UENBM00632
HYDRAULIC EXCAVATOR
PC210 -11E0 PC210LC -11E0 PC210NLC-11E0 PC230NHD-11E0 SERIAL NUMBERS PC210-11E0
- K75350 and up
PC210LC-11E0 - K75350 and up PC210NLC-11E0 - K75210 and up PC230NHD-11E0 - K75008 and up
00 INDEX AND FOREWORD
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-1
INDEX
00 INDEX AND FOREWORD
INDEX 00 INDEX AND FOREWORD ........................................................................................................................ 00-1 ABBREVIATION LIST ........................................................................................................................... 00-20 FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-26 HOW TO READ THE SHOP MANUAL........................................................................................... 00-26 SAFETY NOTICE FOR OPERATION............................................................................................. 00-28 PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-36 ACTIONS IF FIRE OCCURS ......................................................................................................... 00-38 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-39 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-40 METHOD FOR CHECKING ENGINE TYPE .................................................................................. 00-41 PRECAUTIONS FOR DEF............................................................................................................. 00-43 STORE AdBlue/DEF ...................................................................................................................... 00-44 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-45 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-48 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-55 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-57 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-58 PRACTICAL USE OF KOMTRAX .................................................................................................. 00-59 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-60 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-64 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-68 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-69 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-71 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-72 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . ................................................................................................................................................... 00-74 HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-75 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-79 STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-82 CONVERSION TABLE ................................................................................................................... 00-89 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 ............................................................................................................................ 01-16 TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-18 10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1 CONTENTS ............................................................................................................................................ 10-2 ABBREVIATION LIST ............................................................................................................................. 10-6 UREA SCR SYSTEM............................................................................................................................ 10-12 LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-13 UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-18 FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-19 COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-40 BOOT-UP SYSTEM .............................................................................................................................. 10-49 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-49 SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-51 BATTERY DISCONNECT SWITCH ............................................................................................... 10-52 ENGINE SYSTEM ................................................................................................................................ 10-53 LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-53 ENGINE CONTROL SYSTEM ....................................................................................................... 10-55 AUTO-DECELERATION SYSTEM ................................................................................................. 10-58 ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-60 00-2
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00 INDEX AND FOREWORD
INDEX
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-62 TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-65 AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-67 COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-70 COOLING SYSTEM.............................................................................................................................. 10-88 LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-88 FAN SPEED CONTROL SYSTEM OF FAN CLUTCH .................................................................... 10-90 ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH........................................................... 10-92 COMPONENT PARTS OF COOLING SYSTEM............................................................................. 10-94 CONTROL SYSTEM............................................................................................................................. 10-95 LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-95 MACHINE MONITOR SYSTEM ..................................................................................................... 10-98 KomVision SYSTEM ...................................................................................................................... 10-99 KOMTRAX SYSTEM.....................................................................................................................10-113 PPC LEVERS ...............................................................................................................................10-114 AUTOMATIC GREASE SYSTEM ..................................................................................................10-116 COMPONENT PARTS OF CONTROL SYSTEM...........................................................................10-130 SENSOR.......................................................................................................................................10-168 HYDRAULIC SYSTEM.........................................................................................................................10-171 LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-171 CLSS ............................................................................................................................................10-177 ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-196 PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-202 COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-205 WORK EQUIPMENT SYSTEM ............................................................................................................10-290 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-290 STRUCTURE OF VALVE CONTROL............................................................................................10-295 ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-297 PPC LOCK SYSTEM ....................................................................................................................10-299 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-300 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-302 TOOL CONTROL SYSTEM ..........................................................................................................10-305 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-307 SWING SYSTEM .................................................................................................................................10-336 LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-336 SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-340 COMPONENT PARTS OF SWING SYSTEM................................................................................10-344 TRAVEL SYSTEM................................................................................................................................10-359 LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-359 TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-363 COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-365 UNDERCARRIAGE AND FRAME........................................................................................................10-386 LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-386 WORK EQUIPMENT............................................................................................................................10-388 STRUCTURE OF WORK EQUIPMENT ........................................................................................10-388 FUNCTION OF WORK EQUIPMENT ...........................................................................................10-389 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-390 BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-391 CAB AND ITS ATTACHMENTS ...........................................................................................................10-392 ROPS CAB ...................................................................................................................................10-392 CAB MOUNT ................................................................................................................................10-393 CAB TIPPING STOPPER .............................................................................................................10-394 20 STANDARD VALUE TABLE ...................................................................................................................... 20-1 CONTENTS ............................................................................................................................................ 20-2 ABBREVIATION LIST ............................................................................................................................. 20-3 STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9 STANDARD VALUE TABLE FOR ENGINE: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0 ......................................................................................................................... 20-9 PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-3
INDEX
00 INDEX AND FOREWORD
STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-14 STANDARD VALUE TABLE FOR MACHINE: PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0 ....................................................................................................................... 20-14 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-27 STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-31 STANDARD VALUE TABLE FOR ELECTRICAL ............................................................................ 20-31 30 TESTING AND ADJUSTING ..................................................................................................................... 30-1 CONTENTS ............................................................................................................................................ 30-2 ABBREVIATION LIST ............................................................................................................................. 30-5 RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................30-11 TOOLS FOR TESTING AND ADJUSTING......................................................................................30-11 SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-18 ENGINE AND COOLING SYSTEM....................................................................................................... 30-20 TEST ENGINE SPEED .................................................................................................................. 30-20 TEST BOOST PRESSURE............................................................................................................ 30-23 TEST EXHAUST GAS COLOR ...................................................................................................... 30-25 TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-28 TEST COMPRESSION PRESSURE.............................................................................................. 30-31 TEST BLOWBY PRESSURE ......................................................................................................... 30-36 TEST ENGINE OIL PRESSURE .................................................................................................... 30-38 TEST EGR VALVE AND VGT OIL PRESSURE ............................................................................. 30-39 TEST FUEL PRESSURE ............................................................................................................... 30-41 TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-47 BLEEDING AIR FROM FUEL SYSTEM ......................................................................................... 30-54 TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-55 HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-57 HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-58 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-59 TEST FAN BELT AND ALTERNATOR BELT .................................................................................. 30-61 TEST AUTO-TENSIONER ............................................................................................................. 30-62 REPLACING FAN BELT................................................................................................................. 30-63 TEST COOLING FAN SPEED ...................................................................................................... 30-64 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-65 TEST SCR RELATED FUNCTIONS............................................................................................... 30-66 CLEAN AdBlue/DEF TANK ............................................................................................................ 30-91 BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK ................................................... 30-95 POWER TRAIN..................................................................................................................................... 30-97 TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-97 UNDERCARRIAGE AND FRAME......................................................................................................... 30-98 TEST AND ADJUST TRACK TENSION......................................................................................... 30-98 HYDRAULIC SYSTEM.........................................................................................................................30-100 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................30-100 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........ ..................................................................................................................................................30-106 TEST OIL PRESSURE OF CONTROL CIRCUIT ..........................................................................30-116 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ...................................30-118 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT....................................30-122 TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-129 TEST PPC VALVE OUTLET PRESSURE .....................................................................................30-133 TEST ATTACHMENT CIRCUIT OIL PRESSURE..........................................................................30-135 ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-137 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE...30-138 TEST PUMP SWASH PLATE SENSOR........................................................................................30-140 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-141 TEST OIL LEAKAGE ....................................................................................................................30-143 BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-146 CAB AND ITS ATTACHMENTS ...........................................................................................................30-150 TEST CAB TIPPING STOPPER ...................................................................................................30-150 00-4
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
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00 INDEX AND FOREWORD
INDEX
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-151 ELECTRICAL SYSTEM .......................................................................................................................30-159 SETTING AND OPERATION OF MACHINE MONITOR................................................................30-159 ADJUST KomVision CAMERA ANGLE .........................................................................................30-265 ADJUST KomVision RELATED ITEMS .........................................................................................30-270 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-290 HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-291 TEST DIODES ..............................................................................................................................30-292 Pm CLINIC...........................................................................................................................................30-293 Pm CLINIC SERVICE ...................................................................................................................30-293 40 TROUBLESHOOTING .............................................................................................................................. 40-1 CONTENTS ............................................................................................................................................ 40-2 ABBREVIATION LIST ........................................................................................................................... 40-13 RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-19 GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-19 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-20 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-32 CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-34 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-36 TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-38 AUTOMATIC GREASE SYSTEM ................................................................................................... 40-61 PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM.................................................... 40-67 PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-80 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-83 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-87 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................................................................................................ 40-89 CONNECTOR LIST AND LAYOUT ................................................................................................ 40-92 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)..........................40-154 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])..........................................................................................................................40-158 FAILURE CODES TABLE .............................................................................................................40-160 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-178 FAILURE CODE [879AKA]............................................................................................................40-178 FAILURE CODE [879AKB]............................................................................................................40-179 FAILURE CODE [879BKA]............................................................................................................40-180 FAILURE CODE [879BKB]............................................................................................................40-182 FAILURE CODE [879CKA]............................................................................................................40-184 FAILURE CODE [879CKB]............................................................................................................40-185 FAILURE CODE [879DKZ]............................................................................................................40-186 FAILURE CODE [879EMC] ...........................................................................................................40-188 FAILURE CODE [879FMC] ...........................................................................................................40-189 FAILURE CODE [879GKX] ...........................................................................................................40-190 FAILURE CODE [989L00] .............................................................................................................40-192 FAILURE CODE [989M00] ............................................................................................................40-193 FAILURE CODE [989N00] ............................................................................................................40-194 FAILURE CODE [A1U0N3] ...........................................................................................................40-195 FAILURE CODE [A1U0N4] ...........................................................................................................40-197 FAILURE CODE [A900FR]............................................................................................................40-199 FAILURE CODE [A900N6] ............................................................................................................40-200 FAILURE CODE [A900NY]............................................................................................................40-201 FAILURE CODE [AA10NX] ...........................................................................................................40-202 FAILURE CODE [AB00KE] ...........................................................................................................40-204 FAILURE CODE [AQ10N3] ...........................................................................................................40-207 FAILURE CODE [AS00N3]............................................................................................................40-209 PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-5
INDEX
00 INDEX AND FOREWORD
FAILURE CODE [AS00R2]............................................................................................................40-211 FAILURE CODE [AS00R3]............................................................................................................40-212 FAILURE CODE [AS00R4]............................................................................................................40-213 FAILURE CODE [AS00R5]............................................................................................................40-214 FAILURE CODE [AS00R6]............................................................................................................40-215 FAILURE CODE [AS00ZK]............................................................................................................40-216 FAILURE CODE [AS10KM]...........................................................................................................40-217 FAILURE CODE [AS10NR] ...........................................................................................................40-218 FAILURE CODE [AS10NT] ...........................................................................................................40-219 FAILURE CODE [B@BAZG] .........................................................................................................40-220 FAILURE CODE [B@BAZK]..........................................................................................................40-221 FAILURE CODE [B@BCNS] .........................................................................................................40-223 FAILURE CODE [B@BCQA].........................................................................................................40-224 FAILURE CODE [B@BCZK] .........................................................................................................40-226 FAILURE CODE [B@HANS] .........................................................................................................40-228 FAILURE CODE [CA115] ..............................................................................................................40-229 FAILURE CODE [CA122] ..............................................................................................................40-230 FAILURE CODE [CA123] ..............................................................................................................40-232 FAILURE CODE [CA131] ..............................................................................................................40-234 FAILURE CODE [CA132] ..............................................................................................................40-236 FAILURE CODE [CA144] ..............................................................................................................40-238 FAILURE CODE [CA145] ..............................................................................................................40-240 FAILURE CODE [CA153] ..............................................................................................................40-242 FAILURE CODE [CA154] ..............................................................................................................40-245 FAILURE CODE [CA187] ..............................................................................................................40-247 FAILURE CODE [CA221] ..............................................................................................................40-249 FAILURE CODE [CA222] ..............................................................................................................40-251 FAILURE CODE [CA227] ..............................................................................................................40-253 FAILURE CODE [CA234] ..............................................................................................................40-254 FAILURE CODE [CA238] ..............................................................................................................40-255 FAILURE CODE [CA239] ..............................................................................................................40-257 FAILURE CODE [CA249] ..............................................................................................................40-259 FAILURE CODE [CA256] ..............................................................................................................40-261 FAILURE CODE [CA271] ..............................................................................................................40-263 FAILURE CODE [CA272] ..............................................................................................................40-265 FAILURE CODE [CA322] ..............................................................................................................40-267 FAILURE CODE [CA323] ..............................................................................................................40-269 FAILURE CODE [CA324] ..............................................................................................................40-271 FAILURE CODE [CA325] ..............................................................................................................40-273 FAILURE CODE [CA331] ..............................................................................................................40-275 FAILURE CODE [CA332] ..............................................................................................................40-277 FAILURE CODE [CA343] ..............................................................................................................40-279 FAILURE CODE [CA351] ..............................................................................................................40-280 FAILURE CODE [CA352] ..............................................................................................................40-281 FAILURE CODE [CA356] ..............................................................................................................40-284 FAILURE CODE [CA357] ..............................................................................................................40-286 FAILURE CODE [CA386] ..............................................................................................................40-288 FAILURE CODE [CA428] ..............................................................................................................40-289 FAILURE CODE [CA429] ..............................................................................................................40-291 FAILURE CODE [CA435] ..............................................................................................................40-293 FAILURE CODE [CA441] ..............................................................................................................40-295 FAILURE CODE [CA442] ..............................................................................................................40-297 FAILURE CODE [CA449] ..............................................................................................................40-298 FAILURE CODE [CA451] ..............................................................................................................40-299 FAILURE CODE [CA452] ..............................................................................................................40-301 FAILURE CODE [CA488] ..............................................................................................................40-303 FAILURE CODE [CA515] ..............................................................................................................40-304 FAILURE CODE [CA516] ..............................................................................................................40-306 00-6
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00 INDEX AND FOREWORD
INDEX
FAILURE CODE [CA553] ..............................................................................................................40-308 FAILURE CODE [CA555] ..............................................................................................................40-309 FAILURE CODE [CA556] ..............................................................................................................40-310 FAILURE CODE [CA559] ..............................................................................................................40-311 FAILURE CODE [CA595] ..............................................................................................................40-314 FAILURE CODE [CA687] ..............................................................................................................40-315 FAILURE CODE [CA689] ..............................................................................................................40-317 FAILURE CODE [CA691] ..............................................................................................................40-320 FAILURE CODE [CA692] ..............................................................................................................40-322 FAILURE CODE [CA697] ..............................................................................................................40-324 FAILURE CODE [CA698] ..............................................................................................................40-325 FAILURE CODE [CA731] ..............................................................................................................40-326 FAILURE CODE [CA778] ..............................................................................................................40-328 FAILURE CODE [CA1117] ............................................................................................................40-333 FAILURE CODE [CA1664] ............................................................................................................40-334 FAILURE CODE [CA1669] ............................................................................................................40-336 FAILURE CODE [CA1673] ............................................................................................................40-337 FAILURE CODE [CA1677] ............................................................................................................40-338 FAILURE CODE [CA1678] ............................................................................................................40-339 FAILURE CODE [CA1682] ............................................................................................................40-340 FAILURE CODE [CA1683] ............................................................................................................40-342 FAILURE CODE [CA1684] ............................................................................................................40-344 FAILURE CODE [CA1686] ............................................................................................................40-346 FAILURE CODE [CA1691] ............................................................................................................40-347 FAILURE CODE [CA1694] ............................................................................................................40-350 FAILURE CODE [CA1695] ............................................................................................................40-353 FAILURE CODE [CA1696] ............................................................................................................40-354 FAILURE CODE [CA1712] ............................................................................................................40-356 FAILURE CODE [CA1713] ............................................................................................................40-359 FAILURE CODE [CA1714] ............................................................................................................40-361 FAILURE CODE [CA1715] ............................................................................................................40-362 FAILURE CODE [CA1776] ............................................................................................................40-363 FAILURE CODE [CA1777] ............................................................................................................40-366 FAILURE CODE [CA1843] ............................................................................................................40-369 FAILURE CODE [CA1844] ............................................................................................................40-371 FAILURE CODE [CA1879] ............................................................................................................40-374 FAILURE CODE [CA1881] ............................................................................................................40-376 FAILURE CODE [CA1883] ............................................................................................................40-378 FAILURE CODE [CA1885] ............................................................................................................40-381 FAILURE CODE [CA1887] ............................................................................................................40-383 FAILURE CODE [CA1921] ............................................................................................................40-385 FAILURE CODE [CA1922] ............................................................................................................40-388 FAILURE CODE [CA1942] ............................................................................................................40-393 FAILURE CODE [CA1993] ............................................................................................................40-394 FAILURE CODE [CA2185] ............................................................................................................40-397 FAILURE CODE [CA2186] ............................................................................................................40-398 FAILURE CODE [CA2249] ............................................................................................................40-400 FAILURE CODE [CA2271] ............................................................................................................40-401 FAILURE CODE [CA2272] ............................................................................................................40-404 FAILURE CODE [CA2288] ............................................................................................................40-407 FAILURE CODE [CA2311] ............................................................................................................40-408 FAILURE CODE [CA2349] ............................................................................................................40-409 FAILURE CODE [CA2353] ............................................................................................................40-412 FAILURE CODE [CA2357] ............................................................................................................40-414 FAILURE CODE [CA2381] ............................................................................................................40-415 FAILURE CODE [CA2382] ............................................................................................................40-418 FAILURE CODE [CA2383] ............................................................................................................40-421 FAILURE CODE [CA2386] ............................................................................................................40-424 PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-7
INDEX
00 INDEX AND FOREWORD
FAILURE CODE [CA2387] ............................................................................................................40-426 FAILURE CODE [CA2555] ............................................................................................................40-427 FAILURE CODE [CA2556] ............................................................................................................40-430 FAILURE CODE [CA2637] ............................................................................................................40-433 FAILURE CODE [CA2639] ............................................................................................................40-435 FAILURE CODE [CA2771] ............................................................................................................40-438 FAILURE CODE [CA2777] ............................................................................................................40-444 FAILURE CODE [CA2976] ............................................................................................................40-447 FAILURE CODE [CA3133] ............................................................................................................40-449 FAILURE CODE [CA3134] ............................................................................................................40-452 FAILURE CODE [CA3135] ............................................................................................................40-454 FAILURE CODE [CA3142] ............................................................................................................40-457 FAILURE CODE [CA3143] ............................................................................................................40-458 FAILURE CODE [CA3144] ............................................................................................................40-459 FAILURE CODE [CA3146] ............................................................................................................40-461 FAILURE CODE [CA3147] ............................................................................................................40-462 FAILURE CODE [CA3148] ............................................................................................................40-463 FAILURE CODE [CA3151] ............................................................................................................40-465 FAILURE CODE [CA3165] ............................................................................................................40-471 FAILURE CODE [CA3229] ............................................................................................................40-473 FAILURE CODE [CA3231] ............................................................................................................40-475 FAILURE CODE [CA3232] ............................................................................................................40-477 FAILURE CODE [CA3235] ............................................................................................................40-481 FAILURE CODE [CA3239] ............................................................................................................40-483 FAILURE CODE [CA3241] ............................................................................................................40-486 FAILURE CODE [CA3242] ............................................................................................................40-489 FAILURE CODE [CA3251] ............................................................................................................40-492 FAILURE CODE [CA3253] ............................................................................................................40-494 FAILURE CODE [CA3254] ............................................................................................................40-497 FAILURE CODE [CA3255] ............................................................................................................40-500 FAILURE CODE [CA3256] ............................................................................................................40-504 FAILURE CODE [CA3311] ............................................................................................................40-506 FAILURE CODE [CA3312] ............................................................................................................40-508 FAILURE CODE [CA3313] ............................................................................................................40-511 FAILURE CODE [CA3314] ............................................................................................................40-512 FAILURE CODE [CA3315] ............................................................................................................40-513 FAILURE CODE [CA3316] ............................................................................................................40-515 FAILURE CODE [CA3317] ............................................................................................................40-516 FAILURE CODE [CA3318] ............................................................................................................40-517 FAILURE CODE [CA3319] ............................................................................................................40-519 FAILURE CODE [CA3321] ............................................................................................................40-520 FAILURE CODE [CA3322] ............................................................................................................40-522 FAILURE CODE [CA3419] ............................................................................................................40-524 FAILURE CODE [CA3421] ............................................................................................................40-526 FAILURE CODE [CA3497] ............................................................................................................40-528 FAILURE CODE [CA3498] ............................................................................................................40-529 FAILURE CODE [CA3543] ............................................................................................................40-530 FAILURE CODE [CA3545] ............................................................................................................40-537 FAILURE CODE [CA3547] ............................................................................................................40-539 FAILURE CODE [CA3558] ............................................................................................................40-540 FAILURE CODE [CA3559] ............................................................................................................40-542 FAILURE CODE [CA3562] ............................................................................................................40-544 FAILURE CODE [CA3563] ............................................................................................................40-546 FAILURE CODE [CA3567] ............................................................................................................40-549 FAILURE CODE [CA3568] ............................................................................................................40-552 FAILURE CODE [CA3571] ............................................................................................................40-556 FAILURE CODE [CA3572] ............................................................................................................40-558 FAILURE CODE [CA3574] ............................................................................................................40-560 00-8
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00 INDEX AND FOREWORD
INDEX
FAILURE CODE [CA3575] ............................................................................................................40-562 FAILURE CODE [CA3577] ............................................................................................................40-564 FAILURE CODE [CA3578] ............................................................................................................40-566 FAILURE CODE [CA3582] ............................................................................................................40-568 FAILURE CODE [CA3583] ............................................................................................................40-574 FAILURE CODE [CA3596] ............................................................................................................40-576 FAILURE CODE [CA3649] ............................................................................................................40-578 FAILURE CODE [CA3681] ............................................................................................................40-580 FAILURE CODE [CA3682] ............................................................................................................40-585 FAILURE CODE [CA3713] ............................................................................................................40-591 FAILURE CODE [CA3717] ............................................................................................................40-594 FAILURE CODE [CA3718] ............................................................................................................40-595 FAILURE CODE [CA3725] ............................................................................................................40-596 FAILURE CODE [CA3741] ............................................................................................................40-599 FAILURE CODE [CA3748] ............................................................................................................40-600 FAILURE CODE [CA3751] ............................................................................................................40-602 FAILURE CODE [CA3755] ............................................................................................................40-604 FAILURE CODE [CA3866] ............................................................................................................40-606 FAILURE CODE [CA3867] ............................................................................................................40-610 FAILURE CODE [CA3868] ............................................................................................................40-613 FAILURE CODE [CA3899] ............................................................................................................40-617 FAILURE CODE [CA3911] ............................................................................................................40-619 FAILURE CODE [CA3912] ............................................................................................................40-623 FAILURE CODE [CA3932] ............................................................................................................40-625 FAILURE CODE [CA3933] ............................................................................................................40-627 FAILURE CODE [CA3934] ............................................................................................................40-629 FAILURE CODE [CA3935] ............................................................................................................40-632 FAILURE CODE [CA3936] ............................................................................................................40-634 FAILURE CODE [CA4151] ............................................................................................................40-636 FAILURE CODE [CA4152] ............................................................................................................40-640 FAILURE CODE [CA4155] ............................................................................................................40-644 FAILURE CODE [CA4156] ............................................................................................................40-646 FAILURE CODE [CA4157] ............................................................................................................40-648 FAILURE CODE [CA4158] ............................................................................................................40-650 FAILURE CODE [CA4159] ............................................................................................................40-651 FAILURE CODE [CA4161] ............................................................................................................40-652 FAILURE CODE [CA4162] ............................................................................................................40-655 FAILURE CODE [CA4163] ............................................................................................................40-658 FAILURE CODE [CA4164] ............................................................................................................40-659 FAILURE CODE [CA4166] ............................................................................................................40-661 FAILURE CODE [CA4168] ............................................................................................................40-662 FAILURE CODE [CA4169] ............................................................................................................40-665 FAILURE CODE [CA4171] ............................................................................................................40-667 FAILURE CODE [CA4249] ............................................................................................................40-670 FAILURE CODE [CA4251] ............................................................................................................40-672 FAILURE CODE [CA4259] ............................................................................................................40-674 FAILURE CODE [CA4261] ............................................................................................................40-677 FAILURE CODE [CA4277] ............................................................................................................40-680 FAILURE CODE [CA4281] ............................................................................................................40-683 FAILURE CODE [CA4459] ............................................................................................................40-686 FAILURE CODE [CA4461] ............................................................................................................40-689 FAILURE CODE [CA4658] ............................................................................................................40-692 FAILURE CODE [CA4731] ............................................................................................................40-696 FAILURE CODE [CA4732] ............................................................................................................40-697 FAILURE CODE [CA4739] ............................................................................................................40-698 FAILURE CODE [CA4768] ............................................................................................................40-699 FAILURE CODE [CA4769] ............................................................................................................40-701 FAILURE CODE [CA4842] ............................................................................................................40-704 PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-9
INDEX
00 INDEX AND FOREWORD
FAILURE CODE [CA4952] ............................................................................................................40-708 FAILURE CODE [CA5115] ............................................................................................................40-710 FAILURE CODE [CA5179] ............................................................................................................40-713 FAILURE CODE [CA5181] ............................................................................................................40-715 FAILURE CODE [CA5383] ............................................................................................................40-717 FAILURE CODE [D110KB]............................................................................................................40-719 FAILURE CODE [D19JKZ] ............................................................................................................40-721 FAILURE CODE [D811MC] ...........................................................................................................40-724 FAILURE CODE [D862KA]............................................................................................................40-725 FAILURE CODE [D8ALKA] ...........................................................................................................40-727 FAILURE CODE [D8ALKB] ...........................................................................................................40-730 FAILURE CODE [D8AQKR] ..........................................................................................................40-732 FAILURE CODE [D8G1KT] ...........................................................................................................40-739 FAILURE CODE [D8G6KT] ...........................................................................................................40-740 FAILURE CODE [DA20MC] ..........................................................................................................40-741 FAILURE CODE [DA22KK] ...........................................................................................................40-742 FAILURE CODE [DA25KP] ...........................................................................................................40-745 FAILURE CODE [DA26KP] ...........................................................................................................40-748 FAILURE CODE [DA29KQ]...........................................................................................................40-751 FAILURE CODE [DA2LKA] ...........................................................................................................40-753 FAILURE CODE [DA2LKB] ...........................................................................................................40-756 FAILURE CODE [DA2QKR] ..........................................................................................................40-758 FAILURE CODE [DA2RKR] ..........................................................................................................40-767 FAILURE CODE [DAF0KM] ..........................................................................................................40-768 FAILURE CODE [DAF0MB] ..........................................................................................................40-769 FAILURE CODE [DAF0MC] ..........................................................................................................40-770 FAILURE CODE [DAF8KB] ...........................................................................................................40-771 FAILURE CODE [DAF9KQ]...........................................................................................................40-773 FAILURE CODE [DAFGMC] .........................................................................................................40-774 FAILURE CODE [DAFLKA] ...........................................................................................................40-775 FAILURE CODE [DAFLKB] ...........................................................................................................40-778 FAILURE CODE [DAFQKR] ..........................................................................................................40-780 FAILURE CODE [DAZ9KQ]...........................................................................................................40-788 FAILURE CODE [DAZQKR] ..........................................................................................................40-789 FAILURE CODE [DB2QKR] ..........................................................................................................40-796 FAILURE CODE [DBP0KM] ..........................................................................................................40-804 FAILURE CODE [DBP0KT] ...........................................................................................................40-805 FAILURE CODE [DB2RKR] ..........................................................................................................40-806 FAILURE CODE [DBP5KB]...........................................................................................................40-811 FAILURE CODE [DBP5KY]...........................................................................................................40-814 FAILURE CODE [DBPQKR]..........................................................................................................40-817 FAILURE CODE [DDNRKA]..........................................................................................................40-825 FAILURE CODE [DDNRKY]..........................................................................................................40-827 FAILURE CODE [DDNS00]...........................................................................................................40-829 FAILURE CODE [DFB1KZ] ...........................................................................................................40-831 FAILURE CODE [DFB2KZ] ...........................................................................................................40-833 FAILURE CODE [DFB3L8]............................................................................................................40-835 FAILURE CODE [DFB4L8]............................................................................................................40-837 FAILURE CODE [DFB5KZ] ...........................................................................................................40-839 FAILURE CODE [DFB6KZ] ...........................................................................................................40-841 FAILURE CODE [DGH2KA] ..........................................................................................................40-843 FAILURE CODE [DGH2KB] ..........................................................................................................40-845 FAILURE CODE [DHA4KA]...........................................................................................................40-847 FAILURE CODE [DHAAMA]..........................................................................................................40-849 FAILURE CODE [DHACMA] .........................................................................................................40-851 FAILURE CODE [DHPAMA]..........................................................................................................40-853 FAILURE CODE [DHPBMA]..........................................................................................................40-856 FAILURE CODE [DHS3MA] ..........................................................................................................40-859 00-10
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00 INDEX AND FOREWORD
INDEX
FAILURE CODE [DHS4MA] ..........................................................................................................40-862 FAILURE CODE [DHS8MA] ..........................................................................................................40-865 FAILURE CODE [DHS9MA] ..........................................................................................................40-868 FAILURE CODE [DHSAMA]..........................................................................................................40-871 FAILURE CODE [DHSBMA]..........................................................................................................40-874 FAILURE CODE [DHSCMA] .........................................................................................................40-877 FAILURE CODE [DHSDMA] .........................................................................................................40-880 FAILURE CODE [DHSFMA]..........................................................................................................40-883 FAILURE CODE [DHSGMA] .........................................................................................................40-886 FAILURE CODE [DHSHMA] .........................................................................................................40-889 FAILURE CODE [DHSJMA] ..........................................................................................................40-892 FAILURE CODE [DHX1MA] ..........................................................................................................40-895 FAILURE CODE [DHZAMA]..........................................................................................................40-898 FAILURE CODE [DHZCL8] ...........................................................................................................40-902 FAILURE CODE [DKR0MA] ..........................................................................................................40-903 FAILURE CODE [DKR1MA] ..........................................................................................................40-906 FAILURE CODE [DKULKA]...........................................................................................................40-909 FAILURE CODE [DKULKB]...........................................................................................................40-911 FAILURE CODE [DKULKY]...........................................................................................................40-913 FAILURE CODE [DLM5KA]...........................................................................................................40-915 FAILURE CODE [DLM5MB] ..........................................................................................................40-917 FAILURE CODE [DR10KA] ...........................................................................................................40-919 FAILURE CODE [DR12KA] ...........................................................................................................40-922 FAILURE CODE [DR20KA] ...........................................................................................................40-924 FAILURE CODE [DR21KX] ...........................................................................................................40-926 FAILURE CODE [DR30KA] ...........................................................................................................40-928 FAILURE CODE [DR31KX] ...........................................................................................................40-930 FAILURE CODE [DR40KA] ...........................................................................................................40-932 FAILURE CODE [DUMBKA]..........................................................................................................40-934 FAILURE CODE [DUMBKB]..........................................................................................................40-937 FAILURE CODE [DV00KA] ...........................................................................................................40-939 FAILURE CODE [DV00KB] ...........................................................................................................40-940 FAILURE CODE [DV20KB] ...........................................................................................................40-941 FAILURE CODE [DW43KA] ..........................................................................................................40-943 FAILURE CODE [DW43KB] ..........................................................................................................40-945 FAILURE CODE [DW43KY] ..........................................................................................................40-947 FAILURE CODE [DW45KA] ..........................................................................................................40-949 FAILURE CODE [DW45KB] ..........................................................................................................40-952 FAILURE CODE [DW45KY] ..........................................................................................................40-955 FAILURE CODE [DW4CKY]..........................................................................................................40-957 FAILURE CODE [DW91KA] ..........................................................................................................40-959 FAILURE CODE [DW91KB] ..........................................................................................................40-961 FAILURE CODE [DW91KY] ..........................................................................................................40-963 FAILURE CODE [DWA2KA] ..........................................................................................................40-965 FAILURE CODE [DWA2KB] ..........................................................................................................40-967 FAILURE CODE [DWA2KY] ..........................................................................................................40-969 FAILURE CODE [DWK0KA]..........................................................................................................40-971 FAILURE CODE [DWK0KB]..........................................................................................................40-973 FAILURE CODE [DWK0KY]..........................................................................................................40-975 FAILURE CODE [DWK2KA]..........................................................................................................40-977 FAILURE CODE [DWK2KB]..........................................................................................................40-979 FAILURE CODE [DWK2KY]..........................................................................................................40-981 FAILURE CODE [DWK8KA]..........................................................................................................40-983 FAILURE CODE [DWK8KB]..........................................................................................................40-985 FAILURE CODE [DWK8KY]..........................................................................................................40-987 FAILURE CODE [DWN5KA]..........................................................................................................40-989 FAILURE CODE [DWN5KB]..........................................................................................................40-991 FAILURE CODE [DWN5KY]..........................................................................................................40-993 PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-11
INDEX
00 INDEX AND FOREWORD
FAILURE CODE [DWPUKA] ........................................................................................................40-995 FAILURE CODE [DWPUKB] ........................................................................................................40-997 FAILURE CODE [DWPUKY] ........................................................................................................40-999 FAILURE CODE [DXA8KA].........................................................................................................40-1001 FAILURE CODE [DXA8KB].........................................................................................................40-1003 FAILURE CODE [DXA9KA].........................................................................................................40-1005 FAILURE CODE [DXA9KB].........................................................................................................40-1007 FAILURE CODE [DXE0KA].........................................................................................................40-1009 FAILURE CODE [DXE0KB].........................................................................................................40-1010 FAILURE CODE [DXE4KA].........................................................................................................40-1012 FAILURE CODE [DXE4KB].........................................................................................................40-1014 FAILURE CODE [DXE4KY].........................................................................................................40-1016 FAILURE CODE [DXE5KA].........................................................................................................40-1018 FAILURE CODE [DXE5KB].........................................................................................................40-1020 FAILURE CODE [DXE6KA].........................................................................................................40-1022 FAILURE CODE [DXE6KB].........................................................................................................40-1024 FAILURE CODE [DXE7KA].........................................................................................................40-1026 FAILURE CODE [DXE7KB].........................................................................................................40-1028 FAILURE CODE [DXE7KY].........................................................................................................40-1030 FAILURE CODE [DXE8KA].........................................................................................................40-1032 FAILURE CODE [DXE8KB].........................................................................................................40-1034 FAILURE CODE [DXE8KY].........................................................................................................40-1036 FAILURE CODE [DXE9KA].........................................................................................................40-1038 FAILURE CODE [DXE9KB].........................................................................................................40-1040 FAILURE CODE [DXE9KY].........................................................................................................40-1042 FAILURE CODE [DXEAKA] ........................................................................................................40-1044 FAILURE CODE [DXEAKB] ........................................................................................................40-1046 FAILURE CODE [DXEAKY] ........................................................................................................40-1048 FAILURE CODE [DXEKKA] ........................................................................................................40-1050 FAILURE CODE [DXEKKB] ........................................................................................................40-1052 FAILURE CODE [DXEKKY] ........................................................................................................40-1054 FAILURE CODE [DXELKA] ........................................................................................................40-1056 FAILURE CODE [DXELKB].........................................................................................................40-1058 FAILURE CODE [DXELKY].........................................................................................................40-1060 FAILURE CODE [DY20KA] .........................................................................................................40-1062 FAILURE CODE [DY20MA].........................................................................................................40-1064 FAILURE CODE [DY2CKB].........................................................................................................40-1066 FAILURE CODE [DY2DKB].........................................................................................................40-1069 FAILURE CODE [DY2EKB].........................................................................................................40-1071 FAILURE CODE [F313KA] ..........................................................................................................40-1073 FAILURE CODE [F313KB] ..........................................................................................................40-1075 FAILURE CODE [F318KB] ..........................................................................................................40-1078 FAILURE CODE [F318KY] ..........................................................................................................40-1081 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1083 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1083 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1089 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1092 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.....40-1094 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING................................................................................................................................40-1096 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW ...........................................................40-1099 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .................................................40-1100 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .......................................................................................................................................40-1101 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .......................................................................................................................................40-1102 00-12
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00 INDEX AND FOREWORD
INDEX
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING... ................................................................................................................................................40-1103 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............40-1104 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................40-1105 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ...... 40-1106 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......................................................................................................................................40-1107 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1108 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......................................................................................................................................40-1109 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ................. 40-1110 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL............................... 40-1112 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM......................................................................................................................... 40-1113 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE.............................................................................................................. 40-1114 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ............................................................................................................................... 40-1115 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE ............................................................................................................................. 40-1117 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ...................... 40-1118 E-24 FUNCTION SWITCH DOES NOT OPERATE ..................................................................... 40-1119 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)..................40-1120 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF ....................................................................40-1121 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ....................40-1122 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED ....................................................................................................................40-1123 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED ......................................................................................................................40-1124 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .................................................................................................................................40-1125 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE .................................................................................................................................40-1126 E-32 ALARM BUZZER CANNOT BE CANCELED ......................................................................40-1128 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION......... ................................................................................................................................................40-1129 E-34 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1130 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE .... 40-1131 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK........40-1134 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING ....................................................................................................................................40-1136 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE ...............................................................................................40-1139 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR ...............................................................................40-1141 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ...........................40-1144 E-41 ALARM DOES NOT SOUND DURING TRAVEL ................................................................40-1145 E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................40-1147 E-43 HORN DOES NOT SOUND................................................................................................40-1148 E-44 HORN DOES NOT STOP SOUNDING...............................................................................40-1151 E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF . ................................................................................................................................................40-1153 E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE... 40-1154 E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE .........................................................................................................................................40-1156 E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ... ................................................................................................................................................40-1157 PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-13
INDEX
00 INDEX AND FOREWORD
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION . ................................................................................................................................................40-1158 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......... ................................................................................................................................................40-1159 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1160 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ................................................................................................................................................40-1161 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION . ................................................................................................................................................40-1162 E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.40-1163 E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1164 E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .......... ................................................................................................................................................40-1165 E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.......................................40-1167 E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1168 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1169 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1169 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1170 FAILURE MODE AND CAUSE TABLE........................................................................................40-1172 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK......................................40-1181 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER ..................40-1182 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR............................................40-1185 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ..................................40-1186 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..................................................40-1187 H-6 SPEED OR POWER OF BOOM IS LOW .............................................................................40-1189 H-7 ARM SPEED OR POWER IS LOW ......................................................................................40-1193 H-8 BUCKET SPEED OR POWER IS LOW................................................................................40-1198 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .....................................40-1201 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1202 H-11 HYDRAULIC DRIFT OF ARM IS LARGE ...........................................................................40-1204 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1206 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES ........................................................................................................................40-1207 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE .................................................................40-1208 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .........................40-1209 H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................40-1210 H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................40-1211 H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER ...................................................................................................................40-1212 H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY ...... ................................................................................................................................................40-1213 H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW .... ................................................................................................................................................40-1214 H-21 MACHINE DOES NOT TRAVEL STRAIGHT ......................................................................40-1215 H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................40-1217 H-23 TRAVEL SPEED IS LOW ...................................................................................................40-1220 H-24 ONE OF TRACKS DOES NOT RUN ..................................................................................40-1222 H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ..40-1223 H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .................40-1224 H-27 SWINGS ONLY IN ONE DIRECTION.................................................................................40-1225 H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) ......................................................................................................................................40-1226 H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION ....................................................................................................................40-1227 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..................................................................................................................40-1228 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)..................................................................................40-1229 00-14
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00 INDEX AND FOREWORD
INDEX
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .............................40-1230 H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING40-1231 H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)40-1232 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) ........ ................................................................................................................................................40-1233 H-1 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ..............................40-1234 H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1235 H-38 Quick coupler cylinder will not extend.................................................................................40-1236 H-39 Quick coupler cylinder will not retract (but buzzer doesnot sound) .....................................40-1238 H-40 Buzzer does not sound (but quick coupler cylinder doesretract) .........................................40-1240 H-41 Quick coupler cylinder extends and retracts slowly.............................................................40-1242 TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1243 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1243 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION....... ................................................................................................................................................40-1244 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1245 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) ........................................................................................................40-1246 S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1248 S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1250 S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1252 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1254 S-8 ENGINE LACKS POWER.....................................................................................................40-1255 S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1257 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1259 S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1260 S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1261 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ....... ................................................................................................................................................40-1262 S-14 OIL PRESSURE DROPS ...................................................................................................40-1263 S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1265 S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1266 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1267 S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1268 S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1269 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1270 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1271 S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1273 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1274 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1275 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1277 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1278 50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1 CONTENTS ............................................................................................................................................ 50-2 ABBREVIATION LIST ............................................................................................................................. 50-7 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ........................................................ 50-13 HOW TO READ THIS MANUAL..................................................................................................... 50-13 COATING MATERIALS LIST.......................................................................................................... 50-15 SPECIAL TOOLS LIST .................................................................................................................. 50-20 SKETCHES OF SPECIAL TOOLS................................................................................................. 50-32 ENGINE AND COOLING SYSTEM....................................................................................................... 50-38 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-38 REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-44 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-57 REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................ 50-83 REMOVE AND INSTALL EGR COOLER ASSEMBLY.................................................................... 50-86 REMOVE AND INSTALL STARTER ASSEMBLY ........................................................................... 50-95 REMOVE AND INSTALL ALTERNATOR BELT .............................................................................. 50-99 PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0
00-15
INDEX
00 INDEX AND FOREWORD
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 .......................................................................................................50-128 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-129 REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-150 REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-157 REMOVE AND INSTALL FUEL COOLER ASSEMBLY .................................................................50-161 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-163 REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-170 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-186 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-198 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-209 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-216 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-224 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER............................................50-225 REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-230 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-234 REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-243 REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-247 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-259 REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-290 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-297 REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-309 REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-315 REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-321 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-335 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-338 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-343 POWER TRAIN....................................................................................................................................50-345 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-345 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-348 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-361 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-367 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-378 UNDERCARRIAGE AND FRAME........................................................................................................50-380 SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-380 REMOVE AND INSTALL SPROCKET ..........................................................................................50-385 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-387 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-389 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-394 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-397 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-401 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-405 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-410 HYDRAULIC SYSTEM.........................................................................................................................50-420 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-420 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-425 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-428 REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-435 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-442 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-457 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-462 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-464 REMOVE AND INSTALL QUICK COUPLER VALVE.....................................................................50-467 WORK EQUIPMENT............................................................................................................................50-469 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-469 00-16
PC210-11E0, PC210LC-11E0, PC210NLC-11E0, PC230NHD-11E0