circuit) Min. 100 kΩ
SOL (female) (1)
Resistance
Between ground and ECM J1 (female) (76) or EGR-
Min. 100 kΩ
SOL (female) (2)
40-412 PC210LCI-11

quired.
Open circuit of connector 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and connect T-
box (wire breakage or adapter to female side of EGR-SOL or male side of INTER-CONNECT.
5
nector) Between INTER-CONNECT (male) (1) and EGR-SOL
Max. 10 Ω
(female) (1)
Resistance
Between INTER-CONNECT (male) (2) and EGR-SOL
Max. 10 Ω
(female) (2)
quired.
Ground fault of connector 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and connect T-
6 box (contact with ground adapter to female side of EGR-SOL or male side of INTER-CONNECT.
circuit) Between ground and INTER-CONNECT (male) (1) or
Min. 100 kΩ
EGR-SOL (female) (1)
Resistance
Min. 100 kΩ
EGR-SOL (female) (2)
quired.
ness (wire breakage or adapters to each female side.
7
nector) Between ECM J1 (female) (13) and INTER-CONNECT
Max. 10 Ω
(female) (1)
Resistance
Max. 10 Ω
(female) (2)
8 adapter to female side of ECM J1.
ness
Continuity
than pin (13) ty
quired.
Ground fault in wiring 2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
9 harness (contact with adapter to either female side.
ground circuit) Between ground and ECM J1 (female) (13) or INTER-
Min. 100 kΩ
CONNECT (female) (1)
Resistance
Between ground and ECM J1 (female) (76) or INTER-
Min. 100 kΩ
10
PC210LCI-11 40-413
CIRCUIT DIAGRAM (EGR VALVE SOLENOID)
40-414 PC210LCI-11

Failure EGR Valve Solenoid Short Circuit Error (Engine controller system)
L03 CA2353
Detail of fail-
Short circuit occurs in EGR valve solenoid drive circuit.
ure
• Signal current to EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))

1
2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
Defective EGR valve sol-
2 enoid (internal open cir- Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
cuit)
Resistance Min.
Between EGR-SOL (male) (1) and ground
100 MΩ
2. Disconnect connectors INTER-CONNECT and EGR-SOL, and connect T-
3 adapters to male side of INTER-CONNECT.
box
Between INTER-CONNECT (male) (1) and each pin No continui-
Continuity
other than pin (1) ty
side.
3. Turn starting switch to ON position (with connector INTER-CONNECT dis-
4 connected).
harness
REMARK
hot short circuit in negative line
Voltage BetweenINTER-CONNECT (female) (2) and ground Max. 3 V
5
PC210LCI-11 40-415
CIRCUIT DIAGRAM (EGR VALVE SOLENOID)
40-416 PC210LCI-11

Action level Failure code EGR Valve Servo Error
Failure
Details of EGR valve malfunctions. (Responsing value from EGR position sensor is different from the value of
failure EGR valve opening command.)

Phenomenon • Engine output is reduced based on inducement strategy (EU Specification).
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Position (mm))

1
tem
For testing of EGR valve drive pressure, see “TESTING AND ADJUSTING”, “TEST
Defective EGR valve EGR VALVE AND VGT DRIVING OIL PRESSURE”.
2
driving oil pressure
If EGR valve drive pressure is abnormal, perform checks on causes 3 and 4.
• For check of engine oil pressure, see “TESTING AND ADJUSTING”,
Defective engine oil pres- “TEST ENGINE OIL PRESSURE”.
3 sure system (main cir-
cuit) • If engine oil pressure is not normal, perform troubleshooting (S mode).
(Engine oil pressure drops)
Defective EGR valve oil Oil pump and relief valve for EGR valve circuit may be defective. Check them.
4
pump
Defective hydraulic pip- Hydraulic piping for EGR valve circuit may be defective. Check it.
5
ing for EGR valve
Defective hydraulic return Hydraulic return piping for EGR valve circuit may be defective. Check it.
6
piping for EGR valve
• EGR valve may have mechanical trouble. Check it.
7 Defective EGR valve • Check especially that there is no foreign material in oil inlet and outlet of
EGR valve.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If failure code is still displayed after above checks on causes 1 to 8, engine control-
9 ler is defective. (In case of an internal defect, troubleshooting is impossible as an
ler
PC210LCI-11 40-417

Action level Failure code VGT Position Sensor High Error
Failure
Details of
High voltage is generated in VGT position sensor signal circuit.
failure
Action of
controller
Phenomenon
on machine
• Signal voltage from VGT position sensor can be checked with monitoring function. (Code:
48701 (V))
• Position (mm) detected by VGT position sensor can be checked with monitoring function.
Related (Code: 48700 (mm))
information • Engine power deration is canceled when the failure code is cleared and the starting switch

1
2
Defective VGT position 2. Disconnect connector SVGT.
3
sensor (internal defect) 3. Turn starting switch ON (with connector SVGT disconnected).
If failure code [CA2381] changes to [CA2382], the sensor is defective.
2. Disconnect connector INTER-CONNECT.
Defective connector box 3. Turn starting switch to ON position.
4
(internal short circuit) If failure code [CA2381] changes to [CA2382], the connector box is defective.
REMARK
Open circuit of connector 2.
Disconnect connectors INTER-CONNECT and SVGT, and connect T-adapter
box (wire breakage of
5 to male side of INTER-CONNECT or female side of SVGT.
contact of connector) Between INTER-CONNECT (male) (9) and SVGT (fe-
male) (B)
40-418 PC210LCI-11

(female) (9)
ness
Hot short circuit in wiring 2. Disconnect connector SVGT and connect T-adapter to female side.
8
harness 3. Turn starting switch ON (with connector SVGT disconnected).
Voltage Between SVGT (female) (C) and (B) Max. 1 V
Reference
9
ler
Voltage Between ECM J1 (67) and (57) 1.0 to 4.0 V
PC210LCI-11 40-419
CIRCUIT DIAGRAM (VGT POSITION SENSOR)
40-420 PC210LCI-11

Action level Failure code VGT Position Sensor Low Error
Failure
Detail of fail-
Low voltage is generated in VGT position sensor signal circuit.
ure
Action of
controller
Phenomenon
on machine
• Signal voltage from VGT position sensor can be checked with monitoring function. (Code:
48701 (V))
• Position (mm) detected by VGT position sensor can be checked with monitoring function.
(Code: 48700 (mm))
Related • Engine power deration is canceled by turning starting switch to OFF position after this fail-
information ure code is cleared (note that the engine power deration is not canceled right after the fail-
ure code is cleared).

1
first.
2 Disconnect connector SVGT and connect T-adapter to female side.
supply system
Between SVGT (female) 4.75 to
(A) and (B) 5.25 V
2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-
adapter to male side of INTER-CONNECT or female side of SVGT.
If failure code is still displayed after above checks on
Open circuit of connector Max. 10 Ω
Between INTER-CONNECT (male) (8) and SVGT (fe-
box (wire breakage or
3 male) (A)
nector) If failure code is still displayed after above checks on
Resistance
Max. 10 Ω
male) (B)
Max. 10 Ω
male) (C)
PC210LCI-11 40-421

Ground fault of connector adapter to male side of INTER-CONNECT or female side of SVGT.
4 box (contact with ground Between ground and INTER-CONNECT (male) (10) or
circuit) Min. 100 kΩ
SVGT (female) (C)
Resistance
Min. 100 kΩ
SVGT (female) (A)
adapter to male side of INTER-CONNECT or female side of SVGT.
5 Between INTER-CONNECT (male) (9) and (10), or be-
box (internal short circuit) Min. 100 kΩ
tween SVGT (female) (B) and (C)
Resistance
Min. 100 kΩ
tween SVGT (female) (A) and (B)
2. Disconnect connectors INTER-CONNECT and ECM J1, and connect T-
6 (female) (8)
contact of connector) If power supply voltage in check on cause 2 is normal,
Resistance
Max. 10 Ω
(female) (9)
Max. 10 Ω
(female) (10) (sensor output)
Ground fault in wiring 2. Disconnect connectors ECM J1 and SVGT, and connect T-adapter to ei-
7 harness (contact with ther female side.
ground circuit)
tween INTER-CONNECT (female) (10) and ground
ness
If no failure is found in causes 1 through 8 but found in cause 9, the sensor is de-
fective.
Defective VGT position 2. Insert T-adapter into connector ECM J1 or SVGT.
9
sensor
Between ECM J1 (67) and (57), or between SVGT (C)
and (B)
10
40-422 PC210LCI-11
CIRCUIT DIAGRAM (VGT POSITION SENSOR)
PC210LCI-11 40-423

Action level Failure code VGT Solenoid Open Circuit Error
Failure
Detail of fail-
Open circuit occurs in VGT solenoid drive circuit.
ure
Action of
controller
Phenomenon
on machine
• Signal current to VGT solenoid can be checked with monitoring function. (Code: 48600
(mA))

1
Defective VGT solenoid 2.
2 Disconnect connector VGT-SOL, and connect T-adapter to male side.
(internal open circuit)
Resistance Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
3
wiring harness
If resistance is 100 kΩ or higher, wiring harness has open circuit. If resistance is
10 Ω or below, wiring harness has short circuit.
Resistance Between ECM J2 (female) (80) and (2) 5 to 10 Ω
2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapters to
Ground fault in wiring each female side.
4 harness system (contact Between ground and ECM J2 (female) (80) or VGT-
with ground circuit) Min. 100 kΩ
SOL (female) (1)
Resistance
Between ground and ECM J2 (female) (2) or VGT-SOL
Min. 100 kΩ
(female) (2)
40-424 PC210LCI-11

quired.
Open circuit of connector 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and connect T-
box (wire breakage or adapter to female side of VGT-SOL or male side of INTER-CONNECT.
5
nector) Between INTER-CONNECT (male) (6) and VGT-SOL
Max. 10 Ω
(female) (1)
Resistance
Between INTER-CONNECT (male) (7) and VGT-SOL
Max. 10 Ω
(female) (2)
quired.
Ground fault of connector 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and connect T-
6 box (contact with ground adapter to female side of VGT-SOL or male side of INTER-CONNECT.
circuit) Between ground and INTER-CONNECT (male) (6) or
Min. 100 kΩ
VGT-SOL (female) (1)
Resistance
Min. 100 kΩ
VGT-SOL (female) (2)
quired.
Open circuit in wiring har- 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapters to
ness (wire breakage or each female side.
7
Max. 10 Ω
(female) (6)
Resistance
Max. 10 Ω
(female) (7)
2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapter to
8 female side of ECM J2.
ness
Continuity
than pin (80) ty
Ground fault in wiring adapters to each female side.
9 harness (contact with Between ground and ECM J2 (female) (80) or INTER-
ground circuit) Min. 100 kΩ
Resistance
Between ground and ECM J2 (female) (2) or INTER-
Min. 100 kΩ
10
PC210LCI-11 40-425
CIRCUIT DIAGRAM (VGT VALVE SOLENOID)
40-426 PC210LCI-11

Failure VGT Solenoid Short Circuit Error (Engine controller system)
L03 CA2386
Detail of fail-
Short circuit occurs in VGT solenoid drive circuit.
ure
Action of
controller
Phenomenon
on machine
• Signal current to VGT solenoid can be checked with monitoring function. (Code: 48600
(mA))

1
2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
Defective VGT solenoid
2
(internal short circuit) Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between VGT-SOL (male) (1) and ground Min. 100 kΩ
2. Disconnect connectors INTER-CONNECT and VGT-SOL, and connect T-
Short circuit of connector adapters to male side of INTER-CONNECT.
3
box
No continui-
Between INTER-CONNECT (male) (6) and each pin
other than pin (6)
is heard)
side.
3. Turn starting switch to ON position (with connector INTER-CONNECT dis-
4 connected).
harness
REMARK
hot short circuit in negative line
Voltage Between INTER-CONNECT (female) (7) and ground Max. 3 V
5
PC210LCI-11 40-427
CIRCUIT DIAGRAM (VGT VALVE SOLENOID)
40-428 PC210LCI-11

Action level Failure code VGT Servo Error
Failure
Detail of fail- VGT servo error occurs. (Response from VGT position sensor differs from VGT opening command
ure value.)
Action of
controller
Phenomenon
on machine
Related is turned OFF (not canceled only by deactivation of the failure code).

1
tem
For testing of VGT drive pressure, see “TESTING AND ADJUSTING”, “TEST EGR
Insufficient VGT drive VALVE AND VGT DRIVING OIL PRESSURE”.
2
pressure
If VGT drive pressure is abnormal, perform checks on causes 3, 4 and 5.
• For check of engine oil pressure, see “TESTING AND ADJUSTING”,
Defective engine oil pres- “TEST ENGINE OIL PRESSURE”.
3 sure system (main cir-
cuit) • If engine oil pressure is not normal, perform troubleshooting (S mode).
(Engine oil pressure drops)
4 Defective VGT oil pump Oil pump and relief valve for VGT valve circuit may be defective. Check them.
Defective hydraulic pip- Hydraulic piping for VGT circuit may be defective. Check it.
5
ing for VGT
Defective hydraulic return Hydraulic return piping for VGT circuit may be defective. Check it.
6
piping for VGT
VGT may have a mechanical failure. Check it.
Also check that there is no foreign material in oil inlet of VGT servo.
Defective VGT (Mechani- If KDOC inlet temperature: approximately 250 °C or below and VGT solenoid cur-
7
cal failure) rent: approximately 1000 mA are kept after active regeneration for service, VGT is
defective (See failure code CA2639 because approximate manual stationary regen-
eration time depends on the soot level estimation).
Defective VGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
8
sensor
Defective engine control- If failure code is still displayed after above checks, any internal parts in the engine
9
ler controller is defective.
PC210LCI-11 40-429

Action level Failure code Intake Air Heater Relay Open Circuit Error
Failure
Detail of fail-
Open circuit is detected in preheat relay drive circuit (primary circuit).
ure
Action of
None in particular
controller
Phenomenon Intake air heater does not work in auto preheating mode (resulting in degraded startability and emis-
on machine sion of white smoke at low temperatures).

• Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
circuit of pre-heater relay.
Related
• This failure code is detected only when the relay is OFF. Troubleshoot with charge temper-
information ature at -2 °C and above.
• For troubleshooting of secondary circuit of heater relay and pre-heater relay, see E-mode.
Procedure: Turn starting switch to ON position (charge (boost) temperature: Min. -2 °C

1. See descriptions of wiring harness and connectors in “c. METHOD FOR
CHECKING ELECTRIC EQUIPMENT” in “CHECKS BEFORE TROUBLE-
SHOOTING” of “RELATED INFORMATION ON TROUBLESHOOTING”,
Defective wiring harness and check it.
1
connector 2. Turn starting switch to ON position. (charge (boost) temperature: Min.
-2 °C)
2. Disconnect relay R18, and connect T-adapter to male side.
200 to
Resistance Between R18 (male) (1) and (2)
400 Ω
Defective preheating re-
2
lay PHR 1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
If this failure code is cleared, original preheat relay R18 is defective.
Open or short circuit in 2. Disconnect connector J2, and connect T-adapter to female side.
3
wiring harness Between J2 (female) (75) and (61) 200 to
Resistance
Coil resistance of relay R18 400 Ω
40-430 PC210LCI-11

quired.
Open circuit in wiring har- 2. Disconnect connector J2 and relay R18, and connect T-adapter to each fe-
4
ness male side.
Between J2 (female) (75) and R18 (female) (1) Max. 1 Ω
Resistance
Between J2 (female) (61) and R18 (female) (2) Max. 1 Ω
Perform under conditions under which no preheating takes place (engine coolant:
-2 °C or above).
5 2. Insert T-adapter into connector J2.
harness
Voltage Between J2 (75) and (61) Max. 1 V
6
PC210LCI-11 40-431
CIRCUIT DIAGRAM (INTAKE AIR HEATER RELAY)
40-432 PC210LCI-11

Action level Failure code Intake Air Heater Relay Short Circuit Error
Failure
Detail of fail-
Short circuit is detected in intake air heater relay drive circuit (primary circuit).
ure
Action of
None in particular
controller
Phenomenon Intake air heater does not work in auto preheating mode (resulting in degraded startability and emis-
on machine sion of white smoke at low temperatures).

• Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
circuit of pre-heater relay.
Related
• This failure code is detected only when the relay is ON. Troubleshoot with charge temper-
information ature at -3 °C and below.
• For troubleshooting of secondary circuit of heater relay and pre-heater relay, see E-mode.
Procedure: Turn starting switch to ON position (charge (boost) temperature: Max. -3 °C

1. See descriptions of wiring harness and connectors in “c. METHOD FOR
CHECKING ELECTRIC EQUIPMENT” in “CHECKS BEFORE TROUBLE-
SHOOTING” of “RELATED INFORMATION ON TROUBLESHOOTING”,
Defective wiring harness and check it.
1
connector 2. Turn starting switch to ON position. (charge (boost) temperature: Min.
-2 °C)
200 to
400 Ω
Defective preheating re-
2
lay 1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
If this failure code is cleared, original preheat relay R18 is defective.
Ground fault in wiring 2. Disconnect connector J2 and relay R18, and connect T-adapter to either
ground circuit)
Between J2 (female) (75) or R18 (female) (1) and
ground
2. Disconnect connector J2 and relay R18, and connect T-adapter to female
4 side of J2.
ness
Between J2 (female) (75) and each pin other than pin No continui-
Continuity
(75) ty
PC210LCI-11 40-433

5
40-434 PC210LCI-11
CIRCUIT DIAGRAM (INTAKE AIR HEATER RELAY)
PC210LCI-11 40-435

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 effi-
Details of
ciency has dropped (clean the DOC).
failure
2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or drop-
ped efficiency due to damage (Replace KDOC with a new or used one.)
Phenomenon
None
on machine
k Since temperature of the turbocharger exhaust connector, KDOC and KDPF exceeds
500°C, be careful not to get burned.
When KDOC in KDPF is changed, perform reset procedure for KDOC change and then finish repair.
Procedure of performing the manual stationary regeneration from the "active regeneration for serv-
ice".
When soot accumulation is at level 3 or lower, manual stationary regeneration can be performed on-
ly from Active Regeneration for Service.
1. Start engine.
2. Make sure that machine is in safe condition.
Related generation for Service, and then perform “Manual Stationary Regeneration”.
information When operation efficiency of KDOC is decreasing, failure code [AQ10N3] may appear after failure
code [CA2637] is displayed repeatedly. If operation efficiency of KDOC is low, failure code [CA1691]
of regeneration ineffective may appear.
For check of the exhaust gas color, see “30 TESTING AND ADJUSTING”, “TEST EXHAUST GAS
COLOR”.
[Method of clearing failure code]
Start the engine, perform warm-up operation, and operate the machine in normal work for approxi-
mately 3 hours. (The time required for clearing codes will be reduced by high exhaust temperature
conditions.)
NOTICE
Operate the machine approximately 3 hours and check that this failure code is cleared.

1 Defective VGT If failure code [CA238*] is displayed, perform troubleshooting for the code first.
If failure code [CA227*] or [CA23**] is displayed, perform troubleshooting for those
2 Defective EGR valve
codes first.
1. Remove turbocharger exhaust connector
2. Check inside of turbocharger exhaust connector for adhesion of oil and
3 fuel.
exhaust connector
If there is any, perform troubleshooting for failure codes [CA227*], [CA23**], etc.
which are related to EGR valve and VGT.
Defective exhaust con- Check the exhaust system between the turbocharger and KDPF for damages in
4
nector or duct to KDPF connectors or ducts or loose connections.
40-436 PC210LCI-11

1. Suddenly accelerate the engine from low idle to high idle two times, and
then keep the engine running at high idle speed for 5 seconds.
If an excess black smoke is seen at high idle speed during acceleration, perform
Defective exhaust gas “S-9 KDPF GETS CLOGGED IN A SHORT TIME”.
5
color
REMARK
1. Remove KDPF.
2. Remove KDOC.
NOTICE
6 Defective KDOC • Check if KDOC has any cracks (change KDOC if any).
• Check if KDOC inlet surface is clogged with soot 50 % or more (Clean-
ing of KDOC).
• Perform cause 7 when KDOC is changed, and perform causes 7 and 8
when it is cleaned.
1. Attach KDOC and KDPF.
3. On the Service screen of the machine monitor, display “Diagnostic Tests”
screen, open 03 “KDPF Memory Reset”, and perform 03 “KDOC Change”
Reset after KDOC (Reset after KDOC change).
7
change NOTICE
• Check that reset after KDOC change is complete successfully (by re-
set count). If not, perform troubleshooting again.
• If KDOC is changed, troubleshooting is complete without performing
manual stationary regeneration.
1. Perform manual stationary regeneration from active regeneration for serv-
ice.
3. Perform manual stationary regeneration from active regeneration for serv-
Manual stationary regen- ice again (to confirm the completion of the repair).
8
eration performed
NOTICE
If failure code [CA2637] is displayed after performing active regeneration for
service, KDOC's efficiency is degraded. Change KDOC and perform the reset
after KDOC change (see cause 7).
PC210LCI-11 40-437

Failure Manual Stationary Regeneration Request (Engine controller system)
L01 CA2639
The “Manual Stationary Regeneration Request”prompts operator to forcibly perform “Manual Sta-
Details of tionary Regeneration”, which is more effective to remove soot, because soot accumulation in the
failure KCSF of KDPF has exceeded the level for automatic regeneration.
Soot accumulation reaches level 4 or 5.
Action of
Normal control
controller
Phenomenon
None in particular
on machine
NOTICE
• If this failure code [CA2639] is displayed, perform manual stationary regeneration.
• This failure code is displayed during Manual Stationary Regeneration, but it is nor-
mal.
• If this failure code is still displayed after several hours have passed since the man-
ual stationary regeneration, perform the following troubleshooting procedures.
• If KDOC inlet temperature is below approximately 280 °C, fuel dosing is disabled, so ac-
tually regeneration does not start when engine controller started manual stationary regen-
eration.
• VGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
Related • Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
information ing function. (Code: 47400 (°C))
• When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
• For check of the exhaust gas color, see “30 TESTING AND ADJUSTING”, “TEST EX-
HAUST GAS COLOR”.
40-438 PC210LCI-11
• How to perform manual stationary regeneration

1. Start engine.
2. Make sure that machine is in a safe condition.
generation for Service, and then perform Manual Stationary Regeneration.
• Switch operation during manual stationary regeneration: By pressing "1", "2", "3" in order
while numeral input switch [4] is pressed, the screen changes to Monitoring.
Related
information
• If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for these first.

1. Check that “Regeneration Disable” is chosen on the screen of the machine
Increased accumulation monitor. (See operation manual) Cancel the “Regeneration Disable” if it is
1 of soot due to regenera- chosen.
tion disable
2. Cancel regeneration disable and perform cause 2 and subsequent causes.
2
VGT may have a mechanical failure. Check it.
Also check that there is no foreign material in oil inlet of VGT servo.
Defective VGT (Mechani- If KDOC inlet temperature: approximately 250 °C or below and VGT solenoid cur-
3
cal failure) rent: approximately 1000 mA are kept after active regeneration for service, VGT is
defective (See failure code CA2639 because approximate manual stationary regen-
eration time depends on the soot level estimation).
Defective KDPF (KDOC, Perform troubleshooting for “S-22 ACTIVE REGENERATION TAKES TIME” of S
4
or KCSF) mode.
gas color.
5
PC210LCI-11 40-439

6
40-440 PC210LCI-11

Action level Failure code SCR Outlet NOx Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller does not receive SCR outlet NOx sensor data due to a communication error
ure with the SCR outlet NOx sensor.
Action of • Runs the controller using the default NOx emission value (0 ppm).
• NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injec-
Phenomenon tion works inappropriately.
on machine • Engine output is reduced based on inducement strategy.
• SCR outlet NOx concentration detection error
k The turbocharger outlet, the sensor installation piping, KDPF, and KDOC become hot
(Min. 500 °C). Be careful not to get burned.
k SCR assembly, the sensor installation piping, and the sensor probe become hot
• SCR outlet NOx sensor is a smart sensor which communicates with the engine controller
via CAN along with other sensors.
• This failure code is displayed if the sensor connector or a smart sensor (power supply) re-
lay connector is removed.
• CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
[CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are displayed, a
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system
or a ground fault or short circuit or hot short circuit in wiring harness (CAN communication
line) can be suspected.
Related
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
information
using multimeter.
• AdBlue/DEF tank sensor consists of the AdBlue/DEF level sensor, AdBlue/DEF tempera-
ture sensor, and AdBlue/DEF quality sensor and is integrated into one sensor controller
which provides CAN communication with the engine controller.
• The KDPF temperature sensor consists of the KDOC inlet temperature sensor, the KDOC
outlet temperature sensor, and the KDPF outlet temperature sensor and is integrated into
one sensor controller which provides CAN communication with the engine controller.
• For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
• The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
• For replacement of the SCR temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“Remove and install SCR temperature sensor”.

1
connector
PC210LCI-11 40-441

Defective smart sensor disconnect switch to OFF position.
2 power supply relay sys- 3. Disconnect relay connector R52, and connect T-adapter to female side.
tem
6. Perform troubleshooting for failure code [CA1776] if a failure is found.
Voltage Between R52 (female) (5) and (4) Min. 22 V
3. Disconnect connectors E26, E31, E32, E34, E36, and P63.
4. Insert T-adapter into connector R52.
Defective sensor power 6. Turn starting switch to ON position.
3
supply relay
Between R52 (6) and (4) Min. 22 V
Voltage
If all 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed
4 2. Disconnect turbocharger outlet NOx sensor (E31).
outlet NOx sensor
Displaying less than 6 failure codes indicates the disconnected sensor is defective.
If all of 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed.
Defective SCR outlet 2. Disconnect SCR outlet NOx sensor (E36).
5
NOx sensor
If any of these 6 codes disappeared, the sensor which has been disconnected is
defective.
Defective SCR tempera-
6 2. Disconnect SCR temperature sensor (E34).
ture sensor
40-442 PC210LCI-11

Defective ammonia sen-
7 2. Disconnect an ammonia sensor (E32).
sor
If all of 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed.
Defective KDPF temper- 2. Disconnect KDPF temperature sensor (E26).
8
ature sensor
If any of these 6 codes disappeared, the sensor which has been disconnected is
defective.
9 2. Disconnect AdBlue/DEF tank sensor (P63).
tank sensor
2. Disconnect connector K10 and D_RES and connect T-adapter to male
side.
Defective CAN terminat-
10 Approx.
ing resistor Between K10 (male) (A) and (B)
120 Ω
Resistance
Approx.
Between RES (male) (A) and (B)
120 Ω
• Communication line
As CAN terminating resistors of 120 Ω are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 Ω, there is no open circuit.
Open circuit and short 2. Check that system operating lamp does not light up, and then turn battery
circuit in wiring harness disconnect switch to OFF position.
11
(broken or short-circuited
3. Disconnect connectors ECM J2 and E36 and connect T-adapters to each
communication line)
female side.
Approxi-
Between E36 (female) (3) and (2)
mately 60 Ω
Resistance
Approxi-
mately 60 Ω
If no failure is found by above results, this check is not required.
ness (wire breakage or 2. Disconnect connectors R52 and E36 and connect T-adapters to each fe-
12 defective contact of con- male side.
nector) (broken power
line) Between R52 (female) (12) and E36 (female) (1) Max. 10 Ω
Resistance
Between E36 (female) (4) and ground Max. 10 Ω
PC210LCI-11 40-443

required.
Disconnect connectors ECM J2, E36, K10, and K11 and connect T-adapt-
ers to each female side.
13 defective contact of con-
nector) (broken commu- Between ECM J2 (female) (21) and E36 (female) (3) Max. 10 Ω
nication line)
Between K10 (female) (A) and E36 (female) (3) Max. 10 Ω
Resistance
Between K10 (female) (B) and E36 (female) (2) Max. 10 Ω
f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
3. Disconnect all related connectors, and connect T-adapter to the female
Ground fault in wiring side of the connector to be measured.
Between one of ECM J2(female)(21),K10(female)
ground circuit)
(A),K11(female)(A),E31(female)(3),E32(female)
Min.100 kΩ
(2),E26(female)(3),E34(female)(3),E36(female)
(3),P63(female)(2) and ground
Resistance
(B),K11(female)(B),E31(female)(2),E32(female)
Min.100 kΩ
3. Insert T-adapter into one of the related connectors.
15 4. Set battery disconnect switch to ON position.
harness
Between one of ECM J2(21), K10(A), K11 (A), E31(3),
1 to 4 V
E32(2), E26(3), E34(3), E36(3), or P63(2) and ground
Voltage
Between one of ECM J2(45), K10(B), K11 (B), E31(2),
1 to 4 V
2. Replace the SCR outlet NOx sensor (E36).
NOx sensor
40-444 PC210LCI-11

17
PC210LCI-11 40-445
Circuit diagram related to SCR system CAN communication
40-446 PC210LCI-11

Action level Failure code Manual Stationary Regeneration Request but KDPF Regeneration
Failure Disable
- CA2777 (Engine controller system)
• The Manual Stationary Regeneration Request prompts operator to forcibly perform "Man-
ual Stationary Regeneration", which is more effective to remove soot, because soot accu-
Detail of fail- mulation in the KCSF of KDPF has exceeded the level for automatic regeneration. Howev-
ure er, the operator is pressing Regeneration Disable, so regeneration is disabled.
• Soot accumulation reaches level 4 or 5.
Action of
None in particular
controller
Phenomenon
None
on machine
PC210LCI-11 40-447
k If KDOC and KDPF becomes hot (Min. 500 °C). Be careful not to get burned.
REMARK
If manual stationary regeneration is started when KDOC inlet temperature is below approximately
280 °C, fuel dosing is disabled, so actually regeneration does not start.
(Code: 47300 (°C))
• VGT solenoid current can be checked by monitoring function. (Code: 48800 (mA))
(Code: 47400 (°C))
(Code: 47200 (°C))
• The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature can
also be confirmed from the troubleshooting screen.
• All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
• When manual stationary regeneration is in progress, KDOC inlet temperature is 250 to
400 °C, and KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
Related How to perform manual stationary regeneration
information 1. Start the engine.
3. From service menu of machine monitor, display “Diagnostic Tests” screen, open “Active
Regeneration for Service”, clear regeneration disable, and then perform “Manual Station-
ary Regeneration”.
Time required for manual stationary regeneration varies depending on soot accumulation amount in
KCSF. Rough guide is described below.
• Soot accumulation level 4: Approximately 40 minutes to 1 hour
• Soot accumulation level 5: Approximately 1 hour to 2 hours
REMARK
• If this failure code is still displayed after several hours have passed since the manual sta-
tionary regeneration, perform the following troubleshooting procedures.
• If other failure code is also displayed (including manual stationary regeneration), perform
troubleshooting for these first.
• This failure code is not a failure but an information to identify the failure.
• If this failure codes frequently is displayed, ask operator to perform “Cancel of Regenera-
tion Disable”and to execute manual stationary regeneration after securing the safety of the
surroundings and check that there is not a person or combustible around the machine.
40-448 PC210LCI-11

If the failure code is not cleared after Cancel of Regeneration Disable from the ma-
1 chine monitor, the engine controller may be defective (In case of an internal defect,
ler
troubleshooting is impossible as an assembly. Replace whole assembly.)
PC210LCI-11 40-449

Action level Failure code AdBlue/DEF Pump Temperature Sensor Signal Error
Failure
Detail of fail-
Power supply, wiring harness, or sensor for AdBlue/DEF pump temperature is defective.
ure
Action of • The last normal value of AdBlue/DEF pump temperature is valid.
• AdBlue/DEF thawing defective.
Phenomenon
• NOx emission increases in low temperature due to defective AdBlue/DEF pump thawing.
on machine
• Engine output is reduced based on inducement strategy.
• This failure code is displayed when AdBlue/DEF pump connector is disconnected.
Related • Because sensor output is approximately 10 V of pulse waveform, it is not measured by us-
ing multimeter.
information

Defective power supply If failure code [CA3558] or [CA3559] is displayed, perform troubleshooting for
system of AdBlue/DEF [CA3558] or [CA3559] first.
1
pump temperature sen-
sor
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
Defective wiring harness “RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
2
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
Open circuit in wiring har- ther female side.
3 Between ECM J2 (female) (54) and MB02 (female) (8) Max. 10 Ω
nector) Between ECM J2 (female) (79) and MB02 (female) (9) Max. 10 Ω
Resistance
Between ECM J2 (female) (06) and MB02 (female)
Max. 10 Ω
(10)
ther female side.
Short circuit in wiring har- Min. 100 kΩ
4 MB02 (female) (10) and (8)
ness
MB02 (female) (10) and (9)
Min. 100 kΩ
40-450 PC210LCI-11

Ground fault in wiring ther female side.
5 harness (contact with Between ECM J2 (female) (6) or MB02 (female) (10)
GND circuit) Min. 100 kΩ
and ground
Resistance
Between ECM J2 (female) (79) or MB02 (female) (9)
Min. 100 kΩ
and ground
Hot short circuit in wiring 2. Disconnect connector MB02, and connect T-adapter to female side.
6
Voltage Between MB02 (female) (10) and (8) Max. 4.5 V
Defective AdBlue/DEF If no failure is found by preceding checks, AdBlue/DEF pump temperature sensor
7 pump temperature sen- may be defective. (In case of an internal defect, troubleshooting is impossible as an
sor (internal defect) assembly. Replace whole assembly.)
8
Circuit diagram related to AdBlue/DEF pump temperature sensor
PC210LCI-11 40-451

Action level Failure code KDPF outlet pressure sensor high error
Failure
Detail of fail-
High voltage is generated in signal circuit of KDPF outlet pressure sensor.
ure
Action of Drives KDPF outlet pressure sensor at estimated value (gauge pressure). (Operates at 0 kPa
controller (gauge pressure) if other failure code is displayed at the same time).
Phenomenon
None
on machine
k KDPF is heated to 500 °C or higher. Be careful not to get burn injury.

unit.
• If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, ground
line probably has open circuit (defective contact of connector).
Related
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring function.
information
(Code: 47001 (V))
• Differential pressure detected by KDPF outlet pressure sensor can be checked with moni-
toring function. (Code: 47000 (kPa))

1
supply system
4.75 to
5.25 V
Defective KDPF outlet If this failure code is changed to [CA3134], the KDPF outlet pressure sensor is de-
3 fective.
pressure sensor
NOTICE
• If this failure code is displayed, the wiring harness or engine control-
ler is defective.
• Ignore other failure codes displayed.
40-452 PC210LCI-11

quired.
Starting switch: OFF
4 2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
contact of connector) female side.
Resistance Between ECM J2 (female) (32) and E25 (female) (1) Max. 10 Ω
5
ness
No continui-
than pin (42)
is heard)
Hot short circuit in wiring 3. Connect T-adapter to female side of connector E25, or insert T-adapter to
6 harness (Contact with 24 connector ECM J2.
V circuit) 4. Turn starting switch to ON position (with connector E25 disconnected).
Voltage Max. 1 V
E25 (female) (3) and (1)
7
PC210LCI-11 40-453
Circuit diagram related to KDPF outlet pressure sensor
40-454 PC210LCI-11

Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
Detail of fail-
Low voltage is generated in signal circuit of KDPF outlet pressure sensor.
ure
Action of Sets KDPF outlet pressure sensor value to an estimated value (gauge pressure) and continues op-
controller eration (operates at 0 kPa (gauge pressure) if other failure codes appear at the same time).
Phenomenon
None
on machine
k Since KDPF is heated to 500 °C or above, be careful not to get burned.

• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V line probably has open circuit (defective contact
of connector).
Related • This failure code is displayed if sensor connector is disconnected.
information • Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
(Code: 47001 (V))
• Differential pressure detected by KDPF outlet pressure sensor can be checked by monitor-
ing function. (Code: 47000 (kPa))

1
supply system
4.75 to
5.25 V
2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
female side.
3
defective contact of con- Between ECM J2 (female) (32) and E25 (female) (1)
nector)
Between ECM J2 (female) (8) and E25 (female) (4)
PC210LCI-11 40-455

Ground fault in wiring 2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
ground circuit)
tween E25 (female) (3) and ground
5
ness
No continui-
than pin (42)
is heard)
Defective KDPF outlet 2. Insert T-adapter into connector E25.
6
Voltage Between E25 (3) and (1) 0.5 to 4.5 V
7
40-456 PC210LCI-11

Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
Details of Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage is within operating range.)
Action of Sets KDPF outlet pressure sensor value to an estimated value (gauge pressure) and continues op-
controller eration (operates at 0 kPa (gauge pressure) if other failure codes appear at the same time).
Phenomenon
None
on machine
burned.
• KDPF differential pressure sensed by KDPF differential pressure sensor can be checked
by monitoring function. (Code: 47100 (kPa))
• Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
(Code: 47001 (V))
• Outlet pressure sensed by KDPF outlet pressure sensor can be checked by monitoring
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related REMARK
information
Use “Short-circuit connector: 799T-601-4670”.
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
position.
NOTICE
cleared again.
firstly Setting and operating machine monitor, Service mode, Service mode (Engine
Controller Active Fault Clear) to be performed to clearer this failure code.
PC210LCI-11 40-457

3. Check the KDPF differential pressure sensor tube for cracks or damages.
4. Securely connect both ends of the tube and install the KDPF differential
pressure sensor tube.
1 Reference
How to check clogged KDPF differential pressure sensor tube
2. Monitor the outlet pressure by using KDPF outlet pressure sensor on Self-
define Monitoring screen of the machine monitor.
Code 47000(kPa) 0 ± 3( kPa)
supply system
4.75 to
5.25 V
Defective wiring harness ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
3
connector FORMATION ON TROUBLESHOOTING”, and check and repair defects, if
any.
tive.
4 2. Disconnect connector E25 and connect short socket adapter to female
or engine controller
side.
REMARK
Connect 5 V to the signal line. (Short-circuit pins (4) and (3) of connector E25.)
tive.
Defective KDPF outlet If failure codes [CA3134] and [CA3133] are displayed after checks on defective wir-
5
pressure sensor ing harness or engine controller, the KDPF outlet pressure sensor is defective.
6
40-458 PC210LCI-11

k Place the machine on a level place.
4. Display the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature referring to
the related information.
5. After warm-up, set the swing lock to ON, working mode to P, and fuel control dial to MAX position.
6. Operate for 40 seconds in succession with Arm IN relief.
PC210LCI-11 40-459

Action level Failure code SCR Temperature Sensor High Error
Failure
Detail of fail- Open circuit , hot short circuit, or sensor circuit error in SCR temperature sensor measuring section
ure or probe (+)
• Because the SCR temperature is not detected be detected, substitute the SCR outlet tem-
perature for the SCR temperature and run the engine (if the SCR outlet temperature sen-
Action of sor also has an error, use the last normal value).
• AdBlue/DEF injection stops.
k SCR assembly, the sensor installation piping, and the sensor probe become hot (Min.
• Open circuit , hot short circuit, or sensor circuit error in SCR temperature sensor measur-
ing section or probe (+) is sent to the engine controller via CAN communication, and this
failure code is displayed.
Related
information one sensor controller which provides CAN communication with the engine controller.
• For replacement of the SCR temperature sensor, see Disassembly and assembly, “Re-
move and install SCR temperature sensor”.

2. Replace SCR temperature sensor.
1 ture sensor (internal de- 3. Turn starting switch to ON position.
fect) If this failure code is cleared, the original SCR temperature sensor is defective. (In
whole assembly.)
2
40-460 PC210LCI-11

Action level Failure code SCR Temperature Sensor Low Error
Failure
Detail of fail-
Ground fault or sensor circuit error in SCR temperature sensor measuring section or probe (+)
ure
• As the SCR temperature cannot be detected, substitute the SCR outlet temperature for
the SCR temperature and run the engine (if the SCR outlet temperature sensor also has
Action of an error, use the latest normal value).
k SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
sensor controller which provides CAN communication with the engine controller.
Related • Ground fault or sensor circuit error in SCR temperature sensor measuring section or probe
(+) is sent to the engine controller via CAN communication, and this failure code is dis-
information played.
• For the replacement procedure of the SCR temperature sensor, see "Disassembly and as-
sembly," “Remove and install SCR temperature sensor”.

whole assembly.)
2
PC210LCI-11 40-461

Action level Failure code SCR Temperature Sensor In Range Error
Failure
Detail of fail- Temperature difference between SCR temperature sensor and SCR outlet temperature sensor is
ure not the same as the expected value.
Action of • Advances to Inducement strategy.
controller • AdBlue/DEF injection stops.
k Since KDPF, KDOC, and SCR are heated to 500 °C or above, be careful not to get burned.
• For the replacement procedure of the SCR temperature sensor, see “Disassembly and as-
sembly”, “Removal and installation of SCR temperature sensor”.
ON position.
• The temperature detected by the SCR temperature sensor can be confirmed from the Pre-
defined Monitoring screen.
• Use engine operation state diagnosis, AdBlue/DEF level, or AdBlue/DEF quality sensor di-
agnosis on the Pre-defined Monitoring screen. (The following numbers are the monitoring
codes)
01002 Engine speed
• Troubleshooting for AdBlue/DEF level and AdBlue/DEF quality sensors
19100 AdBlue/DEF Concentration
19110 AdBlue/DEF Level
19111 AdBlue/DEF Level Corrected
19115 AdBlue/DEF Temperature in Tank
NOTICE
sure that the failure code is cleared. (Repair completion cannot be judged without rais-
ing the exhaust temperature even if this failure code is cleared by turning ON the start-
ing switch)
40-462 PC210LCI-11

Defective SCR tempera- If failure code [CA3142] or [CA3143] is displayed, perform troubleshooting for
ture sensor (internal [CA3142] or [CA3143].
1
open or short circuit to
ground)
1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL SCR ASSEM-
3 ture sensor (installation BLY” and fix installation error, if any.
error)
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Check the “AdBlue/DEF concentration” on the troubleshooting assistance
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If a failure is found by above checks, it may be contaminated. Replace the
AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
5
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR tempera- perature sensor.
6 ture sensor (internal de- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
fect)
If the failure code is cleared, the SCR temperature sensor may be defective.

REMARK
If this failure code is displayed during “Loaded Diagnostics Operation To Confirm Failure Correction”, return to
troubleshooting.
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
4. Run the engine at low idle speed for approximately 1 minute.
5. After warm-up operation, set the swing lock to ON, the working mode to P, and set fuel control dial to MAX
position.
6. Run the engine at high idle speed for 15 minutes.
7. If this failure code is not displayed, repair is completed.
PC210LCI-11 40-463

Action level Failure code SCR Outlet Temperature Sensor High Error
Failure
Detail of fail- Open circuit , hot short circuit, or sensor circuit error in SCR outlet temperature sensor measuring
ure section or probe (+)
• As the SCR outlet temperature cannot be detected, substitute the SCR temperature for
the SCR outlet temperature and run the engine (if the SCR temperature sensor also has
• AdBlue/DEF injection stops
Related • Open circuit , hot short circuit, or sensor circuit error in SCR outlet temperature sensor
measuring section or probe (+) is sent to the engine controller via CAN communication,
information and this failure code is displayed.
• For the replacement procedure of the SCR outlet temperature sensor, see "Disassembly
and assembly," “Remove and install SCR temperature sensor”.

temperature sensor
If this failure code is cleared, the original sensor is defective. (Troubleshooting of
sensor is impossible.)
2
40-464 PC210LCI-11

Action level Failure code SCR Outlet Temperature Sensor Low Error
Failure
Detail of fail- Ground fault or sensor circuit error in SCR outlet temperature sensor measuring section or probe
ure (+)
• As the SCR outlet temperature cannot be detected, substitute the SCR temperature for
the SCR outlet temperature and run the engine (if the SCR temperature sensor also has
400 °C). be careful not to get burned.
Related • Ground fault or sensor circuit error in SCR outlet temperature sensor measuring section or
probe (+) is sent to the engine controller via CAN communication, and this failure code is
information displayed.
• For the replacement procedure of the SCR outlet temperature sensor, see “Disassembly
and assembly”, “Remove and install SCR temperature sensor”.

temperature sensor
If this failure code is cleared, the original sensor is defective. (Troubleshooting of
sensor is impossible.)
2
PC210LCI-11 40-465

Action level Failure code SCR Outlet Temperature Sensor In Range Error
Failure
Detail of fail- Temperature difference between SCR temperature sensor and SCR outlet temperature sensor is
ure not the same as the expected value.
k Since KDPF, KDOC, and SCR are heated to 500 °C or above, be careful not to get
burned.
• For the replacement procedure of the SCR outlet temperature sensor, see “Disassembly
and assembly”, “Removal and installation of SCR temperature sensor”.
ON position.
codes)
01002 Engine speed
information
• AdBlue/DEF level, AdBlue/DEF quantity sensor diagnosis
NOTICE
ing switch)

Defective SCR outlet If failure code [CA3146] or [CA3147] is displayed, perform troubleshooting for
1
temperature sensor [CA3146] or [CA3147].
40-466 PC210LCI-11

[CA3251].
temperature to SCR)
Defective SCR tempera- See “Disassembly and assembly”, “Removal and installation of SCR temperature
3 ture sensor (installation sensor” and fix installation error, if any.
error or malfunction)
3. Confirm the “AdBlue/DEF concentration” on the Pre-defined Monitoring
4
quality
4. If failure code is still displayed after above checks, it may be contaminated.
Replace the AdBlue/DEF in the tank.
5
Defective SCR outlet perature sensor.
6 temperature sensor (in- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
ternal defect)

REMARK
troubleshooting.
5. After warm-up operation, set the swing lock to ON, the working mode to P, and set fuel control dial to MAX
position.
PC210LCI-11 40-467

Action level Failure code SCR Catalyst Efficiency Low Error 2
Failure
Detail of fail-
The SCR catalyst efficiency has been low (20 % or less).
ure
Action of • AdBlue/DEF injection stops.
k The turbocharger outlet, KDPF, sensor fitting piping, and sensor probe become hot
k The AdBlue/DEF mixing piping, SCR assembly, sensor fitting piping, and sensor
probe become hot (Min. 400 °C). Be careful not to get burned.
k Be careful that AdBlue/DEF leaks when removing AdBlue/DEF mixing piping or AdBl-
ue/DEF injector.
• Due to Engine controller is shut down, the AdBlue/DEF injection activates once. However
If another error is detected, injection stops again.
• This failure code [CA3151] is displayed approximately one hour later after the engine con-
troller performs the Automatic Regeneration. The Automatic Regeneration is activated
Related when the failure code [CA3582] (catalytic efficiency is lower than 70%) is displayed.
information • Make sure the failure code [CA3582] is not displayed when confirming the completion of
repair.
• If the ambient pressure is 80 kPa or less and the ambient temperature is -7 °C or less, the
engine controller does not troubleshoot this failure code (Under this condition, performimg
“Loaded Diagnostics Operation To Clear Failure Code” does not clear this failure code).
Confirm on the “Pre-defined Monitoring” screen.
• Even if loaded diagnostics operation to clear failure code is performed, it cannot be can-
celed when it is under the following condition.
1. When active regeneration is performed
2. AdBlue/DEF injection is stopped by other failure code.
3. When the engine controller does not shut down after this failure code is displayed
• For the procedure to remove and change the AdBlue/DEF injector, see “Disassembly and
assembly of AdBlue/DEF injector”.
40-468 PC210LCI-11
• On the “Pre-defined Monitoring”screen, these 4 diagnosis are displayed. Engine operation

state diagnosis, environment state diagnosis, SCR catalyst and NOx sensor and ammonia
sensor diagnosis, AdBlue/DEF level and AdBlue/DEF quality sensor diagnosis. (The fol-
lowing numbers are the displayed monitoring codes)
01002 Engine speed
• Environmental state diagnosis
37400 Ambient Pressure
18400 Intake Temperature
Related 19203 Turbo Outlet NOx Sensor State
information 19210 SCR Outlet NOx Sensor State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared. (Repair completion cannot be judged without raising the exhaust tem-
perature even if this failure code is cleared by turning ON the starting switch)

tem first.
1
heater)
PC210LCI-11 40-469

heater)
Defective SCR tempera- If failure code [CA3142] or [CA3143] or [CA3144] or [CA3146] or [CA3147] or
ture sensor system [CA3148] or [CA3165] or [CA3229] or [CA3231] or [CA3235] or [CA4152] or
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] is displayed, perform troubleshoot-
fect) ing for these failure codes first.
Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3912], [CA3932], [CA3933], [CA3934],
sor system [CA3935], [CA3936] or [CA4281] is displayed, perform troubleshooting for these
4 (Open circuit, internal de- failure codes first.
heater)
1. If failure code [CA4658] or [CA3568] is displayed, or failure code [CA4658] or
[CA3568] is displayed on the service meter display of the abnormality record
within 2 hours, perform “Loaded Diagnostics Operation To Confirm Failure
Correction”, check if failure code [CA3151], [CA3543], or [CA3582] is dis-
played.
Clogged AdBlue/DEF in-
5 2. If 19205 “Ammonia concentration (compensation value)” indicates a normal
jector
value (5 to 100 ppm) and the failure code is cleared, the repair is completed
(“Loaded Diagnostics Operation To Confirm Failure Correction” has resolved
the clogging problem and the machine has restored normal operation).
3. If the ammonia concentration indicates an abnormal value or either failure
code [CA3151], [CA3543], or [CA3582] is displayed, proceed to the next step.
1. Visually check the piping from the KDPF outlet to the SCR outlet for damage
or defective connection.
Defective mixing tube
6 2. Visually check for white crystallized AdBlue/DEF deposits on the surrounding
(exhaust gas leakage) area.
3. If defective connections or damages are found, fix or replace parts.
leak.
40-470 PC210LCI-11

1. Check the mounting of the AdBlue/DEF quality sensor is secured and the
wiring harness connections are not loosen Repair if any abnormality is
found.
3. Check if failure code [CA3866] or [CA3867] is displayed.
4. Read 19100 “AdBlue/DEF concentration” on the display and confirm that
the concentration is appropriate (29 to 36 %).
5. If failure code [CA3866] or [CA3867] is displayed and the 19100
Improper AdBlue/DEF
8 “AdBlue/DEF concentration” reading is inappropriate, drain the
quality
AdBlue /DEF tank, clean the tank, and refill with genuine AdBlue/DEF.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
7. If the 19205 “Ammonia concentration (compensation value)” reading is
normal (5 to 100 ppm) and the failure code is not redisplayed, the repair is
completed.
8. If the ammonia concentration indicates an abnormal value or this failure
code recurs, proceed to the next step.
1. See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR
SETTING WITH TESTING MENU (SCR SERVICE TEST)” of “SETTING AND
OPERATION OF MACHINE MONITOR”, and perform an “SCR Denitration Ef-
ficiency Test”.
2. If the “SCR Denitration Efficiency Test” has not been completed successfully,
proceed to cause 10.
3. If failure code [CA1694], [CA3751], or [CA3755] is displayed after the “SCR
Defective urea SCR sys- Denitration Efficiency Test”, perform troubleshooting for relevant failure code
tem first.
9 (inspection with SCR RE- 4. After the failure code in the above 3 is cleared, perform “Loaded Diagnostics
MOVAL EFFICIENCY Operation To Clear Failure Code” to check if this failure code is not cleared.
TEST)
5. If 19205 “Ammonia concentration (compensation value)” indicates a normal
value (5 to 100 ppm) and the failure code is cleared, the repair is completed.
6. If the ammonia concentration indicates an abnormal value or this failure code
is not cleared, proceed to cause 13.
7. Even if the SCR REMOVAL EFFICIENCY TEST has been completed success-
fully and any of failure code [CA1694], [CA3751], or [CA3755] is not displayed,
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
TESTING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Injection
Quantity Test” to judge the injector.
2. From the test results, confirm that the AdBlue/DEF injection amount is within
the values specified in “TESTING AND ADJUSTING”.
3. If the AdBlue/DEF injection amount is out of the range specified in “TESTING
Defective AdBlue/DEF in-
10 AND ADJUSTING”, replace the AdBlue/DEF injector.
jector
4. If the AdBlue/DEF injector has been replaced, perform the “AdBlue/DEF Injec-
tion Quantity Test” again. After confirming that the AdBlue/DEF injection
amount is within the range specified in “TESTING AND ADJUSTING”, proceed
to the next cause. (The purpose of this test for two times is to check accumu-
lated urea deposits in the AdBlue/DEF mixing tube )
5. Proceed to the next troubleshooting, even if the “AdBlue/DEF Injection Quanti-
ty Test” results were normal.
PC210LCI-11 40-471

mixing tube
12
If failure code is still displayed after above checks, the intake system may be defec-
tive.
(Offset/drift due to the deteriorated and aged MAF sensor, distorted intake system,
damaged rectifier)
1. Check for a defective air intake pipe and repair or replace any damaged or
Defective air intake sys- defective rectifier, if any.
13
tem 2. Replace mass air flow (MAF) sensor.
4. If 19205 “ammonia concentration (compensation value)” shows an normal
value (5 to 100ppm) and the failure code is cleared again, the repair has
been completed
If failure code is still displayed after above checks, the ammonia sensor may be de-
fective.
(Offset/drift due to the deteriorated and aged ammonia sensor)
1. Replace the ammonia sensor.
2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”,
14 then check if this failure code or failure code [CA3582] is displayed.
sor
3. If 19205 “Ammonia concentration (compensation value)” indicates a nor-
mal value (5 to 100 ppm) and the failure code is cleared, the repair is com-
pleted.
code is not cleared, proceed to the next step.
15

(Make sure that this failure code and failure code [CA3582] are not displayed after this procedure.)
5. After warm-up operation, set the swing lock to ON, the working mode to P, and the fuel control dial to MAX
position.
6. Operate for approximately 30 seconds with Arm IN relief.
REMARK
40-472 PC210LCI-11
7. Run engine at high idle speed for approximately 30 seconds.

8. Repeat above steps 6. and 7. 20 times.
9. If this failure code and failure code [CA3582] are not displayed, repair is completed
If this failure code or failure code [CA3582] is displayed:
1. Display the SCR temperature and ammonia concentration on the Predefined Monitoring screen.
2. Operate so that the SCR temperature 250 °C or above is kept.
3. A normal value of ammonia concentration ranges from 5 to 100(ppm). If 0(ppm) is displayed consistently or
100(ppm) or above is displayed, return to troubleshooting because the repair work is not completed.
PC210LCI-11 40-473

Action level Failure code SCR Outlet Temperature High Error
Failure
Detail of fail-
The SCR outlet temperature has been high.
ure
controller • AdBlue/DEF injection stops
ON position.
• The temperature detected by the SCR outlet temperature sensor can be confirmed from
the “Pre-defined Monitoring” screen.
agnosis on the “Pre-defined Monitoring” screen. (The following numbers are the monitor-
ing codes)
• If regeneration is not performed, the failure code [CA3235] may appear as well.
01002 Engine speed
Related
information
NOTICE
ing switch)
40-474 PC210LCI-11

1
[CA3251].
temperature to SCR)
4
quality
5
ternal defect)

REMARK
If this failure code is displayed during “Loaded Diagnostics Operation To Confirm Failure Correction” return to
troubleshooting.
2. Turn the starting switch to the ON position, and check the failure code is not displayed. If this failure code is
displayed, return to troubleshooting.
3. Start engine.
4. Run the engine at low idle speed for 10 minutes.
PC210LCI-11 40-475

Action level Failure code SCR Temperature High Error
Failure
Detail of fail-
The SCR temperature is been high (800 °C or more).
ure
ON position.
• If regeneration is not implemented, the failure code [CA3231] may be displayed.
codes)
01002 Engine speed
Related
information
NOTICE
ing switch)
40-476 PC210LCI-11

1
ground)
[CA3251].
temperature to SCR)
error)
4
quality
5
fect)

REMARK
troubleshooting.
2. Turn the starting switch to the ON position, and check the failure code is cleared. If this failure code is dis-
played, return to troubleshooting.
6. If this failure code is cleared, repair is completed.
PC210LCI-11 40-477

Action level Failure code SCR Temperature High Error - Non Regeneration
Failure
Detail of fail- The SCR temperature remains at high level (800 °C or more) when active regeneration is not per-
ure formed.
k Since KDPF, KDOC, and SCR are heated to 500 °C or above, be careful not to get burned
ON position.
codes)
01002 Engine speed
Related
information
NOTICE
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure that
the failure code is cleared. (Repair completion cannot be judged without raising the exhaust
temperature even if this failure code is cleared by turning ON the starting switch)

1
ground)
40-478 PC210LCI-11

[CA3251].
temperature to SCR)
error)
4
quality
5
fect)

REMARK
troubleshooting.
PC210LCI-11 40-479

Action level Failure code Turbocharger Outlet NOx Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller cannot receive the data of the turbocharger outlet NOx sensor due to error of
ure communication with the turbocharger outlet NOx sensor.
• The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
Phenomenon
• Engine power deration according to inducement strategy.
on machine
• Turbocharger Outlet NOx Concentration undetectable
k The turbocharger outlet, sensor fitting piping, KDPF, and KDOC become hot (Min.
• The turbocharger outlet NOx sensor is a smart sensor which performs CAN communica-
tion with the engine controller together with the other sensors.
Related • If the sensor connector or smart sensor (power supply) relay connector is disconnected,
this failure code is displayed.
information
• The failure codes of the CAN communication related to the engine sensor are [CA2771],
[CA3232], [CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are
displayed, the cause may be defect of any of the 6 sensors, defective smart sensor power
supply relay, defective relay system, or ground fault, short circuit, or hot short circuit of the
harness (CAN communication line).
using multimeter.

Defective wiring harness Perform checks on causes 1 to 10 for failure code [CA2771].
1
connector
2
communication line)
female side.
Approxi-
mately 60 Ω
Resistance
Approxi-
mately 60 Ω
40-480 PC210LCI-11

Resistance
quired.
Disconnect connectors ECM J2, E26, K10, andK11 and connect T-adapt-
nication line)
Resistance
ground circuit)
Min.100 kΩ
Resistance
Between one of ECM J2(female)(45), K10(female)(B),
K11(female)(B), E31(female)(2), E32(female)(3),
Min.100 kΩ
E26(female)(2), E34(female)(2), E36(female)(2),
P63(female)(1) and ground
harness
Between one of ECM J2(21), K10(A), K11(A), E31(3),
1 to 4 V
Voltage
Between one of ECM J2(45), K10(B), K11(B), E31(2),
1 to 4 V
PC210LCI-11 40-481

2. Replace the turbocharger outlet NOx sensor (E31).
outlet NOx sensor
8
40-482 PC210LCI-11
PC210LCI-11 40-483

Action level Failure code SCR Outlet Temperature High Error - Non Regeneration
Failure
Detail of fail-
SCR outlet temperature remains at high level when active regeneration is not performed.
ure
• For replacement of the SCR temperature sensor, see Disassembly and assembly, “Re-
moval and installation of SCR temperature sensor”.
ON position.
• On the “Pre-defined Monitoring” screen troubleshooting for the engine operation state,
AdBlue/DEF level and AdBlue/DEF quality sensors are used (the figures below denote
monitoring codes).
• The temperature detected by the SCR outlet temperature sensor can be confirmed from
the “Pre-defined Monitoring” screen.
• Engine operation state troubleshooting
01002 Engine Speed
Related 19200 Exhaust Gas Flow Rate
NOTICE

1
40-484 PC210LCI-11

[CA3251].
temperature to SCR)
4
quality
5
ternal defect)

REMARK
If this failure code is displayed during “Loaded Diagnostics Operation To Confirm Failure Correction” return to
troubleshooting.
2. Turn the starting switch to the ON position, and check the failure code is not displayed. If this failure code is
displayed, return to troubleshooting.
3. Start engine.
PC210LCI-11 40-485

Action level Failure code AdBlue/DEF Line Heater 2 Voltage High Error
Failure
Detail of fail- High voltage error is detected in signal circuit of AdBlue/DEF line heater 2 (on high-temperature
ure pressure).
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing.
on machine NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• The AdBlue/DEF line heater 2 operates in AdBlue/DEF supply system thawing, warning,
or implementation of AdBlue/DEF line heater relay 2 test.
• The AdBlue/DEF line heater 2 is operated by the AdBlue/DEF line heater relay 2 in the
AdBlue/DEF heater relay.
Related
• This failure code is detected only when the AdBlue/DEF line heater 2 is OFF.
information
• If the connectors of all heaters connected to the AdBlue/DEF line heater 2 are disconnect-
ed, this failure code is displayed.

1
Open circuit in wiring har- 2. Disconnect connectors ECM J2 and R53A, and connect T-adapters to
2 each female side.
ness
Between ECM J2 (female) (38) and R53A (female) (9) Max. 10 Ω
Resistance
Between R53A (female) (12) and ground Max. 10 Ω
Hot short circuit in wiring 2. Disconnect connector R53A, and connect T-adapter to female side.
3 harness (contact with 24 3. Turn the starting switch to ON position (with connector R53A disconnect-
V circuit) ed).
Voltage Between R53A (female) (9) and (12) Approx. 5 V
4 Disconnect connector MB06B, and connect T-adapter to male side.
line heater
Resistance Between MB06B (male) (1) and (2) 5 to 40 Ω
Open circuit or short cir- 2. Disconnect connector ECM J2, and connect T-adapter to female side.
cuit in wiring harness
5 REMARK
(line heater relay input
side) Resistance is possessed by above-mentioned heater relay.
Resistance Between ECM J2 (female) (38) and ground 10 to 30 kΩ
40-486 PC210LCI-11

Open circuit or short cir- 2. Disconnect the connector R53A, and connect the T-adapter to female side.
6 REMARK
(line heater relay output
side) Resistance is the value of above-mentioned AdBlue/DEF line heater.
Resistance Between R53A (female) (4) and (12) 5 to 40 Ω
7
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
8 relay.
heater relay
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
PC210LCI-11 40-487
Circuit diagram related to AdBlue/DEF line heater
40-488 PC210LCI-11

Action level Failure code AdBlue/DEF line heater 2 voltage low error
Failure
Detail of fail- Low voltage error is detected in signal circuit of AdBlue/DEF line heater 2 (on high-temperature
ure pressure).
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing
• AdBlue/DEF line heater 2 is driven at AdBlue/DEF supply system thawing/thermal insula-
tion or AdBlue/DEF line heater relay 2 test.
• AdBlue/DEF line heater 2 is driven by AdBlue/DEF line heater relay 2 inside AdBlue/DEF
heater relay.
Related • This failure code is detected only when AdBlue/DEF line heater 2 is turned ON.
Procedure: Start the engine in low temperature (engine room temperature is Max. 12 °C)
or perform AdBlue/DEF line heater 2 test.
(See “service modes” of “SET AND OPERATE MACHINE MONITOR”, and “METHOD
FOR OPERATING TESTING MENU (SCR SERVICE TEST)”.)

FORMATION ON TROUBLESHOOTING”, and check them.
Defective wiring harness 2. Start the engine in low temperature (ambient temperature of 5 °C or lower)
1
connector or perform “AdBlue/DEF Line Heater Relay 1 Test”. For details, see SET
AND OPERATE MACHINE MONITOR, “SERVICE MODE” and “METHOD
FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)”.
If this failure code is cleared, the wiring harness connector is defective.
3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
relay.
2 4. Turn the battery disconnect switch ON.
heater relay
5. Perform the “AdBlue/DEF Line Heater Relay 2 Test” by staring the engine
in low ambient temperature (12 °C or below), or by referring “SERVICE
MODE” of setting and operating machine monitor, “METHOD FOR OPER-
ATING TESTING MENU (SCR SERVICE TEST)”.
3 REMARK
side) Resistance is possessed by above-mentioned heater relay.
PC210LCI-11 40-489

2. Disconnect connectors ECM J2, P53A, and MB06B, and connect T-adapt-
Ground fault in wiring er to either female side.
4 harness (contact with Between ground and ECM J2 (female) (38) or R53A
ground circuit) Min. 100 kΩ
(female) (9)
Resistance
Between R53A (female) (4) and ground, or between
Min. 100 kΩ
MB06B (female) (1) and ground
5 Disconnect connector MB06B, and connect T-adapter to male side.
line heater
Resistance Between MB06B (male) (1) and (2) 5 to 40 Ω
Open circuit or short cir- 2. Disconnect the connector R53A, and connect the T-adapter to female side.
6 REMARK
side) Resistance is the value of above-mentioned AdBlue/DEF line heater.
7
40-490 PC210LCI-11
PC210LCI-11 40-491

Action level Failure code AdBlue/DEF Tank Heating Error
Failure
AdBlue/DEF tank heating valve or engine coolant circuit, or both are clogging.
Detail of fail-
ure (The temperature of the AdBlue/DEF tank does not rise though the engine controller turns ON (“1”)
19102 “AdBlue/DEF Tank HtrValve Command” and opens the AdBlue/DEF tank heating valve.)
Action of
None in particular
controller
Phenomenon • AdBlue/DEF line stops thawing.
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• The engine controller judges whether this failure code is displayed only during thawing
control of the AdBlue/DEF tank (The value of 19305 AdBlue/DEF Tank Heating State is
“1”).
• The “Pre-defined Monitoring” screen uses the AdBlue/DEF tank thawing control diagnosis.
• AdBlue/DEF tank thawing control diagnosis
NOTICE
pair.)

tem
system
40-492 PC210LCI-11

See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OPERA-
TION MACHINE MONITOR”, “METHOD FOR SETTING WITH TESTING MENU
(SCR SERVICE TEST)” to perform an “AdBlue/DEF TANK HEATER RELAY TEST”
and check if the AdBlue/DEF tank heater valve is driven normally.
3. Perform an “AdBlue/DEF TANK HEATER RELAY TEST” to drive the
Mechanical failure of
3 AdBlue/DEF tank heating
valve mands.
REMARK
If coolant does not flow out:
Increase the temperature of the inlet side coolant hose to make sure that the cool-
ant flows out.
1. If coolant flows out from the inlet side coolant hose, replace the AdBlue/DEF
tank heating valve.
2. If coolant does not flow out from the inlet side coolant hose, clogging of the
coolant circuit is suspected.
• Check if the engine coolant circuit in the engine or AdBlue/DEF tank is
Failure of engine coolant leaking or clogged.
4
circuit • Also check whether amount of engine coolant is appropriate. If there are
some problems, repair the relevant portions.
sor.
6

2. Start the engine and confirm 19115“AdBlue/DEF tank temperature” on the Pre-defined Monitoring screen.
3. Conduct warm-up operation and raise the 4107 “engine coolant temperature” to 20 °C or more.
1) When the 19115 “AdBlue/DEF tank temperature” is less than 1 °C
If the 4107 “ engine coolant temperature” becomes 0 °C or more, the 19102 “AdBlue/DEF Tank
HtrValve Command” is issued (0 to 1).
Confirmation will be completed if the AdBlue/DEF tank temperature becomes 4 °C or more within an
hour after the AdBlue/DEF tank heating valve open and close command is issued.
2) When the 19115 “AdBlue/DEF tank temperature” is 1 °C or more
Conduct warm-up operation and raise the 4107 “engine coolant temperature” to ambient temperature +
20 °C or more.
3) See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in “SET-
TING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF tank heater relay test”.
PC210LCI-11 40-493
Confirmation will be completed if the AdBlue/DEF tank temperature becomes 5 °C or more within an
hour after starting the AdBlue/DEF tank heater relay test.
screen.
REMARK
If this failure code is cleared at this point, repair is completed, but if not, return to troubleshooting.
40-494 PC210LCI-11

Failure KDOC Inlet Temperature High Error (Engine controller system)
L03 CA3251
Details of
KDOC inlet temperature remains at high level.
failure
Phenomenon
on machine
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• 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 compen-
Related sate for torque drop, causing high exhaust temperature.
information • As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
position.
code is cleared).
NOTICE
again.)
PC210LCI-11 40-495

1
Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDOC inlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
7
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

2. Run the engine at low idle speed for approximately 15 minutes.
NOTICE
If the failure code is cleared, repair work is completed.
40-496 PC210LCI-11

Action level Failure code KDOC Temperature Error - Non Regeneration
Failure
Details of The temperature sensor reading at the KDOC inlet remains high even though active regeneration is
failure not activated.

Phenomenon
on machine
PC210LCI-11 40-497
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• If the engine runs with poor combustion, (poor fuel spray due to troubles in the fuel injec-
tors is one of the examples of root causes but not limited to it), large amount of unburnt
fuel slips out with the exhaust gas and will be trapped in the aftertreatment system. The
trapped unburnt fuel can start burning in the aftertreatment system once the exhaust gas
becomes hot and it can keep burning.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to compen-
sate for torque drop, causing high exhaust temperature.
• Engine controller does not shut itself down immediately after turning the starting switch to
the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
Related lamp in the battery box goes out even if quick re-start becomes necessary.
information
• Engine power deration will be restored only after the following two conditions are met.
(1) Run “Loaded Diagnostics Operation To Clear failure Code” record in Engine controller.
Both Action Level “L03” in the Standard screen and the pop-up window of the failure de-
scription in the Current Abnormality screen shall go out if the failure is corrected.
(2) the starting switch shall be turned to the OFF position.
NOTICE
If this failure code is displayed, it indicates that KCSF may be damaged. After complet-
ing the repair of the problem, check the following. Replace the KCSF if the black smoke
comes out of the exhaust pipe outlet.
• Start the engine, perform the quick acceleration from low idle to high idle two times, and
then keep the engine running at high idle for 5 seconds.
• Check that the black smoke does not come out of the exhaust pipe outlet during this quick
acceleration and high idling.
NOTICE
again.)

Defective KDOC inlet Perform checks on causes 1 to 7 for failure code [CA3251].
1
temperature sensor
40-498 PC210LCI-11

Defective KDOC outlet Perform checks on causes 1 to 7 for failure code [CA3254].
2
temperature sensor
1. Remove KDPF.
2. Remove KDOC.
NOTICE
• Check if KDOC has any cracks (change KDOC if any).
3 Defective KDOC • If KDOC of KDPF is changed, perform the reset after KDOC change,
then troubleshooting is complete without performing manual station-
ary regeneration.
(See cause 7 for failure code [CA2637].)
• Check if KDOC inlet surface is clogged with soot 50 % or more.
(Clean KDOC if it is clogged with soot.)
4
ler

2. Start the engine and run it at low idle speed for 15 minutes.
If the failure code is cleared, repair is complete. Otherwise, perform the following:
NOTICE
If failure code is not cleared after preceding steps 1 and 2 are performed, following temperature re-
quirements are included in condition for clearing failure code. Step 4 to 6 is required to satisfy tem-
perature requirements.
• KDOC inlet temperature 200 °C or above
• KDOC outlet temperature 200 °C or above
3. Display KDOC inlet and outlet temperatures with monitoring function.
6. Set the fuel control dial to MAX position and travel to Hi and drive for 15 minutes in succession with one
side idle running.
REMARK
When the KDOC inlet temperature or KDOC outlet temperature does not exceed 200 °C, perform “Loaded
Diagnostics Operation To Clear failure Code” [CA1883].
7. If the failure code is cleared, repair is complete.
PC210LCI-11 40-499

Failure KDOC Outlet Temperature High Error 1(Engine controller system)
L01 CA3254
Details of
KDOC outlet temperature remains at high level.
failure
Action of
None
controller
Phenomenon
None
on machine
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related 2. Cylinders other than disabled cylinder may increase their fuel injection in order to compen-
information sate for torque drop, causing high exhaust temperature.
lamp in the battery box goes out even if quick restart becomes necessary.
NOTICE
again.)
40-500 PC210LCI-11

1
2
fuel.
tor
1. Remove KDPF.
2. Remove KDOC.
NOTICE
• Check if KDOC has any cracks (change KDOC if any).
6 Defective KDOC • If KDOC of KDPF is changed, perform the reset after KDOC change,
then troubleshooting is complete without performing manual station-
ary regeneration.
(See cause 7 for failure code [CA2637].)
• Check if KDOC inlet surface is clogged with soot 50 % or more.
(Clean KDOC if it is clogged with soot.)
KDOC outlet temperature ASSEMBLY”. Repair as necessary.
7
8
ler

Perform the procedure below to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
1. Turn the starting switch from OFF position to ON position.
2. Start the engine and run it at low idle speed for about 1 minute.
3. Choose manual stationary regeneration for service by Active regeneration for service screen on the moni-
tor.
PC210LCI-11 40-501
4. End active regeneration for service.

NOTICE
• Choose manual stationary regeneration for service by active regeneration for service screen on
the monitor for 15 minutes and more from its start.
• If the failure code is cleared when active regeneration for service is ended, repair is completed.
40-502 PC210LCI-11

Action level Failure code KDPF Temperature Error - Non Regeneration (Engine controller sys-
Failure
L03 CA3255 tem)
Details of
KDPF outlet temperature remains at high level when active regeneration is not performed.
failure
Phenomenon
on machine
PC210LCI-11 40-503
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related OFF position and Engine controller keeps working until the purging is completed. The
information
NOTICE
NOTICE
again.)

1
2
40-504 PC210LCI-11

fuel.
tor
KDPF outlet temperature ASSEMBLY”. Repair as necessary.
6
7
ler

1. Turn the starting switch from OFF to ON and leave it there for 1 minute.
NOTICE
If the failure code is cleared, repair work is complete. Otherwise, perform the following:
REMARK
If failure code is not cleared after preceding steps 1 and 2 are performed, following temperature conditions
are requirements for clearing the failure code. Steps 4 and 6 are required to satisfy temperature require-
ments.
• KDOC outlet temperature 200 °C or above
• KDPF outlet temperature 200 °C or above
3. Display KDOC outlet temperature and KDPF outlet temperature with monitoring function.
6. Set the fuel control dial to MAX position and travel to Hi and drive for 15 minutes with one side idle running.
NOTICE
When the KDOC outlet temperature or KDPF outlet temperature does not exceed 200 °C, perform
“Loaded Diagnostics Operation To Clear failure Code” [CA1883].
PC210LCI-11 40-505
7. If the the failure code is cleared, repair work is complete.
40-506 PC210LCI-11

Action level Failure code KDPF Outlet Temperature High Error 1
Failure
Details of
The SCR outlet temperature has been in a high temperature state
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
information
compensate for torque drop, causing high exhaust temperature.
ON position.
NOTICE
cleared.

1
PC210LCI-11 40-507

2
fuel.
tor
6
7
ler

4. Choose “Manual Stationary Regeneration for Service” by “Active Regeneration for Service” screen on the
“Service Menu” screen of the machine monitor.
5. End “Active Regeneration for Service”.
NOTICE
• Perform “Active Regeneration for Service” for 15 minutes minimum from its start.
• After “Active Regeneration for Service” is ended and if failure code is cleared, repair is complet-
ed.
40-508 PC210LCI-11

Action level Failure code KDOC Outlet Temperature High Error 2
Failure
Details of
KDOC outlet temperature remains at very high level.
failure
Phenomenon
on machine
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related is turned OFF (not canceled only by deactivation of the failure code).
information
NOTICE
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, per-
form “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
PC210LCI-11 40-509

1
2
fuel.
tor
6
7
ler

NOTICE
• The failure code is cleared once when starting switch is turned from OFF position to ON posi-
tion. Check that cleared failure code is not displayed again when engine runs at low idle speed.
2. Start the engine and run it at low idle speed without load for 2 minutes.
NOTICE
If this failure code is displayed when starting switch is turned to ON position but engine is not start-
ed, perform troubleshooting for following failure codes, too, after finishing troubleshooting and re-
pair for this code.
• [CA3316] KDOC Outlet Temperature Sensor Low Error
• [CA3317] KDOC Outlet Temperature Sensor High Error
40-510 PC210LCI-11

Action level Failure code KDPF Outlet Temperature High Error 2
Failure
Details of
KDPF outlet temperature remains at very high level.
failure
• Fuel dosing stops..
Phenomenon
on machine
PC210LCI-11 40-511
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
Related
information the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
NOTICE
NOTICE
the failure code is cleared again.

Defective KDPF outlet If failure code [CA3319] or [CA3321] is displayed, perform troubleshooting for those
1
temperature sensor codes.
40-512 PC210LCI-11

2
fuel.
tor
6
7
ler

NOTICE
• The failure code is cleared once when starting switch is turned from OFF position to ON posi-
tion. Check that cleared failure code is not displayed again when engine runs at low idle speed.
NOTICE
If this failure code is displayed when starting switch is turned to ON position but engine is not start-
ed, perform troubleshooting for following failure codes as well after finishing troubleshooting and
repair for this code.
• [CA3319] KDPF Outlet Temperature Sensor Low Error
• [CA3321] KDPF Outlet Temperature Sensor High Error
PC210LCI-11 40-513

Action level Failure code KDOC inlet temperature sensor low error
Failure
Detail of fail- Ground fault or sensor circuit error in KDOC inlet temperature sensor measuring section or probe
ure (+)
• As the KDOC inlet temperature cannot be detected, substitute the KDOC outlet tempera-
ture for the KDOC inlet temperature and run the engine (if the KDOC outlet temperature
sensor also has an error, use a fixed value (250 °C)).
• NOx emission increases.
Phenomenon • Defective active regeneration control
on machine • KDPF Soot Accumulation High
k Be careful not get burned as the temperature of KDPF and KDOC rises up over
500 °C.
• Ground fault or sensor circuit error in KDOC inlet temperature sensor measuring section
or probe (+) is sent to the engine controller via CAN communication, and this failure code
is displayed.
Related
• For details of access to the KDOC inlet temperature sensor, the KDOC outlet temperature
information
sensor, and the KDPF outlet temperature sensor, see “Chapter 50 DISASSEMBLY AND
ASSEMBLE OF KDPF ASSEMBLY”.
code is cleared).

1
40-514 PC210LCI-11

3. Replace KDPF temperature sensor.
Defective KDOC inlet
temperature sensor
If this failure code is cleared, the original KDOC inlet temperature sensor is defec-
tive. (In case of an internal defect, troubleshooting is impossible as an assembly.
3
PC210LCI-11 40-515

Action level Failure code KDOC Inlet Temperature Sensor High Error
Failure
Detail of fail- Open circuit, hot short circuit, or sensor circuit error in KDOC inlet temperature sensor measuring
• As the KDOC inlet temperature cannot be detected, substitute the KDOC outlet tempera-
ture for the KDOC inlet temperature and run the engine (if the KDOC outlet temperature
• Fuel dosing stops
NOx emission increases.
Phenomenon Defective forcible regeneration control
on machine KDPF Soot Accumulation High
k Be careful not get burned as the temperature of KDPF and KDOC rises up over
500 °C.
• Open circuit, hot short circuit, or sensor circuit error in KDOC inlet temperature sensor
and this failure code is displayed.
Related
• For details of access to the KDOC inlet temperature sensor, the KDOC outlet temperature
information
sensor, and the KDPF outlet temperature sensor, see “Chapter 50 Disassembly and as-
sembly”, “Removal and installation of KDPF assembly” and “Disassembly and assembly of
KDPF assembly”.
ure code is cleared (note the engine power deration is not canceled only by the failure
code is cleared).

Defective KDOC inlet Perform troubleshooting for failure code [CA3313].
1 temperature sensor sys-
tem
40-516 PC210LCI-11

Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
Difference between temperature sensed by KDOC inlet temperature sensor and that by KDOC out-
Details of
let temperature sensor differs from expected value.
failure
(Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine. (If failure is de-
tected in KDOC outlet temperature sensor, too, controller takes it that KDOC inlet temper-
ature is at default value (250 °C) and allows engine to run.)
Phenomenon
on machine
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
Related • Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
information lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
code is cleared).
NOTICE
the failure code is cleared again.
Controller Active Fault Clear) to be performed to clear this failure code.
PC210LCI-11 40-517

Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for those
1
2
fuel.
tor
KDOC inlet temperature ASSEMBLY”. Repair as necessary.
6
Defective KDPF temper- 2. If the failure code displays after performing the preceding troubleshooting,
7
ature sensor replace the KDPF temperature sensor.
ler

1. Clear this failure code by “Engine Controller Active Fault Clear” from the “service mode” of the machine
monitor.
3. Start the engine and run the engine at low idle speed for approximately 1 minute.
position.
NOTICE
• Be careful of overheat of the work equipment oil temperature.
6. Operate 5. for 30 minutes
7. If the failure code is not displayed, repair work is completed.
40-518 PC210LCI-11

Action level Failure code KDOC Outlet Temperature Sensor Low Error
Failure
Detail of fail- Ground fault or sensor circuit error in KDOC outlet temperature sensor measuring section or probe
ure (+)
• As the KDOC outlet temperature cannot be detected, substitute the KDOC inlet tempera-
ture for the KDOC outlet temperature and run the engine (if the KDOC inlet temperature
sensor also has an error, use a fixed value (250 °C).
controller • AdBlue/DEF injection stops
Phenomenon • Defective forcible regeneration control.
on machine • KDPF Soot Accumulation High.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• Ground fault or sensor circuit error in KDOC outlet temperature sensor measuring section
or probe (+) is sent to the engine controller via CAN communication, and this failure code
is displayed.
Related • For details of access to the KDOC inlet temperature sensor, the KDOC outlet temperature
information sensor, and the KDPF outlet temperature sensor, see “Chapter 50 Disassembly and as-
KDPF assembly”.
code is cleared).

1
Defective KDOC outlet
temperature sensor
If this failure code is cleared, the original KDOC outlet temperature sensor is defec-
PC210LCI-11 40-519

3
40-520 PC210LCI-11

Action level Failure code KDOC Outlet Temperature Sensor High Error
Failure
Detail of fail- Open circuit, hot short circuit, or sensor circuit error in KDOC outlet temperature sensor measuring
ure section or probe (+).
• As the KDOC outlet temperature cannot be detected, substitute the KDOC inlet tempera-
ture for the KDOC outlet temperature and run the engine (if the KDOC inlet temperature
• Open circuit, hot short circuit, or sensor circuit error in KDOC outlet temperature sensor
information sensor, and the KDPF outlet temperature sensor, see “Chapter 50 Disassembly and as-
KDPF assembly”.
ure code is cleared (note the engine power deration is not canceled only by the failure
code is cleared).

Defective KDOC outlet Perform troubleshooting for failure code [CA3316].
tem
PC210LCI-11 40-521

Action level Failure code KDOC Outlet Temperature Sensor In Range Error
Failure
Details of The difference between the temperature sensed by KDOC outlet temperature sensor and the tem-
failure perature sensed by KDOC inlet temperature sensor differs from the expected value.
• Substitute the KDOC inlet temperature for the KDOC outlet temperature, and run the en-
gine (if the KDOC inlet temperature sensor also has an error, use the KDOC outlet tem-
perature (250ºC) as a default value).
Phenomenon
on machine
(Code: 47300 (ºC))
(Code: 47400 (ºC))
(Code: 47200 (ºC))
• As to procedure for accessing KDPF temperature sensor, see “REMOVE AND INSTALL
KDPF ASSEMBLY”, and “DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY” in
Chapter 50 DISASSEMBLY AND ASSEMBLY.
Related • Engine controller does not shut itself down immediately after turning the starting switch to
information the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
code is cleared).
NOTICE
Controller Active Fault Clear) to be performed to clearer this failure code.

Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform troubleshooting for those
1
2
40-522 PC210LCI-11

fuel.
tor
6
7
ler

1. Clear this failure code by “Engine Controller Active Fault Clear” from the “service mode” of the machine
monitor.
position.
NOTICE
PC210LCI-11 40-523

Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
Detail of fail- Open circuit, hot short circuit, or sensor circuit error in KDPF outlet temperature sensor measuring
• Substitute the KDOC outlet temperature for the KDPF outlet temperature and run the en-
gine (if the KDOC outlet temperature sensor also has an error, use the default value of the
KDPF outlet temperature (250 °C)).
controller • EGR valve closed.
• Advances to Inducement strategy.
• Open circuit, hot short circuit, or sensor circuit error in KDPF outlet temperature sensor
information sensor, and the KDPF outlet temperature sensor, see “Chapter 50 DISASSEMBLY AND
code is cleared).

Defective KDPF outlet Perform troubleshooting for failure code [CA3321].
tem
40-524 PC210LCI-11

Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
Detail of fail-
Ground fault in KDPF outlet temperature sensor measuring section or probe (+)
ure
KDPF outlet temperature (250 °C).
Phenomenon • Defective forcible regeneration control
on machine • KDPF Soot Accumulation High
• Ground fault in the sensor measuring section or probe (+) is sent to the engine controller
via CAN communication, and this failure code is displayed.
sensor, and the KDPF outlet temperature sensor, see “Chapter 50 DISASSEMBLY AND
information
code is cleared).

1
Defective KDPF outlet
temperature sensor
If this failure code is cleared, the original KDPF outlet temperature sensor is defec-
PC210LCI-11 40-525

3
40-526 PC210LCI-11

Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
Details of Temperature sensed by KDPF outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
KDPF outlet temperature (250 °C).
Phenomenon
on machine
• Engine power deration according to Inducement strategy.
burned.
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEMBLE AND
Related ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND ASSEMBLY. Re-
pair as necessary.
information
NOTICE
• This failure code “Loaded Diagnostics Operation To Confirm Failure Correction”. Af-
ed Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared again.
• Engine power deration is canceled by turning starting switch to OFF position after
this failure code is cleared (note that the engine power deration is not canceled only
by the failure code is cleared).

Defective KDPF outlet If failure code [CA3319] or [CA3321] is displayed, perform troubleshooting for those
1
PC210LCI-11 40-527

2
fuel.
tor
6
7
ler

2. Turn starting switch from OFF position to ON position.
position.
NOTICE
REMARK
• Every failure code is cleared by executing “Reset All Faults” command by using service tool “INSITE”.
• See “INSITE” Operation Manual for working with “INSITE”.
40-528 PC210LCI-11

Action level Failure code Mass air flow sensor sup volt high error
Failure
Detail of fail-
High voltage occurs in mass air flow sensor power supply (12 V) circuit.
ure
Action of
None in particular
controller
Phenomenon
Engine output lowers.
on machine
• If failure code [CA356] or [CA357] is displayed, remedy described in “Action of controller”
of their failure code is performed.
information
ure code is not displayed (note that the deration is not canceled right after the failure code
is not displayed).

Defective mass air flow 3. Starting switch: ON
1
If this failure code is cleared, mass air flow sensor is defective.
Other failure codes are displayed at the same time. This happens because the con-
nector is disconnected. So ignore other codes besides this failure code.
REMARK
Many other failure codes appear at same time because of disconnected connector.
Ignore failure codes other than this.
3
2. Disconnect connector ECM J1 and connect T-adapter to male side.
Defective engine control- Approxi-
ler mately 12 V
internal defect.)
PC210LCI-11 40-529
Circuit diagram related to mass air flow sensor
40-530 PC210LCI-11

Action level Failure code Mass Air Flow Sensor Sup Volt Low Error
Failure
Detail of fail-
Low voltage occurs in mass air flow sensor power supply (12 V) circuit.
ure
Action of
None in particular
controller
Phenomenon
Engine output lowers.
on machine
• If failure code [CA356] or [CA357] is displayed, remedy described in “Action of controller”
of their failure code is performed.
information
ure code is not displayed (note that the deration is not canceled right after the failure code
is not displayed).

1
Defective mass air flow 3. Starting switch: ON
2
If this failure code is cleared, mass air flow sensor is defective.
Other failure codes are displayed at the same time. This happens because the con-
nector is disconnected. So ignore other codes besides this failure code.
REMARK
Many other failure codes appear at same time because of disconnected connector.
Ignore failure codes other than this.
4 female side.
ness
ground circuit)
male) (2)
PC210LCI-11 40-531

2. Disconnect connector ECM J1 and connect T-adapter to male side.
Defective engine control- Approxi-
ler mately 12 V
internal defect.)
Circuit diagram related to mass air flow sensor
40-532 PC210LCI-11

Failure
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank capacity becomes 10 % or less)
ure
Action of
controller
Phenomenon
None in particular
on machine
Related
information
• CA3498 is displayed if usage is continued without refilling AdBlue/DEF and the
AdBlue/DEF level becomes 5 % or less.

tank sensor
3
PC210LCI-11 40-533

Failure
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank capacity becomes 5 % or less)
ure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
Related
information
• CA1673 is displayed and engine output is limited significantly if usage is continued without
refilling AdBlue/DEF and the AdBlue/DEF level becomes 2.5 % or less.

tank sensor
3
40-534 PC210LCI-11

Action level Failure code AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)
Failure
Detail of fail- • The SCR catalyst efficiency is poor (65 % or less) after AdBlue/DEF refilling with coolant.
ure • It is likely that the AdBlue/DEF quality is abnormal.
Action of
controller
Phenomenon • The NOx emission likely to have increased.
PC210LCI-11 40-535
ue/DEF injector.
• This failure code [CA3543] is displayed after the engine controller implements “clearing
active regeneration (approximately one hour) of urea deposit accumulation” when the fail-
ure code [CA3582] is displayed.
• Make sure the failure code [CA3582] is not displayed when confirming the completion of
repair.
Confirm on the Pre-defined Monitoring screen.
Related
information
• For the procedure to remove and change the AdBlue/DEF injector, see “Disassembly and
• On the “Pre-defined Monitoring”screen, these 4 diagnosis are displayed. Engine operation
01002 Engine speed
40-536 PC210LCI-11

Related
information
NOTICE

tem first.
1
heater)
heater)
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] or [CA4261] is displayed, perform
fect) troubleshooting for these failure codes first.
heater)
PC210LCI-11 40-537

found.
Improper AdBlue/DEF
quality
completed.
played.
jector
(“Loaded Diagnostics Operation To Confirm Failure Correction” has resolved
the clogging problem and the machine has restored normal operation).
leak.
40-538 PC210LCI-11

ficiency Test”.
tem first.
TEST)
jector
mixing tube
12
PC210LCI-11 40-539

tive.
damaged rectifier)
13
4. If 19205 “ammonia concentration (compensation value)” shows an normal
value (5 to 100ppm) and the failure code is cleared again, the repair has
been completed
fective.
sor
pleted.
15

(Make sure that this failure code and failure code [CA3582] are not displayed after this procedure.)
position.
REMARK
9. If this failure code and failure code [CA3582] are not displayed, repair is completed
If this failure code or failure code [CA3582] is displayed:
1. Display the SCR temperature and ammonia concentration on the Predefined Monitoring screen.
2. Operate so that the SCR temperature 250 °C or above is kept.
3. A normal value of ammonia concentration ranges from 5 to 100(ppm). If 0(ppm) is displayed consistently or
100(ppm) or above is displayed, return to troubleshooting because the repair work is not completed.
40-540 PC210LCI-11

Action level Failure code SCR Outlet NOx Sensor Unstable Error
Failure
Detail of fail-
The SCR outlet NOx sensor does not become measurable status.
ure
Phenomenon
tion works inappropriately.
on machine
k The KDPF, sensor fitting piping, and sensor probe become hot (Min. 500 °C). Be care-
ful not to get burned.
• The SCR outlet NOx sensor operates when 19302 SCR outlet temperature is 150 °C or
more (19210 SCR outlet NOx sensor measurement state is “1”).
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is (150 °C or
• Pre-defined Monitoring screen uses the engine operation state diagnosis, SCR catalyst,
NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
Related
information
NOTICE
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the
failure code is cleared. (This failure code is not cleared by only turning ON the starting
switch.)

Defective SCR outlet If failure code [CA1887] or [CA3583] or [CA3681] or [CA3717] is displayed, perform
1
NOx sensor system troubleshooting for these failure codes first.
PC210LCI-11 40-541

SCR outlet NOx sensor Check if the SCR outlet NOx sensor probe is installed securely.
2
installation error
NOx sensor
4

3. Run the engine at high idle speed safely to raise the exhaust gas temperature and SCR catalyst tempera-
ture. (Keep the engine speed so that monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or
higher. Check that monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
4. Repair is completed if failure code is not displayed after 3 minutes has passed.
REMARK
40-542 PC210LCI-11

Failure
Detail of fail-
The AdBlue/DEF tank level lowers. (The tank capacity becomes 0.0 % or less)
ure
Action of
Engine power is derated heavily.
controller
• Engine output reduces heavily.
Phenomenon
• If the machine continues to operate without adding, AS00ZK is displayed and engine out-
on machine
put for operation is limited to low idle.
Related When AdBlue/DEF level is 0.0 % or less [CA3547]
information • From the machine monitor, it is possible to perform a temporary restoration from induce-
ment to clear engine output low temporarily.
• After this failure code is cleared, Engine power deration continues until the starting switch

tank sensor
3
PC210LCI-11 40-543

Action level Failure code AdBlue/DEF Pump Voltage High Error
Failure
Detail of fail-
High voltage error occurs in the AdBlue/DEF pump drive circuit.
ure
• AdBlue/DEF pump stops.
Action of
• AdBlue/DEF purging stops.
controller
• If the starting switch is turned ON while the AdBlue/DEF pump connector is removed, this
failure code is displayed.
• The AdBlue/DEF pump operates120 seconds after starting the engine, or it operates, after
Related starting the engine, if not in AdBlue/DEF thawing process, when the KDPF outlet tempera-
information ture becomes over 150 °C, or when AdBlue/DEF pump pressure raising test is implement-
ed.
Procedure: Turn starting switch to ON position or operate the AdBlue/DEF pump.

“RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
1
connector 3. See “SERVICE MODE” and “METHOD FOR SETTING WITH TESTING
MENU (SCR SERVICE TEST)” of SETTING AND OPERATION OF MA-
CHINE MONITOR, and perform an AdBlue/DEF Pump Pressure Up Test.
Open circuit in wiring har- 2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
ness (wire breakage or ther female side.
2
nector) Between ECM J2 (female) (54) and MB02 (female) (8) Max. 10 Ω
Resistance
Between ECM J2 (female) (79) and MB02 (female) (9) Max. 10 Ω
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to fe-
male side of ECM J2.
3 Between ECM J2 (female) (6) and each pin other than No continui-
ness
(6) ty
Continuity
than (79) ty
If failure code is still displayed after above checks, AdBlue/DEF pump may be de-
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly.
pump
5
40-544 PC210LCI-11
Circuit diagram related to AdBlue/DEF pump
PC210LCI-11 40-545

Action level Failure code AdBlue/DEF Pump Voltage Low Error
Failure
Detail of fail-
Low voltage error occurs in the AdBlue/DEF pump drive circuit.
ure
• AdBlue/DEF pump stops.
Action of
• AdBlue/DEF purging stops.
controller
• If the AdBlue/DEF pump connector is removed while the starting switch is ON, this failure
code is displayed.
• The AdBlue/DEF pump operates 120 seconds after starting the engine, or it operates, af-
Related ter starting the engine, if not in AdBlue/DEF thawing process, when the KDPF outlet tem-
information perature becomes over 150 °C, or when AdBlue/DEF pump pressure raising test is imple-
mented.
Procedure: Turn starting switch to ON position or operate the AdBlue/DEF pump.

1
2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
2
ness
Resistance
ther female side.
ness Min. 100 kΩ
Resistance
Min. 100 kΩ
40-546 PC210LCI-11

Ground fault in wiring ther female side.
4 harness (contact with Between ECM J2 (female) (6) or MB02 (female) (10)
GND circuit) Min. 100 kΩ
and ground
Resistance
Between ECM J2 (female) (79) or MB02 (female) (9)
Min. 100 kΩ
and ground
If failure code is still displayed after above checks, AdBlue/DEF pump may be de-
5 fective. (In case of an internal defect, troubleshooting is impossible as an assembly.
pump
6
Circuit diagram related to AdBlue/DEF pump
PC210LCI-11 40-547

Action level Failure code AdBlue/DEF LineHeater Relay 1 Voltage High Error
Failure
Detail of fail-
High voltage error occurs in the AdBlue/DEF line heater relay 1 circuit.
ure
Action of
None in particular
controller
• The AdBlue/DEF line heater relay 1 operates in AdBlue/DEF supply system thawing,
warning, or implementation of AdBlue/DEF line heater relay 1 test.
• The AdBlue/DEF line heater relay 1 is built in the AdBlue/DEF heater relay.
• Troubleshooting of this failure code covers circuits from engine controller through
Related AdBlue/DEF heater relay to power supply.
information • This failure code is detected only when the AdBlue/DEF line heater relay 1 is ON.
Procedure: Starting the engine at low temperature (ambient temperature of 5 °C or less) or
see “Service mode” and “Testing menu (SCR service test) - Operate” of Setting and oper-
ating machine monitor to perform “AdBlue/DEF line heater relay 1 test”.

1
2. Disconnect connector R53A, and connect T-adapter to female side.
2 3. Turn the starting switch to ON position (with connector R53A disconnect-
harness
ed).
Voltage Between R53A (female) (10) and (12) Max. 3 V
relay.
heater relay
5. Start the engine in low temperature (ambient temperature of 5 °C or below)
or see “SERVICE MODE” of “SETTING AND OPERATION OF MACHINE
MONITOR”, and “METHOD FOR SETTING WITH TESTING MENU (SCR
SERVICE TEST)” to perform “AdBlue/DEF Line Heater Relay 1 Test”.
4
40-548 PC210LCI-11
PC210LCI-11 40-549

Action level Failure code AdBlue/DEF LineHeater Relay 1 Voltage Low Error
Failure
Detail of fail-
Low voltage error occurs in the AdBlue/DEF line heater relay 1 circuit.
ure
Action of
controller
Phenomenon
• NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
on machine
• This failure code is displayed if connector of AdBlue/DEF heater relay is removed while
the AdBlue/DEF line heater relay 1 is OFF.
• The AdBlue/DEF line heater relay 1 operates in AdBlue/DEF supply system thawing,
warning, or implementation of AdBlue/DEF line heater relay 1 test.
Related • The AdBlue/DEF line heater relay 1 is built in the AdBlue/DEF heater relay.
information • Troubleshooting of this failure code covers circuits from engine controller through
AdBlue/DEF heater relay to power supply.
• This failure code is detected only when the AdBlue/DEF line heater relay 1 is OFF.

1
Check if fuse No. 14 in fuse box F02 is blown.
Open circuit in wiring har- 3. Disconnect connector R53B, and connect T-adapter to female side.
3 ness (sensor relay power
supply side)
Voltage Between ground and R53B (female) (1) or (2) Min. 22 V
Open circuit in wiring har- 2. Turn the battery disconnect switch to OFF position.
4 ness (line heater relay
drive signal side) 3. Disconnect connectors ECM J2 and R53A, and connect T-adapters to
each female side.
Resistance Between ECM J2 (female) (3) and R53A (female) (10) Max. 10 Ω
40-550 PC210LCI-11

3. Disconnect connectors ECM J2 and R53A, and connect T-adapter to ei-
ground circuit) ther female side.
Between ground and ECM J2 (female) (3) or R53A (fe-
male) (10)
Short circuit in wiring har- 3. Disconnect connectors ECM J2 and R53A, and connect T-adapter to fe-
6
ness male side of ECM J2.
Continuity
pin (3) ty
7 relay.
heater relay
8
PC210LCI-11 40-551
40-552 PC210LCI-11

Action level Failure code AdBlue/DEF Injector Open Circuit Error or Short Circuit Error
Failure
Detail of fail-
Short or open circuit is detected in the AdBlue/DEF injector circuit.
ure
• AdBlue/DEF pump stop
Action of
controller
k The AdBlue/DEF injector become hot (Min. 400 °C). Be careful not to get burned.
• This failure code is displayed when the AdBlue/DEF injection stops due to connector dis-
connection.
• Short circuit is detected in both ends of the connector between (+) and (-) and this failure
code is displayed when AdBlue/DEF injection stops.
• The voltage between the female terminals is 20 V or more when the AdBlue/DEF injector
connector is disconnected and the starting switch is turned ON, so the hot short circuit of
the harness cannot be checked.
• The AdBlue/DEF injector is activated for AdBlue/DEF injection and when AdBlue/DEF
purging.
• This failure code is cleared after repairing, and turning the starting switch from OFF to ON
position to activate AdBlue/DEF injection.
• The AdBlue/DEF pump stops under the following three conditions:
1. The ambient temperature is -24 °C or less.
2. AdBlue/DEF thawing
3. When the failure code of the AdBlue/DEF pump stoppage or the AdBlue/DEF injection
stoppage is displayed.
Related If the AdBlue/DEF injector does not activate be driven due to any of the above-mentioned
information functions, clear the failure code from the monitor after investigating the cause and make
sure that it is not displayed when discrimination is impossible (when AdBlue/DEF injection
stops).
• Because female connector alone is provided in “Socket” for troubleshooting for this injec-
tor, socket cannot be connected to female connector on wiring harness side of injector and
• The Pre-defined Monitoring screen. (The following numbers are the monitoring codes)
• AdBlue/DEF pump diagnosis
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After com-
pleting the repair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make
sure the failure code is cleared if any failure parts are detected. (This failure code is not
cleared by turning ON the starting switch.)
PC210LCI-11 40-553

1
connector 2. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
Defective AdBlue/DEF in- 2. Disconnect connector MB03 and connect socket to male side.
2
jector
Between MB03 (male) (1) 11.4 to
Resistance 20 °C
and (2) 12.6 Ω
3
wiring harness
The resistance is the same as AdBlue/DEF injector.
Between ECM J2 (female) 11.4 to
Resistance 20 °C
(77) and (53) 12.6 Ω
Short circuit in wiring har- male side of connector ECM J2.
4
ness
No continui-
Continuity ty (no
than (77)
sound)
5 harness (contact with male side of connector ECM J2.
ground circuit) Between ECM J2 (female) (77) and ground Min. 100 kΩ
Resistance
2. Disconnect connector MB03.
6 harness (hot short circuit 3. Insert T-adapter into connector ECM J2.
in negative line) 4. Turn starting switch to ON position (with injector disconnected).
Voltage Between ECM J2 (53) and ground Max. 3 V
7

3. Start engine.
4. Check if AdBlue/DEF pump pressure is around 900 kPa after running the engine at low idle speed (with no
load) for 2 minutes.
40-554 PC210LCI-11
REMARK
If this failure code is cleared at this point, repair is completed, but if not, return to troubleshooting.
Circuit diagram related to AdBlue/DEF injector
PC210LCI-11 40-555

Action level Failure code AdBlue/DEF Injector Malfunction
Failure
Detail of fail- The AdBlue/DEF injector or AdBlue/DEF pressure hose is clogged or the AdBlue/DEF injector noz-
ure zle is sticking open.
controller • The AdBlue/DEF pump stops in the case of the AdBlue/DEF injector opening stick.
40-556 PC210LCI-11
k The AdBlue/DEF injector becomes hot (Min. 400 °C). Be careful not to get burned.
ue/DEF supply system (because the AdBlue/DEF injection is disabled, which disables
judgment).
• Make sure that the value of the following 4 states are other than 1 (Thawing) 3 minutes
after the engine is started. (It is not possible to troubleshoot this failure until thawing con-
trol is completed.)
screen.
• The Pre-defined Monitoring screen uses the AdBlue/DEF injector diagnosis and
AdBlue/DEF pump diagnosis. (The following numbers are the monitoring codes)
Related
19202 Turbo Outlet NOx Concentration Corrected
information
47200 KDPF outlet temperature
• AdBlue/DEF level, AdBlue/DEF quality sensor diagnosis
NOTICE
code is cleared. (This failure code is not cleared by only turning ON the starting switch.)

1
Defective AdBlue/DEF in- If failure code [CA3567] is displayed on the abnormality record screen, perform
2
jector system troubleshooting these first.
PC210LCI-11 40-557

See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SET-
TING WITH TESTING MENU (SCR SERVICE TEST)” in “SETTING AND OPERA-
TION OF MACHINE MONITOR” to perform “AdBlue/DEF Injector Rate Test”.
Case 1: AdBlue/DEF injection stops
The AdBlue/DEF injector or the AdBlue/DEF pressure hose may be clogged. Pro-
ceed to cause 4 to determine the cause of the failure.
Failure of the Case 2: AdBlue/DEF injection continues for more than 2 seconds without stoppage
3
AdBlue/DEF injector 1. The AdBlue/DEF injector is stuck open. Replace with a new one.
2. To remove the accumulated deposits of AdBlue/DEF in SCR, see “SET-
TING AND OPERATION OF MACHINE MONITOR” of “SERVICE MODE”,
and “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)” to perform “Active Regeneration for Service” for 3 times (Refer-
ence: Approximately 2 hours is required in total (40 minutes per opera-
tion))
1. Prepare a container at the injector to receive drained AdBlue/DEF.
2. Remove the hose at AdBlue/DEF injector to allow AdBlue/DEF to drain.
3. See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OP-
ERATION OF MACHINE MONITOR”, “METHOD FOR SETTING WITH TEST-
ING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Pump Pres-
sure Up Test”.
4. If AdBlue/DEF flows out from the AdBlue/DEF pressure hose while the AdBl-
Clogged AdBlue/DEF ue/DEF pump pressure does not reach 900 kPa, there is no clogging in the
4
pressure hose AdBlue/DEF pressure hose.
5. The AdBlue/DEF injector is clogged. Replace it.
6. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in the
AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
Failure code [CA1682] may be displayed if the pressure does not rise within 3
minutes while performing the “AdBlue/DEF Pump Pressure Up Test”.
If failure code is still displayed after above checks, the AdBlue/DEF injector may
have been temporarily clogged but is now normal.
5 jector
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If this fail-
(temporarily clogged)
ure code is cleared, repair is completed.
6

(Make sure this failure code is not deisplayed after this procedure.)
1. Perform “Engine Controller Inducement Fault Clear” to cancel engine power deration when inducement
strategy is activated.
3. Start the engine and warm it up.
4. See "TESTING AND ADJUSTING", “Service mode” and “Inspection menu (Active Regeneration for Serv-
ice)” in “SETTING AND OPERATION OF MACHINE MONITOR” to perform “Active Regeneration for Serv-
ice”.
5. Operate at least 10 minutes after the KDPF outlet temperature exceeded 300 °C.
6. Stop the service regeneration (make sure monitoring code 19108 “AdBlue/DEF pump pressure” is around
900 kPa).
40-558 PC210LCI-11
7. Turn the fuel control dial to MAX position, and run the engine at high idle speed under no load for 2 mi-
nutes.
8. Perform work equipment hydraulic relief operation for continuously 3 minutes or longer with fuel control dial
at MAX position. (At this time, if the value of ammonia concentration is not within 10 to 500(ppm), return to
troubleshooting)
9. Repeat above steps 7. and 8. twice.
10. Run the engine at low idle for 15 minutes.
11. Repeat the above steps 7, 8 and 9.
12. If this failure code is not deisplayed, and active regeneration is not started, repair work is completed.
REMARK
• If this failure code is displayed or active regeneration is started, return to troubleshooting.
• If active regeneration is started during “Loaded Diagnostics Operation To Confirm Failure Correction”, restart
troubleshooting after shutting down the engine controller.
• If active regeneration does not stop, press regeneration disable button to stop active regeneration and then
restart troubleshooting.
PC210LCI-11 40-559

Action level Failure code AdBlue/DEF Pump Pressure Sensor High Error
Failure
Detail of fail-
High voltage error is detected in signal circuit of AdBlue/DEF pump pressure sensor.
ure
Operates at fixed value (1300 kPa) of AdBlue/DEF pump pressure.
Action of AdBlue/DEF pump stop
controller AdBlue/DEF purging stops
• NOx emission increases because AdBlue/DEF injection is disabled due to AdBlue/DEF
pump stop.
Phenomenon
• Because AdBlue/DEF purge is impossible, AdBlue/DEF in AdBlue/DEF line may be frozen
on machine at low temperature.
• AdBlue/DEF pump pressure sensor is built in the AdBlue/DEF pump.
Related • If AdBlue/DEF pump pressure sensor is defective, see "Disassembly and assembly," “Dis-
assembly and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.
information

1
Defective power supply If failure code [CA1695] or [CA1696] is also displayed, perform troubleshooting
2 system of AdBlue/DEF these first.
pump pressure sensor
2. Disconnect connector MB02.
pressure sensor
If the displayed failure code changes from [CA3571] to [CA3572], the AdBlue/DEF
pump pressure sensor is defective.
Open circuit in wiring har- 2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
4
nector) Open circuit in GND line
Resistance Between ECM J2 (female) (32) and MB02 (female) (4) Max. 10 Ω
Short circuit in wiring har- 2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to fe-
5
40-560 PC210LCI-11

2. Disconnect connector MB02, and connect T-adapter to female side or in-
Hot short circuit in wiring sert T-adapter to connector ECM J2.
6
Between MB02 (female) (3) and (4), or between ECM
Voltage Max. 1 V
J2 (16) and (32)
7
Circuit diagram related to AdBlue/DEF pump pressure sensor
PC210LCI-11 40-561

Action level Failure code AdBlue/DEF Pump Pressure Sensor Low Error
Failure
Detail of fail-
Low voltage error is detected in signal circuit of AdBlue/DEF pump pressure sensor.
ure
Operates at fixed value (-100 kPa) of AdBlue/DEF pump pressure.
Action of AdBlue/DEF pump stop
controller AdBlue/DEF purging stops
pump stop.
Phenomenon
• This failure code is displayed when AdBlue/DEF pump connector is disconnected.
• AdBlue/DEF pump pressure sensor is built in the AdBlue/DEF pump.
Related • If AdBlue/DEF pump pressure sensor is defective, see "Disassembly and assembly," “Dis-
information assembly and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.

1
If failure code [CA1695] or [CA1696] is also displayed, perform troubleshooting
these first.
Defective power supply
2 system of AdBlue/DEF 2. Disconnect connector MB02, and connect T-adapter to female side.
pump pressure sensor 3. Turn starting switch to ON position.
Between MB02 (female) 4.75 to
Voltage Power supply input
(2) and (4) 5.25 V
2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
each female side.
3
defective contact of con- Between ECM J2 (female) (16) and MB02 (female) (3) Max. 10 Ω
nector)
Short circuit in wiring har- 2.
4 Disconnect connector ECM J2, and connect T-adapter to female side.
ness
40-562 PC210LCI-11

Ground fault in wiring 2. Disconnect MB02, and connect T-adapter to female side or insert T-adapt-
5 harness (contact with er to connector ECM J2.
ground circuit)
Between MB02 (female) (3) or ECM J2 (16) and
ground
2. Insert T-adapter into connector ECM J2 or MB02.
Defective AdBlue/DEF 3. Turn starting switch to ON position.
6
pressure sensor
Between ECM J2 (female)
0.25 to
Voltage (16) and (32), or between Sensor output
4.75 V
7
Circuit diagram related to AdBlue/DEF pump pressure sensor
PC210LCI-11 40-563

Action level Failure code AdBlue/DEF Pump Pressure Too Low Error
Failure
Detail of fail- Failure of the AdBlue/DEF pump, or clogging or rupture of the AdBlue/DEF channel from the AdBl-
ure ue/DEF tank filter to the AdBlue/DEF pump.
Action of • Raise the AdBlue/DEF pump pressure again.
Phenomenon • AdBlue/DEF injection becomes insufficient and NOx emission increases.
after the engine is started. (This failure cannot be repaired until thawing control is complet-
ed)
• The state of each heater is 1: Thawing, 2: Warming, or 0: OFF. (Enter the numbers directly
and confirm the values on the monitoring code screen.)
• This failure code is cleared if the AdBlue/DEF pump pressure rises to around 900 kPa on
Related the AdBlue/DEF pump “Pre-defined Monitoring screen”.
information • The “Pre-defined Monitoring screen” uses the AdBlue/DEF pump diagnosis. (The following
numbers are the monitoring codes)
NOTICE
This failure code requires a inducement error and “Loaded Diagnostics Operation To Clear
Failure Code”. After investigating the cause of the problem and completing the repair, per-
form “Loaded Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared.(This failure code is not cleared by only turning starting switch to ON position.)

1
heater 1
Defective AdBlue/DEF If failure code [CA2976] is also displayed, perform checks on causes 2 and after in
3 pump temperature sen- troubleshooting for this failure code.
sor system
Defective AdBlue/DEF If failure code [CA1669] or [CA3868] or [CA4732] or [CA4739] or [CA4769] is dis-
4
level sensor system played, perform troubleshooting these first.
40-564 PC210LCI-11

If failure code [CA1673] or [CA3497] or [CA3498] or [CA3547] is displayed, trouble-
shoot for those codes first.
5 Low AdBlue/DEF level
If the level is low, replenish AdBlue/DEF until it can be seen in the sight gauge, and
then “Loaded Diagnostics Operation To Clear Failure Code”.
leak.
Check the AdBlue/DEF suction hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
suction hose
Check the AdBlue/DEF tank for entry of foreign material. Check the AdBlue/DEF
Clogged AdBlue/DEF
8 tank strainer for clogging. Repair or replace the part if any abnormality is found.
tank strainer
Use AdBlue/DEF for cleaning.
1. Remove the flange from the AdBlue/DEF tank.
2. Check if a suction tube in the AdBlue/DEF tank is torn apart.
Suction tube clogged or 3. see “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
9 torn apart in the CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
AdBlue/DEF tank TESTING MENU (SCR SERVICE TEST)” to perform “AdBlue/DEF Pump
Pressure Up Test” to check if AdBlue/DEF is not leaking from the suction tube
in the AdBlue/DEF tank visually.
If the interval specified in the Operation and Maintenance Manual has elapsed
since the last time the AdBlue/DEF pump filter was replaced, or foreign material
Clogged AdBlue/DEF
10 was found in the check for cause [5], replace the AdBlue/DEF pump filter. (Refer to
pump filter
“METHOD FOR REPLACING AdBlue/DEF FILTER” in the Operation and Mainte-
nance Manual)
11
pump
12

REMARK
PC210LCI-11 40-565

Action level Failure code AdBlue/DEF Pump Pressure Too High Error
Failure
AdBlue/DEF injector or AdBlue/DEF pressure hose is clogged, AdBlue/DEF pump fails,
Detail of fail-
AdBlue/DEF line from AdBlue/DEF tank filter to AdBlue/DEF pump is clogged, or AdBlue/DEF leaks
ure
because of breakage.
Action of • Stops AdBlue/DEF pump.
• Engine controller does not display this failure code during thawing control of AdBlue/DEF
feed system (since AdBlue/DEF cannot be injected and accordingly correct judgment is
not made).
• Check that values of following 4 states are not “1” (Thawing), 3 minutes after engine is
started (You cannot repair this failure until thawing control is completed).
• State of each heater is 1: Thawing control, 2: Heating, or 3 or 0: OFF (Input numbers di-
rectly on monitoring code screen, and check value.)
19305 SCR Tank Heating State
19306 SCR Line1 Heating State
• If AdBlue pump pressure on AdBlue/DEF pump “Pre-defined Monitoring” screen increases
Related to near 900 kPa, this code is not displayed.
information • The “Pre-defined Monitoring” screen, use AdBlue/DEF Pump Diagnosis. (Following num-
bers are monitoring codes.)
19304 SCR PumpState
19108 Diesel Exhaust Fluid Line Pressure
19136 AdBlue/DEF pump temperature
19109 Diesel Exhaust Fluid Line Pressure Sensor Voltage
19120 Diesel Exhaust Fluid Injection Rate
NOTICE
After inspecting cause of failure and performing repair, perform “Loaded Diagnostics Opera-
tion To Clear Failure Code”, and check that this failure code is canceled. (Display of this fail-
ure code is not canceled by simply turning starting switch to ON position)

1
heater 1
Check the AdBlue/DEF purging hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
purging hose
4
pump pressure sensor
40-566 PC210LCI-11

5

REMARK
PC210LCI-11 40-567

Action level Failure code AdBlue/DEF FCV voltage high error
Failure
Detail of fail-
High voltage error is detected in signal circuit of FCV (valve for purge) of AdBlue/DEF pump.
ure
• AdBlue/DEF pump stop.
Action of
• AdBlue/DEF purge stop.
controller
Phenomenon • NOx emission increases.
on machine • The engine power deration according to inducement strategy.
• AdBlue/DEF FCV is built in the AdBlue/DEF pump.
• This failure code is displayed if MB02 connector is removed.
• AdBlue/DEF FCV operated at the time of AdBlue/DEF purge.
• AdBlue/DEF FCV operates at the end when implementing a AdBlue/DEF pump pressure
Related raise test.
information • If AdBlue/DEF FCV is defective, see “DISASSEMBLY AND ASSEMBLY”, “Disassembly
and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.
• This failure code is detected only when the AdBlue/DEF FCV stops.

1
Defective AdBlue/DEF 2. Disconnect connector MB02, and connect T-adapter to male side.
2
FCV
Between MB02 (male) (11)
Resistance Temperature 23±5 °C 21.1±3 Ω
and (12)
3
wiring harness
The resistance value is the same as the AdBlue/DEF FCV value
(81) and (57)
40-568 PC210LCI-11
REMARK
quired.
ness (wire breakage or 2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
4
defective contact of con- each female side.
nector)
Max. 10 Ω
(11)
Resistance
Max. 10 Ω
(12)
Hot short circuit in wiring 2. Disconnect connector MB02, and connect T-adapter to female side.
5 harness (contact with 24
3. Turn starting switch to ON position (with the connector disconnected).
V circuit)
Voltage Between MB02 (female) (11) and (12) Max. 4.5 V
Short circuit in wiring har- male side of ECM J2.
6
ness
No continui-
Continuity ty (no
than (81)
sound)
7
Circuit diagram related to AdBlue/DEF FCV
PC210LCI-11 40-569

Action level Failure code AdBlue/DEF FCV Voltage Low Error
Failure
Detail of fail-
Low voltage error is detected in signal circuit of FCV (valve for purge) of AdBlue/DEF pump.
ure
AdBlue/DEF pump stop
Action of
AdBlue/DEF purge stop
controller
pump stop.
Phenomenon
• AdBlue/DEF FCV is built in the AdBlue/DEF pump.
• Short circuit is detected in both ends of the connector between (+) and (-) and this failure
code is displayed when driving the AdBlue/DEF FCV.
• This failure code is cleared after implementing AdBlue/DEF FCV drive again turning the
starting switch from OFF to ON after abnormality repair.
• AdBlue/DEF FCV operated at the time of AdBlue/DEF purge.
Related
• AdBlue/DEF FCV operates at the end when implementing a AdBlue/DEF pump pressure
information
raise test.
• If AdBlue/DEF FCV is defective, see “DISASSEMBLY AND ASSEMBLY”, “Disassembly
and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.
• This failure code is detected only when the AdBlue/DEF FCV operates.
Procedure: Operating AdBlue/DEF FCV

1
2
wiring harness
The resistance value is the same as the AdBlue/DEF FCV value
(81) and (57)
40-570 PC210LCI-11

Short circuit in wiring har- male side of ECM J2.
3
ness
No continui-
Continuity ty (no
than (81)
sound)
Ground fault in wiring 2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
4 harness (contact with each female side.
ground circuit) Open circuit in GND line
Defective AdBlue/DEF 2. Disconnect connector MB02, and connect T-adapter to male side.
5
FCV
Between MB02 (male) (11)
and (12)
6
Circuit diagram related to AdBlue/DEF FCV
PC210LCI-11 40-571

Action level Failure code SCR Catalyst Efficiency Low Error 1
Failure
Detail of fail-
The SCR catalyst efficiency remains low (70 % or less).
ure
Action of • The engine controller performs clearing active regeneration (approximately one hour) of
controller urea deposit accumulation in repair limit.
Phenomenon • The clearing active regeneration (approximately one hour) of urea deposit accumulation is
on machine performed automatically.
k Be careful of the attachment of AdBlue/DEF because AdBlue/DEF leaks when remov-
ing AdBlue/DEF mixing piping or AdBlue/DEF injector.
• The failure state is not cleared after performing clearing active regeneration of urea depos-
it accumulation. Start clearing active regeneration of urea deposit accumulation again
when performing repair limit again 20 or more minutes after.
• After the previous active regeneration (clearing of soot, time management, urea deposit
accumulation), do not start active regeneration of urea deposit accumulation if any failures
occur within 20 minutes.
Related
information
Confirm on the Pre-defined Monitoring screen.
• For the procedure to remove and change the AdBlue/DEF injector, see “REMOVE AND
INSTALL AdBlue/DEF INJECTOR”.
• The cause of this failure code is cleared after accumulation of urea deposit is resolved by
active regeneration. Troubleshooting is not necessary.
• If active regeneration is performed frequently after the active regeneration which is auto-
matically performed is normally finished, identify the cause according to the following pro-
cedure.
40-572 PC210LCI-11
• On the Pre-defined Monitoring screen, these 4 diagnosis are displayed. Engine operation
01002 Engine speed
Related
information
19202 AFT Intake NOx Corrected
19205 AFT NH3 Sensor Corrected
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.
(This failure code is not cleared by only turning ON the starting switch again.)

tem first.
1
heater)
PC210LCI-11 40-573

heater)
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] is displayed, perform troubleshoot-
fect) ing for these failure codes first.
heater)
played.
jector
(Loaded Diagnostics Operation To Confirm Failure Correction has resolved the
clogging problem and the machine has restored normal operation).
leak.
40-574 PC210LCI-11

found.
Improper AdBlue/DEF
quality
completed.
ficiency Test”.
tem first.
TEST)
jector
PC210LCI-11 40-575

mixing tube
12
tive.
damaged rectifier)
13
pleted.
fective.
sor
pleted.
15

(Make sure that this failure code is cleared after this procedure.)
position.
REMARK
40-576 PC210LCI-11

REMARK
If the failure is cleared, the repair is completed.
8. After this failure code is cleared, repair is completed.
In case this failure code is displayed:
1. Display the SCR temperature and ammonia concentration on the Troubleshooting screen.
2. Perform operation so that the SCR temperature is kept 250 °C or above.
3. A normal value of ammonia concentration ranges from 5 to 100(ppm). If 0(ppm) is shown consistently or
100(ppm) or above is shown, return to troubleshooting because the repair is not completed.
PC210LCI-11 40-577

Action level Failure code SCR Outlet NOx Sensor Heater Warming up Error
Failure
Detail of fail- There is an abnormality in the heater part of the SCR outlet NOx sensor. (It is not heated or the
ure temperature cannot be kept)
Phenomenon
on machine
• The SCR outlet NOx sensor operates when 19302 SCR outlet temperature is 150 °C or
more (19210 SCR outlet NOx sensor measurement state is “1”).
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or
• The Pre-defined Monitoring screen uses the engine operation state diagnosis, SCR cata-
lyst, NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
Related
information
NOTICE
sure the failure code is cleared. (This failure code is not cleared by only turning ON the
starting switch.)

1
cation system
40-578 PC210LCI-11

2
Defective SCR outlet If failure code [CA1887] or [CA3681] or [CA3717] is displayed, perform trouble-
NOx sensor system shooting for these failure codes first.
heater)
NOx sensor
5

3. Run the engine at high idle speed safely to raise the exhaust gas temperature and SCR catalyst tempera-
ture. (Keep the engine speed so that monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or
higher. Check that monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
PC210LCI-11 40-579

Action level Failure code AdBlue/DEF Pump Pressure Unstable Error
Failure
Detail of fail- A failure of the AdBlue/DEF pump pressure sensor, clogging of each AdBlue/DEF hose, or
ure AdBlue/DEF pump is found.
Action of • Raise the AdBlue/DEF pump pressure.
Phenomenon • Engine power deration according to inducement strategy.
on machine • NOx emission increases because AdBlue/DEF injection is disabled.
after the engine is started. (This failure cannot be repaired until thawing control is complet-
ed)
• The state of each heater is 1: Thawing, 2: Warming, or 0: OFF. (Enter the numbers directly
and confirm the values on the monitoring code screen.)
• 19305 AdBlue/DEF Tank Heating State
• This failure code is cleared if the AdBlue/DEF pump pressure rises to around 900 kPa on
Related the AdBlue/DEF pump “Pre-defined Monitoring screen”.
information • The “Pre-defined Monitoring screen” uses the AdBlue/DEF pump diagnosis. (The following
numbers are the monitoring codes)
NOTICE
This failure code requires a inducement error and “Loaded Diagnostics Operation To Clear
Failure Code”. After investigating the cause of the problem and completing the repair, per-
form a“Loaded Diagnostics Operation To Clear Failure Code” to make sure the failure code
is cleared.(This failure code is not cleared by only turning starting switch to ON position.)

If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] or [CA4169] or
1 [CA4171] or [CA4249] or [CA4251] is displayed on the abnormality record screen,
pump system
perform troubleshooting these first.
AdBlue/DEF pump pres- Perform checks on causes 1 to 3 for failure code [CA3575]. (This failure code may
2
sure raise be displayed with “[CA3575] AdBlue/DEF pump pressure high error”.)
AdBlue/DEF pump pres- Perform checks on causes 1 to 10 for failure code [CA3574]. (This failure code may
3
sure drop be displayed in place of “[CA3574] AdBlue/DEF pump pressure low error”.)
Defective AdBlue/DEF AdBlue/DEF pump pressure sensor in AdBlue/DEF pump may be defective. Re-
4
pressure sensor place the AdBlue/DEF pump.
40-580 PC210LCI-11

5

3. Check if monitoring code 19108 “AdBlue/DEF Pump Pressure” is 900 ± 100 kPa within 5 minutes after
starting the engine.
REMARK
PC210LCI-11 40-581

Action level Failure code Turbocharger Outlet NOx Sensor Heater Warming up Error
Failure
Detail of fail- There is an abnormality in the heater part of the turbocharger outlet NOx sensor. (It is not heated or
ure the temperature cannot be kept)
Phenomenon
on machine
• The turbocharger outlet NOx sensor operates when 47300 “KDOC inlet temperature” is
150 °C or more (19203 “turbocharger outlet NOx sensor measurement state” is “1”).
• Use engine operation state diagnosis, SCR catalyst, NOx sensor, and ammonia sensor di-
ing codes)
Related 01002 Engine speed
information 19200 Exhaust gas flow rate
NOTICE
switch.)

1
tem error
40-582 PC210LCI-11

2
Defective turbocharger If failure code [CA1885] or [CA3682] or [CA3718] is displayed, perform trouble-
outlet NOx sensor sys- shooting for these failure codes first.
3 tem
(internal circuit abnormal-
ity)
(Offset/drift due to sulfur-poisoned turbocharger outlet NOx sensor)
Defective turbocharger 1. Turn starting switch to OFF position.
4
outlet NOx sensor
2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
5

monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or higher. Check that monitoring code
19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1).
REMARK
If the turbocharger outlet NOx sensor does not activate (that is, 19203 “Turbo Outlet NOx Sensor State” remains
as 0), return to troubleshooting.
PC210LCI-11 40-583

Action level Failure code SCR Outlet NOx Sensor Power Voltage Error
Failure
Detail of fail- The value of the SCR outlet NOx sensor cannot be measured due to a supply voltage error of the
ure SCR outlet NOx sensor.
Phenomenon
on machine
• The SCR outlet NOx sensor operates when 19302 “SCR outlet temperature” is 150 °C or
more (19210 “SCR outlet NOx sensor measurement state” is “1”).
• The SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °Cor
ing codes)
Related 01002 Engine speed
information 19200 Exhaust gas flow rate
NOTICE
starting switch.)
40-584 PC210LCI-11

1
2
cation system
See descriptions of wiring harness and connectors in “Electrical equipment” in
3 “CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
connector
TROUBLESHOOTING”, and check it.
• Power line
2. Disconnect connector E36, and connect T-adapter to female side.
Open cCauseircuit in wir- If no failure is found by this check, perform checks on causes 8 and after.
ing harness (wire break-
Voltage Between E36 (female) (1) and (4) Min. 22 V
4 age or defective contact
of connector) (broken If no failure is found by above results, this check is not required.
power line) 1. Turn starting switch to OFF position.
2. Disconnect connectors R52 and E36 and connect T-adapters to each fe-
male side.
Between R52 (female) (12) and E36 (female) (1) Max. 10 Ω
Resistance
7
supply relay
NOx sensor
9

PC210LCI-11 40-585
monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or higher. Check that monitoring code
19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
REMARK
40-586 PC210LCI-11
PC210LCI-11 40-587
40-588 PC210LCI-11

Action level Failure code Turbocharger Outlet NOx Sensor Power Voltage Error
Failure
Detail of fail- The turbocharger outlet NOx sensor does not display any values due to a supply voltage error of the
ure turbocharger outlet NOx sensor.
Phenomenon
on machine
PC210LCI-11 40-589
• The engine controller refers to the fluctuation of the KDPF differential pressure sensor and
KDPF outlet pressure sensor to judge the error of this failure code only when the exhaust
gas pressure is stable.
unit.
ing codes)
Related
•
information
01002 Engine speed
NOTICE
switch.)

1
2
cation system
See descriptions of wiring harness and connectors in “Electrical equipment” in
3 “CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
connector
40-590 PC210LCI-11

• Power line
Open cCauseircuit in wir- If no failure is found by this check, perform checks on causes 8 and after.
ing harness (wire break-
4 age or defective contact
of connector) (broken If no failure is found by above results, this check is not required.
power line) 1. Turn starting switch to OFF position.
male side.
Resistance
7
supply relay
8
outlet NOx sensor
9

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
3. Run the engine at high idle speed with safe condition in order to raise the exhaust gas temperature. (Keep
the engine speed so that the monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or high-
er. Check that the monitoring code 19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
PC210LCI-11 40-591
4. After the procedure in 3., if failure code is not displayed after 3 minutes have passed with running the en-
gine at low idle speed, repair is completed.
REMARK
If the turbocharger outlet NOx sensor cannot be activated (that is, the monitoring code 19203 “Turbo Outlet NOx
Sensor State” remains as 0), return to troubleshooting.
40-592 PC210LCI-11
PC210LCI-11 40-593
40-594 PC210LCI-11

Action level Failure code AdBlue/DEF Line Heater 1 Voltage High Error
Failure
Detail of fail- High voltage error is detected in signal circuit of AdBlue/DEF line heater 1 (on low-temperature
ure pressure, intake, and purge).
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing.
• The AdBlue/DEF line heater 1 operates in AdBlue/DEF supply system thawing, warning,
or implementation of AdBlue/DEF line heater relay 1 test.
• The AdBlue/DEF line heater 1 is operated by the AdBlue/DEF line heater relay 1 in the
AdBlue/DEF heater relay.
Related
• This failure code is detected only when the AdBlue/DEF line heater 1 is OFF.
information
• If the connectors of all heaters connected to the AdBlue/DEF line heater 1 are disconnect-
ed, this failure code is displayed.

1
ness (wire breakage or 2. Disconnect connectors ECM J2 and R53A, and connect T-adapters to
2 each female side.
nector) Between ECM J2 (female) (39) and R53A (female) (8) Max. 10 Ω
Resistance
Between R53A (female) (12) and ground Max. 10 Ω
3 3. Turn the starting switch to ON position (with connector R53A disconnect-
harness
ed).
Voltage Between R53A (female) (8) and (12) Approx. 5 V
2. Disconnect connectors MB04 and MB06A, and connect T-adapters to
Defective AdBlue/DEF each male side.
4
line heater
Between MB04 (male) (1) and (2) 5 to 40 Ω
Resistance
Between MB06A (male) (1) and (2) 5 to 40 Ω
PC210LCI-11 40-595

5 REMARK
side) Internal resistance is possessed by above-mentioned heater relay.
Open circuit or short cir- REMARK
6 Resistance value is the internal resistance value of the heater relay mentioned
side) above.
Between R53A (female) (5) and (12) 5 to 40 Ω
Resistance
7 relay.
heater relay
8
40-596 PC210LCI-11
PC210LCI-11 40-597

Action level Failure code SCR Outlet NOx Sensor Voltage Mismatch Error
Failure
Detail of fail- The engine controller voltage setting and SCR outlet NOx sensor voltage specifications are not con-
ure sistent. (The sensor part numbers are different)
Phenomenon
on machine
Related ambient temperature is not high.
information • A sensor different from genuine spare parts may have been installed when changing this
sensor.

1
cation system
2
2. Check the Part No. of the NOx sensor.
Defective SCR outlet 3. Replace the SCR outlet NOx sensor.
3
NOx sensor
If this failure code is cleared, the SCR outlet NOx sensor is defective.
4
40-598 PC210LCI-11

Action level Failure code Turbocharger Outlet NOx Sensor Voltage Mismatch Error
Failure
Detail of fail- ne controller voltage setting and turbocharger outlet NOx sensor voltage specifications are not con-
ure sistent. (The sensor part numbers are different)
Related ambient temperature is not high.
information • A sensor different from genuine spare parts may have been installed when changing this
sensor.

1
tem error
2
2. Check the Part No. of the NOx sensor.
Defective turbocharger 3. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3
outlet NOx sensor 4. Turn starting switch to ON position.
4
PC210LCI-11 40-599

Action level Failure code Turbocharger Outlet NOx Sensor Unstable Error
Failure
Detail of fail-
The turbocharger NOx sensor does not become measurable status.
ure
40-600 PC210LCI-11
• The engine controller refers to the fluctuation of KDPF differential pressure sensor and
KDPF outlet pressure sensor to judge the error of this failure code only when the exhaust
gas pressure is stable.
unit.
• If failure code is cleared immediately after displayed, it is suspected that detection of tur-
bocharger outlet NOx sensor was unstable for a moment.
(For example, when repeat running the engine continuously at low idle speed for a long
time.)
REMARK
Related Turbocharger outlet NOx sensor is not defective, therefore it has no problems if this failure
code does not appear repeatedly or continuously.
information
ing codes)
01002 Engine speed
NOTICE
starting switch.)
PC210LCI-11 40-601

1
tem error
Defective KDPF differen- If failure code [CA1879] or [CA1881] or [CA1883] is displayed, perform trouble-
2 tial pressure sensor sys- shooting for these failure codes first.
tem
Defective KDPF outlet If failure code [CA3133] or [CA3134] or [CA3135] is displayed, perform trouble-
3
pressure sensor system shooting for these failure codes first.
Defective turbocharger If failure code [CA1885], [CA3649], [CA3682], and [CA3718] is displayed, perform
4 outlet NOx sensor sys- troubleshooting for these failure codes first.
tem
Defective turbocharger Check if the turbocharger outlet NOx sensor is installed securely.
5 outlet NOx sensor instal-
lation error
6
outlet NOx sensor
7

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
3. Run the engine at high idle speed with safe condition in order to raise the exhaust gas temperature. (Keep
the engine speed so that the monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or high-
er. Check that the monitoring code 19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
4. After the procedure in 3., if failure code is not displayed after 3 minutes have passed with running the en-
gine at low idle speed, repair is completed.
REMARK
If the turbocharger outlet NOx sensor cannot be activated (that is, the monitoring code 19203 “Turbo Outlet NOx
Sensor State” remains as 0), return to troubleshooting.
40-602 PC210LCI-11

Action level Failure code Common Rail Pressure Valve Trip Error
Failure
Details of
Engine controller determines that common rail pressure limiter valve opens.
failure
Action of • Lowers set value of common rail pressure.
Phenomenon Engine power deration.
on machine Engine may not start again.
• Signal voltage from common rail pressure sensor can be checked with monitoring func-
tion. (Code: 36401 (V))
Related • Pressure sensed by common rail pressure sensor can be checked with monitoring func-
information tion. (Code: 36400 (MPa))

Common rail pressure Perform troubleshooting for failure code [CA449].
1
limiter valve is open.
PC210LCI-11 40-603

Action level Failure code Turbocharger Outlet NOx Sensor Stuck In Range Error
Failure
Detail of fail- The NOx emission value of the engine output does not change regardless of the change in the en-
ure gine operation state.
Action of
Operate using the NOx value in the memory.
controller
• The turbocharger outlet NOx sensor operates when 47300 KDOC inlet temperature is
150 °C or more (19203 turbocharger outlet NOx sensor measurement state is “1”).
• The KDPF temperature sensor is composed of the KDOC inlet temperature sensor, the
KDOC outlet temperature sensor, and the KDPF outlet temperature sensor and provides
CAN communication with the engine controller integrated into one sensor controller.
• For the replacement procedure of the KDPF temperature sensor, see “DISASSEMBLY
AND ASSEMBLY”, “REMOVE AND INSTALL SCR ASSEMBLY”.
• The Pre-defined Monitoring screen uses the engine operation state diagnosis, SCR cata-
lyst, NOx sensor, and ammonia sensor diagnosis.
01002 Engine speed
NOTICE
pair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure the
switch.)
40-604 PC210LCI-11

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], or [CA3718] is displayed,
outlet NOx sensor sys- perform troubleshooting for these failure codes first.
tem
1
heater)
2. Check if the turbocharger outlet NOx sensor is disconnected from the exhaust
Turbocharger outlet NOx
2 pipe or loose.
sensor installation error
3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
1. If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform trou-
bleshooting for [CA3313], [CA3314] or [CA3315] first.
Defective KDOC inlet 2. If the KDOC inlet temperature does not rise up to 150 °C during “Loaded
3 temperature sensor sys- Diagnostics Operation To Clear Failure Code”, replace the KDPF tempera-
tem ture sensor.
3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
Defective turbocharger sensor may be defective.
outlet NOx sensor 1. Turn starting switch to OFF position.
4
(Clogged sensor due to 2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
soot, etc.)
3. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
5

Check if the repair has been completed with the following operation:
1. Turn the starting switch to the OFF position, and shut down the engine controller.
2. Start engine.
3. Run the engine at high idle speed safely to raise the exhaust gas temperature. (Keep the engine speed so
that monitoring code 47300 “KDOC 1 Inlet Temperature” is 150 °C or higher.)
4. After the procedure in 3., check if the turbocharger outlet NOx sensor activates within 3 minutes (OK as far
as 19203 “AFT Intake Dew Point” changes from “0” to “1”)
5. Ensure the above 4., and set the swing lock to ON, the fuel control dial to 2/3 position, and the working
mode to P.
REMARK
8. Repeat the above Steps 6. and 7. up to 20 times until this failure code is cleared.
REMARK
If this failure code is not cleared, return to troubleshooting.
PC210LCI-11 40-605

Action level Failure code SCR Catalyst Degradation Error
Failure
Detail of fail-
Denitration efficiency does not increase though the AdBlue/DEF injection amount is sufficient.
ure
Action of
None in particular
controller
Phenomenon It is possible that the NOx emission increases, or ammonia is discharged due to insufficient denitra-
on machine tion efficiency.
k The temperature of aftertreatment devices such as SCR assembly and AdBlue/DEF

mixing piping becomes high (Min. 400 °C). Be careful not to get burned.
k Be careful of the attachment of AdBlue/DEF because AdBlue/DEF leaks when remov-
ing AdBlue/DEF mixing piping or AdBlue/DEF injector.
REMARK
• This failure code occurs only in the “SCR Denitration Efficiency Test” implemented to locate
Related the failure points when a failure code such as [CA3151], [CA3543], and [CA3582] is dis-
information played.
• The SCR catalyst cannot be replaced alone. (SCR assembly needs to be changed)
NOTICE
• For this failure code, after investigating the cause of the problem and completing the
repair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure
the failure code is cleared. (This failure code is not cleared by only turning ON the
starting switch.)

Defective SCR catalyst 1. Deterioration, dissolution, or damage of SCR catalyst can be suspected.
1 (Deterioration, dissolu- Replace the SCR assembly.
tion, damage) 2. Perform “Loaded Diagnostics Operation To Clear failure Code”.
2

2. Turn the starting switch to ON position, and start engine.
4. See “TESTING AND ADJUSTING”, “Service mode” and “Test menu (SCR Service Test)” in “SETTING AND
OPERATION OF MACHINE MONITOR” to perform “SCR removal efficiency test” (maximum duration of the
removal efficiency: 1.5 h).
5. The test condition on the monitor changes from “0” to “10”, then to “20”. (“14” may be shown during few
minutes due to temperature transition)
6. When the test is completed after the test condition on the monitor shows “20”, stop the engine and shut
down the engine controller (wait for a few minutes after the shutdown, then the starting switch to OFF posi-
tion).
7. Turn the starting switch to ON position again to check if this failure code is cleared. If the failure code is
cleared, repair work is completed.
40-606 PC210LCI-11
REMARK
PC210LCI-11 40-607

Action level Failure code AdBlue/DEF Dosing Performance Degradation Error
Failure
Detail of fail-
Actual AdBlue/DEF dosing performance is less than that which is indicated.
ure
Action of
None in particular
controller
Phenomenon
The AdBlue/DEF injection becomes inappropriate, and then NOx emission increases.
on machine
ue/DEF injector.
• This failure code occurs only in the “SCR Denitration Efficiency Test”(denitration efficiency
test time is up to 1.5 hours) implemented to locate the failure points when a failure code
Related such as [CA3151], [CA3543], and [CA3582] is displayed.
information • For the procedure to remove and change the AdBlue/DEF injector, see “Disassembly and
NOTICE
pair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure the
failure code is cleared. (This failure code is not cleared by turning ON the starting
switch.)

2. Remove the AdBlue/DEF injector.
3. Refer to “Testing and adjusting”, “SETTING AND OPERATION OF MA-
1 CHINE MONITOR”, “Service mode”, “Operation method of testing menu
jector
(SCR Service Test)” to perform an “AdBlue/DEF injector injection amount
test” to judge the injector.
3. See Testing and adjusting, “service modes” of “setting and operating ma-
chine monitor”, “operating method of testing menu (SCR service test)” to
Clogged AdBlue/DEF perform an “AdBlue/DEF pump pressure rising test”.
2
supply line 4. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in
the AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
minutes while performing the “AdBlue/DEF pump pressure rising test”.
40-608 PC210LCI-11

3
outlet NOx sensor
4. Performing “Loaded Diagnostics Operation To Clear Failure Code”.
(Offset/drift due to sulfur-poisoned SCR outlet NOx sensor)
Defective SCR outlet 1. Turn starting switch to OFF position.
4
NOx sensor 2. Replace the SCR outlet NOx sensor.
tive.
damaged rectifier)
Defective air intake sys- 1. Check for a defective air intake pipe and repair or replace any damaged or
5
tem defective rectifier, if any.
2. Replace mass air flow (MAF) sensor.
6

2. Turn the starting switch to ON position, and start engine.
4. See “TESTING AND ADJUSTING”, “Service mode” and “Test menu (SCR Service Test)” in “SETTING AND
OPERATION OF MACHINE MONITOR” to perform “SCR removal efficiency test” (maximum duration of the
removal efficiency: 1.5 h).
5. The test condition on the monitor changes from “0” to “10”, then to “20”. (“14” may be shown during few
minutes due to temperature transition)
6. When the test is completed after the test condition on the monitor shows “20”, stop the engine and shut
down the engine controller (wait for a few minutes after the shutdown, then the starting switch to OFF posi-
tion).
7. Turn the starting switch to ON position again to check if this failure code is cleared. If the failure code is
cleared, repair work is completed.
REMARK
PC210LCI-11 40-609

Action level Failure code AdBlue/DEF Low Concentration Error 2
Failure
Detail of fail-
The more NOx emission increases, the lower concentration AdBlue/DEF gets.
ure
• Advances to Inducement strategy (EU Specification).
Action of
• AdBlue/DEF injection stops (EU Specification).
controller
• AdBlue/DEF pump stops (EU Specification).
Phenomenon • Engine power deration according to inducement strategy (EU Specification).
on machine • NOx conversion rate is lower.
• If SCR efficiency is degraded due to lowered AdBlue/DEF concentration, failure code
[CA3582] SCR Catalyst Efficiency Low Error 1 may be displayed.
• A surface in AdBlue/DEF fluctuates more in work on slopes or travel on uneven ground,
possibly disabling to detect the correct level or concentration.
• If AdBlue/DEF level monitor is illuminated in red or a warning on the concentration is dis-
played, move to a flat place as soon as possible and refill AdBlue/DEF. If this phenomenon
persists, refill AdBlue/DEF extra in AdBlue/DEF tank.
• If AdBlue/DEF tank temperature is 0 °C or below, the engine controller does not trouble-
shoot this failure code (“Loaded Diagnostics Operation To Clear Failure Code” does not
clear this failure code).
• Make sure that AdBlue/DEF tank temperature is 0 °C or above on the Pre-defined Monitor-
ing screen before troubleshooting this failure code.
• When AdBlue/DEF tank level is 0 %, the engine controller does not troubleshoot this fail-
ure code (“Loaded Diagnostics Operation To Clear Failure Code” does not clear this failure
code).
• Make sure that AdBlue/DEF tank temperature is 20 % or above on the Pre-defined Moni-
toring screen before troubleshooting this failure code.
Related • For draining and cleaning procedures of AdBlue/DEF tank, see Testing and adjusting,
information
“AdBlue/DEF Tank Washing”.
• For the replacement procedure of AdBlue/DEF level sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF level sensor”.
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF level and
AdBlue/DEF quality sensors are used (the figures below denote monitoring codes).
NOTICE
agnostics Operation To Clear Failure Code” to make sure that the failure code is
cleared.
40-610 PC210LCI-11

1. If failure code [CA1669] or [CA1677] or [CA1678] or [CA1686] or [CA1714]
or [CA1715] or [CA3868] or [CA4277] or [CA4731] or [CA4732] or
Defective AdBlue/DEF [CA4739] or [CA4768] or [CA4769] is displayed, perform troubleshooting
1 these first.
tank sensor system
2. If troubleshooting has been performed, carry out “Loaded Diagnostics Op-
eration To Clear Failure Code” topics.
1. Check that the “AdBlue/DEF concentration” displayed on the Pre-defined
Monitoring screen is in the normal range (29 to 36 %).
2. If the “AdBlue/DEF concentration” is normal, perform “Loaded Diagnostics
Operation To Clear Failure Code”.
3. If the “AdBlue/DEF concentration” falls outside of this range, use a porta-
Low AdBlue/DEF con-
ble concentration meter to recheck the concentration. If the concentration
2 centration (entrained wa-
still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
ter, etc.)
from the tank and refill with fresh AdBlue/DEF.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the portable concentration meter reading is in the range of 31.5 to
33.5 %, proceed to the next troubleshooting.
1. Drain more than 1 ℓ of AdBlue/DEF to check that it is not contaminated
with foreign material, etc.
2. If the drained AdBlue/DEF is contaminated, drain all of the AdBlue/DEF
and refill with fresh AdBlue/DEF.
Contaminated 3. If it is heavily contaminated with sand, dirt, etc., clean the AdBlue/DEF
3
AdBlue/DEF tank.
5. If the “AdBlue/DEF concentration” is out of the normal range, proceed to
the next troubleshooting.
REMARK
• If new AdBlue/DEF has not been refilled at the cause 3, and if it would take
some time to remove the sensor, drain all of AdBlue/DEF, and refill with
fresh AdBlue/DEF, and check the output of the sensor.
• For the removal procedure of the AdBlue/DEF tank sensor, see “DISAS-
SEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL AdBlue/DEF TANK
SENSOR FLANGE ASSEMBLY”.
Foreign matter adhered
1. Remove the AdBlue/DEF level sensor to gain access to the “AdBlue/DEF
4 to the sensing part of the
AdBlue/DEF tank sensor concentration” sensing part (end of sensor).
2. Wipe the “AdBlue/DEF concentration” sensing part with a dry, clean cloth.
Install the AdBlue/DEF level sensor.
3. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
screen falls in the range of 29 to 36 %, perform “Loaded Diagnostics Oper-
ation To Clear Failure Code” topics to complete the repair.
4. If the “AdBlue/DEF concentration” falls outside of this range, proceed to
PC210LCI-11 40-611

screen falls in the range of 29 to 36%, perform “Loaded Diagnostics Oper-
5 tank sensor (internal de-
fect)
1. Replace the engine controller.
Defective engine control- 2. If “AdBlue/DEF concentration” ranges from 29 to 36 % on the Trouble-
6
ler shooting Pre-defined Monitoring screen, perform “Loaded Diagnostics Op-
eration To Clear Failure Code” and repair is completed.

3. Display monitoring code 19115 “AdBlue/DEF Temperature in Tank” on “Pre-defined Monitoring” screen.
4. Stand by with the lever and pedal of the machine not operated.
Standby time depends on the initial value of the AdBlue/DEF Temperature in tank as follows.
• When the value is 0 °C or below, run the engine and wait for 0 °C or above in tank temperature (about
60 minutes).
• When the value ranges from 0 to 5 °C, stand by for 30 minutes. (engine may be either started or not.)
• When the value is 5 °C or above, stand by for 10 minutes. (engine may be either started or not.)
40-612 PC210LCI-11

Action level Failure code AdBlue/DEF Low Concentration Error 1
Failure
― CA3867 (Engine controller system)
Detail of fail-
AdBlue/DEF low concentration (25 % or below) is detected.
ure
Action of
None in particular
controller
Phenomenon
AdBlue/DEF is consumed largely
on machine
No error is displayed on the machine monitor.
A surface in AdBlue/DEF fluctuates more in work on slopes or travel on uneven ground, possibly
disabling to detect the correct level or concentration.
If AdBlue/DEF level monitor is illuminated in red or a warning on the concentration is displayed,
move to a flat place as soon as possible and refill AdBlue/DEF. If this phenomenon persists, refill
AdBlue/DEF extra in AdBlue/DEF tank.
• Make sure that AdBlue/DEF tank temperature is 0 °C or above on the “Pre-defined Moni-
toring” screen before troubleshooting this failure code.
• When AdBlue/DEF level is 0 %, the engine controller does not troubleshoot this failure
code (“Loaded Diagnostics Operation To Clear Failure Code” does not clear this failure
code).
• Make sure that AdBlue/DEF tank temperature is 20 % or above on the “Pre-defined Moni-
Related • For draining and cleaning procedures of AdBlue/DEF tank, see Testing and adjusting,
“CLEAN AdBlue/DEF TANK”.
information
• For the replacement procedure of AdBlue/DEF/level sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF/level sensor”.
• On the “Pre-defined Monitoring” screen troubleshooting for AdBlue/DEF level and
AdBlue/DEF quality sensors are used.
NOTICE
PC210LCI-11 40-613

1 these first.
tank sensor system
Low AdBlue/DEF con-
ble concentration meter to recheck the concentration. If the concentration
2 centration (entrained wa-
still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
ter, etc.)
3
AdBlue/DEF tank.
REMARK
40-614 PC210LCI-11

fect)
6

Standby time depends on the initial value of the AdBlue/DEF Temperature in tank as follows.
• When the value is 0 °C or below, run the engine and wait for 0 °C or above in tank temperature (about
60 minutes).
PC210LCI-11 40-615

Action level Failure code AdBlue/DEF Tank Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller cannot receive the data of the AdBlue/DEF tank sensor due to error of com-
ure munication with the AdBlue/DEF tank sensor.
Action of
controller
• The AdBlue/DEF level, quality, and temperature cannot be measured.
Phenomenon • NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injec-
on machine tion works inappropriately.
• The AdBlue/DEF tank is a smart sensor which performs CAN communication with the en-
gine controller together with the other sensors.
• If the sensor connector or smart sensor (power supply) relay connector is disconnected,
this failure code is displayed.
• The failure codes of the CAN communication related to the engine sensor are [CA2771],
[CA3232], [CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are
displayed, the cause may be defective smart sensor power supply relay, defective relay
Related system, or ground fault, short circuit, or hot short circuit of the harness (CAN communica-
information tion line).
using multimeter.
• The AdBlue/DEF tank sensor is composed of the AdBlue/DEF level sensor, AdBlue/DEF
temperature sensor, and AdBlue/DEF quality sensor and provides CAN communication
with the engine controller integrated into one sensor controller.

1
connector
sistance is 60 Ω
, there is no open circuit.
Open circuit and short
circuit in wiring harness 2. Check that system operating lamp does not light up, and then turn battery
2 disconnect switch to OFF position.
communication line) 3. Disconnect connectors ECM J2 and P63 and connect T-adapters to each
female side.
Approxi-
Between P63 (female) (2) and (1)
mately 60 Ω
Resistance
Approxi-
mately 60 Ω
40-616 PC210LCI-11

• Power line
2. Disconnect connector P63, and connect T-adapter to female side.
ness (wire breakage or Voltage Between P63 (female) (4) and (3) Min. 22 V
3 defective contact of con- If no failure is found by above results, this check is not required.
nector) (broken power 1. Turn starting switch to OFF position.
line)
2. Disconnect connectors R52 and P63 and connect T-adapters to each fe-
male side.
Between R52 (female) (11) and P63 (female) (4) Max. 10 Ω
Resistance
quired.
Disconnect connectors ECM J2, P63, K10, and K11 and connect T-adapt-
nector) (broken commu- Between ECM J2 (female) (21) and P63 (female) (2) Max. 10 Ω
nication line)
Between K10 (female) (A) and P63 (female) (2) Max. 10 Ω
Resistance
Between K10 (female) (B) and P63 (female) (1) Max. 10 Ω
Between K11 (female) (A) and P63 (female) (2) Max. 10 Ω
Between K11 (female) (B) and P63 (female) (1) Max. 10 Ω
ground circuit)
Min.100 kΩ
Resistance
Min.100 kΩ
PC210LCI-11 40-617

harness
1 to 4 V
Voltage
1 to 4 V
2. Replace AdBlue/DEF tank sensor (P63).
tank sensor
8
40-618 PC210LCI-11
PC210LCI-11 40-619

Action level Failure code SCR NH3 Sensor Circuit Error
Failure
Detail of fail-
Ammonia sensor controller detected an ammonia sensor circuit error.
ure
Action of • Uses AdBlue/DEF injection control without using the ammonia sensor.
controller • Advances to Inducement strategy. (EU Specification).
Phenomenon
on machine
• Engine output is reduced based on inducement strategy. (EU Specification).
k SCR assembly, the sensor installation piping, and the sensor probe become hot (400 °C).
Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the ambi-
ent temperature is not high.
• If the ammonia sensor controller detects a circuit error of the ammonia sensor, the error is
sent to the engine controller via CAN communication, and this failure code is displayed.
• This failure code is displayed when a connector at the sensor probe is removed during the
machine operation. In this case, failure code [CA3935] is displayed when setting the start-
ing switch to ON position.
• If the exhaust temperature is 150 °C or below, this sensor does not detect any value (The
sensor does not work by only setting the starting switch to ON position even if the sensor
is normal).
Related
• On the “Pre-defined Monitoring” screen troubleshooting for the engine operation state are
information used (the figures below denote monitoring codes).
Engine operation state troubleshooting
01002 Engine Speed
19200 Exhaust Gas Flow Rate
NOTICE
agnostics Operation To Confirm Failure Correction” to make sure that the failure code is
cleared.

1
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code persists after the above checks, the sensor may be defective.
Defective ammonia sen- 2. Replace the ammonia sensor.
2
sor
If the failure code is cleared, the original ammonia sensor may be defective.
40-620 PC210LCI-11

1. Perform the above checks and “Loaded Diagnostics Operation To Confirm
Failure Correction”.
2. If this failure code is displayed in above diagnosis, replace an ammonia sensor
Defective ammonia sen- controller.
3
sor controller
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
4

3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.
PC210LCI-11 40-621

Action level Failure code SCR NH3 Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller does not receive ammonia sensor data due to a communication error with the
ure ammonia sensor.
Phenomenon tion works inappropriately.
• Ammonia concentration is undetectable.
• The ammonia sensor is separated from the sensor controller and communicated via CAN
with the engine controller along with other sensors.
• This failure code is displayed if the sensor controller's connector or a smart sensor (power
Related supply) relay connector is disconnected.
information • CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system,
or a ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
using multimeter.

1
connector
2
communication line) 3. Disconnect connectors ECM J2 and E32 and connect T-adapters to each
female side.
Approxi-
mately 60 Ω
Resistance
Approxi-
mately 60 Ω
40-622 PC210LCI-11

Resistance
If failure code (no open circuit) is still displayed after above checks in cause 2, this
check is not required.
nication line)
Resistance
ground circuit)
Min.100 kΩ
Resistance
Min.100 kΩ
harness
1 to 4 V
Voltage
1 to 4 V
PC210LCI-11 40-623

2. Replace the ammonia sensor (E32).
sor
8
40-624 PC210LCI-11
PC210LCI-11 40-625

Action level Failure code SCR NH3 Sensor Heater Warming up Error
Failure
Detail of fail-
Temperature control of the ammonia sensor is not working correctly.
ure
controller • Advances to Inducement strategy (EU Specification).
Phenomenon
on machine
• Engine output is reduced based on inducement strategy (EU Specification).
(min. 400 °C). Be careful not to get burned.
• On the Pre-defined Monitoring screen troubleshooting for the engine operation state is
used (the figures below denote monitoring codes).
Related Engine operation state troubleshooting

information 01002 Engine Speed
NOTICE
cleared.

Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3932], [CA3933], [CA3934], [CA3935] or
sor system [CA3936] is displayed, perform troubleshooting for these failure codes first.
heater)
2
3
sor
40-626 PC210LCI-11

2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
4
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
tive.
5

REMARK
PC210LCI-11 40-627

Action level Failure code SCR NH3 Sensor Heater Voltage High Error
Failure
Detail of fail-
The ammonia sensor controller is determined as having excessive heater control voltage.
ure
Phenomenon
on machine
k SCR Ass'y, the sensor installation piping, and the sensor probe become hot (Min.
Related • Engine operation state troubleshooting

NOTICE
cleared.

1
2
sor
3
tive.
40-628 PC210LCI-11

4

REMARK
PC210LCI-11 40-629

Action level Failure code SCR NH3 Sensor Heater Voltage Low Error
Failure
Detail of fail-
The ammonia sensor controller is determined as having heater control under-voltage.
ure
Phenomenon
on machine

NOTICE
cleared.

1
2
sor
3
tive.
40-630 PC210LCI-11

4

REMARK
PC210LCI-11 40-631

Action level Failure code SCR NH3 Sensor Power Interrupt Error
Failure
Detail of fail-
A momentary power failure is detected in the ammonia sensor.
ure
Phenomenon
on machine
• Momentary power failure is mostly caused by defective contact. Perform visual check a
torn harness coating.
• To detect an incomplete wire breakage, sway the wiring harness as much as possible at
the resistance measurement to check if the resistance can change or not.
• If the exhaust temperature is 150 °C or below, this sensor does not detect any value (The
sensor does not work by only setting the starting switch to ON position even if the sensor
is normal).
Related • On the “Pre-defined Monitoring” screen troubleshooting for the engine operation state are
information used (the figures below denote monitoring codes).
01002 Engine Speed
NOTICE
cleared.

Defective sensor power Perform troubleshooting for failure code [CA1776].
1
supply relay system
Defective sensor power 3. Insert T-adapter into connector R52.
2 supply relay (defective in- 4.
Disconnect connector E32.
ternal circuit)
Voltage Between R52 (7) and (4) Min. 22 V
40-632 PC210LCI-11

Open circuit in wiring har- 2. Disconnect connector E32, and connect T-adapter to female side.
3
ness 3. Turn starting switch to ON position.
1. Perform the above checks and “Loaded Diagnostics Operation To Confirm
Failure Correction”.
2. If this failure code is displayed in above diagnosis, replace an ammonia sensor
Defective ammonia sen- controller.
4
sor controller
tive.
1. If the failure code persists after the above checks, replace the engine con-
troller.
5 2.
ler Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code disappeared, the engine controller may be defective.
1. If the failure code persists after the above checks, replace the engine harness.
6 Defective engine harness 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the engine harness may be defective.

REMARK
PC210LCI-11 40-633
CIRCUIT DIAGRAM (AMMONIA SENSOR)
40-634 PC210LCI-11

Action level Failure code SCR NH3 Sensor Trim Resistance Error
Failure
Detail of fail-
The ammonia sensor controller fails to catch a resistance value of the trim attached to the probe.
ure
Phenomenon
on machine
• This failure code is displayed if the sensor connector is disconnected when setting the
Related
information
01002 Engine Speed
NOTICE
cleared.

1
2
sor
PC210LCI-11 40-635

3
tive.
4

REMARK
40-636 PC210LCI-11

Action level Failure code SCR NH3 Sensor Internal Circuit Error
Failure
Detail of fail-
The ammonia sensor controller fails.
ure
Phenomenon
on machine
• Internal failure of the sensor controller itself
NOTICE
cleared.

1
2
tive.
3

PC210LCI-11 40-637
REMARK
40-638 PC210LCI-11

Action level Failure code KDOC and KDPF Temperature Sensor Datalink Timeout Error
Failure
• The engine controller does not receive data from KDOC inlet temperature sensor, KDOC
outlet temperature sensor, and KDPF outlet temperature sensor due to a communication
Detail of fail- error with KDPF temperature sensor.
ure • This occurs when information on the KDOC inlet temperature sensor, the KDOC outlet
temperature sensor, and the KDPF outlet temperature sensor cannot be received for a
certain amount of time.
• Run the engine by using the default value of the KDOC inlet temperature, KDOC outlet
temperature, and the KDPF outlet temperature (250 °C).
Action of • AdBlue/DEF injection stops
• Defective forcible regeneration control.
Phenomenon • KDPF Soot Accumulation High.
on machine • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detec-
tion error.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over
500 °C.
k The turbocharger outlet, the sensor installation piping, KDPF, and KDOC become hot
Related
information
using multimeter.
code is cleared).
PC210LCI-11 40-639

1
connector
2
communication line)
female side.
Approxi-
mately 60 Ω
Resistance
Approxi-
mately 60 Ω
• Power line
ness (wire breakage or Voltage Between E26 (female) (4) and (1) Min. 22 V
line)
male side.
Resistance
quired.
nication line)
Resistance
40-640 PC210LCI-11

ground circuit)
Min.100 kΩ
Resistance
Min.100 kΩ
harness
1 to 4 V
Voltage
1 to 4 V
Defective KDPF temper-
ature sensor
8
PC210LCI-11 40-641
40-642 PC210LCI-11

Action level Failure code SCR Temperature Sensor Datalink Timeout Error
Failure
Detail of fail- The engine controller does not receive SCR temperature sensor data due to a communication error
ure with the SCR temperature sensor.
• Stops AdBlue/DEF injection.
Action of • Runs the SCR temperature sensor and the SCR outlet temperature sensor using the last
controller normal values.
Phenomenon
on machine
• SCR temperature and SCR outlet temperature detection error.
k SCR assembly, the sensor installation piping, and the sensor probe become hot (Min.
Related line) can be suspected.
information • Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• For replacement of the SCR temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“Remove and install SCR temperature sensor”.

1
connector
2
communication line) 3. Disconnect connectors ECM J2 and E34 and connect T-adapters to each
female side.
Approxi-
mately 60 Ω
Resistance
Approxi-
mately 60 Ω
PC210LCI-11 40-643

• Power line
ness (wire breakage or Voltage Between E34 (female) (4) and (1) Min. 22 V
line)
male side.
Resistance
quired.
nication line)
Resistance
ground circuit)
Min.100 kΩ
Resistance
Min.100 kΩ
40-644 PC210LCI-11

harness
1 to 4 V
Voltage
1 to 4 V
2. Replace SCR temperature sensor (E34).
ture sensor
8
PC210LCI-11 40-645
40-646 PC210LCI-11

Action level Failure code AdBlue/DEF Pump Heater Relay Voltage High Error
Failure
Detail of fail-
A high voltage error is detected in AdBlue/DEF pump heater relay circuit.
ure
Action of
controller
Phenomenon
• AdBlue/DEF thawing defective.
on machine
• NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• Connectors of electrical parts around engine may be defective due to heat and vibration.
See descriptions of wiring harness and connectors in “Electrical equipment” in “CHECKS
BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON TROUBLESHOOT-
ING”, and check them.
• AdBlue/DEF pump heater relay is driven at AdBlue/DEF supply system thawing/thermal
insulation or an AdBlue/DEF pump heater relay test.
Related • AdBlue/DEF pump heater relay is integrated in the AdBlue/DEF heater relay.
information • Troubleshooting of this failure code covers circuits from engine controller through
AdBlue/DEF heater relay to ground.
• This failure code is detected only when the AdBlue/DEF pump heater relay is turned OFF.
• This failure code is displayed if the connector is removed.

Defective wiring harness 2. See “service modes” of “setting and operating machine monitor”, “operating
1
connector method of testing menu (SCR service test)” to perform an “AdBlue/DEF pump
heater relay test”.
1.Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J2, R53A and MB02, and connect T-adapters to
2
nector) Between R53A (female) (12) and ground Max. 10 Ω
Resistance
Hot short circuit in wiring 2. Disconnect connector R53A, and connect T-adapter to female side.
3
Voltage Between R53A (female) (3) and (12) Max. 4.5 V
PC210LCI-11 40-647

4 relay.
heater relay
5
40-648 PC210LCI-11
Electrical circuit diagram related to AdBlue/DEF heater relay
PC210LCI-11 40-649

Action level Failure code AdBlue/DEF Pump Heater Relay Voltage Low Error
Failure
Detail of fail-
A low voltage error is detected in AdBlue/DEF pump heater relay circuit.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF thawing defective.
• AdBlue/DEF pump heater relay is driven at AdBlue/DEF supply system thawing/thermal
insulation or “a AdBlue/DEF pump heater relay test”.
• AdBlue/DEF pump heater relay is integrated in the AdBlue/DEF heater relay.
Related AdBlue/DEF heater relay to ground.
information • This failure code is detected only when the AdBlue/DEF pump heater relay is turned ON.
Procedure: Start the engine in low temperature (ambient temperature of 5 °C or below) or
see “service modes” of “setting and operating machine monitor”, and “explanation of oper-
ating method of testing menu (SCR service test)” to perform “AdBlue/DEF pump heater re-
lay test”.

Defective wiring harness 2. See “service modes” of “setting and operating machine monitor”, “operating
1
connector method of testing menu (SCR service test)” to perform an “AdBlue/DEF pump
heater relay test”.
Open circuit in wiring har- 2. Disconnect connectors ECM J2, R53A and MB02, and connect T-adapters to
3
nector) Between R53A (female) (12) and ground Max. 10 Ω
Resistance
2. Disconnect connectors ECM J2, and R53A, and connect T-adapter to any of
harness
4 female sides.
(Contact with ground cir-
cuit) Between ECM J2 (female) (83) and ground, or be-
tween R53A (female) (3) and ground
40-650 PC210LCI-11

5 relay.
heater relay
6
PC210LCI-11 40-651
Electrical circuit diagram related to AdBlue/DEF heater relay
40-652 PC210LCI-11

Action level Failure code AdBlue/DEF FCV Malfunction
Failure
Detail of fail-
A FCV (valve for purge) valve inside the AdBlue/DEF pump may be defective.
ure
Action of
AdBlue/DEF intake is inhibited.
controller
Phenomenon
Pump may break when it is frozen and it may result in failure of AdBlue/DEF injection.
on machine
• The engine controller does not display this failure code when controlling thawing of the
AdBlue/DEF supply system (because AdBlue/DEF injection is disabled and no judgment
cannot be made).
• 3 minutes after engine started, make sure that the value of the following 4 state is other
than 1 (Thawing). (This failure cannot be repaired until thawing control is complete.)
• State of each heater is either 1: Thawing 2: Heating 3 or 0: OFF. (Check the value by en-
tering a figure directly on the monitoring code screen).
19306 AdBlue/DEF intake return line heater state
19309 AdBlue/DEF Pump Heater State
• The Pre-defined Monitoring screen troubleshooting for AdBlue/DEF pump and aftertreat-
ment system are used (the figures below denote monitoring codes).
• Troubleshooting for AdBlue/DEF pump
19304 AdBlue/DEF Pump State
Related
information
19109 AdBlue/DEF Pump PressSensor Volt
• Aftertreatment system
47000 KDPF outlet differential pressure
47200 KDPF outlet temperature 1
47300 KDOC inlet temperature 1
47400 KDOC outlet temperature 1
19305 Dosing Fuel Pressure
NOTICE
After inspecting cause of failure and performing repair, perform “Loaded Diagnostics Opera-
tion To Clear Failure Code”, and check that this failure code is canceled. (Display of this fail-
ure code is not canceled by simply turning starting switch to ON position)

If failure code [CA2976] or [CA3558] or [CA3559] or [CA3571] or [CA3572] or
1 [CA3577] or [CA3578] is displayed on the abnormality record screen, perform trou-
pump system
bleshooting these first.
2
pump
PC210LCI-11 40-653

3

3. See “TESTING AND ADJUSTING”, “Service mode” and “Diagnostic Tests menu (Active Regeneration for
Service)” in “SETTING AND OPERATION OF MACHINE MONITOR” to perform “Manual Stationary Regen-
eration”.
4. Check monitoring code 47200 “KDPF 1 Outlet Temperature” exceeds 300 °C and monitoring code 19108
“AdBlue/DEF Pump Pressure” is 900 ± 100 kPa on “Pre-defined Monitoring” screen.
REMARK
For judgment criteria of this troubleshooting, it is necessary for KDPF outlet temperature to be 300 °C or
more in step 7. So raise exhaust temperature by using manual stationary regeneration.
5. Stop “Manual Stationary Regeneration”.
6. Turn the starting switch to OFF position while the KDPF outlet temperature is 300 °C or more and stop the
engine.
REMARK
If the KDPF outlet temperature is 400 °C or more, do not stop the engine to protect devices.
7. Shut down the engine controller, and turn the starting switch to ON position.
REMARK
40-654 PC210LCI-11

Action level Failure code KDOC and KDPF Temperature Sensor Internal Circuit Error
Failure
Detail of fail- An abnormality was detected in any of the sensor circuits: KDOC inlet temperature sensor, KDOC
ure outlet temperature sensor, and KDPF outlet temperature sensor.
• Operate with the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature set to the default value (250 °C).
on machine • Any of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
ture cannot be detected.
• The KDPF temperature sensor is composed of the KDOC inlet temperature sensor, the
KDOC outlet temperature sensor, and the KDPF outlet temperature sensor and provides
CAN communication with the engine controller integrated into one sensor controller.
Related • For the replacement procedure of the KDPF temperature sensor, see “DISASSEMBLY
AND ASSEMBLY”, “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
information
code is cleared).

1
connector
ature sensor
3
PC210LCI-11 40-655

Action level Failure code SCR Temperature Sensor Internal Circuit Error
Failure
Detail of fail- An abnormality is detected in either of the sensor circuits: SCR temperature sensor and SCR outlet
ure temperature sensor.
• The SCR temperature sensor and SCR outlet temperature sensor operate at the latest
Action of normal value.
• Defective detection of SCR temperature or SCR outlet temperature
Phenomenon
on machine
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
Related sensor controller which provides CAN communication with the engine controller.
information • For the replacement procedure of the SCR temperature sensor, see “Disassembly and as-

1
connector
whole assembly.)
3
40-656 PC210LCI-11

Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage High Error
Failure
Detail of fail-
A battery high voltage error is detected in the KDPF temperature sensor controller.
ure
• Run the engine by using the fixed value of the KDOC inlet temperature, KDOC outlet tem-
perature, and the KDPF outlet temperature (250 °C).
Phenomenon • KDPF accumulated soot level is high.
on machine • All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
Related • For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
information
code is cleared).

1
connector
2. Check that system operating lamp is not illuminated, and then turn the battery
3. Disconnect connector R52, and connect T-adapter to female side.
2 High battery voltage
Between R52 (female) (1) and (4) 22 to 30 V
Voltage Between R52 (female) (2) and (4) 22 to 30 V
PC210LCI-11 40-657

ature sensor
4
40-658 PC210LCI-11
Circuit diagram related to KDOC/KDPF temperature sensor
PC210LCI-11 40-659

Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage Low Error
Failure
Detail of fail-
A battery low voltage error is detected in the KDPF temperature sensor controller.
ure
• Run the engine by using the fixed value of the KDOC inlet temperature, KDOC outlet tem-
perature, and the KDPF outlet temperature (250 °C).
on machine • All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
Related
information
code is cleared).

1
connector
ature sensor
40-660 PC210LCI-11

4
PC210LCI-11 40-661
Circuit diagram related to KDOC/KDPF temperature sensor
40-662 PC210LCI-11

Action level Failure code KDOC and KDPF Temperature Sensor ECU Over Temperature Error
Failure
Detail of fail-
KDOC/KDPF temperature sensor controller temperature high error
ure
Action of
None in particular
controller
• Defective forcible regeneration control
Phenomenon
• All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
on machine
• For replacement of the KDPF temperature sensor, see Disassembly and assembly, “Dis-
Related assembly and assembly of KDPF assembly”.
information NOTICE
ing switch)

Exhaust gas leakage Check if the temperature sensor controller environmental temperature is extraordi-
1 (high environmental tem- nary high (150 °C or above).
perature)
ature sensor
3

REMARK
troubleshooting.
PC210LCI-11 40-663

Action level Failure code SCR Temperature Sensor ECU Voltage High Error
Failure
Detail of fail-
High voltage error is detected in power supply voltage of SCR temperature sensor controller.
ure
• The SCR temperature and SCR outlet temperature are the latest normal value for opera-
Action of tion.
• Defective detection of SCR temperature and SCR outlet temperature.
Phenomenon
on machine
information • For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.

1
connector
whole assembly.)
4
40-664 PC210LCI-11
Electrical circuit diagram related to SCR temperature sensor
PC210LCI-11 40-665

Action level Failure code SCR Temperature Sensor ECU Voltage Low Error
Failure
Detail of fail-
Low voltage error is detected in power supply voltage of SCR temperature sensor controller.
ure
• The SCR temperature and SCR outlet temperature are the latest normal value for opera-
Action of tion.
• Defective detection of SCR temperature and SCR outlet temperature.
Phenomenon
on machine
information • For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.

1
connector
2 Low battery voltage
whole assembly.)
4
40-666 PC210LCI-11
PC210LCI-11 40-667

Action level Failure code SCR Temperature Sensor ECU High Temperature Error
Failure
Detail of fail- High temperature error is detected in SCR temperature sensor controller.
ure (Min. 150 °C)
Action of
None in particular
controller
Phenomenon
• Defective detection of SCR temperature and SCR outlet temperature
on machine
• For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
Related ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.
information NOTICE
ing switch)

Exhaust gas leakage Check if the temperature sensor controller environmental temperature is extraordi-
1 (high environmental tem- nary high (150 °C or above).
perature)
whole assembly.)
3

REMARK
troubleshooting.
40-668 PC210LCI-11

Action level Failure code AdBlue/DEF Pump Heater ON Stuck Error
Failure
Detail of fail- • A pump drive in AdBlue/DEF heater relay is working unnecessarily.

ure • AdBlue/DEF heater relay (pump heater relay) may be defective.
Action of
None in particular
controller
Phenomenon
AdBlue/DEF pump is defective.
on machine
• This failure code may be displayed when there is a hot heat source around the
AdBlue/DEF pump.
• If the initial temperature of 19136 AdBlue/DEF Pump Temperature is found to exceed
42 °C from this troubleshooting, the “Loaded Diagnostics Operation To Confirm Failure
Correctionis” not available repair result cannot be judged.
• When it is not in normal low temperature, 19309 AdBlue/DEF Pump Heater State stays as
“0”. (1: Thawing 2: Heating 3 or 0: OFF)
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF pump thawing con-
trol is used (the figures below denote monitoring codes).
• Troubleshooting for AdBlue/DEF pump thawing control
Related 19107 AdBlue/DEF Pump Heater Control Command
information 19309 AdBlue/DEF Pump Heater State
03203 Battery Power Supply
NOTICE
pair.)

Defective AdBlue/DEF Perform troubleshooting for failure code [CA3558] or [CA3559] or [CA2976].
1
pump system
Defective AdBlue/DEF Perform troubleshooting for failure codes [CA4155] and [CA4156].
2 pump heater relay sys-
tem
Check for ambient temperature of 5 °C or above (condition under which
AdBlue/DEF pump heater is not working).
3 2. Disconnect connector MB02, and connect T-adapter to female side.
harness
Voltage Between MB02 (female) (5) and (6) Max. 1 V
4
PC210LCI-11 40-669

1. Turn the starting switch to ON position (Do not start the engine).
2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 42 °C or less and 19107“AdBlue/DEF
Pump Heater 1 Command” is “0” on the “Pre-defined Monitoring” screen.
3. Wait for 10 minutes.
4. If the AdBlue/DEF Pump Temperature rises 12 °C or less after the starting switch is turned to ON, repair will
be completed.
5. After the repair is completed, see “PROCEDURE FOR TESTING AND TROUBLESHOOTING” to clear the
failure code and make sure that the failure code has been cleared from the Abnormality Record screen.
REMARK
If the increase of “AdBlue/DEF Pump Temperature” is 12 °C or more after the starting switch is turned to ON,
40-670 PC210LCI-11
Electrical circuit diagram related to AdBlue/DEF pump heater
PC210LCI-11 40-671

Action level Failure code AdBlue/DEF Pump Heater OFF Stuck Error
Failure
Detail of fail-
AdBlue/DEF pump thawing is not complete.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF pump thawing con-
trol is used.
• 19309 “AdBlue/DEF Pump Heater State”, 1: Thawing 2: Heating 3 or 0: OFF
(the figures below denote monitoring codes).
Troubleshooting for AdBlue/DEF pump thawing control
19107 AdBlue/DEF Pump Heater Control Command
Related 03203 Battery Power Supply
information NOTICE
agnostics Operation To Confirm Failure Correction” to check if the repair is completed.
(Clearing the failure code does not determine the completion of repair.)
(This failure code is not cleared by starting switch at ON position or “AdBlue/DEF pump
heater relay drive test” only.)
• If “AdBlue/DEF pump temperature ” is 45 °C or higher when starting switch is turned
to ON position, “Loaded Diagnostics Operation To Confirm Failure Correction” can-
not determine if the repair is completed successfully, therefore, wait until
“AdBlue/DEF pump temperature” becomes 45 °C or lower.
• In addition, if “AdBlue/DEF pump temperature ” is 55 °C or higher, “AdBlue/DEF
pump heater relay drive test” in “Loaded Diagnostics Operation To Confirm Failure
Correction” is disabled.

1
pump system
tem
Defective AdBlue/DEF 2. If the AdBlue/DEF pump temperature does not rise by at least 5 °C during
3
pump heater the test, replace the AdBlue/DEF pump.
4
40-672 PC210LCI-11

2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 45 °C or below (If not, wait until moni-
toring code 19136 “AdBlue/DEF Pump Temperature” falls down to below 45 °C).
3. See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in “SET-
TING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF Pump Heater Relay Test”.
4. When the increase of monitoring code 19136“AdBlue/DEF Pump Temperature” is 5 °C or more from the
start of testing within 30 minutes, repair is completed.
screen.
REMARK
When the increase of “AdBlue/DEF Pump Temperature is not ” 5 °C or more from the start of testing after 30
minutes, return to troubleshooting.
PC210LCI-11 40-673

Action level Failure code AdBlue/DEF Pump Thawing Error
Failure
Detail of fail-
AdBlue/DEF pump thawing is not complete.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed.
• 19309 AdBlue/DEF Pump Heater State, 1: Thawing 2: Heating 3 or 0: OFF
Related NOTICE
information After investigating the cause of the problem and completing the repair, perform “Loaded Di-
• If “AdBlue/DEF pump temperature ” is 45 °C or higher when starting switch is turned
• In addition, if “AdBlue/DEF pump temperature” is 55 °C or higher, “AdBlue/DEF

1
pump system
tem
Open or short circuit in 2. Disconnect connector R53A, and connect T-adapter to female side.
4
wiring harness
40-674 PC210LCI-11

5
pump heater the test, replace the AdBlue/DEF pump.
6

screen.
REMARK
PC210LCI-11 40-675
Electrical circuit diagram related to AdBlue/DEF pump heater
40-676 PC210LCI-11

Action level Failure code AdBlue/DEF Pump Temperature Sensor 1 In Range Error
Failure
Detail of fail-
AdBlue/DEF pump temperature sensor 1 response is poor.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed.
Related NOTICE
• If “AdBlue/DEF pump temperature” is 45 °C or higher when starting switch is turned

1
pump system
tem
3 pump temperature sen-
the test, replace the AdBlue/DEF pump.
sor
4

PC210LCI-11 40-677
screen.
REMARK
40-678 PC210LCI-11

Action level Failure code AdBlue/DEF Pump Temperature Sensor 2 In Range Error
Failure
Detail of fail-
AdBlue/DEF pump temperature sensor 2 response is poor.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed
Related NOTICE
• If “AdBlue/DEF pump temperature” is 45 °C or higher when starting switch is turned

1
pump system
tem
3 pump temperature sen-
the test, replace the AdBlue/DEF pump.
sor
4

PC210LCI-11 40-679

3. See "TESTING AND ADJUSTING", “Special functions of machine monitor”, “Testing”, “SCR Service Test” to
perform “AdBlue/DEF pump heater relay drive test”.
4. Continue the test approximately for 15 minutes.
5. When on the screen displaying "Test State", Test State parameter “10” and “12” are blinking alternately, re-
pair is completed.
screen.
REMARK
If Test State does not change to “12”, return to troubleshooting.
40-680 PC210LCI-11

Action level Failure code KDOC and KDPF Temperature Sensor Power Interrupt Error
Failure
Detail of fail- KDPF temperature sensor interrupt power failure error (12 open circuits are detected in the power
ure supply line in 60 seconds.)
Normal control
• Default value of the KDOC inlet temperature, KDOC outlet temperature, and the KDPF
outlet temperature (250 °C).
Action of
controller
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detec-
tion error.
Phenomenon • Defective regeneration control.
on machine • NOx emission increases because AdBlue/DEF injection is disabled.
• KDPF accumulated soot level is high.
• Mostly, momentary power failure is caused by defective contact and visually check a torn
harness coating and check for defective contact at the connector.
the resistance measurement to check if the resistance can change or not.
Related • Note that sensor power supply relay connector is energized even if starting switch is
information turned to OFF position.
• For replacement of the KDPF temperature sensor, see Disassembly and assembly, “Dis-
assembly and assembly of KDPF assembly”.
Procedure: Start engine and travel (vibrate the machine).
code is cleared).

1
supply relay system
PC210LCI-11 40-681

2. Check that system operating lamp does not light up, and then turn battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector R52.
2 4. Disconnect connector E26.
supply relay
3
Defective KDPF temper- If failure code is still displayed after above checks, KDPF temperature sensor may
4 ature sensor (defective be defective. (In case of an internal defect, troubleshooting is impossible as an as-
internal circuit) sembly. Replace whole assembly.)
5
If there is no abnormality in above diagnosis, defective contact of harness is a pos-
6 Defective wiring harness
sibility (Replace harness).
40-682 PC210LCI-11
Circuit diagram related to KDPF temperature sensor
PC210LCI-11 40-683

Action level Failure code SCR Temperature Sensor Power Interrupt Error
Failure
Detail of fail- Interrupted power failure error in SCR temperature sensor is detected. (12 open circuits are detect-
ure ed in the power supply line in 60 seconds.)
• Holds the SCR temperature and the SCR outlet temperature using the last normal values.
Action of
controller
• SCR temperature and SCR outlet temperature have detection errors.
Phenomenon
on machine
• Mostly, momentary power failure is caused by defective contact and visually check a torn
harness coating and check for defective contact at the connector.
Related the resistance measurement to check if the resistance can change or not.
information • The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
• Note that smart sensor relay connector is energized even if starting switch is turned to
OFF position.
• For replacement of the SCR outlet temperature sensor, see Disassembly and assembly,
“Removal and installation of SCR temperature sensor”.
Procedure: Start engine and travel (vibrate the machine).

1
supply relay system
2. Check that system operating lamp does not light up, and then turn battery dis-
Defective sensor power 3. Insert T-adapter into connector R52.
2 supply relay (defective in- 4. Disconnect connector E34.
ternal circuit)
3
Defective SCR tempera- If failure code is still displayed after above checks, SCR temperature sensor may
4 ture sensor (internal de- be defective. (In case of an internal defect, troubleshooting is impossible as an as-
fect) sembly. Replace whole assembly.)
40-684 PC210LCI-11

5
If the failure code persists even after replacing the engine controller, defective con-
6 Defective wiring harness
tact of harness is a possibility (Replace harness).
PC210LCI-11 40-685
40-686 PC210LCI-11

Action level Failure code AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error
Failure
Detail of fail-
AdBlue/DEF sensor stays in disabling to measure the sensor quality.
ure
Action of
None in particular
controller
Phenomenon
Quality of AdBlue/DEF cannot be measured.
on machine
• AdBlue/DEF quality sensor is one of AdBlue/DEF tank sensors and is integrated with
AdBlue/DEF level sensor and AdBlue/DEF temperature sensor, providing CAN communi-
• When the AdBlue/DEF quality sensor cannot recognize liquid, AdBlue/DEF concentration
on the monitor shows the last value.
• Make sure that AdBlue/DEF tank temperature is 0 °C or above on the “Pre-defined Moni-
code).
• Make sure that AdBlue/DEF tank temperature is 20 % or above on the “Pre-defined Moni-
• For draining and cleaning procedures of AdBlue/DEF tank, see Testing and adjusting,
Related “AdBlue/DEF Tank Washing”.
information • For the replacement procedure of AdBlue/DEF/level sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF/level sensor”.
NOTICE
PC210LCI-11 40-687

1 these first.
tank sensor system
1. Check that the value of AdBlue/DEF level is displayed correctly with moni-
toring function.
REMARK
If AdBlue/DEF is empty and AdBlue/DEF level sensor cannot be sensed, 7 %
is displayed as the AdBlue/DEF level (compensation value).
2 Low AdBlue/DEF amount
2. When AdBlue/DEF is empty, refill AdBlue/DEF.
3. After finishing the work, perform “Loaded Diagnostics Operation To Clear
Failure Code” and the repair is completed.
4. If this failure code is displayed even if AdBlue/DEF level is displayed cor-
rectly, proceed to the next troubleshooting.
3
AdBlue/DEF tank.
REMARK
fect)
40-688 PC210LCI-11

Defective engine control- 2.
6 Perform “Loaded Diagnostics Operation To Clear Failure Code”.
ler
3. If this failure code is displayed, perform troubleshooting again.

3. Wait for 30 minutes. (It is not necessary to start the engine.)
PC210LCI-11 40-689

Action level Failure code SCR NH3 Sensor Stuck Response Error
Failure
Detail of fail-
Ammonia concentration in ammonia sensor changes slow.
ure
Action of
Uses AdBlue/DEF injection control without using the ammonia sensor.
controller
(min. 400 °C). Be careful not to get burned.
• This failure code is displayed when ammonia sensor value cannot be detected; a sensor
probe is not attached to the exhaust pipe.
• This failure occurs also when AdBlue/DEF injector is clogged, and when [CA3568] or
[CA3582] or [CA4658] is displayed, repair these codes first.
• If AdBlue/DEF injector is clogged when outside air temperature is -5 °C or below, this error
may appear solely.
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF injector and the en-
gine operation state are used (the figures below denote monitoring codes).
• Troubleshooting for AdBlue/DEF injector
Related 19120 AdBlue/DEF Injection Quantity
information 19205 ammonia concentration (compensation value)
19202 Turbo Outlet NOx Corrected
47200 KDPF Outlet Temperature
• Engine operation state troubleshooting
01002 Engine Speed
NOTICE
(This failure code is not cleared by only turning starting switch to ON position.)

Defective AdBlue/DEF in- If failure code [CA3568] or [CA4658] is displayed, perform troubleshooting for the
1
jector system code first.
2 Defective SCR catalyst If failure code [CA3582] is displayed, perform troubleshooting for the code first.
40-690 PC210LCI-11

Defective ammonia sen- 2. Check if the ammonia sensor probe is correctly installed on SCR catalyst and
3 sor is not loose.
(improper installation) 3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
Low AdBlue/DEF con-
4 2. If the “AdBlue/DEF concentration” is out of the normal range, replace the
centration
AdBlue/DEF in the AdBlue/DEF tank, and perform “Loaded Diagnostics
1. Start engine.
2. When SCR temperature is 200 °C or higher on the Pre-defined Monitoring
screen, check for ammonia concentration.
Clogged AdBlue/DEF in- 1) If ammonia concentration indicates approximately 5 to 150(ppm), perform
5 jector “Loaded Diagnostics Operation To Clear Failure Code” because a clogged
AdBlue/DEF injector failure is cleared. (AdBlue/DEF injector is not clogged
anymore.)
2) If ammonia concentration stays at 0ppm, perform “Testing and adjusting”,
“SPECIAL FUNCTIONS OF MACHINE MONITOR”, “Testing”, “Active Re-
generation for Service”. (Clogged AdBlue/DEF injector)
6
sor
7
tive.
8
outlet NOx sensor
tive.
damaged rectifier)
Defective air intake sys- 1. Check for a defective air intake pipe and repair or replace any damaged or
9
tem defective rectifier, if any.
2. Replace mass air flow (MAF) sensor.
PC210LCI-11 40-691

1. If the failure code persists after the above checks, replace the engine con-
troller.
10 2.
ler Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code disappeared, the engine controller may be defective.

3. Secure a safety condition and keep the engine running for approximately 1 minute at low idle speed.
4. After warm-up operation, set the swing lock to ON, the fuel dial to High idle (MAX) position, and the opera-
tion mode to P.
NOTICE
Make sure that the 19300 “SCR Temperature” is 290 °C or more and the 19202 “Turbo Outlet NOx
Corrected” is 120 ppm or more on the Pre-defined Monitoring screen.
6. Run engine at high idle speed (with no load) for approximately 30 seconds.
NOTICE
Make sure that the 19300 “SCR Temperature” is around 250 °C on the Pre-defined Monitoring
screen.
7. Repeat above steps 5) and 6) up to 20 times.
8. Repeat high idle run under no load for 5 minutes and arm IN relief for 3 minutes, 5 times.
REMARK
• If this failure code is not cleared, return to troubleshooting.
40-692 PC210LCI-11

Action level Failure code AdBlue/DEF line heater relay 2 voltage high error
Failure
Detail of fail-
High voltage error occurs in AdBlue/DEF line heater relay 2 circuit.
ure
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing
• AdBlue/DEF line heater relay 2 is driven at AdBlue/DEF supply system thawing/thermal in-
sulation or “AdBlue/DEF Line Heater Relay 2 Test”.
• AdBlue/DEF line heater relay 2 is built in AdBlue/DEF heater relay.
AdBlue/DEF heater relay to power supply.
Related
• This failure code is detected only when AdBlue/DEF line heater 2 is turned ON.
information
Procedure: Start the engine in low temperature (engine room temperature is Max. 12 °C)
or perform AdBlue/DEF line heater 2 test.
(See “service modes” of “SET AND OPERATE MACHINE MONITOR”, and “METHOD
FOR OPERATING TESTING MENU (SCR SERVICE TEST)”.)

2. Start the engine in low temperature (engine room temperature of 12 °C or
1 lower) or perform “AdBlue/DEF Line Heater Relay 2 Test”. For details, see
connector
SET AND OPERATE MACHINE MONITOR, “SERVICE MODE” and
“METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)”.
If this failure code is displayed, the wiring harness connector is defective.
2 4. Turn the battery disconnect switch to ON position.
harness
5. Turn the starting switch to ON position (with connector R53A disconnect-
ed).
Voltage Between R53A (female) (11) and (12) Max. 3 V
PC210LCI-11 40-693

relay.
heater relay
5. Perform the “AdBlue/DEF line heater relay 2 test”by staring the engine in
low ambient temperature (12 °C or below), or by referring “SERVICE
MODES” of setting and operating machine monitor, “METHOD FOR OP-
ERATING TESTING MENU (SCR SERVICE TEST)”.
4
40-694 PC210LCI-11
PC210LCI-11 40-695

Action level Failure code AdBlue/DEF line heater relay 2 voltage low error
Failure
Detail of fail-
A low voltage error occurs in AdBlue/DEF line heater relay 2 circuit.
ure
Action of
controller
Phenomenon
on machine
• AdBlue/DEF line heater relay 2 is driven at AdBlue/DEF supply system thawing/thermal in-
sulation or “AdBlue/DEF line heater relay 2 test”.
• AdBlue/DEF line heater relay 2 is integrated in the AdBlue/DEF heater relay.
Related AdBlue/DEF heater relay to power supply.
information • This failure code is detected only when the AdBlue/DEF line heater relay 2 is turned OFF.
• This failure code is displayed if connector R53A is removed when AdBlue/DEF line heater
2 is turned OFF.

2. Start the engine in low temperature (engine room temperature of 12 °C or
1 lower) or perform “AdBlue/DEF Line Heater Relay 2 Test”. For details, see
connector
SET AND OPERATE MACHINE MONITOR, “SERVICE MODE” and
“METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)”.
If this failure code is displayed, the wiring harness connector is defective.
Open circuit in wiring har- 3. Disconnect connector R53B, and connect T-adapter to female side.
3 ness (sensor relay power
supply side)
Voltage Between ground and R53B (female) (1) or (2) Min. 22 V
Open circuit in wiring har- 2. Turn the battery disconnect switch to OFF position.
4 ness (line heater relay
drive signal side) 3. Disconnect connectors ECM J2 and R53A, and connect T-adapters to
each female side.
Resistance Between ECM J2 (female) (7) and R53A (female) (11) Max. 10 Ω
40-696 PC210LCI-11

3. Disconnect connectors ECM J2 and R53A, and connect T-adapter to ei-
ground circuit) ther female side.
Between ground and ECM J2 (female) (7) or R53A (fe-
male) (11)
Short circuit in wiring har- 3. Disconnect connectors ECM J2 and R53A, and connect T-adapter to fe-
6
Continuity
pin (7) ty
7 relay.
heater relay
8
PC210LCI-11 40-697
40-698 PC210LCI-11

Action level Failure code AdBlue/DEF Flow Low Error
Failure
Detail of fail-
Clogged AdBlue/DEF injector and AdBlue/DEF pressure hose
ure
Action of
• None in particular
controller
Phenomenon
on machine
PC210LCI-11 40-699
k The AdBlue/DEF injector becomes hot (Min. 400 °C). Be careful not to get burned.
• This failure code is displayed together with failure codes whose possible cause is clogging
of AdBlue/DEF hose. These are the failure codes to identify the position where failure is
occurring, and they need not to be treated individually.
• If failure codes [CA3151] and [CA3568] appear together and these failure codes alone still
appear after finishing the repair, identify the cause according to the following procedure.
ue/DEF supply system (because the AdBlue/DEF injection is disabled, which disables
judgment).
• Make sure that the value of the following four states are other than 1 (Thawing) 3 minutes
after the engine is started. (It is not possible to troubleshoot this failure until thawing con-
trol is completed)
screen.
Related
• The “Pre-defined Monitoring” screen uses the AdBlue/DEF injector diagnosis and
information AdBlue/DEF pump diagnosis. (The following numbers are the monitoring codes)
19205 AFT NH3 Sensor Corrected
19202 Turbo Outlet NOx Corrected
47200 KDPF Outlet Temperature
19109 AdBlue/DEF Pump PressSensor Volt
NOTICE
(This failure code is not cleared by only turning starting switch to ON position.)

1. Start the engine, run it with low idle.
2. At approximately 2 minutes after the starting of the engine, check that
19108 AdBlue/DEF pump pressure is kept around 900 kPa.
Reset of judgment condi- 3. Check that 19120 AdBlue/DEF Injection Quantity is “0”.
1
tions If it is still injected (the injection quantity is not “0”), wait for the injection to
stop. (It takes Max. 30 minutes to stop AdBlue/DEF. )
4. Wait 3 minutes after AdBlue/DEF Injection Quantity becomes “0”.
40-700 PC210LCI-11

2
Defective AdBlue/DEF in- If failure code [CA3567] is displayed on the abnormality record screen, perform
3
jector system troubleshooting these first.
See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SET-
TING WITH TESTING MENU (SCR SERVICE TEST)” in “SETTING AND OPERA-
TION OF MACHINE MONITOR” to perform “AdBlue/DEF Injector Rate Test”.
Case 1: AdBlue/DEF injection stops
The AdBlue/DEF injector or the AdBlue/DEF pressure hose may be clogged. Pro-
ceed to cause 5 to determine the cause of the failure.
Failure of the Case 2: AdBlue/DEF injection continues for more than 2 seconds without stoppage
4
AdBlue/DEF injector 1. The AdBlue/DEF injector is stuck open. Replace with a new one.
2. To remove the accumulated deposits of AdBlue/DEF in SCR, see “SET-
TING AND OPERATION OF MACHINE MONITOR” of “SERVICE MODE”,
and “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)” to perform “Active Regeneration for Service” for 3 times (Refer-
ence: Approximately 2 hours is required in total (40 minutes per opera-
tion))
3. See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OP-
ERATION OF MACHINE MONITOR”, “METHOD FOR SETTING WITH TEST-
ING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Pump Pres-
sure Up Test”.
4. If AdBlue/DEF flows out from the AdBlue/DEF pressure hose while the AdBl-
Clogged AdBlue/DEF ue/DEF pump pressure does not reach 900 kPa, there is no clogging in the
5
pressure hose AdBlue/DEF pressure hose.
5. The AdBlue/DEF injector is clogged. Replace it.
6. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in the
AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
minutes while performing the “AdBlue/DEF Pump Pressure Up Test”.
If failure code is still displayed after above checks, the AdBlue/DEF injector may
have been temporarily clogged but is now normal.
6 jector
Perform “Loaded Diagnostics Operation To Clear Failure Code”. If this failure code
is cleared, repair is completed.
7

2. Start the engine and warm it up.
3. Make sure monitoring code 19108 “AdBlue/DEF pump pressure” is around 900 kPa.
4. Turn the fuel control dial to MAX position, and run the engine at high idle speed under no load for 30 sec-
onds.
PC210LCI-11 40-701
5. Perform work equipment hydraulic relief operation for continuously 30 seconds or longer with fuel control
dial at MAX position.
6. Repeat above steps 4 and 5 for 20 times.
REMARK
• If this failure code is cleared during or after the operation (no longer displayed), repair work is completed.
• If this failure code is not cleared, return to troubleshooting.
40-702 PC210LCI-11

Action level Failure code AdBlue/DEF Temperature Sensor Transmission Data Error
Failure
Detail of fail-
Temperature data sent by AdBlue/DEF sensor is abnormal.
ure
Action of
Advances to Inducement strategy. (EU Specification).
controller
Phenomenon • AdBlue/DEF temperature cannot be measured.
• AdBlue/DEF level sensor is one of AdBlue/DEF tank sensors and is integrated with AdBl-
ue/DEF temperature sensor and AdBlue/DEF quality sensor, providing CAN communica-
Related tion with the engine controller.
information • This failure code is displayed unless an approved sensor is installed.

1
tank sensor
3
PC210LCI-11 40-703

Action level Failure code AdBlue/DEF Level Sensor Transmission Data Error
Failure
Detail of fail-
Level data sent by AdBlue/DEF sensor is abnormal.
ure
Action of
controller
Phenomenon • AdBlue/DEF level cannot be measured.
Related tion with the engine controller.
information • This failure code is displayed unless an approved sensor is installed.

1
tank sensor
3
40-704 PC210LCI-11

Action level Failure code AdBlue/DEF Level Sensor Internal Circuit Error
Failure
Detail of fail-
AdBlue/DEF level sensor is defective (an error is detected in level measurement circuit)
ure
Action of
controller
Phenomenon • AdBlue/DEF level cannot be measured.
tion with the engine controller.
Related
• This failure code is displayed when the engine controller receives information stating the
information level measurement circuit is abnormal.

1
tank sensor
3
PC210LCI-11 40-705

Action level Failure code Fuel in AdBlue/DEF Tank Error
Failure
Detail of fail-
AdBlue/DEF tank is contaminated with diesel fuel.
ure
• Stops AdBlue/DEF injection.
Action of
• Stops AdBlue/DEF pump.
controller
on machine • Engine power deration.
code).
Related
information “AdBlue/DEF Tank Washing”.
• For the replacement procedure of AdBlue/DEF tank sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF tank sensor”.
code is cleared).
NOTICE

or [CA3868] or [CA4731] or [CA4732] or [CA4768] is displayed, perform
Defective AdBlue/DEF troubleshooting these first.
1
tank sensor system
1. Drain total amount of the AdBlue/DEF to check that it is not contaminated
with diesel fuel. (Drain total amount of the AdBlue/DEF, since diesel fuel is
lighter than urea solution.)
AdBlue/DEF tank is con-
2 taminated with diesel 2. If it is contaminated with diesel fuel, clean AdBlue/DEF tank.
fuel. 3. After refill with the new AdBlue/DEF, perform “Loaded Diagnostics Opera-
tion To Clear Failure Code”.
4. If this failure code is displayed, proceed to the next troubleshooting.
40-706 PC210LCI-11

fect)
Defective engine control- 2.
4 Perform “Loaded Diagnostics Operation To Clear Failure Code”.
ler
3. If this failure code is displayed, perform troubleshooting again.

3. Wait for 10 minutes. (Do not start the engine)
4. After the deactivation of this failure code, diesel fuel may remain, so test and replace the SCR system
(pump, hose, etc.).
PC210LCI-11 40-707

Action level Failure code AdBlue/DEF Level Measurement Impossible
Failure
Detail of fail-
AdBlue/DEF level sensor stays in disabling to measure AdBlue/DEF level.
ure
Action of
controller
• AdBlue/DEF level cannot be measured.
Phenomenon
• AdBlue/DEF level on the monitor changes.
on machine
• Displayed when AdBlue/DEF tank is completely empty.
• Contaminated sensing part or a failure in the sensor can be suspected as a cause other
than empty AdBlue/DEF tank.
• This failure code cannot be cleared if AdBlue/DEF tank temperature is 0 °C or lower.
• On the Pre-defined Monitoring screen troubleshooting for AdBlue/DEF level and quality
sensors is used.
• Troubleshooting for AdBlue/DEF level and quality sensors
Related 19110 AdBlue/DEF Level
information 19111 AdBlue/DEF Level Corrected
NOTICE
agnostics Operation To Clear Failure Code” to make sure that the failure code is
cleared .
40-708 PC210LCI-11

3. If there is no AdBlue/DEF, or AdBlue/DEF level is low.
1) Refill with AdBlue/DEF.
2) Turn starting switch to OFF position.
3) If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code”and repair is
completed.
AdBlue/DEF tank remain- 4) If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
1
ing amount check mains changed even after AdBlue/DEF has been refilled, proceed to cause
2.
4. If AdBlue/DEF level is normal
1) Turn starting switch to OFF position.
2) If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
mains changed even after AdBlue/DEF has been refilled, proceed to cause
2.
3) If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code”and repair is
completed.
1. Turn starting switch OFF, and confirm the following.
1) There is no foreign material such as dirt in AdBlue/DEF tank.
2) There is not a problem in quality and concentration of AdBlue/DEF.
3) There is no foreign material such as dirt attached to AdBlue/DEF sensor.
4) AdBlue/DEF float is not stuck.
2. Repair, or replace to solve if any of these failures are found.
Check inside conditions
2
of AdBlue/DEF tank 3. Turn starting switch to ON position.
4. If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code” and repair
is completed.
5. If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
mains changed even after performing remedy for these, proceed to cause
3.
• Check the sensor connector for contamination and damage.
• Make sure that DEF tank contains 15 % or more of AdBlue/DEF.
Defective AdBlue/DEF 2. Replace the AdBlue/DEF tank sensor.
3
tank sensor
4. If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code” and repair is
completed.
4

PC210LCI-11 40-709

Standby time depends on the initial value of the AdBlue/DEF temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 2 hours after the temperature in tank rises
up to 0 °C or above.
40-710 PC210LCI-11

Action level Failure code AdBlue/DEF High Concentration Error
Failure
Detail of fail-
AdBlue/DEF concentration is high (40 % or higher)
ure
• Advances to Inducement strategy. (EU Specification).
Action of
• Stops AdBlue/DEF injection (EU Specification).
controller
• Stops AdBlue/DEF pump. (EU Specification).
Phenomenon
Engine output is reduced based on inducement strategy. (EU Specification).
on machine
AdBlue/DEF level changes with machine operation on the slop or travel on even ground, possibly
disabling to detect the correct level or concentration.
If AdBlue/DEF level monitor is illuminated in red or a warning on the concentration is displayed,
move to a flat place as soon as possible and refill AdBlue/DEF. If this phenomenon persists, refill
AdBlue/DEF extra in AdBlue/DEF tank.
code).
“AdBlue/DEF Tank Washing”.
Related
information • For the replacement procedure of AdBlue/DEF level sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF level sensor”.
NOTICE
This failure code denotes requires “Loaded Diagnostics Operation To Clear Failure
Code”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Clear Failure Code” to make sure that the failure
code is cleared.
PC210LCI-11 40-711

1 these first.
tank sensor system
High AdBlue/DEF con- ble concentration meter to recheck the concentration. If the concentration
2
centration still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
3
AdBlue/DEF tank.
REMARK
40-712 PC210LCI-11

fect)
6

Standby time depends on the initial value of the AdBlue/DEF temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 2 hours after the temperature in tank rises
up to 0 °C or above.
PC210LCI-11 40-713

Action level Failure code System Operating Lamp Short Circuit (Engine Controller)
Failure
― CA4952 (Engine controller system)
Detail of fail- Engine controller determines that system operating lamp circuit shorts because voltage of output
ure circuit does not become Low level while engine controller outputs current to system operating lamp.
Action of
Stops driving system operating lamp.
controller
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
Related
• Although engine controller is not able to light up system operating lamp, no trouble will re-
information sult unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.

1
2. Remove fuse No. 16 in fuse box F01.
2 3. Disconnect connectors CP02, CK01, CM01, J2, CS03, CW03, CA02 and
ness
L19, and connect T-adapter to female side of connector L19.
Resistance Between L19 (female) (1) and (2) Min. 1 MΩ
Hot short circuit in wiring 2. Disconnect connector L19, and connect T-adapter to female side.
3
harness 3. Turn starting switch to ON position .
Voltage Between L19 (female) (2) and ground Max. 1 V
4
40-714 PC210LCI-11
Circuit diagram related to system operating lamp
PC210LCI-11 40-715

Action level Failure code AdBlue/DEF Line Heater 1 Voltage Low Error
Failure
Detail of fail- A low voltage error occurs in AdBlue/DEF line heater 1 ( low-temperature pressure, intake and re-
ure turn side) signal circuit.
Action of
None in particular
controller
• AdBlue/DEF line heater 1 is driven at AdBlue/DEF supply system thawing/thermal insula-
tion or “AdBlue/DEF line heater relay 1 test”.
• AdBlue/DEF line heater 1 is driven by AdBlue/DEF line heater relay 1 inside AdBlue/DEF
heater relay.
Related • This failure code is detected only when the AdBlue/DEF line heater 1 is turned ON.
Procedure: Start the engine in low temperature (ambient temperature of 5 °C or below) or
see “service modes” of “setting and operating machine monitor”, and “explanation of oper-
ating method of testing menu (SCR service test)” to perform “AdBlue/DEF line heater relay
1 test”.

1
2. Disconnect connectors MB04 and MB06A, and connect T-adapters to
Defective AdBlue/DEF each male side.
2
line heater
Between MB04 (male) (1) and (2) 5 to 40 Ω
Resistance
Between MB06A (male) (1) and (2) 5 to 40 Ω
2. Disconnect connectors ECM J2 and R53A, and connect T-adapter to fe-
3 male side of ECM J2.
ness
Continuity
than pin (39) ty
4 REMARK
side) Internal resistance is possessed by above-mentioned heater relay.
40-716 PC210LCI-11

2. Disconnect connectors ECM J2, R53A, MB04, and MB06A, and connect
T-adapter to either female side.
Ground fault in wiring Between ground and ECM J2 (female) (39) or R53A
Min. 100 kΩ
5 harness (contact with (female) (8)
ground circuit)
MB06A (female) (1) and ground
Min. 100 kΩ
MB04 (female) (1) and ground
Open circuit or short cir- REMARK
6 Resistance value is the internal resistance value of the heater relay mentioned
side) above.
Resistance
relay.
heater relay
5. Perform the “AdBlue/DEF Line Heater Relay 1 Test” by staring the engine
in low ambient temperature (5 °C or below), or by referring “SERVICE
MODE” of setting and operating machine monitor, “METHOD FOR OPER-
ATING TESTING MENU (SCR SERVICE TEST)”.
8
PC210LCI-11 40-717
40-718 PC210LCI-11

Action level Failure code Engine Room Temperature Sensor High Error
Failure
Detail of fail-
A high voltage error occurs in signal circuit of engine room temperature sensor.
ure
Action of
Run the engine by using the default value of the engine room temperature (25 °C).
controller
on machine • NOx emission may increase because AdBlue/DEF line stops thawing.
• This failure code is displayed when the engine room temperature sensor connector is re-
Related moved.

1
REMARK
If a resistance value of the engine room temperature sensor ranges from 280 Ω to
382 kΩ, the engine room temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
Defective engine room 109 kΩ
2
temperature sensor
0 °C 29 to 36 kΩ
7.3 to
Between `P66 (male) (A) 30 °C
Resistance 8.8 kΩ
and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
REMARK
3 Use an engine room temperature sensor resistance characteristics table for
wiring harness
check on cause 2 as a resistance value.
280 Ω to
382 kΩ
PC210LCI-11 40-719

Hot short circuit in wiring 2. Insert T-adapter into connector ECM J2.
4
5
CIRCUIT DIAGRAM (ENGINE ROOM TEMPERATURE SENSOR)
40-720 PC210LCI-11

Action level Failure code Engine room temperature sensor low error
Failure
Detail of fail-
A low voltage error occurs in signal circuit of engine room temperature sensor.
ure
Action of
Run the engine by using the default value of the engine room temperature (25 °C).
controller
on machine • NOx emission may increase because AdBlue/DEF line stops thawing.

1
REMARK
If a resistance value of the engine room temperature sensor ranges from 280 Ω to
382 kΩ, the engine room temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
Defective engine room 0 °C 29 to 36 kΩ
2
temperature sensor
7.3 to
Between `P66 (male) (A) 30 °C
8.8 kΩ
and (B)
Resistance 2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
Between P66 (male) (B)
General Min. 100 kΩ
and ground
REMARK
3 Use an engine room temperature sensor resistance characteristics table for
ness
check on cause 2 as a resistance value.
280 Ω to
382 kΩ
PC210LCI-11 40-721

Ground fault in wiring 2. Disconnect connectors ECM J2 and P66, and connect T-adapter to female
4
harness side of ECM J2.
5
CIRCUIT DIAGRAM (ENGINE ROOM TEMPERATURE SENSOR)
40-722 PC210LCI-11

Action level Failure code Ash Accumulation High Error
Failure
— CA5383 (Engine controller system)
Detail of fail-
Ash accumulation in KDPF is high and ash accumulated in KDPF needs to be cleaned.
ure
Action of
None in particular
controller
Phenomenon
KCSF may be damaged.
on machine
(Code: 47300 (°C))
(Code: 47400 (°C))
(Code: 47200 (°C))
• Ash accumulation in KDPF is high and ash accumulated in KDPF needs to be cleaned.
• As to procedure for accessing KDPF temperature sensor, see “50 Disassembly and as-
sembly”, “Removal and installation of KDPF assembly”.
Related ON position.
information • See Testing and adjusting, “service modes” of “setting and operating machine monitor”
and “setting method of testing menu (ash in soot accumulation correction)” to check ash
accumulation.
• This failure code is displayed when ash accumulation reaches the upper limit of its allowa-
ble amount.
• When the ash accumulation reaches the upper limit, KDPF is experiencing very high pres-
sure loss and ash cleaning is required.
• For resetting KDPF cleaning and KDPF change, see Testing and adjusting, “service
modes” of “setting and operating machine monitor” and “setting method of testing menu
(KDPF memory reset)”.
• This failure code is cleared on the user screen of the machine monitor but is displayed on
“Abnormality Record”screen and in service mode of the machine monitor and KOMTRAX.
NOTICE
• When this failure code is displayed, troubleshoot causes 1 and 2, then make sure to
perform ash cleaning in cause 3.
• After ash cleaning, reset KDPF cleaning and KDPF change.
• Otherwise, KCSF may be damaged.

Defective KDPF differen- If failure code [CA1879] or [CA1881] or [CA1883] is displayed, perform trouble-
1
tial pressure sensor shooting for [CA1879] or [CA1881] or [CA1883] first.
PC210LCI-11 40-723

Defective KDPF (KDOC, Perform troubleshooting for 1 through 11 in “Active regeneration is executed fre-
2
or KCSF) quently” in S mode.
NOTICE
• Be sure to perform:
1. Remove KDPF and flush ash accumulated in KDPF (see Related informa-
tion).
Excessive ash accumula-
tion
3. Perform Reset after KDPF cleaning (see Related information).
4. Perform Reset after KDPF change (see Related information).
5. Make sure that ash accumulation is 0 on the monitor (see Related informa-
tion).
4
40-724 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [D110KB]
FAILURE CODE [D110KB]

Action level Failure code Battery Relay Output Short Circuit
Failure
L01 D110KB (Pump controller system)
Detail of fail-
Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
ure
Stops 24 V output to battery relay primary circuit (coil side).
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Each controller may fail in writing of data into its ROM (non-volatile memory).
on machine
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
Related • Output (ON/OFF) to battery relay can be checked with monitoring function. (Code: 03700
information Controller output 1)
Procedure: Turn starting switch from ON to OFF position.
Defective battery relay 1. Turn starting switch to OFF position.

1
(internal short circuit) Continuity Between terminals R01(E) and R02(BR) Continuity
2. Turn battery disconnect switch to OFF position (to prevent short circuit dur-
Ground fault in wiring ing work).
harness 3. Disconnect terminals R01 and R02, and disconnect connectors D01, H15,
2 and CP02.
cuit) Between terminal R02 (BR) and ground Min. 1 MΩ
Resistance Between ground and terminal CP02 (female) (108),
Min. 1 MΩ
R02 (harness side), D01 (female) (1) or (2)
If no failure is found by preceding checks, pump controller is defective.
• Reference
2. Insert T-adapter to connector D01.
3 Defective pump controller
4. Measure voltage within several seconds after turning staring switch to OFF
position from ON position.
Voltage Between D01 (1) and ground 20 to 30 V
PC210LCI-11 40-725
FAILURE CODE [D110KB] 40 TROUBLESHOOTING
Circuit diagram related to battery relay
40-726 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [D19JKZ]
FAILURE CODE [D19JKZ]

Action level Failure code Personal Code Relay Open Circuit or Short Circuit
Failure
L03 D19JKZ (Machine monitor system)
Detail of fail-
Open error or short circuit occurs in primary (coil) circuit of personal code relay.
ure
None in particular (when open error occurred)
Stops driving personal code relay (when short circuit occurred).
Action of ma-
chine monitor If cause of failure disappears, machine becomes normal by itself (when open error occurred).
to OFF position (when short circuit occurred).
Phenomenon
on machine
• This failure code is displayed only when engine lock function is enabled.
Related Procedure: Turn starting switch to ON position (when open circuit occurred). Failure code
information cannot be reproduced on the machine (when short circuit occurred).
• Troubleshooting for this failure code covers circuits from fuse No. 3 in fuse box F01
through primary (coil) circuit of personal code relay R07 to machine monitor.

Defective fuse No. 3 (3rd If fuse is burnt out, circuit may have ground fault.
1 from the top right) of fuse
box F01
200 to
600 Ω
Defective personal code
2
relay R07 1. Turn starting switch to OFF position.
2. Replace relay R07 with preheating relay R18.
If this failure code is cleared, original personal code relay R07 is defective.
Open or short circuit or 3. Disconnect connectors CM01 and S14, and connect T-adapter to female
3 ground fault in wiring har- side of CM01.
ness
200 to
Between F01-3 and CM01 (female) (6)
Resistance 600 Ω
Between F01-3 or CM01 (female) (6) and ground Min. 1 MΩ
If failure code still displays after above checks on cause 3, this check is not re-
quired.
4 3.
ness Disconnect connector CM01 and relay R07, and connect T-adapter to fe-
male side of CM01.
Between F01-3 and R07 (female) (1) Max. 1 Ω
Resistance
Between R07 (female) (2) and CM01 (female) (6) Max. 1 Ω
PC210LCI-11 40-727
FAILURE CODE [D19JKZ] 40 TROUBLESHOOTING

quired.
Ground fault in wiring 3.
5 Disconnect connector CM01 and relay R07, and connect T-adapter to fe-
harness
male side of CM01 or R07.
Between F01-3 or R07 (female) (1) and ground Min. 1 MΩ
Resistance Between R07 (female) (2) and ground, or between
Min. 1 MΩ
CM01 (female) (6) and ground
3. Disconnect connectors CM01 and relay R07, and connect T-adapter to fe-
Short circuit in wiring har- male side of connector CM01.
6
ness
No continui-
Between CM01 (female) (6) and each pin other than ty
Continuity
(6) (No sound is
heard.)
7
40-728 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [D19JKZ]
Circuit diagram related to personal code relay
PC210LCI-11 40-729
FAILURE CODE [D811MC] 40 TROUBLESHOOTING
FAILURE CODE [D811MC]

Failure KOMTRAX Malfunction (KOMTRAX system)
- D811MC
Details of
KOMTRAX Error
failure
Action of
None in particular
controller
Phenomenon
KOMTRAX system does not operate normally.
on machine

Defective KOMTRAX (In case of an internal defect, troubleshooting is impossible
1 KOMTRAX Error
as an assembly. Replace whole assembly.)
40-730 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [D862KA]
FAILURE CODE [D862KA]

Action level Failure code GPS Antenna Open Circuit
Failure
- D862KA (KOMTRAX system)
Details of
Open circuit occurs in GPS antenna circuit.
failure
Action of • None in particular
Phenomenon
GPS positioning system does not work.
on machine

Defective GPS antenna GPS antenna may be defective, or antenna cable may have open or short circuit,
1
or antenna cable or poor contact at terminal area (GPS).
Configuration diagram of GPS system
PC210LCI-11 40-731
FAILURE CODE [D8ALKA] 40 TROUBLESHOOTING
FAILURE CODE [D8ALKA]

Action level Failure code System Operating Lamp Open Circuit (KOMTRAX)
Failure
- D8ALKA (KOMTRAX system)
KOMTRAX terminal has detected an open circuit because the output line voltage of system operat-
Detail of fail-
ing lamp is approximately 5 V and below while the KOMTRAX terminal does not output the voltage
ure
for approximately 3 seconds after the starting switch is turned to ON position.
• Stops driving system operating lamp.
Action of
• Even if cause of failure is eliminated, machine does not become normal until starting
controller
Phenomenon
None in particular
on machine
is lit.
• Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.
dure.
REMARK
Defective fuse No. 16 in
1 If room lamp lights up, this check is not required.
fuse box F01.
If fuse is blown, circuit probably has ground fault.
ness (wire breakage or 3. Disconnect connectors CK01 and L19, and connect T-adapters to each fe-
2 male side.
nector)
Between CK01 (female) (15) and L19 (female) (2) Max. 1 Ω
Resistance
Between F01-16 and L19 (female) (1) Max. 1 Ω
If no failure is found by preceding checks, KOMTRAX terminal is defective. (In case
Defective KOMTRAX ter-
3 of an internal defect, troubleshooting is impossible as an assembly. Replace whole
minal
assembly.)
40-732 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [D8ALKA]
PC210LCI-11 40-733
FAILURE CODE [D8ALKB] 40 TROUBLESHOOTING
FAILURE CODE [D8ALKB]

Action level Failure code System Operating Lamp Short Circuit (KOMTRAX)
Failure
- D8ALKB (KOMTRAX system)
Detail of fail- KOMTRAX terminal has detected a short circuit because voltage of output circuit does not become
ure low level while KOMTRAX terminal outputs current to system operating lamp.
• Stops driving the system operating lamp.
Action of
controller
Phenomenon
None in particular
on machine
is lit.
Related • Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is turned to OFF position.
dure.

2. Remove the fuse-16 in fuse box F01.
Short circuit in wiring har- 3. Disconnect the connectors CP02, CK01, CM01, ECM J2, CS03, CW03,
1
ness CA02, and L19, and connect the T-adapter to female side of connector
L19.
2
minal
assembly.)
40-734 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [D8ALKB]
PC210LCI-11 40-735
FAILURE CODE [D8AQKR] 40 TROUBLESHOOTING
FAILURE CODE [D8AQKR]

Action level Failure code CAN 2 Defective Communication (KOMTRAX) (Detected by machine
Failure monitor)
- D8AQKR (Machine monitor system)
Detail of fail-
Machine monitor does not recognize KOMTRAX over CAN communication-2 line (KOMNET/c).
ure
Action of ma-
None
chine monitor
Phenomenon
None
on machine
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 6 different failure codes, [D8AQKR], [DA2QKR], [DB9QKR], [DAZQKR], [DB2QKR] and
[DBRQKR] are used for defective CAN communication by CAN 2 when it is detected by
machine monitor. When all of these 6 failure codes are displayed, ground fault, short cir-
cuit or hot short circuit in wiring harness (CAN communication circuit) can be suspected.
REMARK
Related • Also display [DBPQKR] for the KomVision specifications.
information • If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
short circuit occurring in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
using multimeter.

2. Disconnect fusible link F05 and connect T-adapter to female side.
1 Defective fusible link F05 Resistance Between F05 (female) (1) and (2) Max. 1 Ω
REMARK
If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in 2.
2 Remove fuse No. 17 in fuse box F01.
fuse box F01.
Defective power supply Perform troubleshooting for “KOMTRAX SYSTEM DOES NOT OPERATE NOR-
3
to KOMTRAX terminal MALLY” of E mode.
Defective CAN communi- Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR].
4
cation 2 system
minal
assembly.)
6
40-736 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [D8AQKR]
Circuit diagram related to KOMTRAX
PC210LCI-11 40-737
FAILURE CODE [DA20MC] 40 TROUBLESHOOTING
FAILURE CODE [DA20MC]

Action level Failure code Pump Controller Malfunction
Failure
― DA20MC (Pump controller system)
Detail of fail-
Malfunction of pump controller operation
ure
Action of
controller
Phenomenon
The work equipment, traveling, and turning operations cannot be performed normally.
on machine

Defective pump controller
Mulfunction pump con-
troller
40-738 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA22KK]
FAILURE CODE [DA22KK]

Action level Failure code Pump Controller Solenoid Power Voltage Low Error
Failure
L03 DA22KK (Pump controller system)
Detail of fail-
Power supply voltage of controller for driving solenoids is below 20 V.
ure
Stops detection of failures (open circuit and short circuit) in all solenoid systems while this failure
Action of
code is active.
controller
If cause of failure disappears, machine becomes normal by itself.
Phenomenon No solenoid valve is energized properly, so machine does not work properly.
on machine (Work equipment, swing, and travel systems do not work.)
• If failure code [D110KB] is displayed, perform troubleshooting these first.
Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information

1 Defective fusible link F04 If fusible link F04 is blown, circuit probably has ground fault (see cause 6).
Defective fuse No. 2 in If fuse is blown, circuit probably has ground fault (see cause 6).
2
fuse box F01
3 Improper battery voltage 2. After measuring voltage, measure it again when starting engine.
Voltage Between battery (+) and ground 20 to 30 V
OFF position.
4 Defective wiring harness 3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Between ground and each of CP02 (female) (116),
Voltage 20 to 30 V
(118) and (121)
If no failure is found on cause 3, this check is not required.
If fuse or fusible link is burnt out, replace it with new one.
OFF position.
Between R03 and each of CP02 (female) (116), (118)
Open circuit in wiring har- Resistance Max. 1 Ω
5 and (121)
ness
In addition, disconnect fusible link F04 and connect T-adapter to male side of F04
and female side of CP02.
Between F04 (male) (2) and each of CP02 (female)
Max. 1 Ω
Resistance (116), (118), and (121)
Between F04 (male) (1) and terminal R03 (M) Max. 1 Ω
PC210LCI-11 40-739
FAILURE CODE [DA22KK] 40 TROUBLESHOOTING

quired.
OFF position.
Ground fault in wiring 2. Remove wire from terminal R03.
harness 3.
6 Disconnect fusible link F04 and connector CP02, and connect T-adapters
(Contact with ground cir- to female side of CP02 and male side of F04.
cuit)
Between ground and CP02 (female) (116), (118),
Min. 1 MΩ
(121), or F04 (male) (2)
Resistance
Between ground and F04 (male) (1) or terminal R03
Min. 1 MΩ
(M)
If no failure is found by preceding checks, pump controller is defective. (In case of
7 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).
40-740 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA22KK]
Circuit diagram related to pump controller solenoid power supply
PC210LCI-11 40-741
FAILURE CODE [DA25KP] 40 TROUBLESHOOTING
FAILURE CODE [DA25KP]

Action level Failure code 5 V Sensor 1 Power Voltage Low Error
Failure
― DA25KP (Pump controller system)
Detail of fail-
Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
ure
Stops output of power from 5 V sensor power supply output 1.
Action of
controller
to OFF position.
Signal of pressure sensor is not input properly.
The error code for the pressure sensor is displayed as well.
Phenomenon
Travel and work equipment speeds are slow.
on machine
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.

2. Disconnect connectors of the following sensors one by one and turn start-
ing switch to ON position each time.
REMARK
If this failure code is cleared, a disconnected sensor is defective.
REMARK
Since connector is disconnected, other failure codes appear but ignore all
of displayed failure codes other than this one.
Left front travel pressure sensor P09
Defective pressure sen- Left rear travel pressure sensor P10

1 sor Right front travel pressure sensor P11
(internal short circuit)
Right rear travel pressure sensor P12
F pump pressure sensor P25
R pump pressure sensor P26
Connector F pump swash plate sensor P27
R pump swash plate sensor P28
Overload pressure sensor P46
Service pressure sensor (dummy) P49
Fan speed sensor M16
Attachment pressure sensor (R.H.) PA20
Attachment pressure sensor (L.H.) PA21
40-742 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA25KP]

To measure voltage before controller stops output of power.
Hot short circuit in wiring 2. Disconnect connectors P09 to P12, P25 to P28, P46, P49, M16, PA20 and
harness PA21.
2
(Contact with 24 V cir- 3. Connect T-adapter to female side of connector P09.
cuit)
4. Turn starting switch to ON position (with connector disconnected).
Voltage Between P09 (female) (3) and ground 4.5 to 5.5 V
Ground fault in wiring 2. Disconnect connectors P09 to P12, P25 to P28, P46, P49, M16, PA20 and
harness
3 PA21.
(Contact with ground cir- 3. Connect T-adapter to female side of connector CP01.
cuit)
Resistance Between CP01 (female) (6) and ground Min. 1 MΩ
assembly).
PC210LCI-11 40-743
Circuit diagram related to pump controller 5V sensor power supply
40-744 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA26KP]
FAILURE CODE [DA26KP]

Action level Failure code 5 V Sensor 2 Power Voltage Low Error
Failure
- DA26KP (Pump controller system)
Detail of fail-
Voltage of 5 V sensor power supply output 2 circuit is 2.5 V or less or 6.0 V or more.
ure
Stops output of power from 5 V sensor power supply output 2.
Action of
Even if cause of failure is eliminated, machine does not become normal until the starting switch is
controller
turned to OFF position once.
Phenomenon
on machine
• Signal of pressure sensor is not input properly.
• Failure code of pressure sensor is displayed at the same time.
• Travel and work equipment speeds are slow.
Related • Automatic gear shift function of travel does not work.
information • Auto-decelerator function remains activated, and fine control performance of work equip-
ment is poor.

2. Disconnect connectors of the following sensors one by one and turn start-
ing switch to ON position each time.
REMARK
If this failure code is cleared, a disconnected sensor is defective.
1 Defective 5 V sensor REMARK
Since connector is disconnected, other failure codes appear but ignore all
of displayed failure codes other than this one.
Left front travel pressure sensor P09
Connector
Left rear travel pressure sensor P10
2. Disconnect the connectors CP01, M22, and M23, and connect the T-
2 adapter to any female side.
harness
Between ground and any of CP01 (female) (63), M22
(female) (6), and M23 (female) (6)
2. Disconnect the connectors M22 and M23, and connect the T-adapter to ei-
Hot short circuit in wiring ther female side.
3
harness 3. Turn the starting switch to ON position.
Between ground and either M22 (female) (6) or M23
(female) (6)
If no failure is found by above checks, pump controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed).
PC210LCI-11 40-745
Circuit diagram related to pump controller 5V sensor power supply
40-746 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA29KQ]
FAILURE CODE [DA29KQ]

Action level Failure code Model Selection Signal Mismatch (Pump Controller)
Failure
L01 DA29KQ (Pump controller system)
Detail of fail-
Model code signal for model which is not registered in controller is input.
ure
Controls machine by regarding machine as default model (PC210 standard specification machine).
Action of
controller
to OFF position.
Phenomenon
No problem appears if machine is PC210 standard specification machine.
on machine
• Part number of pump controller assembly can be checked with monitoring function. (Code:
20229 assembly part number (pump controller))
• Signal state (ON/OFF) of model selection signal can be checked with monitoring function.
(Code: 02201 switch input 2)
• PC210
Model selection 1:OFF
Model selection 3:ON
Related Model selection 4:OFF
information Model selection 5:OFF
• PC210LC
Procedure: Method of reproducing failure code: Turn starting switch to ON position.

Pump controller with Use monitoring function to display assembly part number and check whether it is
1
wrong part number identical to that listed in Parts book.
2. Disconnect connector S30, and connect T-adapter to female side.
Between S30 (female) (1) PC210
Min. 1 MΩ
and (8) PC210LC
Between S30 (female) (3) PC210

Defective model selec- Max. 1 Ω
and (8) PC210LC
tion connector
2
(Internal open or short Between S30 (female) (4) PC210
circuit) Resistance Min. 1 MΩ
and (8) PC210LC
Between S30 (female) (2) PC210 Min. 1 MΩ

and (8) PC210LC Max. 1 Ω
Between S30 (female) (7) PC210 Min. 1 MΩ

and (8) PC210LC Max. 1 Ω
PC210LCI-11 40-747
FAILURE CODE [DA29KQ] 40 TROUBLESHOOTING

Open circuit in wiring har- Between CP01 (female) PC210
ness Max. 1 Ω
(21) and ground PC210LC
3
(Wire breakage or defec-
Between CP01 (female)
tive contact of connector) Resistance PC210LC Max. 1 Ω
(40) and ground
PC210LC Max. 1 Ω
(58) and ground
PC210LC Min. 1 MΩ
(40) and ground
harness Between CP01 (female)
4 PC210LC Min. 1 MΩ
(Contact with ground cir- (58) and ground
cuit) Resistance
Between CP01 (female) PC210
Min. 1 MΩ
Between CP01 (female) PC210

Min. 1 MΩ
2. Disconnect the connectors CS01, and S30, and connect the T-adapter to
female side of connector CP01.
Between CP01 (female) PC210 No continui-
(21) and each pin other
PC210LC ty
than (21)

5 (40) and (40) PC210LC ty
ness
Continuity Between CP01 (female) PC210 No continui-
(58) and (58) PC210LC ty

(59) and (59) PC210LC ty

(77) and (77) PC210LC ty

assembly).
40-748 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA29KQ]
Circuit diagram related to machine model setting system
PC210LCI-11 40-749
FAILURE CODE [DA2LKA] 40 TROUBLESHOOTING
FAILURE CODE [DA2LKA]

Action level Failure code System Operating Lamp Open Circuit (Pump Controller)
Failure
― DA2LKA (Pump controller system)
Pump controller determines that system operating lamp circuit is open because voltage of output
Detail of fail-
circuit remains at approximately 5 V or below for approximately 3 seconds after starting switch is
ure
turned to ON position, during which pump controller outputs no current to system operating lamp.
Action of
None in particular
controller
Phenomenon
None in particular
on machine
is lit.
• Pump controller is not able to light up system operating lamp.
• Although work equipment controller is not able to light up system operating lamp, no trou-
ble will result unless battery disconnect switch is turned to OFF position.
Defective fuse No. 16 in If room lamp lights up, this check is not required.
1
fuse box F01. If fuse is blown, circuit probably has ground fault.
ness (wire breakage or 3. Disconnect connectors CP02 and L19, and connect T-adapters to each fe-
2 male side.
nector)
Between CP02 (female) (100) and L19 (female) (2) Max. 1 Ω
Resistance
assembly).
40-750 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA2LKA]
PC210LCI-11 40-751
FAILURE CODE [DA2LKB] 40 TROUBLESHOOTING
FAILURE CODE [DA2LKB]

Action level Failure code System Operating Lamp Short Circuit (Pump Controller)
Failure
― DA2LKB (Pump controller system)
Detail of fail- Pump controller determines that system operating lamp circuit shorts because voltage of output cir-
ure cuit does not become Low level while pump controller outputs current to system operating lamp.
Action of
None in particular
controller
Phenomenon
None in particular
on machine
is lit.
Related • Pump controller is not able to light up system operating lamp.
• Although work equipment controller is not able to light up system operating lamp, no trou-
ble will result unless battery disconnect switch is turned to OFF position.

1 3. Disconnect connectors CP02, CK01, CM01, J2, CS03, CW03, CA02 and
ness
L19, and connect T-adapter to female side of connector L19.
2
assembly).
40-752 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA2LKB]
PC210LCI-11 40-753
FAILURE CODE [DA2QKR] 40 TROUBLESHOOTING
FAILURE CODE [DA2QKR]

Action level Failure code Controller Area Network 2 Defective Communication (Pump Control-
Failure ler)
L03 DA2QKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize pump controller through CAN communication 2 line
ure (KOMNET/c).
Action of
Retains information when the failure occurred.
controller
Phenomenon Information to be obtained from pump controller is not displayed and special functions do not work.
Or update of received data is stopped (such as failure codes and monitoring codes sent from the
on machine pump controller).
troller.
REMARK
• Also display [DBPQKR] for the KomVision specifications.
Related
• If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
information
• This can be activated even when power supply to pump controller is turned off.
using multimeter.

2. Disconnect fusible link F05 and connect T-adapter to female side.
1 Defective fusible link F05 Resistance Between F05 (female) (1) and (2) Max. 1 Ω
REMARK
If fusible link is blown, circuit may have ground fault.
Defective fuse No. 17 in
2 2. Remove fuse No. 17 in fuse box F01.
fuse box F01.
REMARK
Check ground terminal T04 for looseness and rust.
Improper power supply to 2.
3 Disconnect connector CP01 and connect T-adapter to female side.
pump controller
Voltage
40-754 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA2QKR]

quired.
1. Turn starting switch to OFF position, and set battery disconnect switch to
OFF position.
ness 3. Disconnect fusible link F05 and connector CP01, and connect T-adapters
4 to each female side connector.
(Wire breakage or defec-
tive contact of connector) Between terminal R04 and F05 (female) (1) Max. 1 Ω
Between F05 (female) (2) and F01-16G Max. 1 Ω
Resistance
Between F01-17 and CP01 (female) (1) Max. 1 Ω
Between F01-17 and CP01 (female) (4) Max. 1 Ω
Defective CAN communi- Perform checks on causes 4 to 9 in troubleshooting for failure code [DB2QKR].
5
cation 2 system
assembly).
7
PC210LCI-11 40-755
FAILURE CODE [DA2QKR] 40 TROUBLESHOOTING
Circuit diagram related to pump controller power supply
40-756 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DA2RKR]
FAILURE CODE [DA2RKR]

Action level Failure code Controller Area Network 1 Defective Communication (Pump Control-
Failure ler)
L04 DA2RKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize pump controller through CAN communication 1 line
ure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Retains information when the failure occurred.
• Information to be obtained from pump controller is not displayed and special functions that
need information do not work. Or update of received data is stopped.
• Pump control is disabled.
Phenomenon
• Hydraulic oil temperature gauge pointer disappears on machine monitor screen.
on machine
• Windshield wiper operation is disabled.
• Washer operation is disabled.
• Flow rate of attachment oil pressure line cannot be controlled.
troller.
• 4 different failure codes, [DA2RKR], [DB2RKR], [DB9RKR], and [DBRRKR] are used for
defective CAN communication by CAN 1 when it is detected by machine monitor. When all
of these 4 failure codes are displayed, ground fault, short circuit or hot short circuit in wir-
ing harness (CAN communication circuit) can be suspected.
Related • Terminating resistor of CAN 1 on cab side is provided in machine monitor, and that on en-
information gine side is connector TERMINATOR PORT.
using multimeter.

Defective pump controller Perform checks on causes 1 to 4 in troubleshooting for failure code [DA2QKR].
1
power supply system
Defective CAN communi- Perform checks on causes 2 to 8 in troubleshooting for failure code [DB2RKR].
2
cation 1 system
assembly).
4
PC210LCI-11 40-757
FAILURE CODE [DA2RKR] 40 TROUBLESHOOTING
Circuit diagram related to CAN communication 1
40-758 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DAF0MB]
FAILURE CODE [DAF0MB]

Action level Failure code Monitor ROM Abnormality
Failure
- DAF0MB (Machine monitor system)
Detail of fail-
Machine monitor program is rewritten (program error).
ure
Action of Even if cause of failure is eliminated, machine does not become normal until starting switch is
controller turned to OFF position.
Phenomenon • Machine monitor display is unreliable.

on machine • It can neither transmit the data to controllers nor receive the data from them.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

Defective machine moni- Defective machine monitor (Because this is an internal defect, troubleshooting can-
1
tor not be performed.)
PC210LCI-11 40-759
FAILURE CODE [DAF0MC] 40 TROUBLESHOOTING
FAILURE CODE [DAF0MC]

Action level Failure code Monitor Malfunction
Failure
- DAF0MC (Machine monitor system)
Detail of fail-
Malfunction of machine monitor
ure
Action of Even if cause of failure is eliminated, machine does not become normal until starting switch is
controller turned to OFF position.
Phenomenon • Machine monitor display is unreliable.

on machine • It can neither transmit the data to controllers nor receive the data from them.
Related After completion of repair, check if the failure code is cleared by the following procedure.

Defective machine moni- Defective machine monitor (Because this is an internal defect, troubleshooting can-
1
tor not be performed.)
40-760 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DAF8KB]
FAILURE CODE [DAF8KB]

Failure Camera Power Supply Short Circuit (Machine monitor system)
L03 DAF8KB
Detail of fail- Output power supply voltage (rating: 8 V) from machine monitor to camera is 10 V and above when
ure no current is outputted.
• Stops output power supply voltage to camera.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
Phenomenon
Camera image is not displayed on machine monitor.
on machine
Related After repair is completed, check if the failure code is cleared by the following procedure.

2. Disconnect connector A45 of camera, and turn starting switch to ON posi-
Defective camera
1 tion.
(internal short circuit)
If failure code is cleared after disconnecting camera to perform operation of repro-
ducing procedure, internal defect of camera is detected.
2. Disconnect connector CM04.
Defective machine moni- 3.
2 Connect T-adapter to male side of CM04.
tor
Voltage Between CM04 (male) (1) and ground 6 to 10 V
harness 2. Disconnect camera connector A45 from connector CM04.
3
(Contact with ground cir- 3. Connect T-adapter to female side of connector CM04.
cuit)
Resistance Between CM04 (female) (1) and ground Min. 1 MΩ
2. Disconnect connector A45 of camera.
Hot short circuit in wiring 3. Insert T-adapter into connector CM04.
4 harness (contact with 24
V circuit) 4. Turn starting switch to ON position.
(Disconnect camera and check that it is normal, in advance.)
Voltage Between CM04 (1) and (5) Max. 10 V
PC210LCI-11 40-761
FAILURE CODE [DAF8KB] 40 TROUBLESHOOTING
Circuit diagram related to camera power supply
40-762 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DAF9KQ]
FAILURE CODE [DAF9KQ]

Action level Failure code Model Selection Signal Mismatch (Monitor)
Failure
L03 DAF9KQ (Machine monitor system)
Detail of fail- Machine model registered in machine monitor and pump controller differs.
ure (Machine monitor or pump controller of wrong part number is installed for replacement.)
Action of
controller
Phenomenon
Machine does not operate normally.
on machine
• Assembly part number of pump controller program can be checked with monitoring func-
tion. (Code: 20229)
Related • Assembly part number of machine monitor program can be checked with monitoring func-
information tion. (Code: 20227)

Turn starting switch ON and perform troubleshooting (with monitoring function).
Monitoring code: 02201 SW input 2
Model Selection 1 ON
Defective machine model Model Selection 2 OFF
1
code signal
Normal dis-
play
Model Selection 4 OFF
Defective machine moni- Display assembly part number by monitoring function, and check that displayed
2
tor number is same as the one in Parts Book.
Use monitoring function to display assembly part number and check whether it is
identical to that listed in Parts book.
PC210LCI-11 40-763
FAILURE CODE [DAFGMC] 40 TROUBLESHOOTING
FAILURE CODE [DAFGMC]

Action level Failure code GPS Module Malfunction
Failure
- DAFGMC (KOMTRAX system)
Details of No position data is sent from GPS module (inside of machine monitor) to KOMTRAX communica-
failure tion modem more than 50 seconds since the startup of KOMTRAX.

Phenomenon
None in particular
on machine
After repairing, check if the failure code is cleared by the following procedure.
Related
Procedure: Turn starting switch to ON position. (Wait for more than 50 seconds after the switch is
information
turned ON.)

Defective machine moni- GPS module of machine monitor may be defective. (Because this is an internal de-
1
tor fect, troubleshooting cannot be performed.)
40-764 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DAFLKA]
FAILURE CODE [DAFLKA]

Action level Failure code System Operating Lamp Open Circuit (Monitor)
Failure
- DAFLKA (Machine monitor system)
Machine monitor has detected an open circuit because the output line voltage of system operating
Detail of fail-
lamp is approximately 5 V and below while the machine monitor does not output the voltage for ap-
ure
proximately 3 seconds after the starting switch is turned to ON position.
• Stops driving system operating lamp.
Action of
controller
Phenomenon
None in particular
on machine
is lit.
• You cannot make system operating lamp light up from machine monitor.
Related • Although machine monitor is not able to light up system operating lamp, no trouble will re-
sult unless battery disconnect switch is turned to OFF position.
information
dure.
Defective fuse No. 16 in If room lamp lights up, this check is not required.
1
fuse box F01. If fuse is blown, circuit probably has ground fault.
ness (wire breakage or 3. Disconnect connectors CM01 and L19, and connect T-adapters to each fe-
2 male side.
nector)
Between CM01 (female) (8) and L19 (female) (2) Max. 1 Ω
Resistance
Defective machine moni- If no failure is found by preceding checks, machine monitor is defective. (Because
3
tor this is an internal defect, troubleshooting cannot be performed.)
PC210LCI-11 40-765
FAILURE CODE [DAFLKA] 40 TROUBLESHOOTING
40-766 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DAFLKB]
FAILURE CODE [DAFLKB]

Action level Failure code System Operating Lamp Short Circuit (Monitor)
Failure
- DAFLKB (Machine monitor system)
Detail of fail- Machine monitor has detected a short circuit because voltage of output circuit does not become low
ure level while machine monitor outputs current to system operating lamp.
• Turns driving the system operating lamp to OFF.
Action of
controller
Phenomenon
None in particular
on machine
is lit.
• You cannot make system operating lamp light up from machine monitor.
Related
• Although machine monitor is not able to light up system operating lamp, no trouble will re-
information
sult unless battery disconnect switch is turned to OFF position.
dure.

1
L19.
2
Defective machine moni- If no failure is found by preceding checks, machine monitor is defective. (Because
3
tor this is an internal defect, troubleshooting cannot be performed.)
PC210LCI-11 40-767
FAILURE CODE [DAFLKB] 40 TROUBLESHOOTING
40-768 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DAFQKR]
FAILURE CODE [DAFQKR]

Action level Failure code CAN 2 Defective Communication (Monitor)
Failure
- DAFQKR (KOMTRAX system)
Detail of fail-
KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
ure
Action of
None in particular
controller
Phenomenon
KOMTRAX system may not function normally.
on machine
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Related Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
information not displayed on machine monitor and it can be observed only through KOMTRAX sys-
tem.
using multimeter.

Defective power supply Perform troubleshooting for “When starting switch is turned to ON position, ma-
1
to machine monitor chine monitor displays nothing” of E mode.
Defective CAN communi- Perform checks on cause 5 and subsequent causes in troubleshooting for failure
2
cation code [DB2QKR].
PC210LCI-11 40-769
FAILURE CODE [DAZ9KQ] 40 TROUBLESHOOTING
FAILURE CODE [DAZ9KQ]

Action level Failure code Model Selection Signal Mismatch (Air conditioner)
Failure
- DAZ9KQ (Machine monitor system)
Details of Model in machine monitor program is different from that in air conditioner controller program (re-
failure placed machine monitor or air conditioner controller is wrong in part No.)
Action of
controller
Phenomenon
Machine does not operate normally.
on machine
• Model code specified by air conditioner controller program cannot be checked with moni-
toring function.
• Model code of machine monitor program can be checked with monitoring function (Code:
00500).
Related • Air conditioner control data (model and series) of machine monitor can be checked with
monitoring function (Code: 55200).
information
• Control data of air conditioner controller (model and series names) can be checked with
monitoring function (Code: 55201). (If control data is 01 (indicating hydraulic excavator), it
is correct.)

Turn starting switch ON and perform troubleshooting (with monitoring function).
Monitoring code: 02201 SW input 2
Defective machine model Model Selection 2 OFF
1
code signal
Normal dis-
play
Defective machine moni- Defective machine monitor (Programmed machine model is different.)
2
tor
Defective air conditioner Defective monitor controller (Wrong machine model is programmed.)
3
controller
40-770 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DAZQKR]
FAILURE CODE [DAZQKR]

Action level Failure code CAN 2 Defective Communication (Air Conditioner)
Failure
L01 DAZQKR (Machine monitor system)
Detail of fail- In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air conditioner con-
ure troller.
Action of
controller
Information obtained from engine controller is not displayed.
Phenomenon (Such as failure codes and monitoring codes sent from the engine controller)
on machine Air conditioner cannot be controlled (air does not blow out).
Air conditioner operation screen of machine monitor is not displayed properly.
troller.
REMARK
using multimeter.

Defective power supply Perform Chapter 80 “Troubleshooting for power supply system”.
1 to air conditioner control-
ler
Defective CAN terminat- 2. Disconnect connectors CM02 and K02, and connect T-adapters to male
ing resistor side.
2
(Internal open or short
Between K02 (male) (A) and (B) 120±12 Ω
circuit) Resistance
Between CM02 (male) (7) and (9) 120±12 Ω
PC210LCI-11 40-771
FAILURE CODE [DAZQKR] 40 TROUBLESHOOTING

CAN communication line
REMARK
CAN terminating resistor of 120 Ω is also located in machine monitor. That is, two
CAN terminating resistors of 120 Ω are connected in parallel. When circuit resist-
ance is measured at connector of controller other than machine monitor, if com-
bined resistance is 60 Ω, wiring harness does not have open circuit.
OFF position.
2. Disconnect related connectors, and connect T-adapter to connector to be
measured.
REMARK
If short circuit is found (resistance between 2 terminals is 1 Ω or less), disconnect
Open or short circuit in all CAN communication connectors of every controller and check whether short cir-
3 cuit occurs between wiring harnesses or inside controller.
wiring harness
Approx.
Between CM02 (female) (8) and (9)
120 Ω
Approx.
60 Ω
Approx.
Between CP01 (female) (45) and (64)
60 Ω
Resistance
Approx.
Between AC01 (female) (1) and (2)
60 Ω
Approx.
Between CK01 (female) (10) and (11)
60 Ω
Approx.
Between K02 (female) (A) and (B)
120 Ω
40-772 PC210LCI-11

ACC signal of starting switch (start of CAN communication is not recognized)
OFF position.
2. Disconnect connectors to be measured and insert T-adapters.
3. Turn battery disconnect switch to ON position, and turn starting switch to
ON position.
Voltage
Between AC02 (4) and (1) 20 to 30 V
Between CK02 (3) and (1) 20 to 30 V
REMARK
required.
Open circuit in wiring har- 1. Turn starting switch to OFF position, and set battery disconnect switch to
ness OFF position.
4
(Wire breakage or defec- 2. Disconnect related connectors, and connect T-adapter to each female side
tive contact of connector) connector to be measured.
Between CM02 (female) (8) and CP01 (female) (45) Max. 1 Ω
Between CM02 (female) (8) and ECM J2 (female) (22) Max. 1 Ω
Between CM02 (female) (8) and AC01 (female) (2) Max. 1 Ω
Resistance
Between CM02 (female) (8) and CK01 (female) (10) Max. 1 Ω
Between CM02 (female) (8) and H14 (female) (17) Max. 1 Ω
Between ECM J2 (female) (22) and K02 (male) (A) Max. 1 Ω
Between ECM J2 (female) (46) and K02 (male) (B) Max. 1 Ω
If no failure (no open circuit) is found by check on cause 3, measure resistance at
any one place in each case.
Ground fault in wiring OFF position.
harness 2. Disconnect related connectors, and connect T-adapter to each female side
5 connector to be measured.
cuit) Between ground and any point in CP01 (female) (45),
Min. 1 MΩ
CM02 (female) (7), (8) or ECM J2 (female) (22)
Resistance
Between ground and any point in CP01 (female) (64),
Min. 1 MΩ
CM02 (female) (9), or ECM J2 (female) (46)
PC210LCI-11 40-773
FAILURE CODE [DAZQKR] 40 TROUBLESHOOTING

OFF position.
Open circuit or hot short 2. Insert T-adapter into connector to measure.
circuit in wiring harness 3.
6 Set battery disconnect switch to ON position.
(Contact with 24 V cir-
cuit)
Between ground and any of CM02 (8), CK01 (10),
1 to 4 V
AC01 (2), and ECM J2 (22)
Voltage
1 to 4 V
AC01 (1), and ECM J2 (46)
If all four failure codes [DA2QKR], [DB2QKR], [D8AQKR], and [DAZQKR] are dis-
played:
Identify which controller is defective by disconnecting them one by one from CAN
communication line by repeating the following steps 1 to 3.
OFF position.
ler, pump controller, air 2. Disconnect CAN communication connector of engine controller (connector
7 ECM J2), pump controller (connector CP01), air conditioner unit (connec-
conditioner unit, or KOM-
TRAX terminal tor AC01), and KOMTRAX terminal (connector CK01) one by one in turn.
3. Turn battery disconnect switch to ON position, and turn the starting switch
to ON position.
4. Return to step 1. to check next controller.
Has the number of displayed failure co- If YES, the disconnected controller is de-
des decreased from four? fective.
controller
9
40-774 PC210LCI-11
Circuit diagram related to air conditioner CAN2 system
PC210LCI-11 40-775
FAILURE CODE [DB2QKR] 40 TROUBLESHOOTING
FAILURE CODE [DB2QKR]

Action level Failure code CAN 2 Defective Communication (Engine Controller)
Failure
L03 DB2QKR (Machine monitor system)
Detail of fail-
Machine monitor cannot recognize engine controller over CAN communication-2 line (KOMNET/c).
ure
Action of
controller
Information to be obtained from engine controller is not displayed and special functions that need
Phenomenon
information do not work. Or update of received data is stopped.
on machine
(Such as failure codes and monitoring codes sent from the engine controller)
troller.
• If failure code [DB2RKR] is also displayed, engine controller is probably defective.
REMARK
Related
• If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
information short circuit occurring in wiring harness (CAN communication line).
• Air conditioner can be controlled even when failure code is displayed on the monitor
screen. If air conditioner is controlled, there is no possibility of ground fault, short circuit, or
hot short circuit occurring in wiring harness (CAN communication line).
using multimeter.

Defective fuse -14 or -18
1 2. Remove fuses -14 and -18 from fuse box F01.
in fuse box F01
If fuse is blown, the engine controller probably has short circuit.
REMARK
If the fuse is not blown out, this check is not required.
Defective engine control- 1. Turn the starting switch to OFF position.
2
ler 2. Disconnect connector ECM J2 and connect T-adapter to male side.
Between ECM J2 (male) (25) and (49) Min. 10 Ω
Resistance
Between ECM J2 (male) (27) and (51) Min. 10 Ω
40-776 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB2QKR]

1. Check ground terminal T12 for looseness and rust.
Defective power supply 4. Turn starting switch to ON position.
3
to engine controller
5. If abnormal, perform troubleshooting for [CA441].
Between ECM J2 (female) (1) and (73) 20 to 30 V
Voltage
Between ECM J2 (female) (25) and (49) 20 to 30 V
ing resistor side.
4
(internal open or short
circuit) Resistance
REMARK
OFF position.
measured.
REMARK
wiring harness
Approx.
120 Ω
Approx.
60 Ω
Approx.
60 Ω
Resistance
Approx.
60 Ω
Approx.
60 Ω
Approx.
120 Ω
PC210LCI-11 40-777

OFF position.
ON position.
Voltage
quired.
Open circuit in wiring har- OFF position.
ness 2. Disconnect related connectors, and connect T-adapter to each female side
6
(wire breakage or defec- connector to be measured.
tive contact of connector)
Resistance
Min. 1 MΩ
Resistance
Min. 1 MΩ
40-778 PC210LCI-11

OFF position.
2. Insert T-adapter into connector to measure.
Short circuit or hot short
8 circuit in wiring harness 3. Set battery disconnect switch to ON position.
(contact with 24 V circuit) 4. Turn starting switch to ON position.
1 to 4 V
AC01 (2), and ECM J2 (22)
Voltage
1 to 4 V
AC01 (1), and ECM J2 (46)
played:
OFF position.
to ON position.
10
PC210LCI-11 40-779
CIRCUIT DIAGRAM (CAN2 COMMUNICATION)
40-780 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB2RKR]
FAILURE CODE [DB2RKR]

Action level Failure code CAN 1 Defective Communication (Engine Controller)
Failure
L04 DB2RKR (Machine monitor system)
Detail of fail-
Machine monitor does not recognize engine controller over CAN communication-1 line (KOMNET/r).
ure
• Retains current working mode.
Action of
• Retains current selection of auto-deceleration.
controller
• Retains information when the failure occurred.
• Information to be obtained from engine controller is not displayed and special functions
that need information do not work. Or update of received data is stopped.
Phenomenon • Engine is uncontrollable.
on machine • Engine speed and coolant temperature are undetectable.
• A gauge pointer for engine coolant temperature and hydraulic oil temperature disappears
on machine monitor screen.
troller.
• If failure code [DB2QKR] is also displayed, engine controller system is probably defective.
Related
• CAN1 terminating resistor is located in the center of the machine monitor on operator's
information side.
using multimeter.

Defective engine control- Perform checks on causes 1 to 3 in troubleshooting for failure code [DB2QKR].
1
ler system
2. Disconnect connectors CM02 and TERMINATOR PORT, and connect T-
2 ing resistor (internal open adapters to male side.
or short circuit) Between TERMINATOR PORT (male) (A) and (B) 120±12 Ω
Resistance
PC210LCI-11 40-781
FAILURE CODE [DB2RKR] 40 TROUBLESHOOTING

REMARK
OFF position.
2. Disconnect connectors CM02, CP01, ECM J1, and TERMINATOR PORT
one by one, and connect T-adapters to each female side.
3
wiring harness If short circuit is found (resistance between 2 terminals is 1 Ω or less), disconnect
all CAN communication connectors of every controller and check whether short cir-
cuit occurs between wiring harnesses or inside controller.
Approx.
120 Ω
Approx.
60 Ω
Resistance
Approx.
Between TERMINATOR PORT (female) (A) and (B)
120 Ω
Approx.
Between (94) and ECM J1 (female) (70)
60 Ω
40-782 PC210LCI-11

OFF position.
2. Disconnect connectors CM01, CP01, and ECM J2 and insert T-adapters.
ON position.
Between CP01 (2) and each of (24), (43), and (80) 20 to 30 V
quired.
ness
4 OFF position.
tive contact of connector) 2. Disconnect connectors CM02, CP01, ECM J1, and TERMINATOR PORT,
and connect T-adapters to each female side.
Between CM02 (female) (11) and ECM J1 (female)
Max. 1 Ω
(70)
Resistance Between CM02 (female) (12) and ECM J1 (female)

Max. 1 Ω
(94)
Between ECM J1 (female) (70) and TERMINATOR
Max. 1 Ω
PORT (male) (A)
Max. 1 Ω
PORT (male) (B)
OFF position.
2. Disconnect connectors CM02, CP01, ECM J1, and TERMINATOR PORT,
Ground fault in wiring and connect T-adapter to either female side.
harness
5 Between ground and any point in CP01 (female) (7),
(contact with ground cir- CM02 (female) (10), (11), ECM J1 (female) (70), or Min. 1 MΩ
cuit) TERMINATOR PORT (female) (A)
Resistance
CM02 (female) (12), ECM J1 (female) (94) or TERMI- Min. 1 MΩ
NATOR PORT (female) (B)
PC210LCI-11 40-783

OFF position.
2. Disconnect either of connectors CM02, CP01, and TERMINATOR PORT,
and connect T-adapter to female side.
3. Set battery disconnect switch to ON position.
6 circuit in wiring harness
(contact with 24 V circuit)
CM02 (female) (10), (11) or TERMINATOR PORT (fe- 1 to 4 V
male) (A)
Voltage
CM02 (female) (12), or TERMINATOR PORT (female) 1 to 4 V
(B)
• When failure code [DA2RKR] is also displayed
Disconnect pump controller and engine controller one by one from CAN
communication line to determine which controller is defective.
OFF position.
7 Defective pump controller 2. Disconnect pump controller (connector CP01).
ON position.
Does either of failure codes [DA2RKR] If YES, the pump controller is defective.
and [DB2RKR] for CAN1 communication
error disappear?
REMARK
Disconnect pump controller and engine controller one by one from CAN com-
munication line to determine which controller is defective.
1. Turn the starting switch to OFF position, and turn the battery disconnect
Defective engine control- switch to OFF position.
8
ler 2. Disconnect engine controller (connector ECM J1).
3. Turn the battery disconnect switch to ON position, and turn the starting
switch to ON position.
Does number of CAN1 communication
failure codes decrease from those on If YES, the engine controller is defective.
[DA2RKR] and [DB2RKR]?
9
40-784 PC210LCI-11
PC210LCI-11 40-785
FAILURE CODE [DB90MC] 40 TROUBLESHOOTING
FAILURE CODE [DB90MC]

Action level Failure code Work Equipment Controller Reset
Failure
- DB90MC (Work equipment controller system)
Detail of fail-
Work equipment controller malfunctions.
ure
Action of
Work equipment controller restarts.
controller
Phenomenon
None in particular
on machine
Related After completion of repair, check that the failure code is cleared by the following procedure.

Defective work equip- Work equipment controller is defective. (Since this is an internal defect, trouble-
1
ment controller shooting cannot be performed.)
40-786 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB92KK]
FAILURE CODE [DB92KK]

Action level Failure code Work Equipment Controller Solenoid Power Voltage Low Error
Failure
L03 DB92KK (Work equipment controller system)
Detail of fail-
Power voltage for work equipment controller loads (relays and solenoids) is 17 V and below.
ure
Action of
Stops driving source output.
controller
Phenomenon
Work equipment cannot be operated.
on machine
• “Sensors are invalid” is displayed in control box.
• If the battery relay does not turn ON, see “ENGINE DOES NOT START (ENGINE DOES
Related NOT CRANK)” in E-mode.
information • After completion of repair, check that the failure code is cleared by the following proce-
dure.

If the fuse No.8 in the fuse box F13 is blown out, the circuit probably has ground
1 Defective fuse box
fault. In this case, perform check on cause 6 first.
Loose terminal or open Turn the starting switch to OFF position.

2
circuit at terminal Check the terminals of battery, battery relay, etc.
Perform the troubleshooting with starting switch at OFF position and when starting
Voltage Between battery terminals (+) and (-) 20 to 30 V
3. Insert the T-adapter into connector CW03.
Defective wiring harness 4. Turn the battery disconnect switch to ON position.
4 or work equipment con- 5. Turn the starting switch to ON position.
troller
Between CW03 (2) and (21) 20 to 30 V
Voltage Between CW03 (12) and (31) 20 to 30 V
If no failure is found by check on cause 4, this check is not required.
2. Turn the battery disconnect switch to OFF position .
3. Disconnect the connector CW03, and connect the T-adapter to female
side.
5 ness (wire breakage or Between ground and each of CW03 (female) (21),
defective contact) (31), (32) and (33)
Max. 1 Ω
REMARK
Resistance
Check the terminal T37 for looseness and rust.
Between M terminal and each of CW03 (female) (2),
Max. 1 Ω
(12) and (22)
PC210LCI-11 40-787
FAILURE CODE [DB92KK] 40 TROUBLESHOOTING

2. Turn the battery disconnect switch to OFF position .
6 harness (contact with 3. If the fuse No.8 in the fuse box F13 is blown out, replace the fuse.
ground circuit) 4. Disconnect the connector CW03, and connect the T-adapter to female
side.
Resistance Between ground and CW03 (female) (2), (12), or (22) Min. 1 MΩ
Defective work equip- If no failure is found by preceding checks, the work equipment controller is defec-
7
ment controller tive. (Since this is an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to work equipment controller solenoid
40-788 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB95KP]
FAILURE CODE [DB95KP]

Action level Failure code Work Equipment 5V Sensor 0 Power Voltage Low Error
Failure
L01 DB95KP (Work equipment controller system)
Detail of fail- Voltage of 5 V power supply (0) circuit from work equipment controller to sensors is 2.5 V and below
ure or 6.0 V and above.
Action of
Stops driving power supply.
controller
Phenomenon Sensor value of spool stroke sensor and PPC pressure sensor which are connected to this power
on machine supply becomes abnormal.

Related • After completion of repair, check that the failure code is cleared by the following proce-
information dure.

2. Disconnect the following connectors one by one, and turn the starting
switch to ON position each time.
If this failure code is cleared, disconnected sensor or device is defective.
REMARK
Other failure codes (many) are also displayed at the same time. This is due to dis-
Defective sensors (inter-
1 connection of connector. Ignore failure codes other than this [DB95KP].
nal defect)
Boom spool stroke sensor PA14
Arm spool stroke sensor PA15
Boom RAISE lever PPC pressure sensor P06A
Connector
Boom LOWER lever PPC pressure sensor P02A
Arm OUT lever PPC pressure sensor P08A
Arm IN lever PPC pressure sensor P04A
Defective work equip- 2. Disconnect the connector CW01, and connect the T-adapter to male side.
2
ment controller 3. Turn the starting switch to ON position.
Voltage Between CW01 (male) (22) and (21) 2.5 to 6.0 V
2. Disconnect all the connectors CW01, PA14, PA15, P02A, P04A, P06A and
Ground fault in wiring P08A, and connect the T-adapter to any female side.
Between ground and any of CW01 (female) (22), PA14
ground circuit)
(female) (1), PA15 (female) (1), P02A (female) (3),
P04A (female) (3), P06A (female) (3) and P08A (fe-
male) (3)
PC210LCI-11 40-789
FAILURE CODE [DB95KP] 40 TROUBLESHOOTING

2. Disconnect all the connectors PA14, PA15, P02A, P04A, P06A and P08A,
and connect the T-adapter to any female side.
4
harness Between PA14 (female) (1) and (2), between PA15 (fe-
male) (1) and (2), between P02A (female) (3) and (1),
Voltage between P04A (female) (3) and (1), between P06A (fe- 2.5 to 6.0 V
male) (3) and (1) and between P08A (female) (3) and
(1)
40-790 PC210LCI-11
Circuit diagram related to 5 V sensor power supply output (0)
PC210LCI-11 40-791
40-792 PC210LCI-11
FAILURE CODE [DB96KP]

Action level Failure code Work Equipment Controller 5V Sensor 1 Power Voltage Low Error
Failure
L01 DB96KP (Work equipment controller system)
Detail of fail- Voltage of 5 V power supply (1) circuit from work equipment controller to sensors is 2.5 V and below
ure or 6.0 V and above.
Action of
controller
Phenomenon Sensor value of PPC pressure sensor which are connected to this power supply becomes abnor-
on machine mal.

information dure.

REMARK
connection of connector. Ignore failure codes other than this [DB96KP].
Bucket DUMP lever PPC pressure sensor P05A
Defective sensors (inter- Bucket CURL lever PPC pressure sensor P01A
1
nal defect) Boom RAISE PPC pressure sensor P06
Boom LOWER PPC pressure sensor P02
Arm OUT PPC pressure sensor P08
Connector Arm IN PPC pressure sensor P04
Bucket DUMP PPC pressure sensor P05
Bucket CURL PPC pressure sensor P01
Swing LEFT PPC pressure sensor P03
Swing RIGHT PPC pressure sensor P07
PPC source pressure sensor PA10
2. Disconnect the connector CW02, and connect the T-adapter to male side.
Defective work equip- 3.
2 Insert the T-adapter into connector CW01.
ment controller
Voltage Between CW02 (male) (1) and CW01 (4) 2.5 to 6.0 V
PC210LCI-11 40-793

2. Disconnect all the connectors CW02, P01, P01A, P02, P03, P04, P05,
P05A, P06, P07, P08 and PA10, and connect the T-adapter to any female
Ground fault in wiring side.
Between ground and each of CW02 (female) (1), P01
ground circuit)
(female) (3), P01A (female) (3), P02 (female) (3), P03
Resistance (female) (3), P04 (female) (3), P05 (female) (3), P05A Min. 1 MΩ
(female) (3), P06 (female) (3), P07 (female) (3), P08
(female) (3) and PA10 (female) (3)
2. Disconnect all the connectors P01, P01A, P02, P03, P04, P05, P05A, P06,
P07, P08 and PA10, and connect the T-adapter to any female side.
Hot short circuit in wiring Between P01 (female) (3) and (1), between P01A (fe-
4 male) (3) and (1), between P02 (female) (3) and (1),
harness
between P03 (female) (3) and (1), between P04 (fe-
male) (3) and (1), between P05 (female) (3) and (1),
between P05A (female) (3) and (1), between P06 (fe-
male) (3) and (1), between P07 (female) (3) and (1),
between P08 (female) (3) and (1) and between PA10
40-794 PC210LCI-11
PC210LCI-11 40-795
40-796 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB99KQ]
FAILURE CODE [DB99KQ]

Action level Failure code Model Selection Signal Mismatch (Work Equipment Controller)
Failure
L04 DB99KQ (Work equipment controller system)
Detail of fail-
Model code signal for model which is not registered in controller is inputted.
ure
Action of
Controls it as default model (PC210LCI-11).
controller
• Auto grade assist and stop control does not operate normally in semi-auto mode.
Phenomenon
• Semi-auto mode cannot be selected in Manual mode.
on machine
• Manual mode is automatically selected in semi-auto mode.
• “Sensors are invalid” is displayed on the control box.
• Assembly part number of work equipment controller can be checked with monitoring func-
tion. (Code: 20244)
• Signal state (ON/OFF) of model selection signal can be checked with monitoring function.
(Code: 40981)
• If failure code [DB99KQ] and [DBR9KQ] are also displayed, ground fault or short circuit of
the wiring harness which is branched from the connector S31 may be a cause of failure.
Related • PC210LCI-11
information Model selection 1:ON
• After completion of repair, check with the following operation that the failure code is
cleared.

Wrong part number of 1. Display the assembly part number with monitoring function, and check if
1 work equipment control- the displayed number is same as the one in the parts book.
ler
2. Disconnect the connector S31, and connect the T-adapter to female side.
Between S31 (female) (1) and (2) Max. 1 Ω
Defective model selec-
2 Between S31 (female) (1) and (5) Max. 1 Ω
tion connector
Resistance Between S31 (female) (1) and (3) Min. 1 MΩ
Between S31 (female) (1) and (4) Min. 1 MΩ
Open circuit in wiring har- side.
3
ness
Between CW02 (female) (13) and (27) Max. 1 Ω
Resistance
Between CW02 (female) (13) and (37) Max. 1 Ω
PC210LCI-11 40-797
FAILURE CODE [DB99KQ] 40 TROUBLESHOOTING

2. Disconnect the connectors CS01, CS02, and CW02, and connect the T-
adapter to female side of connector CW02.
4
harness Between CW02 (female) (7) and ground Min. 1 MΩ
Resistance Between CW02 (female) (13) and ground Min. 1 MΩ
Between CW02 (female) (17) and ground Min. 1 MΩ
2. Disconnect the connectors CS01, CS02, CW02, and S31, and connect the
T-adapter to female side of connector CS01, CS02, and CW02.
No continui-
Between CS01 (female) (5) and each pin other than (5)
ty
Between CS01 (female) (11) and each pin other than No continui-
(11) ty
(17) ty
(23) ty
5 Between CS02 (female) (13) and each pin other than No continui-
ness
(13) ty
Continuity
Between CW02 (female) (7) and each pin other than No continui-
(7) ty
(13) ty
(17) ty
(27) ty
(37) ty
6
40-798 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB99KQ]
Circuit diagram related to model selection
PC210LCI-11 40-799
FAILURE CODE [DB9LKA] 40 TROUBLESHOOTING
FAILURE CODE [DB9LKA]

Action level Failure code Operating Lamp Open Circuit (Work Equipment Controller)
Failure
- DB9LKA (Work equipment controller system)
The work equipment controller has detected an open circuit because the output line voltage of sys-
Detail of fail-
tem operating lamp is approximately 5 V and below when the work equipment controller does not
ure
output the voltage for approximately 3 seconds after the starting switch is turned to ON position.
Action of
None in particular
controller
Phenomenon Do not turn the battery disconnect switch to OFF position while the system operating lamp is lit. If
the battery disconnect switch is turned to OFF position while the system operating lamp is lit, the
on machine data stored in work equipment controller memory may be destroyed.
• When this system is normal, any controller can make system operating lamp light up.
While this failure code is displayed, work equipment controller cannot make system oper-
ating lamp light up, but no trouble will result unless battery disconnect switch is turned to
OFF position.
Related • When controller lights up system operating lamp, output circuit voltage is at low level.
information • Since no controller drives system operating lamp for approximately 3 seconds after start-
dure.

1 Defective fuse box If the fuse No.16 in the fuse box F01 is blown out, circuit probably has ground fault.
2. Remove the fuse No.16 in fuse box F01
ness (wire breakage or 3. Disconnect the connectors CW03 and L19, and connect the T-adapter to
2 each female side.
nector)
Between CW03 (female) (34) and L19 (female) (2) Max. 1 Ω
Resistance
Between L19 (female) (1) and F01-16 Max. 1 Ω
3
40-800 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB9LKA]
PC210LCI-11 40-801
FAILURE CODE [DB9LKB] 40 TROUBLESHOOTING
FAILURE CODE [DB9LKB]

Action level Failure code Operating Lamp Hot Short Circuit (Work Equipment Controller)
Failure
- DB9LKB (Work equipment controller system)
Detail of fail- Work equipment controller has detected a hot short circuit because voltage of output circuit does
ure not become low level while work equipment controller outputs current to system operating lamp.
• Turns the system operating lamp output to “OFF”.
Action of
controller
on machine data stored in work equipment controller memory may be destroyed.
Related OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
dure.

1
L19.
2
3
40-802 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DB9LKB]
PC210LCI-11 40-803
FAILURE CODE [DB9QKR]

Action level Failure code CAN 2 Defective Communication (Work Equipment Controller)
Failure
L03 DB9QKR (Machine monitor system)
Detail of fail- Machine monitor cannot recognize work equipment controller on CAN 2 communication line (KOM-
ure NET/c).
Action of
None
controller
Phenomenon
None
on machine
• ACC signal of starting switch is the command to start CAN communication of each control-
ler.
REMARK
using multimeter.

1 Defective fusible link If the fusible link F05 is blown out, circuit probably has ground fault.
4 or work equipment con- 4. Turn the battery disconnect switch to ON position.
troller 5. Turn the starting switch to ON position.
Voltage
40-804 PC210LCI-11

side.
Max. 1 Ω
REMARK
Resistance
Check the terminal TA01 for looseness and rust.
Between the battery relay and each of CW03 (female)
Max. 1 Ω
(1) and (11)
3. If the fuse No.1 in the fuse box F13 is blown out, replace the fuse.
side.
Between ground and each of CW03 (female) (1) and
(11)
ing resistor side.
7
circuit) Resistance
PC210LCI-11 40-805

REMARK
OFF position.
measured.
REMARK
wiring harness
Approx.
120 Ω
Approx.
60 Ω
Approx.
60 Ω
Resistance
Approx.
60 Ω
Approx.
60 Ω
Approx.
120 Ω
40-806 PC210LCI-11

OFF position.
ON position.
Voltage
quired.
9
Resistance
Min. 1 MΩ
Resistance
Min. 1 MΩ
PC210LCI-11 40-807

OFF position.
1 to 4 V
AC01 (2), and ECM J2 (22)
Voltage
1 to 4 V
AC01 (1), and ECM J2 (46)
played:
OFF position.
to ON position.
13
14 case of an internal defect, troubleshooting is impossible as an assembly. Replace
tor
whole assembly.)
40-808 PC210LCI-11
PC210LCI-11 40-809
40-810 PC210LCI-11
FAILURE CODE [DB9RKR]

Action level Failure code CAN 1 Defective Communication (Work Equipment Controller)
Failure
L03 DB9RKR (Machine monitor system)
Detail of fail- Machine monitor cannot recognize work equipment controller on CAN 1 communication line (KOM-
ure NET/r).
Action of
controller
Phenomenon Information to be obtained from work equipment controller is not displayed and special functions
on machine that need information do not work. Or update of received data is stopped.
• ACC signal of starting switch is the command to start CAN communication.

• Terminating resistor of CAN 1 on cab side is provided in machine monitor, and that on en-
Related
gine side is connector TERMINATOR PORT.
information
using multimeter.

1 Defective fusible link If the fusible link F05 is blown out, circuit probably has ground fault.
4 or work equipment con- 4. Turn the battery disconnect switch to ON position.
troller 5. Turn the starting switch to ON position.
Voltage
PC210LCI-11 40-811

side.
Max. 1 Ω
REMARK
Resistance
Check the terminal TA01 for looseness and rust.
Between the battery relay and each of CW03 (female)
Max. 1 Ω
(1) and (11)
3. If the fuse No.1 in the fuse box F13 is blown out, replace the fuse.
side.
Between ground and each of CW03 (female) (1) and
(11)
Resistance
REMARK
OFF position.
8
Approx.
120 Ω
Approx.
60 Ω
Resistance
Approx.
120 Ω
Approx.
60 Ω
40-812 PC210LCI-11

OFF position.
ON position.
quired.
ness
9 OFF position.
Max. 1 Ω
(70)

Max. 1 Ω
(94)
Max. 1 Ω
PORT (male) (A)
Max. 1 Ω
PORT (male) (B)
OFF position.
harness
Resistance
PC210LCI-11 40-813

OFF position.
male) (A)
Voltage
(B)
OFF position.
ON position.
error disappear?
REMARK
13
14
tor
whole assembly.)
40-814 PC210LCI-11
PC210LCI-11 40-815
40-816 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBP0KM]
FAILURE CODE [DBP0KM]

Action level Failure code KomVision Setting Error
Failure
L01 DBP0KM (KomVision controller system)
Detail of fail-
There is an error or an incomplete item in the KomVision controller setting.
ure
Action of
Stops the image output of KomVision
controller
Phenomenon
Display area of KomVision is displayed in black.
on machine
dure.
information Procedure: Turn the starting switch to ON position and display a Bird's Eye View

Incomplete KomVision See testing and adjusting“ADJUST KomVision RELATED ITEMS”, and check that
1
Setting the setting is done correctly.
PC210LCI-11 40-817
FAILURE CODE [DBP0KT] 40 TROUBLESHOOTING
FAILURE CODE [DBP0KT]

Action level Failure code KomVision Controller Abnormality
Failure
L01 DBP0KT (KomVision controller system)
Detail of fail-
Abnormal operation of KomVision controller
ure
Action of
Stops the image output of KomVision
controller
Phenomenon
Display area of KomVision is displayed in black.
on machine
dure.
information Procedure: Turn the starting switch to ON position and display a Bird's Eye View

Defective KomVision KomVision controller is defective. (Since this is an internal defect, troubleshooting
1
controller cannot be performed.)
40-818 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBPQKR]
FAILURE CODE [DBPQKR]

Action level Failure code CAN 2 Defective Communication (KomVision)
Failure
L01 DBPQKR (Machine monitor system)
Detail of fail- Machine monitor cannot recognize KomVision controller through CAN communication 2 line (KOM-
ure NET/c).
Action of
None in particular
controller
Phenomenon
Screen operation of KomVision becomes impossible.
on machine
troller.
• 7 different failure codes, [D8AQKR], [DA2QKR], [DB9QKR], [DAZQKR], [DB2QKR],
[DBRQKR], and [DBPQKR] are used for defective CAN communication by CAN 2 when it
is detected by machine monitor. When all of these 7 failure codes are displayed, ground
fault, short circuit or hot short circuit in wiring harness (CAN communication circuit) can be
suspected.
REMARK
If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
Related
information
• This can be activated even when power supply to KomVision controller is turned off.
• This can be activated if "With KomVision" is selected when setting the machine monitor for
the machine without KomVision specification.
using multimeter.

2. Check that system operating lamp is not lit, and then turn the battery dis-
3. Remove the fuse No. 15 in fuse box F02. Check visually if it is not burnt
1 Defective fuse out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
PC210LCI-11 40-819
FAILURE CODE [DBPQKR] 40 TROUBLESHOOTING

3. Disconnect connector CA02 and connect T-adapter to female side.
Defective KomVision
2 controller power supply
circuit REMARK
If there is no failure, troubleshooting for No. 3 is not required.
Between CA02 (female) (112) and (104) 20 to 30 V
Voltage
2. Check that system operating lamp is turned off, and then turn the battery
3. Remove fuse No.15 in fuse box F02
Open circuit in wiring har- 4. Disconnect connector CA02 and connect T-adapter to female side.
3
ness
Between CA02 (female) (112) and F02-15 Max. 1 Ω
Resistance
Between CA02 (female) (104) and ground Max. 1 Ω
3. Disconnect the connector CA02, and connect the T-adapter to female side.
Defective KomVision 4. Turn the battery disconnect switch to ON position.
4 controller ACC signal cir- 5. Turn the starting switch to ON position.
cuit
REMARK
If there is no failure, troubleshooting for No. 5 is not required.
Voltage
Open circuit in wiring har- 4. Disconnect the connector CA02, and connect the T-adapter to female side.
5
ness
Resistance
2. Disconnect the connectors CM02 and K02, and connect the T-adapter to
Defective CAN 2 termi- each male side.
6
nating resistor
Resistance
40-820 PC210LCI-11

3. Disconnect the connectors CA02, CK01, and K02, and connect the T-
Open circuit in wiring har- adapter to each female side.
7 ness (CAN 2 communi- Between CA02 (female) (110) and CM02 (female) (7) Max. 1 Ω
cation line)
Between CA02 (female) (110) and CM02 (female) (8) Max. 1 Ω
Resistance Between CA02 (female) (111) and CM02 (female) (9) Max. 1 Ω
Between CA02 (female) (110) and K02 (female) (A) Max. 1 Ω
Between CA02 (female) (111) and K02 (female) (B) Max. 1 Ω
3. Disconnect the connector CA02 and CM02, and connect the T-adapter to
8 harness (CAN 2 commu- 4. Disconnect the connectors, terminals, and fuses of all the devices which
nication line) branch out from connector CA02 (110) and (111).
Between ground and any of CA02 (female) (110),
Min. 1 MΩ
CM02 (female) (7), and (8)
Resistance
Between ground and either CA02 (female) (111) or
Min. 1 MΩ
CM02 (female) (9)
3. Insert T-adapter into connector K02.
9 harness (CAN 2 commu- 5. Turn the starting switch to ON position.
nication line) REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and K02 (A) 1 to 4 V
Voltage
Between ground and K02 (B) 1 to 4 V
Defective KomVision If no failure is found by above checks, KomVision controller is defective. (Since this
10
controller is an internal defect, troubleshooting cannot be performed).
11
PC210LCI-11 40-821
FAILURE CODE [DBPQKR] 40 TROUBLESHOOTING
Circuit diagram related to CAN2 communication
40-822 PC210LCI-11
Circuit diagram related to KomVision controller power supply
PC210LCI-11 40-823
FAILURE CODE [DBR0MC] 40 TROUBLESHOOTING
FAILURE CODE [DBR0MC]

Action level Failure code ICT Sensor Controller Reset
Failure
- DBR0MC (ICT sensor controller system)
Detail of fail-
ICT sensor controller malfunction
ure
Action of
ICT sensor controller restarts.
controller
Phenomenon
None in particular
on machine

Defective ICT sensor ICT sensor controller is defective. (Since this is an internal defect, troubleshooting
1
controller cannot be performed.)
40-824 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBR2KK]
FAILURE CODE [DBR2KK]

Action level Failure code ICT Sensor Controller Solenoid Power Low Error
Failure
L01 DBR2KK (ICT sensor controller system)
Detail of fail-
Power voltage for ICT sensor controller loads (relays and solenoids) is 17 V and below.
ure
Action of
Stops driving source output.
controller
Phenomenon
None in particular
on machine
• If the battery relay does not turn ON, see “ENGINE DOES NOT START (ENGINE DOES
Related NOT CRANK)” in E-mode.
information • After completion of repair, check that the failure code is cleared by the following proce-
dure.


2
3. Insert the T-adapter into connector CS03.
4 5.
or ICT sensor controller Turn the starting switch to ON position.
Between CS03 (2) and (21) 20 to 30 V
Voltage Between CS03 (12) and (31) 20 to 30 V
3. Disconnect the connector CS03, and connect the T-adapter to female side.
REMARK
Open circuit in wiring har- Check the ground terminal for looseness and rust.
5 ness (wire breakage or
defective contact) Between CS03 (female) (21) and ground Max. 1 Ω
Between CS03 (female) (31) and ground Max. 1 Ω
Resistance
Between M terminal and each of CS03 (female) (2),
Max. 1 Ω
(12) and (22)
PC210LCI-11 40-825
FAILURE CODE [DBR2KK] 40 TROUBLESHOOTING

Ground fault in wiring 2. Turn the battery disconnect switch to OFF position.
3. If the fuse F13-7 is blown out, replace the fuse.
ground circuit)
Resistance Between ground and CS03 (female) (2), (12), or (22) Min. 1 MΩ
Defective ICT sensor If no failure is found by preceding checks, ICT sensor controller is defective. (Since
7
controller this is an internal defect, troubleshooting cannot be performed).
40-826 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBR2KK]
Circuit diagram related to ICT sensor controller solenoid power supply
PC210LCI-11 40-827
FAILURE CODE [DBR5KP] 40 TROUBLESHOOTING
FAILURE CODE [DBR5KP]

Action level Failure code ICT Controller 5V Sensor 0 Power Low Error
Failure
L01 DBR5KP (ICT sensor controller system)
Detail of fail- Voltage of 5 V power supply (0) circuit from ICT sensor controller to sensors is 2.5 V and below or
ure 6.0 V and above.
Action of
controller
Phenomenon Sensor value of stroke sensor and reset sensor for cylinder which is connected to this power supply
on machine becomes abnormal.

information dure.

Defective stroke sensor
for boom cylinder or
stroke sensor for arm cyl- REMARK
1 inder or stroke sensor for
bucket cylinder or stroke
connection of connector. Ignore failure codes other than this [DBR5KP].
sensor for bucket tilt cyl-
inder (internal defect) Stroke sensor for boom cylinder PA01
Stroke sensor for arm cylinder PA02
Connector
Stroke sensor for bucket cylinder PA03
Stroke sensor for bucket tilt cylinder AA29
Defective ICT sensor 2. Disconnect the connector CS01, and connect the T-adapter to male side.
2
controller 3. Turn the starting switch to ON position.
Voltage Between CS01 (male) (22) and (21) 2.5 to 6.0 V
2. Disconnect the connectors CS01, PA01, PA02, PA03 and AA40, and con-
nect the T-adapter to any female side.
ground circuit) Between ground and CS01 (female) (22) or PA01 (fe-
Resistance male) (C) or PA02 (female) (C) or PA03 (female) (C) or Min. 1 MΩ
AA29 (female) (C)
2. Disconnect the connectors PA01, PA02, PA03 and AA40, and connect the
T-adapter to any female side.
4 3. Turn the starting switch to ON position.
harness
Between PA01 (female) (C) and (D) or between PA02
Voltage (female) (C) and (D) or PA03 (female) (C) and (D) or 2.5 to 6.0 V
AA29 (female) (C) and (D)
40-828 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBR5KP]
PC210LCI-11 40-829
FAILURE CODE [DBR6KP] 40 TROUBLESHOOTING
FAILURE CODE [DBR6KP]

Action level Failure code ICT Controller 5V Sensor 1 Power Low Error
Failure
L01 DBR6KP (ICT sensor controller system)
Detail of fail- Voltage of 5 V power supply (1) circuit from ICT sensor controller to sensors is 2.5 V and below or
ure 6.0 V and above.
Action of
controller
Phenomenon Sensor value of stroke reset encoder for cylinder which is connected to this power supply becomes
on machine abnormal.

information dure.

Defective stroke reset 3. Each time troubleshooting is finished, return to step 1.
encoder for arm cylinder If this failure code is cleared, disconnected sensor or device is defective.
1 or stroke reset encoder
for boom cylinder (inter- REMARK
nal defect) Other failure codes (many) are also displayed at the same time. This is due to dis-
connection of connector. Ignore failure codes other than this [DBR6KP].
Stroke reset encoder for boom cylinder PA18
Connector
Stroke reset encoder for arm cylinder PA19
Defective ICT sensor 2. Disconnect the connector CS02, and connect the T-adapter to male side.
2
Voltage Between CS02 (male) (1) and (29) 2.5 to 6.0 V
Ground fault in wiring 2. Disconnect all the connectors CS02, PA19 and PA18, and connect the T-
3 harness (contact with adapter to any female side.
ground circuit)
Between ground and each of CS02 (female) (1), PA19
(female) (1) and PA18 (female) (1)
2. Disconnect all the connectors PA19 and PA18, and connect the T-adapter
Hot short circuit in wiring to either female side.
4
Between PA19 (female) (1) and (2), and between PA18
40-830 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBR6KP]
PC210LCI-11 40-831
FAILURE CODE [DBR9KQ] 40 TROUBLESHOOTING
FAILURE CODE [DBR9KQ]

Action level Failure code Model Selection Signal Mismatch (ICT Sensor Controller)
Failure
L04 DBR9KQ (ICT sensor controller system)
Detail of fail-
Model code signal for model which is not registered in controller is inputted.
ure
Action of
Controls it as default model (PC210LCI-11).
controller
• Auto grade assist and stop control does not operate normally in semi-auto mode.
Phenomenon
• Semi-auto mode cannot be selected in Manual mode.
on machine
• Manual mode is automatically selected in semi-auto mode.
• Assembly part number of ICT sensor controller can be checked with monitoring function.
(Code: 20292)
• Signal state (ON/OFF) of machine model selection can be checked with monitoring func-
tion. (Code: 74200)
• If failure code [DB99KQ] and [DBR9KQ] are also displayed, ground fault or short circuit of
the wiring harness which is branched from the connector S31 may be a cause of failure.
Related • PC210LCI-11
information Model selection 1:ON
dure.

Wrong part number of Display assembly part number by monitoring function, and check that displayed
1
ICT sensor controller number is same as the one in the parts book.
2. Disconnect the connector S31, and connect the T-adapter to female side.
Between S31 (female) (1) and (2) Max. 1 Ω
Defective model selec-
2 Between S31 (female) (1) and (5) Max. 1 Ω
tion connector
Resistance Between S31 (female) (1) and (3) Min. 1 MΩ
2. Disconnect the connectors CS01 and CS02, and connect the T-adapter to
3
ness
Between CS01 (female) (17) and (23) Max. 1 Ω
Resistance
Between CS01 (female) (17) and CS02 (female) (13) Max. 1 Ω
40-832 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBR9KQ]

2. Disconnect the connectors CS01, CS02, and CW02, and connect the T-
adapter to female side of connector CS01.
4
harness Between CS01 (female) (5) and ground Min. 1 MΩ
Resistance Between CS01 (female) (11) and ground Min. 1 MΩ
Between CS01 (female) (17) and ground Min. 1 MΩ
2. Disconnect the connectors CS01, CS02, CW02, and S31, and connect the
T-adapter to female side of connector CS01, CS02, and CW02.
No continui-
Between CS01 (female) (5) and each pin other than (5)
ty
(11) ty
(17) ty
(23) ty
5 Between CS02 (female) (13) and each pin other than No continui-
ness
(13) ty
Continuity
(7) ty
(13) ty
(17) ty
(27) ty
(37) ty
6
PC210LCI-11 40-833
FAILURE CODE [DBR9KQ] 40 TROUBLESHOOTING
Circuit diagram related to model selection
40-834 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBRLKA]
FAILURE CODE [DBRLKA]

Action level Failure code Operating Lamp Open Circuit (ICT Controller)
Failure
- DBRLKA (ICT sensor controller system)
ICT sensor controller determines that system operating lamp circuit is open because voltage of out-
Detail of fail-
put circuit remains at 5 V and below for approximately 3 seconds after starting switch is turned to
ure
ON position, during which ICT sensor controller outputs no current to system operating lamp.
Action of
None in particular
controller
on machine data stored in ICT sensor controller memory may be destroyed.
OFF position.
• When controller makes system operating lamp light up, output circuit voltage is at low lev-
Related
el.
information
dure.

1 Defective fuse box If the fuse No.16 in the fuse box F01 is blown out, circuit probably has ground fault.
ness (wire breakage or 3. Disconnect the connectors CS03 and L19, and connect the T-adapter to
2 each female side.
nector)
Between CS03 (female) (34) and L19 (female) (2) Max. 1 Ω
Resistance
Between L19 (female) (1) and F01-16 Max. 1 Ω
3
PC210LCI-11 40-835
FAILURE CODE [DBRLKA] 40 TROUBLESHOOTING
40-836 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBRLKB]
FAILURE CODE [DBRLKB]

Action level Failure code Operating Lamp Hot Short (ICT Sensor Controller)
Failure
- DBRLKB (ICT sensor controller system)
ICT sensor controller determines that system operating lamp circuit has hot short circuit because
Detail of fail-
voltage of output circuit does not become low level while ICT sensor controller outputs current to
ure
system operating lamp.
• Turns the system operating lamp output to “OFF”.
Action of
controller
on machine data stored in ICT sensor controller memory may be destroyed.
OFF position.
Related
• When controller makes system operating lamp light up, output circuit voltage is at low lev-
information el.
dure.

1
L19.
2
3
PC210LCI-11 40-837
FAILURE CODE [DBRLKB] 40 TROUBLESHOOTING
40-838 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBRQKR]
FAILURE CODE [DBRQKR]

Action level Failure code CAN 2 Defective Communication (ICT Controller)
Failure
L01 DBRQKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize ICT sensor controller through CAN communication 2 line
ure (KOMNET/c).
Action of
None
controller
Phenomenon
None
on machine
REMARK
Related
using multimeter.


2
4 5.
PC210LCI-11 40-839
FAILURE CODE [DBRQKR] 40 TROUBLESHOOTING

5 ness (wire breakage or Between ground and each of CS03 (female) (21), (31),
defective contact) (32), and (33)
Max. 1 Ω
REMARK
Resistance
Check the ground terminal for looseness and rust.
Max. 1 Ω
(12) and (22)
ground circuit)
ing resistor side.
7
circuit) Resistance
40-840 PC210LCI-11

REMARK
OFF position.
measured.
REMARK
wiring harness
Approx.
120 Ω
Approx.
60 Ω
Approx.
60 Ω
Resistance
Approx.
60 Ω
Approx.
60 Ω
Approx.
120 Ω
PC210LCI-11 40-841

OFF position.
ON position.
Voltage
quired.
9
Resistance
Min. 1 MΩ
Resistance
Min. 1 MΩ
40-842 PC210LCI-11

OFF position.
1 to 4 V
AC01 (2), and ECM J2 (22)
Voltage
1 to 4 V
AC01 (1), and ECM J2 (46)
played:
OFF position.
to ON position.
13
tor
whole assembly.)
PC210LCI-11 40-843
40-844 PC210LCI-11
PC210LCI-11 40-845
FAILURE CODE [DBRRKR] 40 TROUBLESHOOTING
FAILURE CODE [DBRRKR]

Action level Failure code CAN 1 Defective Communication (ICT Controller)
Failure
L01 DBRRKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize ICT sensor controller through CAN communication 1 line
ure (KOMNET/r).
Action of
controller
Phenomenon Information to be obtained from ICT controller is not displayed and special functions that need infor-
on machine mation do not work. Or update of received data is stopped.

• Terminating resistor of CAN 1 on cab side is provided in machine monitor, and that on en-
Related
gine side is connector TERMINATOR PORT.
information
using multimeter.


2
4 5.
40-846 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBRRKR]

5 ness (wire breakage or Between ground and each of CS03 (female) (21), (31),
defective contact) (32), and (33)
Max. 1 Ω
REMARK
Resistance
Check the ground terminal for looseness and rust.
Max. 1 Ω
(12) and (22)
ground circuit)
Resistance
REMARK
OFF position.
8
Approx.
120 Ω
Approx.
60 Ω
Resistance
Approx.
120 Ω
Approx.
60 Ω
PC210LCI-11 40-847

OFF position.
ON position.
quired.
ness
9 OFF position.
Max. 1 Ω
(70)

Max. 1 Ω
(94)
Max. 1 Ω
PORT (male) (A)
Max. 1 Ω
PORT (male) (B)
OFF position.
harness
Resistance
40-848 PC210LCI-11

OFF position.
male) (A)
Voltage
(B)
OFF position.
ON position.
error disappear?
REMARK
13
14
tor
whole assembly.)
PC210LCI-11 40-849
40-850 PC210LCI-11
PC210LCI-11 40-851
FAILURE CODE [DBRSKB] 40 TROUBLESHOOTING
FAILURE CODE [DBRSKB]

Action level Failure code Battery Relay Output Short Circuit (ICT Sensor Controller)
Failure
L01 DBRSKB (ICT controller system)
Detail of fail- When controller outputs 17 V to primary (coil side) circuit of battery relay, abnormal current flows
ure through circuit.
• Stops outputting 17 V to primary (coil side) circuit of battery relay.
Action of
controller
• There may be a trouble in writing the data into EEPROM (a memory which can be cleared
electrically and recorded contents is not cleared even if the power is turned off) of each
Phenomenon
controller.
on machine
• Since the battery relay is turned off, the phenomenon is same as that the starting switch is
turned to OFF position (the machine stops suddenly).
information Procedure: Turn the starting switch to ON position and OFF position, and then wait for 0.5 seconds.
Defective battery relay 1. Turn starting switch to OFF position.

1
(internal short circuit) Continuity Between terminals R01(E) and R02(BR) Continuity
3. Disconnect the terminals R01 and R02, and connectors D01, H15 and
CS03.
2 harness (contact with Between R02 (BR) terminal and ground Min. 1 MΩ
ground circuit)
Between ground and each of R02 terminal (harness
Min. 1 MΩ
Resistance side) and D01 (female) (1) or (2)
Between CS03 (female) (4) and ground Min. 1 MΩ
Between D01 (female) (5) and ground Min. 1 MΩ
If no failure is found by preceding checks, ICT sensor controller is defective.
Reference
Defective ICT sensor 2. Insert the T-adapter into connector D01.
3
4. Turn the starting switch to ON position and OFF position, and then wait for
4 to 7 seconds.
Voltage Between D01 (1) and ground 20 to 30 V
40-852 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBRSKB]
Circuit diagram related to ICT controller battery relay
PC210LCI-11 40-853
FAILURE CODE [DBRTKB] 40 TROUBLESHOOTING
FAILURE CODE [DBRTKB]

Action level Failure code Control Box Starting Power Short Circuit (ICT Controller)
Failure
L01 DBRTKB (ICT sensor controller system)
Detail of fail-
Abnormal current flows through control box starting circuit.
ure
Action of
None in particular
controller
Phenomenon
Control box shuts down.
on machine
• State of control box starting circuit can be checked with monitoring function. (Code:
75001)
Related
information
dure.

Defective control box (in- 2.
1 Disconnect the connector AA28, and connect the T-adapter to male side.
ternal short circuit)
Resistance Between AA28 (male) (Y) and ground Min. 1 MΩ
Ground fault in wiring 2. Disconnect the connectors CS02 and CS03, and connect the T-adapter to
2 harness (contact with each female side.
ground circuit)
Between CS02 (female) (19) and each of CS03 (fe-
male) (31), (32) and (33)
2. Disconnect the connectors CS02, AA27 and AA28, and connect the T-
Ground fault in wiring adapter to each female side.
ground circuit) Between ground and CS02 (female) (19) or AA27 (fe-
Min. 1 MΩ
male) (20)
Resistance
Between ground and AA27 (female) (20) or AA28 (fe-
Min. 1 MΩ
male) (Y)
4
40-854 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBRTKB]
Circuit diagram related to control box
PC210LCI-11 40-855
FAILURE CODE [DBUSKR] 40 TROUBLESHOOTING
FAILURE CODE [DBUSKR]

Action level Failure code Ethernet 0 Defective Communication (GNSS Controller)
Failure
L01 DBUSKR (ICT sensor controller system)
Detail of fail-
Control box cannot recognize GNSS receiver.
ure
Action of
None in particular
controller
Phenomenon
Machine image stops on the screen of control box.
on machine
• The message of “GPS receiver not connected!” is displayed on control box.
information dure.

2. Turn off the power supply of the control box.
Open circuit in Ethernet 4. Disconnect the connectors CG01 and AA28, and connect the T-adapter to
wiring harness (wire each female side.
1
breakage or defective
contact) Between AA28 (female) (V) and CG01 (female) (23) Max. 1 Ω
Between AA28 (female) (W) and CG01 (female) (33) Max. 1 Ω
Resistance
Between AA28 (female) (T) and CG01 (female) (3) Max. 1 Ω
Between AA28 (female) (U) and CG01 (female) (13) Max. 1 Ω
4. Disconnect the connectors CX03 and CG01, and connect the T-adapter to
female side of CG01.
REMARK
Check it by using multimeter in continuity mode.
No continui-
Between CG01 (female) (3) and each pin other than
Short circuit in Ethernet ty (no sound
2 (3)
wiring harness is heard)
No continui-
ty (no sound
(13)
is heard)
Continuity
No continui-
ty (no sound
(23)
is heard)
No continui-
ty (no sound
(33)
is heard)
40-856 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBUSKR]

4. Disconnect the connectors CG01 and CX03, and connect the T-adapter to
Ground fault in Ethernet
each female side.
3 wiring harness (contact
with ground circuit) Between CG01 (female) (23) and ground Min. 1 MΩ
Between CG01 (female) (33) and ground Min. 1 MΩ
Resistance
Open circuit in GNSS re-
ceiver power signal wir- 3. Turn the battery disconnect switch to OFF position.
4
ing harness (wire break- 4. Disconnect the connectors CG01 and AA28, and connect the T-adapter to
age or defective contact) each female side.
Resistance Between AA28 (female) (N) and CG01 (female) (24) Max. 1 Ω
Ground fault in GNSS re-
ceiver power signal wir- 3. Turn the battery disconnect switch to OFF position.
5
ing harness (contact with 4. Disconnect the connectors CG01, CS03 and CX02, and connect the T-
GND circuit) adapter to each female side.
Resistance Between CG01 (female) (24) and (16) or ground Min. 1 MΩ
6 Defective control box 4. Insert the T-adapter into connector AA28.
6. Turn on the power supply of the control box.
Voltage Between AA28 (N) and (r) 20 to 30 V
PC210LCI-11 40-857
FAILURE CODE [DBUSKR] 40 TROUBLESHOOTING

4. Disconnect the connector CG01, and connect the T-adapter to female
side.
Between CG01 (female) (16) and ground Max. 1 Ω
Resistance Between CG01 (female) (26) and ground Max. 1 Ω
Open circuit in GNSS re-
7 ceiver GND wiring har- Between CG01 (female) (36) and ground Max. 1 Ω
ness
If any failure is found by preceding checks, perform the following troubleshooting.
4. Disconnect the connectors CG01 and AA28, and connect the T-adapter to
each female side.
Resistance Between CG01 (female) (16) and AA28 (female) (r) Max. 1 Ω
3. While pressing “FN button” (2) at Main side of the GNSS receiver, turn the
8 Defective GNSS receiver 4. Check that LED (3) at the side of “FN button” (2) flashes in orange and
changes to green, and then release “FN button”.
5. Perform 2 through 4 on “FN button” (4) at auxiliary side as well.
If this failure code is not cleared after performing 1 through 5, the GNSS receiver
(1) is defective (Since this is an internal defect, troubleshooting cannot be per-
formed).
GNSS receiver
40-858 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DBUSKR]
Circuit diagram related to control box
PC210LCI-11 40-859
FAILURE CODE [DD20MA] 40 TROUBLESHOOTING
FAILURE CODE [DD20MA]

Action level Failure code Auto/Manual Selector Switch Error
Failure
L01 DD20MA (Work equipment controller system)
Detail of fail- Auto/manual switch circuit has an open circuit or ground fault, and semi-auto mode and manual
ure mode are switched unintentionally.
Action of • Semi-auto mode cannot be selected in manual mode.
controller • Manual mode is automatically selected in semi-auto mode.
• Even if the auto/manual switch is pressed, semi-auto mode and manual mode are not
Phenomenon switched correctly.
on machine • Even if the auto/manual switch is not pressed, semi-auto mode and manual mode are
switched.
information dure.
Procedure: Turn the starting switch to ON position, and turn on the auto/manual switch.

3. While applying the multimeter, operate the auto/manual switch.
REMARK
If there is a failure in this check, open circuit in wiring harness or internal defect of
1 the switch is suspected, but the switch cannot be checked as a unit.
With the switch not press-
Between CW01 (23) and Max. 3 V
ed
ground
With the switch pressed Min. 3 V
Voltage
Between CW01 (17) and Min. 3 V
ed
ground
With the switch pressed Max. 3 V
2. Disconnect the connectors AA28 and CX01, and connect the T-adapter to
male side of AA28.
REMARK
2 If there is a failure in this check, open circuit in wiring harness or internal defect of
ness
the switch is suspected, but the switch cannot be checked as a unit.
Continuity (a
Between AA28 (male) (Z)
With the switch pressed sound is
and AA28 (male) (r)
heard)
Continuity
Continuity (a
Between AA28 (male) (a) With the switch not press-
sound is
and AA28 (male) (r) ed
heard)
40-860 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DD20MA]

2. Disconnect the connectors AA28 and CX01, and connect the T-adapter to
each male side.
REMARK
3 If there is a failure in this check, open circuit in wiring harness or internal defect of
ness
the switch is suspected, but the switch cannot be checked as a unit.
Between AA28 (male) (Z) No continui-
and each pin other than With the switch pressed ty (no sound
(Z) and (r) is heard)
Continuity
Between AA28 (male) (a) No continui-
and each pin other than ty (no sound
ed
(a) and (r) is heard)
2. Disconnect the connectors AA28 and CW01, and connect the T-adapter to
each female side.
Open circuit in wiring har- Continuity (a
4
ness Between CW01 (female) (23) and AA28 (female) (Z) sound is
heard)
Continuity
Continuity (a
Between CW01 (female) (17) and AA28 (female) (a) sound is
heard)
2. Disconnect the connectors AA28 and CW01, and connect the T-adapter to
female side of CW01.
Short circuit in wiring har- Continuity (a
5 Between CW01 (female) (23) and each pin other than
ness sound is
(23)
heard)
Continuity
Continuity (a
Between CW01 (female) (17) and each pin other than
sound is
(17)
heard)
6 2. Disconnect the connectors AA28, and connect the T-adapter to female
ness
side of AA28.
Resistance Between AA28 (female) (r) and ground Max. 1 Ω
Short circuit in wiring har- 2. Disconnect the connectors AA28, and connect the T-adapter to female
7
ness side of AA28.
Voltage Between AA28 (female) (r) and ground 0 V
PC210LCI-11 40-861
FAILURE CODE [DD20MA] 40 TROUBLESHOOTING

8
Circuit diagram related to auto/manual switch
40-862 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DDNRKA]
FAILURE CODE [DDNRKA]

Action level Failure code Work Equipment Lever Lock Switch Open Circuit
Failure
L03 DDNRKA (Pump controller system)
• No current flows on the PPC lock lever relay side when the work equipment lock lever is in
Detail of fail- RELEASE position, so the open circuit is detected.
ure • No current flows on the controller side when the work equipment lock lever is in LOCK po-
sition, so the open circuit is detected.
Action of • None in particular (Lock lever automatic lock control may operate wrongly.)
Phenomenon
• Starting motor does not start.
on machine
• Condition of lock lever can be checked with monitoring function. (Code: 02203)
Lock lever (start side) ON: Lock/OFF: Free
Related Lock lever 2 (solenoid side) ON: Lock/OFF: Free
Procedure: Turn starting switch to ON position and lock and unlock work equipment lock
lever.

Defective fuse No. 3 in If fuse is burnt out, circuit may have ground fault.
1
fuse box F01
2. Disconnect connector S14 and connect T-adapter to female side.
Defective lock lever
2 switch 3. Operate lock lever and perform troubleshooting.
(internal short circuit) Lock lever: LOCK Min. 1 MΩ
Between S14 (female) (1)
Resistance
and (2) Lock lever: FREE Max. 1 Ω
2. Disconnect connectors CP01 and S14, and connect T-adapters to female
side of CP01 and male side of S14.
3 Between CP01 (female)
ness LOCK Max. 1 Ω
(79) and S14 (male) (3)
Resistance
Free Max. 1 Ω
(78) and S14 (male) (2)
assembly).
PC210LCI-11 40-863
FAILURE CODE [DDNRKA] 40 TROUBLESHOOTING
Circuit diagram related to PPC lock switch
40-864 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DDNRKY]
FAILURE CODE [DDNRKY]

Action level Failure code Work Equipment Lever Lock Switch Short Circuit
Failure
L03 DDNRKY (Pump controller system)
• PPC lock signal voltage of circuit on controller side is 5.2 V or higher when work equip-
Detail of fail- ment lock lever is in RELEASE position.
ure • Signal voltage of circuit on PPC lock lever relay side is 5.2 V or higher when work equip-
ment lock lever is in LOCK position.
Action of • Stops PPC lock relay output.
Phenomenon
None of work equipment, swing or travel works.
on machine
• Condition of lock lever can be checked with monitoring function. (Code: 02203)
Lock lever (start side) ON: Lock/OFF: Free
Related Lock lever 2 (solenoid side) ON: Lock/OFF: Free
Procedure: Turn starting switch to ON position and lock and unlock work equipment lock
lever.

2. Disconnect connector S14 and connect T-adapter to female side.
Defective lock lever
1 switch 3. Operate lock lever and perform troubleshooting.
(internal short circuit) Lock lever: LOCK Min. 1 MΩ
Between S14 (female) (1)
Resistance
and (2) Lock lever: FREE Max. 1 Ω
2. Disconnect connector S14, and connect T-adapter to male side.
2
harness Between S14 (male) (2) and ground Max. 1 V
Voltage
Between S14 (male) (3) and ground Max. 1 V
assembly).
PC210LCI-11 40-865
FAILURE CODE [DDNRKY] 40 TROUBLESHOOTING
40-866 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DDNS00]
FAILURE CODE [DDNS00]

Action level Failure code Lock Lever Auto Lock Release Switch Operation
Failure
- DDNS00 (pump controller system)
Details of Lock lever automatic lock release switch operation is detected when lock lever is locked automati-
failure cally.

controller • Lock lever automatic lock does not operate.
Phenomenon • Lock lever automatic lock function does not operate.
on machine • Automatic lock release switch monitor is displayed in red on machine monitor.
• Connectors CP01 and S25 do not provide T-adapter for measuring voltage, and use con-
Related nector D03 for troubleshooting.
Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.

Lock lever automatic lock If lock lever automatic lock function operates normally, turn lock lever automatic
1
cancel switch ON lock cancel switch OFF.
Hot short circuit in wiring 2.
2 Insert T-adapter into connector D03.
harness
Voltage Between D03 (7) and ground Max. 1 V
assembly).
PC210LCI-11 40-867
FAILURE CODE [DDNS00] 40 TROUBLESHOOTING
40-868 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DFB1KZ]
FAILURE CODE [DFB1KZ]

Action level Failure code Service Lever Potentiometer 1 Open or Short Circuit
Failure
L01 DFB1KZ (Pump controller system)
Detail of fail- Signal voltage of service lever (proportional control lever) potentiometer 1 (main) is 0.4 V or less or
ure 4.6 V or more.
Action of
Stops driving attachment flow adjustment EPC valve 1.
controller
• Hydraulic oil does not flow normally to hydraulic circuit for attachment 1.
Phenomenon
• Manual mode can not be switched to semi-auto mode.
on machine
• Semi-auto mode is switched to manual mode automatically.
• If failure code [DA26KP] is also displayed, perform troubleshooting for it first.
• Signal voltage of service lever (proportional control lever) potentiometer 1 (main) can be
Related checked with monitoring function. (Code: 42008)
information • After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Starting switch is turned to ON position + Operate (vertical direction) service
lever (proportional control lever)

2. Disconnect the connectors CP01 and M22, and connect the T-adapter to
each female side.
1
ness Between CP01 (female) (63) and M22 (female) (6) Max. 1 Ω
Resistance Between CP01 (female) (48) and M22 (female) (9) Max. 1 Ω
Between CP01 (female) (18) and M22 (female) (7) Max. 1 Ω
harness
Between ground and either CP01 (female) (48) or M22
(female) (9)
Hot short circuit in wiring 2. Disconnect the connector M22, and connect the T-adapter to female side.
3
Voltage Between M22 (female) (9) and (7) Max. 1 V
4 female side of CP01.
ness
Between CP01 (female) (48) and each pin other than No continui-
Continuity
(48) ty
Defective service lever 2. Insert the T-adapter into connector M22.
(proportional control lev- 3.
5 Turn the starting switch to ON position.
er) potentiometer 1
(main) 4. Operate (vertical direction) service lever (proportional control lever).
Voltage Between M22 (female) (9) and (7) 0.7 to 4.3 V
PC210LCI-11 40-869
FAILURE CODE [DFB1KZ] 40 TROUBLESHOOTING

Circuit diagram related to service lever potentio 1
40-870 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DFB2KZ]
FAILURE CODE [DFB2KZ]

Action level Failure code Service Lever Potentiometer 2 Open or Short Circuit
Failure
L01 DFB2KZ (Pump controller system)
Detail of fail- Signal voltage of service lever (proportional control lever) potentiometer 2 (main) is 0.4 V or less or
ure 4.6 V or more.
Action of
controller
• Hydraulic oil does not flow normally to hydraulic circuit for attachment 1.
Phenomenon
• Manual mode can not be switched to semi-auto mode.
on machine
• Semi-auto mode is switched to manual mode automatically.
• If failure code [DA26KP] is also displayed, perform troubleshooting for it first.
Related checked with monitoring function. (Code: 42010)
information • After completion of repair, check that the failure code is cleared by the following operation.

each female side.
1
ness Between CP01 (female) (63) and M23 (female) (6) Max. 1 Ω
Resistance Between CP01 (female) (67) and M23 (female) (9) Max. 1 Ω
Between CP01 (female) (18) and M23 (female) (7) Max. 1 Ω
harness
Between ground and either CP01 (female) (67) or M23
(female) (9)
Hot short circuit in wiring 2. Disconnect the connector M23, and connect the T-adapter to female side.
3
Voltage Between M23 (female) (9) and (7) Max. 1 V
4 female side of CP01.
ness
Between CP01 (female) (67) and each pin other than No continui-
Continuity
(67) ty
er) potentiometer 2
PC210LCI-11 40-871
FAILURE CODE [DFB2KZ] 40 TROUBLESHOOTING

Circuit diagram related to service lever potentiometer 2
40-872 PC210LCI-11
40 TROUBLESHOOTING FAILURE CODE [DFB3L8]
FAILURE CODE [DFB3L8]

Action level Failure code Service Lever 1 Potentiometer Signal Incompatibility
Failure
L01 DFB3L8 (Pump controller system)
Detail of fail- Total of signal voltage of service lever (proportional control lever) potentiometer 1 (main) and serv-
ure ice lever (proportional control lever) potentiometer 1 (sub) is 4.41 V or less or 5.59 V or more.
Action of
controller
Phenomenon
Hydraulic oil does not flow normally to hydraulic circuit for attachment 1.
on machine
• If failure code [DFB1KZ] or [DFB5KZ] is also displayed, perform troubleshooting for it first.
checked with monitoring function. (Code: 42008)
Related • Signal voltage of service lever (proportional control lever) potentiometer 1 (sub) can be
information checked with monitoring function. (Code: 42009)

er) potentiometer 1
2. Insert the T-adapter into connector M22.
Defective service lever
2 (proportional control lev- 3. Turn the starting switch to ON position.
er) potentiometer 1 (sub) 4. Operate (vertical direction) service lever (proportional control lever).
PC210LCI-11 40-873
FAILURE CO

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SEN06616-03

HYDRAULIC PC210LCI -11

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Purpose of use (major ap-

Communication Global Navigation Satellite System: This system

Steering This function uses a combination of hydraulic

Purpose of use (major ap-

Komatsu Catalyzed This filter captures soot in exhaust gas.

Purpose of use (major ap-

Sturcture protects the operator who wear the

Purpose of use (major ap-

*1: Code for applicable machine model

Abbreviation Actual word spelled out

FOREWORD, SAFETY, BASIC INFORMATION

SAFETY NOTICE FOR OPERATION

• Always wear the protective eyeglasses when hitting parts

Precautions during work

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

Precautions for slinging work and making signals

Precautions for disconnecting air conditioner piping

PRECAUTIONS TO PREVENT FIRE

ACTIONS IF FIRE OCCURS

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

PRECAUTIONS FOR DEF

PRECAUTIONS FOR ADDING

PRECAUTIONS FOR STORING

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE

THE OTHER PRECAUTIONS

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

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

Sealing of openings (prevention of flowing out of oil)

Preventing intrusion of foreign materials during refilling

Replacing hydraulic oil while its temperature is high

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

Hose side Pipe joint side

Hose side Pipe joint side

Nomi Bolt pitch (mm) Hose side Tube side

Nomi Bolt pitch (mm) Hose side Tube side

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

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

Nominal Plug (1)

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415

06 R3/4 07042-00617 07043-00617

14 R11/2 07042-01422 07043-01422