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4 0 121 MB
SEN06701-C0
HYDRAULIC EXCAVATOR
PC210 -10M0 PC210LC-10M0 SERIAL NUMBERS
C00001
and up
00 INDEX AND FOREWORD
PC210-10M0, PC210LC-10M0
00-1
INDEX
00 INDEX AND FOREWORD
INDEX 00 INDEX AND FOREWORD ........................................................................................................................ 00-1 ABBREVIATION LIST ........................................................................................................................... 00-14 FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-19 HOW TO READ THE SHOP MANUAL........................................................................................... 00-19 SAFETY NOTICE FOR OPERATION............................................................................................. 00-21 PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-29 ACTIONS IF FIRE OCCURS ......................................................................................................... 00-30 PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS ................................................ 00-31 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-32 PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS ...................................... 00-35 PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT............................................. 00-42 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-44 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-45 PRACTICAL USE OF KOMTRAX .................................................................................................. 00-46 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-47 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-51 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-55 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-56 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-58 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-59 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . ................................................................................................................................................... 00-61 HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-62 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-66 STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-69 CONVERSION TABLE ................................................................................................................... 00-76 01 SPECIFICATION....................................................................................................................................... 01-1 CONTENTS ............................................................................................................................................ 01-2 ABBREVIATION LIST ............................................................................................................................. 01-3 SPECIFICATION..................................................................................................................................... 01-8 SPECIFICATION DRAWING............................................................................................................ 01-8 WORKING RANGE DRAWINGS ....................................................................................................01-11 SPECIFICATION............................................................................................................................ 01-14 WEIGHT TABLE ............................................................................................................................ 01-20 FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE ................................ 01-23 10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1 CONTENTS ............................................................................................................................................ 10-2 ABBREVIATION LIST ............................................................................................................................. 10-5 BOOT-UP SYSTEM .............................................................................................................................. 10-10 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-10 SYSTEM OPERATING LAMP SYSTEM .........................................................................................10-11 BATTERY DISCONNECT SWITCH ............................................................................................... 10-12 ENGINE SYSTEM ................................................................................................................................ 10-13 LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-13 ENGINE CONTROL SYSTEM ....................................................................................................... 10-14 AUTO-DECELERATION SYSTEM ................................................................................................. 10-16 ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-18 OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-20 TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-23 COOLING SYSTEM.............................................................................................................................. 10-24 LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-24 CONTROL SYSTEM............................................................................................................................. 10-26 LAYOUT DRAWING OF CONTROL SYSTEM PARTS................................................................... 10-26 MACHINE MONITOR SYSTEM ..................................................................................................... 10-28 KOMTRAX SYSTEM...................................................................................................................... 10-30 CONTROL SYSTEM...................................................................................................................... 10-31 00-2
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
INDEX
HYDRAULIC SYSTEM.......................................................................................................................... 10-55 LAYOUT DRAWING OF HYDRAULIC SYSTEM ............................................................................ 10-55 CLSS ............................................................................................................................................. 10-58 ENGINE AND PUMP COMBINED CONTROL SYSTEM................................................................ 10-77 PUMP AND VALVE CONTROL SYSTEM ...................................................................................... 10-82 COMPONENT PARTS OF HYDRAULIC SYSTEM ........................................................................ 10-85 WORK EQUIPMENT SYSTEM ............................................................................................................10-153 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-153 ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-157 PPC LOCK SYSTEM ....................................................................................................................10-159 ATTACHMENT OIL FLOW ADJUSTER SYSTEM .........................................................................10-161 WORK EQUIPMENT SYSTEM .....................................................................................................10-163 SWING SYSTEM .................................................................................................................................10-186 LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-186 SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-188 SWING SYSTEM ..........................................................................................................................10-192 TRAVEL SYSTEM................................................................................................................................10-204 LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-204 TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-206 FUNCTION OF TRAVEL CONTROL SYSTEM .............................................................................10-207 TRAVEL SYSTEM.........................................................................................................................10-208 FUNCTION OF SWING CIRCLE..........................................................................................................10-227 UNDERCARRIAGE AND FRAME........................................................................................................10-228 LAYOUT DRAWING OF UNDERCARRIAG ..................................................................................10-228 WORK EQUIPMENT............................................................................................................................10-230 STRUCTURE OF WORK EQUIPMENT ........................................................................................10-230 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-231 BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-232 CAB RELATED PARTS........................................................................................................................10-233 ROPS CAB ...................................................................................................................................10-233 CAB MOUNT ................................................................................................................................10-234 CAB TIPPING STOPPER .............................................................................................................10-236 20 STANDARD VALUE TABLE ...................................................................................................................... 20-1 CONTENTS ............................................................................................................................................ 20-2 ABBREVIATION LIST ............................................................................................................................. 20-3 STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-8 STANDARD VALUE TABLE FOR ENGINE: PC210-10M0 ............................................................... 20-8 STANDARD VALUE TABLE FOR MACHINE: PC210-10M0........................................................... 20-12 STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0 ......................................................... 20-26 STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0 ...................................................... 20-30 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE ............................. 20-44 30 TESTING AND ADJUSTING ..................................................................................................................... 30-1 CONTENTS ............................................................................................................................................ 30-2 ABBREVIATION LIST ............................................................................................................................. 30-5 RELATED INFORMATION ON TESTING AND ADJUSTING ................................................................ 30-10 TOOLS FOR TESTING AND ADJUSTING..................................................................................... 30-10 SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-15 ENGINE AND COOLING SYSTEM....................................................................................................... 30-17 TEST ENGINE SPEED .................................................................................................................. 30-17 Test boost pressure........................................................................................................................ 30-20 TEST EXHAUST GAS COLOR ...................................................................................................... 30-23 Test and adjust valve clearance ..................................................................................................... 30-26 TEST COMPRESSION PRESSURE.............................................................................................. 30-29 TEST BLOWBY PRESSURE ......................................................................................................... 30-32 TEST ENGINE OIL PRESSURE .................................................................................................... 30-35 Test fuel pressure........................................................................................................................... 30-37 Test fuel discharged volume, return rate, and leakage ................................................................... 30-44 BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-50 PC210-10M0, PC210LC-10M0
00-3
INDEX
00 INDEX AND FOREWORD
Test fuel system for leakage........................................................................................................... 30-52 CYLINDER CUT-OUT MODE OPERATION ................................................................................... 30-54 NO-INJECTION CRANKING OPERATION .................................................................................... 30-55 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-56 POWER TRAIN..................................................................................................................................... 30-58 Test swing circle bearing clearance................................................................................................ 30-58 UNDERCARRIAGE AND FRAME......................................................................................................... 30-59 Test and adjust track shoe tension ................................................................................................. 30-59 HYDRAULIC SYSTEM.......................................................................................................................... 30-61 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-61 Test and adjust oil pressure in work equipment, swing, and travel circuits...................................... 30-64 TEST OIL PRESSURE OF CONTROL CIRCUIT ........................................................................... 30-74 Test and adjust oil pressure in pump PC control circuit .................................................................. 30-76 Test and adjust oil pressure in pump LS control circuit ................................................................... 30-80 Test outlet pressure of solenoid valve ............................................................................................ 30-88 Test PPC valve outlet pressure ...................................................................................................... 30-92 Adjust play of work equipment and swing PPC valve ..................................................................... 30-95 TesTest pump swash plate sensor.................................................................................................. 30-96 Test parts causing hydraulic drift in work equipment ...................................................................... 30-97 Test oil leakage .............................................................................................................................. 30-99 Bleed air from hydraulic system ....................................................................................................30-104 CAB RELATED PARTS........................................................................................................................30-109 Test cab tipping stopper ................................................................................................................30-109 ADJUST MIRRORS ......................................................................................................................30-110 ELECTRICAL SYSTEM .......................................................................................................................30-115 SETTING AND OPERATION OF MACHINE MONITOR................................................................30-115 START UP KOMTRAX TERMINAL ...............................................................................................30-178 Adjust rearview camera angle .......................................................................................................30-182 ENGINE CONTROLLER VOLTAGE CIRCUIT ..............................................................................30-184 TEST DIODES ..............................................................................................................................30-185 Pm-CLINIC ..........................................................................................................................................30-186 PM CLINIC SERVICE ...................................................................................................................30-186 40 TROUBLESHOOTING .............................................................................................................................. 40-1 ABBREVIATION LIST ............................................................................................................................. 40-2 CONTENTS ............................................................................................................................................ 40-7 RELATED INFORMATION TO TROUBLESHOOT ................................................................................ 40-13 PRECAUTIONS FOR TROUBLESHOOTING ................................................................................ 40-13 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-14 CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-16 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-18 CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER ...................................................... 40-27 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH ....................................... 40-38 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL ........................................ 40-41 DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR ....................................................... 40-42 DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE............................. 40-44 PROCEDURE FOR TROUBLESHOOTING ................................................................................... 40-45 INFORMATION DESCRIBED IN TROUBLESHOOTING................................................................ 40-46 DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS .... ................................................................................................................................................... 40-49 CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE............................................... 40-52 CONNECTOR LAYOUT ................................................................................................................40-126 CONNECTOR CONTACT IDENTIFICATION ................................................................................40-132 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-174 FUSE LOCATION AND CONNECTION TABLE ............................................................................40-180 DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING .......40-183 FAILURE CODES TABLE .............................................................................................................40-185 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-193 FAILURE CODE [602KNX]............................................................................................................40-193 00-4
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
INDEX
FAILURE CODE [6AZ0ZG] ...........................................................................................................40-196 FAILURE CODE [879AKA]............................................................................................................40-200 FAILURE CODE [879AKB]............................................................................................................40-202 FAILURE CODE [879BKA]............................................................................................................40-204 FAILURE CODE [879BKB]............................................................................................................40-207 FAILURE CODE [879CKA]............................................................................................................40-210 FAILURE CODE [879CKB]............................................................................................................40-212 FAILURE CODE [879DKZ]............................................................................................................40-214 FAILURE CODE [879EMC] ...........................................................................................................40-218 FAILURE CODE [879FMC] ...........................................................................................................40-220 FAILURE CODE [879GKX] ...........................................................................................................40-222 FAILURE CODE [989L00] .............................................................................................................40-225 FAILURE CODE [989M00] ............................................................................................................40-227 FAILURE CODE [989N00] ............................................................................................................40-229 FAILURE CODE [AA10NX] ...........................................................................................................40-230 FAILURE CODE [AB00KE] ...........................................................................................................40-233 FAILURE CODE [B@BAZG] .........................................................................................................40-237 FAILURE CODE [B@BAZK]..........................................................................................................40-241 FAILURE CODE [B@BCZK] .........................................................................................................40-244 FAILURE CODE [B@BCNS] .........................................................................................................40-246 FAILURE CODE [B@BCQA].........................................................................................................40-250 FAILURE CODE [B@HANS] .........................................................................................................40-252 FAILURE CODE [CA111] ..............................................................................................................40-254 FAILURE CODE [CA115] ..............................................................................................................40-259 FAILURE CODE [CA122] ..............................................................................................................40-267 FAILURE CODE [CA123] ..............................................................................................................40-270 FAILURE CODE [CA131] ..............................................................................................................40-274 FAILURE CODE [CA132] ..............................................................................................................40-277 FAILURE CODE [CA144] ..............................................................................................................40-281 FAILURE CODE [CA145] ..............................................................................................................40-285 FAILURE CODE [CA153] ..............................................................................................................40-289 FAILURE CODE [CA154] ..............................................................................................................40-293 FAILURE CODE [CA155] ..............................................................................................................40-297 FAILURE CODE [CA187] ..............................................................................................................40-299 FAILURE CODE [CA221] ..............................................................................................................40-302 FAILURE CODE [CA222] ..............................................................................................................40-305 FAILURE CODE [CA227] ..............................................................................................................40-308 FAILURE CODE [CA234] ..............................................................................................................40-311 FAILURE CODE [CA238] ..............................................................................................................40-313 FAILURE CODE [CA271] ..............................................................................................................40-316 FAILURE CODE [CA272] ..............................................................................................................40-319 FAILURE CODE [CA322] ..............................................................................................................40-321 FAILURE CODE [CA323] ..............................................................................................................40-325 FAILURE CODE [CA324] ..............................................................................................................40-329 FAILURE CODE [CA325] ..............................................................................................................40-333 FAILURE CODE [CA331] ..............................................................................................................40-337 FAILURE CODE [CA332] ..............................................................................................................40-341 FAILURE CODE [CA342] ..............................................................................................................40-345 FAILURE CODE [CA351] ..............................................................................................................40-350 FAILURE CODE [CA352] ..............................................................................................................40-355 FAILURE CODE [CA386] ..............................................................................................................40-358 FAILURE CODE [CA435] ..............................................................................................................40-360 FAILURE CODE [CA441] ..............................................................................................................40-363 FAILURE CODE [CA442] ..............................................................................................................40-368 FAILURE CODE [CA449] ..............................................................................................................40-372 FAILURE CODE [CA451] ..............................................................................................................40-378 FAILURE CODE [CA452] ..............................................................................................................40-381 FAILURE CODE [CA488] ..............................................................................................................40-384 PC210-10M0, PC210LC-10M0
00-5
INDEX
00 INDEX AND FOREWORD
FAILURE CODE [CA553] ..............................................................................................................40-387 FAILURE CODE [CA559] ..............................................................................................................40-392 FAILURE CODE [CA689] ..............................................................................................................40-400 FAILURE CODE [CA731] ..............................................................................................................40-405 FAILURE CODE [CA757] ..............................................................................................................40-410 FAILURE CODE [CA778] ..............................................................................................................40-415 FAILURE CODE [CA2185] ............................................................................................................40-422 FAILURE CODE [CA2186] ............................................................................................................40-424 FAILURE CODE [CA2249] ............................................................................................................40-427 FAILURE CODE [CA2311] ............................................................................................................40-435 FAILURE CODE [CA2555] ............................................................................................................40-442 FAILURE CODE [CA2556] ............................................................................................................40-446 FAILURE CODE [D110KB]............................................................................................................40-450 FAILURE CODE [D19JKZ] ............................................................................................................40-453 FAILURE CODE [D1N0KA] ...........................................................................................................40-458 FAILURE CODE [D1N0KB] ...........................................................................................................40-460 FAILURE CODE [D1N0KY] ...........................................................................................................40-462 FAILURE CODE [D811MC] ...........................................................................................................40-463 FAILURE CODE [D862KA]............................................................................................................40-464 FAILURE CODE [D8AQKR] ..........................................................................................................40-466 FAILURE CODE [D8ALKA] ...........................................................................................................40-474 FAILURE CODE [D8ALKB] ...........................................................................................................40-478 FAILURE CODE [DA20MC] ..........................................................................................................40-481 FAILURE CODE [DA22KK] ...........................................................................................................40-482 FAILURE CODE [DA25KP] ...........................................................................................................40-487 FAILURE CODE [DA26KP] ...........................................................................................................40-491 FAILURE CODE [DA29KQ]...........................................................................................................40-497 FAILURE CODE [DA2LKA] ...........................................................................................................40-502 FAILURE CODE [DA2LKB] ...........................................................................................................40-506 FAILURE CODE [DA2QKR] ..........................................................................................................40-509 FAILURE CODE [DA2RKR] ..........................................................................................................40-518 FAILURE CODE [DAF0MB] ..........................................................................................................40-526 FAILURE CODE [DAF0MC] ..........................................................................................................40-527 FAILURE CODE [DAF9KQ]...........................................................................................................40-528 FAILURE CODE [DAFGMC] .........................................................................................................40-530 FAILURE CODE [DAFLKA] ...........................................................................................................40-531 FAILURE CODE [DAFLKB] ...........................................................................................................40-535 FAILURE CODE [DAFQKR] ..........................................................................................................40-538 FAILURE CODE [DAZ9KQ]...........................................................................................................40-547 FAILURE CODE [DAZQKR] ..........................................................................................................40-549 FAILURE CODE [DB2QKR] ..........................................................................................................40-557 FAILURE CODE [DDPAKA] ..........................................................................................................40-566 FAILURE CODE [DGH2KA] ..........................................................................................................40-569 FAILURE CODE [DGH2KB] ..........................................................................................................40-572 FAILURE CODE [DHA4KA]...........................................................................................................40-575 FAILURE CODE [DHE5MA] ..........................................................................................................40-578 FAILURE CODE [DHPAMA] ..........................................................................................................40-582 FAILURE CODE [DHPBMA]..........................................................................................................40-586 FAILURE CODE [DHS3MA] ..........................................................................................................40-590 FAILURE CODE [DHS4MA] ..........................................................................................................40-594 FAILURE CODE [DHS8MA] ..........................................................................................................40-598 FAILURE CODE [DHS9MA] ..........................................................................................................40-602 FAILURE CODE [DHSAMA]..........................................................................................................40-606 FAILURE CODE [DHSBMA]..........................................................................................................40-610 FAILURE CODE [DHSCMA] .........................................................................................................40-614 FAILURE CODE [DHSDMA] .........................................................................................................40-618 FAILURE CODE [DHSFMA]..........................................................................................................40-622 FAILURE CODE [DHSGMA] .........................................................................................................40-626 00-6
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
INDEX
FAILURE CODE [DHSHMA] .........................................................................................................40-630 FAILURE CODE [DHSJMA] ..........................................................................................................40-634 FAILURE CODE [DJG1KX] ...........................................................................................................40-638 FAILURE CODE [DKR0MA] ..........................................................................................................40-642 FAILURE CODE [DKR1MA] ..........................................................................................................40-646 FAILURE CODE [DKR2MA] ..........................................................................................................40-650 FAILURE CODE [DKR2NX] ..........................................................................................................40-654 FAILURE CODE [DLM5KA]...........................................................................................................40-656 FAILURE CODE [DLM5MB] ..........................................................................................................40-660 FAILURE CODE [DR21KX] ...........................................................................................................40-664 FAILURE CODE [DR31KX] ...........................................................................................................40-667 FAILURE CODE [DV20KB] ...........................................................................................................40-668 FAILURE CODE [DW43KA] ..........................................................................................................40-671 FAILURE CODE [DW43KB] ..........................................................................................................40-674 FAILURE CODE [DW43KY] ..........................................................................................................40-677 FAILURE CODE [DW45KA] ..........................................................................................................40-679 FAILURE CODE [DW45KB] ..........................................................................................................40-683 FAILURE CODE [DW45KY] ..........................................................................................................40-687 FAILURE CODE [DW91KA] ..........................................................................................................40-690 FAILURE CODE [DW91KB] ..........................................................................................................40-692 FAILURE CODE [DW91KY] ..........................................................................................................40-695 FAILURE CODE [DW97KA] ..........................................................................................................40-697 FAILURE CODE [DW97KB] ..........................................................................................................40-699 FAILURE CODE [DW97KY] ..........................................................................................................40-702 FAILURE CODE [DWA2KA] ..........................................................................................................40-704 FAILURE CODE [DWA2KB] ..........................................................................................................40-706 FAILURE CODE [DWA2KY] ..........................................................................................................40-709 FAILURE CODE [DWK0KA]..........................................................................................................40-711 FAILURE CODE [DWK0KB]..........................................................................................................40-713 FAILURE CODE [DWK0KY]..........................................................................................................40-716 FAILURE CODE [DWK2KA]..........................................................................................................40-718 FAILURE CODE [DWK2KB]..........................................................................................................40-720 FAILURE CODE [DWK2KY]..........................................................................................................40-723 FAILURE CODE [DWK8KA]..........................................................................................................40-725 FAILURE CODE [DWK8KB]..........................................................................................................40-727 FAILURE CODE [DWK8KY]..........................................................................................................40-730 FAILURE CODE [DWN5KA]..........................................................................................................40-732 FAILURE CODE [DWN5KB]..........................................................................................................40-735 FAILURE CODE [DWN5KY]..........................................................................................................40-738 FAILURE CODE [DXA8KA]...........................................................................................................40-740 FAILURE CODE [DXA8KB]...........................................................................................................40-743 FAILURE CODE [DXA9KA]...........................................................................................................40-747 FAILURE CODE [DXA9KB]...........................................................................................................40-750 FAILURE CODE [DXE0KA]...........................................................................................................40-754 FAILURE CODE [DXE0KB]...........................................................................................................40-756 FAILURE CODE [DXE4KA]...........................................................................................................40-759 FAILURE CODE [DXE4KB]...........................................................................................................40-761 FAILURE CODE [DXE4KY]...........................................................................................................40-764 FAILURE CODE [DXE5KA]...........................................................................................................40-766 FAILURE CODE [DXE5KB]...........................................................................................................40-768 FAILURE CODE [DXE6KA]...........................................................................................................40-771 FAILURE CODE [DXE6KB]...........................................................................................................40-773 FAILURE CODE [DY20KA] ...........................................................................................................40-776 FAILURE CODE [DY20MA]...........................................................................................................40-780 FAILURE CODE [DY2CKB]...........................................................................................................40-784 FAILURE CODE [DY2DKB]...........................................................................................................40-789 FAILURE CODE [DY2EKB]...........................................................................................................40-792 FAILURE CODE [F@BBZL] ..........................................................................................................40-795 PC210-10M0, PC210LC-10M0
00-7
INDEX
00 INDEX AND FOREWORD
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ...........................................................40-798 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ................................................40-798 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK..........................................................40-808 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ....................................................40-812 E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP .......... ..................................................................................................................................................40-816 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING..................................................................................................................................40-821 E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW .............................................................40-826 E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW .........................................40-828 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION . ..................................................................................................................................................40-830 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION ..... ..................................................................................................................................................40-832 E-10 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION..........................................................................................................................................40-834 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .......40-836 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .............40-840 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .......... ..................................................................................................................................................40-841 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...................................................................................................................................40-842 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .... ..................................................................................................................................................40-844 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .......................................................................................................................................40-845 E-17 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM ...................................40-847 E-18 FUEL GAUGE INDICATES INCORRECT LEVEL .................................................................40-850 E-19 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM40-852 E-20 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE ..............40-853 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM. ..................................................................................................................................................40-855 E-22 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE ....40-858 E-23 MACHINE MONITOR SHOWS INCORRECT MODEL .........................................................40-860 E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ........................40-861 E-25 FUNCTION SWITCH DOES NOT OPERATE .......................................................................40-862 E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) ..............40-863 E-27 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED ...........................................................................................40-865 E-28 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION .............................................................................................................................40-866 E-29 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED...............................................................................................................................40-869 E-30 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED ................................................................................................................................40-870 E-31 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED.........................................................................................................................................40-871 E-32 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED.................40-872 E-33 ALARM BUZZER DOES NOT STOP ....................................................................................40-874 E-34 SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION.......... ..................................................................................................................................................40-875 E-35 MACHINE DOES NOT CHANGE TO SERVICE MODE........................................................40-876 E-36 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE..............................40-877 E-37 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK.....................................40-881 E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED ....................................................................................................................................40-883 00-8
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
INDEX
E-39 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON ............40-887 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY........................................................................................................40-890 E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED................................40-894 E-42 TRAVEL ALARM DOES NOT SOUND .................................................................................40-896 E-43 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS...........................................40-899 E-44 HORN DOES NOT SOUND..................................................................................................40-901 E-45 HORN DOES NOT STOP.....................................................................................................40-905 E-46 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED . ..................................................................................................................................................40-907 E-47 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED .............................40-908 E-48 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED .............................................................................................................................................40-911 E-49 BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION ..................40-914 E-50 BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION ................40-915 E-51 ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION ................40-916 E-52 ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION ............................40-917 E-53 BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION.......40-918 E-54 BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION .......40-919 E-55 SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION.............................40-920 E-56 TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION ...........................40-921 E-57 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION ............40-922 E-58 ATTACHMENT CIRCUIT CANNOT BE CHANGED ..............................................................40-925 E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ...................................................40-927 E-60 QUICK COUPLER DOES NOT WORK.................................................................................40-929 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .......................40-934 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE) .................................40-934 H-1 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK .....................................40-935 H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER .....................40-937 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR..............................................40-950 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ....................................40-955 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ....................................................40-957 H-6 BOOM SPEED OR POWER IS LOW .....................................................................................40-966 H-7 Arm speed or power is low. ....................................................................................................40-978 H-8 BUCKET SPEED OR POWER IS LOW..................................................................................40-989 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .......................................40-999 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1003 H-11 HYDRAULIC DRIFT OF ARM IS LARGE ...........................................................................40-1005 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1009 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES ........................................................................................................................40-1012 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE .................................................................40-1014 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .........................40-1021 H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................40-1024 H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................40-1026 H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER ...................................................................................................................40-1028 H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY ...... ................................................................................................................................................40-1030 H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW ........ ................................................................................................................................................40-1031 H-21 MACHINE DOES NOT TRAVEL STRAIGHT ......................................................................40-1032 H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................40-1043 H-23 TRAVEL SPEED IS SLOW.................................................................................................40-1058 H-24 ONE OF TRACKS DOES NOT RUN ..................................................................................40-1069 H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ..40-1078 H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT.........................................................40-1081 H-27 SWINGS ONLY IN ONE DIRECTION.................................................................................40-1086 PC210-10M0, PC210LC-10M0
00-9
INDEX
00 INDEX AND FOREWORD
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) ......................................................................................................................................40-1089 H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION .........40-1096 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..................................................................................................................40-1100 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)..................................................................................40-1102 H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS.................................................40-1106 H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS ...................40-1108 H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)40-1111 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)........ ................................................................................................................................................ 40-1113 H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE) .................... 40-1117 H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN ......................................................... 40-1119 50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1 CONTENTS ............................................................................................................................................ 50-2 ABBREVIATION LIST ............................................................................................................................. 50-6 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .........................................................50-11 HOW TO READ THIS MANUAL......................................................................................................50-11 COATING MATERIALS LIST.......................................................................................................... 50-13 SPECIAL TOOLS LIST .................................................................................................................. 50-17 SKETCHES OF SPECIAL TOOLS................................................................................................. 50-26 PREPARATION..................................................................................................................................... 50-32 DRAIN AND ADD COOLANT......................................................................................................... 50-32 DRAIN AND AD HYDRAULIC OIL ................................................................................................. 50-35 DRAIN AND ADD FUEL................................................................................................................. 50-38 COLLECT AND REFILL REFRIGERANT....................................................................................... 50-42 ENGINE AND COOLING SYSTEM....................................................................................................... 50-43 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-43 REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-52 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-63 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY ........................................................... 50-90 REMOVE AND INSTALL ALTERNATOR BELT .............................................................................. 50-95 REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-102 REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY......................................................50-108 REMOVE AND INSTALL AFTER COOLER ASSEMBLY...............................................................50-115 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY ....................................................................50-121 REMOVE AND INSTALL FAN .......................................................................................................50-132 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-134 REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-168 REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-174 REMOVE AND INSTALL FUEL COOLER ASSEMBLY .................................................................50-180 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-183 REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-187 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-198 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-202 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-208 POWER TRAIN....................................................................................................................................50-212 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-212 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-217 REMOVE AND INSTALL SWIVEL MOTOR AND SWING MACHINERY ASSEMBLY ...................50-235 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-242 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-258 UNDERCARRIAGE AND FRAME........................................................................................................50-260 SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-260 REMOVE AND INSTALL SPROCKET ..........................................................................................50-267 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-269 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-272 00-10
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
INDEX
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY................................................50-281 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-285 DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY ............................................50-289 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-294 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-301 HYDRAULIC SYSTEM.........................................................................................................................50-304 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-304 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-312 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-316 REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-327 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-342 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-368 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-371 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-374 WORK EQUIPMENT............................................................................................................................50-377 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-377 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-384 CAB RELATED PARTS........................................................................................................................50-399 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY ..............................................................50-399 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-420 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-433 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-443 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-458 REMOVE AND INSTALL OPERATOR SEAT ................................................................................50-475 REMOVE AND INSTALL SEATBELT ............................................................................................50-478 REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-480 ELECTRICAL SYSTEM .......................................................................................................................50-494 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-494 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-498 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-504 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-511 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-516 60 MAINTENANCE STANDARD.................................................................................................................... 60-1 CONTENTS ............................................................................................................................................ 60-2 ABBREVIATION LIST ............................................................................................................................. 60-3 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD............................................................. 60-8 ENGINE AND COOLING SYSTEM....................................................................................................... 60-10 MAINTENANCE STANDARD OF ENGINE MOUNT ...................................................................... 60-10 MAINTENANCE STANDARD OF COOLING SYSTEM ...................................................................60-11 POWER TRAIN..................................................................................................................................... 60-13 MAINTENANCE STANDARD OF SWING CIRCLE ........................................................................ 60-13 MAINTENANCE STANDARD OF SWING MACHINERY................................................................ 60-14 MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-17 MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-19 SPROCKET TOOTH PROFILE FULL-SCALE DRAWING.............................................................. 60-20 UNDERCARRIAGE AND FRAME......................................................................................................... 60-21 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-21 MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-22 MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-24 MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-26 MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-27 MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-30 MAINTENANCE STANDARD OF SWAMP SHOE.......................................................................... 60-31 MAINTENANCE STANDARD OF ROAD LINER ............................................................................ 60-32 HYDRAULIC SYSTEM.......................................................................................................................... 60-33 MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-33 MAINTENANCE STANDARD OF MAIN PUMP .............................................................................. 60-34 MAINTENANCE STANDARD OF LS-EPC VALVE ......................................................................... 60-36 PC210-10M0, PC210LC-10M0
00-11
INDEX
00 INDEX AND FOREWORD
MAINTENANCE STANDARD OF PC-EPC VALVE......................................................................... 60-37 MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-38 MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-40 MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-43 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-53 MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-56 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-59 MAINTENANCE STANDARD OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE................. 60-60 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE ..................................... 60-61 MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-62 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) ........................................................................................................................................ 60-64 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) ........................................................................................................................................ 60-65 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-66 WORK EQUIPMENT............................................................................................................................. 60-67 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-67 DIMENSIONS OF ARM ................................................................................................................. 60-73 DIMENSIONS OF BUCKET ........................................................................................................... 60-75 MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-77 MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-78 MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-79 80 OTHERS ................................................................................................................................................... 80-1 ABBREVIATION...................................................................................................................................... 80-2 AIR CONDITIONER SYSTEM ................................................................................................................ 80-7 PRECAUTIONS FOR REFRIGERANT ............................................................................................ 80-7 LAYOUT DRAWING OF AIR CONDITIONER SYSTEM................................................................... 80-8 SPECIFICATION OF AIR CONDITIONER ..................................................................................... 80-10 CONFIGURATION OF REFRIGERATION CYCLE..........................................................................80-11 FUNCTION OF REFRIGERATION CYCLE .................................................................................... 80-12 SYSTEM DIAGRAM OF AIR CONDITIONER ....................................................................................... 80-13 COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-14 AIR CONDITIONER UNIT.............................................................................................................. 80-14 AIR CONDITIONER CONTROLLER.............................................................................................. 80-20 COMPRESSOR ............................................................................................................................. 80-22 CONDENSER ................................................................................................................................ 80-23 AIR CONDITIONER RELATED SENSORS.................................................................................... 80-25 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER............ 80-26 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .. .......................................................................................................................................................... 80-29 TEST AIR LEAKAGE (DUCT CONNECTION) ...................................................................................... 80-33 TEST AIR LEAKAGE (DUCT CONNECTION) ............................................................................... 80-33 TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION ............................................................ 80-36 TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-37 TEST VENT (MODE) CHANGEOVER ........................................................................................... 80-37 TEST FRESH/RECIRC AIR CHANGEOVER ........................................................................................ 80-39 TEST FRESH/RECIRC AIR CHANGEOVER ................................................................................. 80-39 TEST SUNLIGHT SENSOR.................................................................................................................. 80-40 TEST SUNLIGHT SENSOR........................................................................................................... 80-40 TEST DUAL PRESSURE SWITCH....................................................................................................... 80-41 TEST DUAL PRESSURE SWITCH................................................................................................ 80-41 TEST RELAY ........................................................................................................................................ 80-42 TEST RELAY ................................................................................................................................. 80-42 SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS ........................................ 80-44 PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER................................................... 80-45 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-46 FAILURE CODE [879AKA].................................................................................................................... 80-49 FAILURE CODE [879AKB].................................................................................................................... 80-51 00-12
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
INDEX
FAILURE CODE [879BKA].................................................................................................................... 80-53 FAILURE CODE [879BKB].................................................................................................................... 80-56 FAILURE CODE [879CKA].................................................................................................................... 80-59 FAILURE CODE [879CKB].................................................................................................................... 80-61 FAILURE CODE [879DKZ].................................................................................................................... 80-63 FAILURE CODE [879EMC] ................................................................................................................... 80-67 FAILURE CODE [879FMC] ................................................................................................................... 80-69 FAILURE CODE [879GKX] ................................................................................................................... 80-71 A-1 AIR CONDITIONER DOES NOT OPERATE .................................................................................. 80-74 A-2 DEFECTIVE COOLING .................................................................................................................. 80-77 A-3 HEATER DOES NOT OPERATE .................................................................................................... 80-86 A-4 COOL AIR DOES NOT COME OUT............................................................................................... 80-90 A-5 NO AIR COMES OUT OR AIR FLOW IS ABNORMAL ................................................................... 80-96 A-6 FRESH/RECIRC AIR CHANGEOVER NOT POSSIBLE................................................................80-100 CONNECT SERVICE TOOL ................................................................................................................80-104 CONNECT SERVICE TOOL .........................................................................................................80-105 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING........80-106 HANDLE COMPRESSOR OIL .............................................................................................................80-108 REPLACE DESICCANT.......................................................................................................................80-110 90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1 CONTENTS ............................................................................................................................................ 90-2 ABBREVIATION LIST ............................................................................................................................. 90-3 HOW TO READ THE CODES FOR ELECTRIC CABLE ......................................................................... 90-8 HYDRAULIC CIRCUIT DIAGRAM ........................................................................................................ 90-13 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM ................................................................ 90-13 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................. 90-17 ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-19 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-19 ELECTRICAL CIRCUIT DIAGRAM (1/7)........................................................................................ 90-23 ELECTRICAL CIRCUIT DIAGRAM (2/7)........................................................................................ 90-25 ELECTRICAL CIRCUIT DIAGRAM (3/7)........................................................................................ 90-27 ELECTRICAL CIRCUIT DIAGRAM (4/7)........................................................................................ 90-29 ELECTRICAL CIRCUIT DIAGRAM (5/7)........................................................................................ 90-31 ELECTRICAL CIRCUIT DIAGRAM (6/7)........................................................................................ 90-33 ELECTRICAL CIRCUIT DIAGRAM (7/7)........................................................................................ 90-35 CONNECTOR AND WIRING HARNESS CHART ................................................................................. 90-37 CONNECTOR AND WIRING HARNESS CHART (1/11) ................................................................ 90-39 CONNECTOR AND WIRING HARNESS CHART (2/11) ................................................................ 90-41 CONNECTOR AND WIRING HARNESS CHART (3/11) ................................................................ 90-43 CONNECTOR AND WIRING HARNESS CHART (4/11) ................................................................ 90-45 CONNECTOR AND WIRING HARNESS CHART (5/11) ................................................................ 90-47 CONNECTOR AND WIRING HARNESS CHART (6/11) ................................................................ 90-49 CONNECTOR AND WIRING HARNESS CHART (7/11) ................................................................ 90-51 CONNECTOR AND WIRING HARNESS CHART (8/11) ................................................................ 90-53 CONNECTOR AND WIRING HARNESS CHART (9/11) ................................................................ 90-55 CONNECTOR AND WIRING HARNESS CHART (10/11) .............................................................. 90-57 CONNECTOR AND WIRING HARNESS CHART (11/11)............................................................... 90-59 INDEX..................................................................................................................................................................1
PC210-10M0, PC210LC-10M0
00-13
ABBREVIATION LIST
00 INDEX AND FOREWORD
ABBREVIATION LIST •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
•
Abbreviations that are used in general society may not be included.
•
Special abbreviations that appear infrequently are noted in the text.
•
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
Steering
ARAC
Automatic Retarder Accelerator Control
Travel and brake
ARSC
Automatic Retarder Speed Control
Travel and brake (HD, HM)
(WA)
(HD, HM)
Travel and brake (HD, HM)
Explanation A function that releases the brakes when the tires skid (wheels stop rotating), and applies the brakes again when the wheels start to rotate. A function that automatically sets the idle speed. A function that uses a lever to perform the steering operations instead of a steering wheel. Moreover, the lever is used to shifts gear and changes direction (FORWARD, REVERSE). A function that automatically applies the retarder with a constant braking force when the accelerator pedal is released while the machine is traveling downhill. A function that automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when the accelerator pedal is released while the machine is traveling downhill.
ASR
Automatic Spin Regula- Travel and brake tor (HD, HM)
A function that automatically uses the optimum braking force to drive both wheels when the tires spin on soft ground.
ATT
Attachment
A device that can be fixed onto the standard machine in order to enable it to do different jobs.
BCV
Brake cooling oil control Brake valve (HD)
CAN
Controller Area Network
Communication and electronic control
One of communication standards that are used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve that is installed to KCCV ventilator. It is written as CDR valve and it is not used singly.
CLSS
Closed-center Load Sensing System
Hydraulic system
A system that simultaneously actuates multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
A function that maintains optimum fuel injection amount and fuel injection timing by engine controller electronically controlling supply pump, common rail, and injector.
CRI
00-14
Common Rail Injection
WORK EQUIPMENT
A valve that divides part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used.
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Travel Suspension System (WA)
A system that ensures smooth high-speed travel by absorbing vibration of machine during travel with spring effect of accumulator.
ECU
Electronic Control Unit
An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
A function that recirculates part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of NOx.
Equipment ManageMACHINE MONITOR ment Monitoring System
A system which enables data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor to be checked on the monitor.
EPC
Electromagnetic ProporHydraulic system tional Control
This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Cab and canopy Structure
EMMS
F-N-R
GPS
GNSS
Forward-Neutral-Reverse Global Positioning System
Electronic control system
Transmission (D, HD, WA, etc)
Electronic control system
Operation Communication (KOMTRAX, KOMTRAX Plus)
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
Explanation An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECU) A proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.
A structure that protects the operator's head from falling objects. ISO 3449 compliant Forward - Neutral - Reverse A system that uses satellites to determine the current location on the earth 1. A system that uses satellites such as GPS, GALILEO, etc. to determine location on the earth. A function which uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly, machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
Steering
HST
Hydrostatic Transmission
Transmission
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
IMA
Inlet Metering Actuator
PC210-10M0, PC210LC-10M0
(D Series)
(D, WA)
A hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears.
00-15
ABBREVIATION LIST
Abbreviation
IMU
Actual word spelled out
Inertial Measurement Unit
00 INDEX AND FOREWORD
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
A device that detects the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV (+)
Inlet Metering Valve
Engine
A valve which is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
A mechanism that separates oil in blowby gas and send it back to the intake side for it to be burned again. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
Engine
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
A filter that captures soot in exhaust gas. It is built in to KDPF A catalyst that is used for purifying exhaust gas.
Engine
Komatsu Diesel ParticuEngine late Filter
It is built in to KDPF or used in combination with the muffler in some cases. A component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler. A function that recovers the driving force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle machine travels on the soft ground road.
Komatsu Traction Control System
Travel and brake
LCD
Liquid Crystal Display
MACHINE MONITOR
A display equipment such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic parts
It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
One of communication standards that are used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
One of communication standards that are used in the network on the machine
MAF
Mass Air Flow
Engine
This indicates engine intake air flow. Mass air flow sensor is described as MAF sensor in some cases.
MMS
Multimedia Messaging Service
Communication
A service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
NC
Normally Closed
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally closed if it is not actuated (it opens when it is actuated).
NO
Normally Open
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally open if it is not actuated (it closes when it is actuated).
KTCS
00-16
(HM)
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
Abbreviation OLSS PC
PCCS
Actual word spelled out Open-center Load Sensing System
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system) Hydraulic system
Pressure Compensation Hydraulic system Palm command control system
Steering (D Series)
Explanation A hydraulic system that can operate multiple actuators at the same time regardless of the load. A function used to correct oil pressure. A function that electronically controls the engine and transmission. It is done by a controller that instantly analyses data from each lever, pedal, and dial.
PCV
Pre-stroke Control Valve Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This system is used for controlling proportional pressure. It moves actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power train system
PTP
Power Tilt and power Pitch dozer
WORK EQUIPMENT
ROPS
Roll-Over Protective Structure
Hydraulic system Hydraulic system (D, PC, etc)
(D Series)
Cab and canopy
A piston type hydraulic pump and motor A mechanism that takes out the force for the work equipment separately from the travel. A function that hydraulically performs tilt operation and pitch operation of the bulldozer blade. A protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. ISO 3471 compliant
SCR
Selective Catalytic Reduction
Urea SCR system
An exhaust gas purifier using urea water to convert nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It Done also be mentioned as exhaust gas purification catalyst , or part of the of related devices.
Le Système internationUnit al d'unités
A universal unit system and "a single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
An actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
A solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
The turbocharger on which the cross-section area of the exhaust passage is made variable.
SI
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
PC210-10M0, PC210LC-10M0
00-17
ABBREVIATION LIST
00 INDEX AND FOREWORD
List of abbreviations used in the circuit diagrams Abbreviation A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
00-18
Actual word spelled out
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
HOW TO READ THE SHOP MANUAL
FOREWORD, SAFETY, BASIC INFORMATION HOW TO READ THE SHOP MANUAL •
Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.
•
The materials and specifications are subject to change without notice.
•
Shop Manuals are available for "machine part" and "engine part". For the engine unit, see the shop manual for the machine which has the same engine model.
•
Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.
Composition of the shop manual This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION This section describes the structure and operation of each component with respect to each system. "STRUCTURE AND FUNCTION" is helpful in not only understanding the structure of each component but performing troubleshooting.
20 STANDARD VALUE TABLE This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 TESTING AND ADJUSTING This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in "STANDARD VALUE TABLE".
40 TROUBLESHOOTING This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams This section describes hydraulic circuit diagrams and electrical circuit diagrams.
PC210-10M0, PC210LC-10M0
00-19
HOW TO READ THE SHOP MANUAL
00 INDEX AND FOREWORD
Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effectively. Symbol
Item
Remark
Danger
This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.
Warning
This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.
Caution
This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
Weight
This signal indicates the weight of parts and components, and items which requires great attention to a selection of wires and working posture for slinging work.
Tightening torque
This signal indicates the tightening torque for portions which requires special care in assembling work.
Coat
This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.
Oil and coolant
This signal indicates a place to supply oil, coolant, etc. and the quantity.
Draining
This signal indicates a place to drain oil, coolant, etc. and the quantity.
Signal word Signal word for notice and remark describes the following. Symbol
Item
NOTICE
Notice
REMARK
Remark
Remark If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur. This signal word contains useful information to know.
Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
00-20
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
SAFETY NOTICE FOR OPERATION
SAFETY NOTICE FOR OPERATION •
Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.
•
The symbol mark
is indicated for such matters that require special precautions. The work indicated with
should be performed according to the instructions with special attention. Should a this warning mark hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.
Safety matters •
Well organized work place
•
Correct work clothes
•
Observance of work standard
•
Enforcement of hand signals
•
Prohibition against unlicensed persons operating and handling the machine
•
Safety check before starting work
•
Wear of dust glasses (for cleaning or grinding work)
•
Wear of welding goggles and protectors (for welding work)
•
Being in good physical condition, and good preparation
•
Always be alert and careful.
General precautions k
If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the operation and maintenance manual before operation. Read and understand what is described in this manual before operation.
•
Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.
•
Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.
•
Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
•
Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.
PC210-10M0, PC210LC-10M0
00-21
SAFETY NOTICE FOR OPERATION
00 INDEX AND FOREWORD
•
Always wear the protective eyeglasses when hitting parts with a hammer.
•
Always wear the protective eyeglasses when grinding parts with a grinder, etc.
•
When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals. Hang "UNDER REPAIR" warning tag in the operator's compartment Before starting work.
•
Work and operation which require license or qualification should be performed by qualified workers.
•
Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
•
Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.
•
Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.
,&
Precautions for preparatory work •
Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.
•
Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang "UNDER REPAIR" warning tag on them.
•
When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
•
Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed. Repair it or replace it immediately. ,&
Precautions during work •
For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position. REMARK Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type. For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.
•
For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-). REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).
00-22
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
SAFETY NOTICE FOR OPERATION
•
Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.
•
When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
•
The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.
•
Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.
•
When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
•
When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.
•
When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.
•
When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
•
Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.
PC210-10M0, PC210LC-10M0
,&
00-23
SAFETY NOTICE FOR OPERATION
00 INDEX AND FOREWORD
•
Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not be damaged by contact with other parts when the machine is operated.
•
When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.
•
When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.
•
Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
•
Check that the measuring tools are correctly installed when measuring hydraulic pressure.
•
Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.
•
If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.
,&
Precautions for slinging work and making signals •
Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely.
k k k k k
Never stand under the load. Do not move a load over a person. Never step on the load. Do not prevent the load from swinging or falling down by holding it simply with the hands. The sling workers and assistant workers other than the guide must move to a place where they are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly.
•
Check the slings before starting sling work.
•
Keep putting on gloves during sling work. (Put on leather gloves, if available.)
•
Measure the weight of the load by the eye and check its center of gravity.
•
Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.
•
Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.
k
Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.
•
Hanging angle must be 60 ° or smaller as a rule.
•
When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook.
00-24
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
SAFETY NOTICE FOR OPERATION
REMARK When slinging a load with 2 or more ropes, the force subjected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, they can sling up to 2000 kg of total weight. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 2000 kg load at a hanging angle of 150 °, each rope is subjected to a force as large as 39.2 kN {4000 kg} . •
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.
•
Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
•
Apply wire ropes to the middle part of the hook. k k
Do not use hooks if it does not have a latch system. Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting.
REMARK The strength of the hook is maximum at its central part.
•
Never use a wire rope which has breaks in strands (A), reduced diameter (B), or kinks (C). There is a danger that the rope may break during the towing operation.
Precautions for slinging up •
Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.
•
After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
•
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
•
Do not lift up the load at an angle.
Precautions for slinging down •
When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
•
Check that the load is stable, and then remove the sling.
•
Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane k
When raising a heavy component (heavier than 25 kg), use a hoist or crane.
PC210-10M0, PC210LC-10M0
00-25
SAFETY NOTICE FOR OPERATION
00 INDEX AND FOREWORD
REMARK in "DISASSEMBLY AND
Weight of component whose weight is heavier than 25 kg is shown with symbol ASSEMBLY". •
Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing caution lamp, and check the following safety items. •
Observe the signals for sling work.
•
Operate the hoist at a safe place.
•
Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.
•
Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
•
Do not raise or lower a load while the crane is moving longitudinally or laterally.
•
Do not drag a sling.
•
When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
•
Consider the travel route in advance and lift up a load to a safe height.
•
Place the control switch in a position where it is not an obstacle to work and passage.
•
After operating the hoist, do not swing the control switch.
•
Remember the position of the main switch so that you can turn off the power immediately in an emergency.
•
If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition.
•
If you find an obstacle around the hoist, stop the operation.
•
After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
Selecting wire ropes Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below. REMARK The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope. Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
00-26
Nominal diameter of rope ( mm)
Allowable load ( kN { t} )
10
8.8 {0.9}
12
12.7 {1.3}
14
17.3 {1.7}
16
22.6 {2.3}
18
28.6 {2.9}
20
35.3 {3.6}
25
55.3 {5.6}
30
79.6 {8.1}
40
141.6 {14.4}
50
221.6 {22.6}
60
318.3 {32.4}
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
SAFETY NOTICE FOR OPERATION
Precautions for disconnecting air conditioner piping NOTICE When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses. REMARK • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). • Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k
•
Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are collecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite. When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping •
When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
•
Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
•
Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
•
When removing the O-rings, use a soft tool so that the piping is not damaged.
•
Check that the O-ring is not damaged or deteriorated.
•
Apply compressor oil for refrigerant (R134a) to O-ring. REMARK Do not apply oil to the threaded portion of a bolt, nut or union. Manufacturer
Part name
DENSO
ND-OIL8
VALEO THERMAL SYSTEMS
ZXL100PG (PAG46 or equivalent)
SANDEN
SP-10
When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).
PC210-10M0, PC210LC-10M0
00-27
SAFETY NOTICE FOR OPERATION
00 INDEX AND FOREWORD
REMARK • The figure shows an example of fitting of O-ring. • An O-ring is fitted to every joint of the air conditioner piping. For tightening torques, see THE OTHER INFORMATION, "Precautions for disconnection and connection of air conditioner piping".
00-28
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS TO PREVENT FIRE
PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, coolant or window washer fluid Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following. •
Do not smoke or use any open flame near fuel or other flammable substances.
•
Shut down the engine before adding fuel.
•
Do not leave the machine when adding fuel or oil.
•
Tighten all the fuel and oil caps securely.
•
Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.
•
After adding fuel or oil, wipe up any spilled fuel or oil.
•
Put greasy cloths and other flammable materials into a safe container to maintain safety at the workplace.
•
When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire.
•
Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.
•
Determine well-ventilated areas for storing oil and fuel. Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.
•
When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.
,&
,&
Fire caused by accumulation or attachment of flammable material •
Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the under-covers.
•
To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.
Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following. •
Keep all the electric wiring connections clean and securely tightened.
•
Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.
Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position. If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.
Explosion caused by lighting equipment •
When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.
•
When taking the electrical power for the lighting equipment from the machine, follow the instructions in Operation and Maintenance Manual.
PC210-10M0, PC210LC-10M0
00-29
ACTIONS IF FIRE OCCURS
00 INDEX AND FOREWORD
ACTIONS IF FIRE OCCURS •
Turn the starting switch to OFF position to stop the engine.
•
Use the handrails and steps to get off the machine.
•
Do not jump off the machine. You may fall and suffer serious injury.
•
The fumes generated by a fire contain harmful materials which have a bad influence on your body when they are inhaled. Do not breathe the fumes.
•
After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on your body. Be sure to wear rubber gloves when handling the materials left after the fire. The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment). When wearing cotton work gloves, wear rubber gloves under them.
00-30
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS To prevent environmental pollution, be very careful about the disposal of waste materials. •
Always drain the waste into containers such as cans, tanks. Never pour the waste into the ground, or to the river, sewage, sea or lake.
•
When disposing of harmful substances such as oil, fuel, cooling water, solvents, filters, batteries, obey the applicable laws and regulations.
Some of the rubber and plastics generate harmful gases that can cause adverse effects on the human body when burned. •
Disposal of rubber, plastic, and other components (hoses, cables, harnesses, etc.) which contains rubber and plastics shall be entrusted to the processing contractor in accordance with applicable laws and regulations.
PC210-10M0, PC210LC-10M0
00-31
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.
Select an appropriate workplace •
In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the machine.
Disassembly and maintenance work in the field k
Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit and it may result in serious personal injury or death when removing and disassembling of the hydraulic equipment is performed. k Release the remaining pressure from the hydraulic circuit always before performing the work. •
In the field, there is a risk of dust entering the component during disassembling or maintenance work, and performance check is hardly performed. Replacement of the assembly is recommended.
•
Perform disassembling and maintenance work in the dust proof area.
Sealing of openings (prevention of flowing out of oil) Plug the openings of the piping and the device which have been removed to prevent foreign material from entering and oil from flowing out. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment. Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately. REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.
00-32
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
Preventing intrusion of foreign materials during refilling •
During refilling with the hydraulic oil, do not let water enter the electrical components.
•
Clean the oil filler port and its around, refilling pump, oil jug, or etc.
•
Refilling by using an oil cleaning device is better method since it can filtrate the contaminants accumulated in the oil during storage.
Replacing hydraulic oil while its temperature is high •
The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high.
•
Old hydraulic oil needs to be drained as much as possible when replacing. NOTICE Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludges, and the service life of the hydraulic oil is shortened. REMARK Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.
Avoid reusing the hydraulic oil and lubricating oil Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine. If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation •
Flushing is required to completely dislodge the contaminants and sludges, and existing oil containing those inside the hydraulic circuit after disassembling and assembling, and when replacing the oil with the new one.
•
Normally, flushing is performed twice. Primary flushing is performed by using the flushing oil (1) and the secondary flushing is performed by using the specified hydraulic oil.
Cleaning operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine.
PC210-10M0, PC210LC-10M0
00-33
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
00 INDEX AND FOREWORD
REMARK The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment cannot remove. So, it is very effective device.
00-34
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and assembly" of the components, observe the following precautions.
Precautions for removal and disassembling work •
If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.
•
After disconnecting the hoses or tubes, plug them to prevent dust from entering.
•
When draining oil, prepare a container with sufficient capacity.
•
Check the matchmarks which indicate the installing position, and put matchmarks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.
•
Hold the wiring connectors when disconnecting the connectors, and do not apply excessive force to the wiring.
•
Place tags to the wirings and hoses in order not to install them to wrong positions.
•
Check the quantity and thickness of shims when storing shims.
•
Prepare the slings with sufficient strength for hoisting the components.
•
When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
•
Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.
•
To disconnect the face seal type hose from the cylinder tube connected to the cylinder with the face joint seal, loosen it by gripping the two wrenches together, one is the wrench (1) on the hose side, and the other is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only. Check after the hose is disconnected that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient. NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
•
After disconnecting the piping or removing a pipe joint, install the following plugs. NOTICE When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions. REMARK The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.
PC210-10M0, PC210LC-10M0
00-35
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
00 INDEX AND FOREWORD
Introduction of parts for the disassembly of the face seal type hoses and tubes
Hose side
Pipe joint side
Plug (1)
Nut (2)
02
07376-70210
02789-00210
02896-11008
03
07376-70315
02789-00315
02896-11009
04
07376-70422
02789-00422
02896-11012
05
07376-70522
02789-00522
02896-11015
06
07376-70628
02789-00628
02896-11018
Nominal No.
O-ring (3)
Introduction of parts for the disconnection of the taper seal type hoses and tubes
Hose side
Pipe joint side
Plug (1)
Nut (2)
02
07376-50210
07222-00210
03
07376-50315
07222-00312
04
07376-50422
07222-00414
05
07376-50522
07222-00515
06
07376-50628
07222-00616
10
07376-51034
07222-01018
12
07376-51234
07222-01219
14
07376-51443
07222-01422
Nominal No.
00-36
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
Introduction of parts for the disconnection of the split flange type hoses and tubes
Hose side Nomi Bolt pitch ( mm) nal a b Flange (1) No.
Tube side Split flange (2)
Sleeve head (3)
O-ring (4)
Bolt (5)
Washer (6)
04
38.1
17.5
07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05
42.9
19.8
07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06
47.6
22.2
07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10
52.4
26.2
07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7
30.2
07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
66.7
31.8
07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9
35.8
07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
79.4
36.5
07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8
42.8
07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
96.8
44.5
07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24
88.9
50.8
07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30
106.4
62
07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34
120.6
69.8
07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40
130.2
77.8
07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50
152.4
92
07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645
12
14
20
Introduction of parts for the removal of O-ring boss type joint
PC210-10M0, PC210LC-10M0
00-37
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
00 INDEX AND FOREWORD
Nominal No.
Plug (1)
O-ring (2)
08
07040-10807
07002-10823
10
07040-11007
07002-11023
12
07040-11209
07002-11223
14
07040-11409
07002-11423
16
07040-11612
07002-11623
18
07040-11812
07002-11823
20
07040-12012
07002-12034
24
07040-12412
07002-12434
30
07041-13012
07002-13034
33
07040-13316
07002-13334
36
07041-13612
07002-13634
42
07040-14220
07002-14234
52
07040-15223
07002-15234
Introduction of parts for the removal of taper pipe thread type joint
Plug (1)
Nominal No.
Nominal thread size
Square head type (A)
Hexagonal socket head (B)
01
R 1/8
07042-00108
07043-00108
02
R 1/4
07042-00211
07043-00211
03
R 3/8
07042-00312
07043-00312
04
R 1/2
07042-00415
07043-00415
06
R 3/4
07042-00617
07043-00617
10
R1
07042-01019
07043-01019
12
R1 1/4
07042-01222
07043-01222
14
R1 1/2
07042-01422
07043-01422
20
R2
07042-02026
07043-02026
Precautions for installation and assembling work •
Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
•
Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.
•
Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
00-38
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
•
Bend the cotter pins and lock plates securely.
•
When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to the threaded portion.
•
When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dust or damage.
•
Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
•
Apply engine oil to the rotating parts and sliding surface.
•
Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
•
After installing the snap ring, check that the snap ring is settled in the ring groove completely.
•
When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then connect them securely.
•
Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.
•
When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
•
As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure. REMARK If the threaded portion is difficult to degrease, you may use a seal tape. When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the third thread in the advancing direction of the threads seeing from the screw end. NOTICE If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come off. If the sealed tip is pushed outside, it may cause oil leakage.
•
To connect the face seal type hose to the cylinder tube connected to the cylinder with the face joint seal, tighten it by gripping the two wrenches together, one is the wrench (1) on the hose side, and the other is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only. Check after the hose is connected that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient. NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.
NOTICE When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure. 1. Start the engine, and run it at low idle. 2.
Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximately 100 mm before the stroke end for 4 or 5 times.
3.
Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4times.
NOTICE After repair is finished, when operating the machine which has been stored for a long period, bleed air from the hydraulic circuit according to the same procedure. PC210-10M0, PC210LC-10M0
00-39
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
00 INDEX AND FOREWORD
Precautions at the time of completion of work Refilling of coolant, oil, and grease •
Supply the specified amount of grease to the work equipment parts.
•
When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.
•
When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.
•
If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuilding the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds •
Check the cylinder head and intake and exhaust manifold mountings for looseness.
•
If there is any looseness, perform re-tightening. REMARK For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness Intake and exhaust system Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak of air or exhaust gas from connecting portion. If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water leak from connecting portion. If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion. If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage. REMARK When an equipment is described as an exhaust equipment, it is one of the following. (The applications or components of equipment are different depending on its models or specifications.) • Muffler • Exhaust pipe • Parts which connects the above, or etc. Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there is any damage, replace the part. Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the installation portion. If there is any looseness, retighten the part.
00-40
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
Check of function of muffler in exhaust system REMARK When an equipment is described as an muffler in exhaust system, it is one of the following. (The applications or components of equipment are different depending on its models or specifications.) • Muffler • Exhaust pipe • Parts which connects the above, or etc. Check that there is no unusual noise by comparing to it of the time when the machine was new. If there is any unusual noise, repair muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY AND ASSEMBLY".
PC210-10M0, PC210LC-10M0
00-41
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT
00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed. This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical equipment".
Handling wiring harnesses and connectors •
Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.
•
Compared with other electrical components fitted in boxes or cases, wiring harnesses are likely to be directly affected by rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling and maintenance of the wiring harnesses.
Main causes of failure in wiring harness Defective contact of connectors (defective contact between male and female connectors) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.
Defective crimping or soldering of connectors The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage.
00-42
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT
Disconnection in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the soldering, or break the wiring harness.
Water entering the connector by high-pressure jetting The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Do not spray water directly on the connector. If the connector is waterproof, intruded water is hardly drained. If water enters into the connector, water goes through pins to cause short-circuit. Drying the drenched connector or take appropriate actions before providing electricity.
Water, sand, soil, dust entering the connector when the connector is disconnected If any water, mud or dirt is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a piece of dry cloth or blow it with compressed air.
Oil, grease, sand, soil, sand attaching to the connector If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through, resulting in defective contact. If any oil or grease, mud or dirt is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air and spray it with electrical contact restorer. NOTICE • When wiping the jointed portion of the connector, do not apply excessive force or deform the pins. • If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from.
PC210-10M0, PC210LC-10M0
00-43
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Sealing the opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment. Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.
How to clean parts when dirt is stuck If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge. NOTICE The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.
00-44
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an appropriate workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.
Sealing the opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering. NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter it.
PC210-10M0, PC210LC-10M0
00-45
PRACTICAL USE OF KOMTRAX
00 INDEX AND FOREWORD
PRACTICAL USE OF KOMTRAX Various information which KOMTRAX system transmits by using the radio communication is useful for KOMTRAX operator to provide various services for the customers. When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently. Large-sized models are equipped with KOMTRAX Plus which can use more detailed information. REMARK (KOMTRAX may not be installed to the machine in some countries or areas.)
Merit of using KOMTRAX •
The location where the machine is working at can be checked on the map in a personal computer.
•
Operation information such as service meter, operating hours, fuel consumption, and occurred caution as well as failure code can be checked.
•
The operator can check the hours used and replacement interval of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
•
Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be checked, and it is used to presume the machine operating condition.
•
Various reports such as "Fuel saving operation support", "Operation summary", etc. is generated, and it is utilized as an advice tool for the user and operator.
•
KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the soundness of machine, in addition to KOMTRAX function described above. These data can be used on personal computer screens.
How to make a full use of KOMTRAX Making use of KOMTRAX enables the following activities. •
•
Quick response to a request for immediate repair 1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair request from a user. 2.
To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
3.
To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
Proactive maintenance 1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure code indicated by a red or yellow flag. 2. To check the condition of the machine with the customer and to make a plan to visit. 3.
•
To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.
Practice of periodic maintenance and periodic inspection service 1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits for the consumable parts indicated by red flags are over. 2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer. 3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.
00-46
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER REMARK • Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank. • Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER Disconnection 1.
Hold adapter (1), and push hose joint (2) into mating adapter (3). REMARK • Push it in approximately 3.5 mm. • Do not hold rubber cap portion (4).
2.
While having adapter (3) inserted into hose side joint (2), insert rubber cap (4) to adapter (3) side until it clicks.
3.
Hold hose adapter (1) or hose (5), and pull it out. REMARK Provide an oil container to receive a quantity of hydraulic oil which may flow out.
Connection 1.
Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis. REMARK Do not hold rubber cap portion (4).
PC210-10M0, PC210LC-10M0
00-47
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
2.
00 INDEX AND FOREWORD
After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition. REMARK When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a problem.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER Disconnection 1.
Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2.
While keeping the condition of step 1, turn lever (3) to the right (clockwise).
3.
While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out.
00-48
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
Connection Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER Disconnection 1.
Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
2.
While keeping the condition of step 1, push cover (3) straight until it contacts contact surface (a) of the hexagonal portion on the male side.
3.
While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it. REMARK Provide an container to receive a quantity of hydraulic oil which may flow out.
PC210-10M0, PC210LC-10M0
00-49
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
00 INDEX AND FOREWORD
Connection Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.
00-50
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS Disconnecting connectors 1.
Hold the connectors when disconnecting. When disconnecting the connectors, always hold the connecting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel. NOTICE Do not pull the connectors with one hand. REMARK If it is a lock stopper type connector, pull it out as pushing the stopper (1) with your thumb.
2.
When removing a connector from a clip •
Both of the connector and clip have stoppers (2), which are engaged with each other when the connector is connected.
•
When removing a connector from a clip, pull the connector in parallel with the clip as removing stoppers. NOTICE If the connector is pried up and down or to the right or left, it may break the housing.
3.
Action to be taken after removing connectors After removing the connector, cover it with plastic bags to prevent entry of dust, dirt, oil, or water in the contact portion. NOTICE Be sure to cover the connector with plastic bags when leaving the machine disassembled for a long time, otherwise defective contact may occur.
Connecting connectors 1.
Check the connector visually.
PC210-10M0, PC210LC-10M0
00-51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
00 INDEX AND FOREWORD
•
Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).
•
Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
•
Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE • If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is any water intrusion into the connector, warm the inside of the connector and harness with a dryer. Do not overheat the connector, otherwise short circuit may occur. • If there is any damage or breakage, replace the connector. 2.
Connecting the connector securely Position connector (1) correctly, and fit it in securely. REMARK If the connector is lock stopper type, insert it until it clicks.
3.
Correct the protrusion of the boot and misalignment of the wiring harness.
•
If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position. REMARK If the protrusion of the boot and misalignment of the wiring harness cannot be fixed, remove the clamp to adjust them.
•
If the connector clamp is removed, be sure to return it to its original position. Check that there is no looseness.
Drying wiring harness REMARK If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing. If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.
00-52
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
1.
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
Disconnect the connector and wipe off the water with a dry cloth. NOTICE If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow.
2.
Dry the inside of the connector with a dryer. If water enters inside the connector, use a dryer to dry the connector. NOTICE Hot air from a dryer can be used, but limit the time of using a dryer to prevent the connector or related parts from becoming too hot, as this will cause deformation or damage to the connector.
3.
Perform a continuity test on the connector. After drying, leave the wiring harness disconnected, connect T-adapter(1), and perform a continuity test to check for any short circuits between pins caused by water or etc. REMARK After the connector is completely dried, blow the contact restorer, and reassemble them.
Handling controller
k
When performing arc welding on the machine body, disconnect all of the wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
PC210-10M0, PC210LC-10M0
00-53
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
00 INDEX AND FOREWORD
NOTICE • Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine. • Do not leave things on the controller. • Cover the connector portion of the controller with a tape and a plastic bag. Do not touch the connecting portion of connector. • Do not leave the controller in a place where it is exposed to rain. • Do not place the controller on oil, water, soil or any places where the temperature is likely to be high even for a short period of time (Place it on a suitable dry stand).
Precautions for troubleshooting electrical circuits •
Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
•
Before performing troubleshooting, check all the related connectors for loose connection. REMARK Check the related connectors for their performance by disconnecting and connecting them several times.
•
Be sure to connect all the disconnected connectors before proceeding to the next step. NOTICE If the starting switch is turned to ON position while the connectors are disconnected, an unrelated failure beside the actual failed part may be displayed.
•
When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change. NOTICE If the value changes on the multimeter, there may be a defective contact in the circuit.
00-54
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR Method for disconnecting Deutsch connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2).
Method for connecting Deutsch connector 1.
Push in female connector (2) horizontally, and insert it straight until it clicks. (Arrow: x)
2.
In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z) REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.
PC210-10M0, PC210LC-10M0
00-55
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 1.
Slide lock (L1) to the right.
2.
While pressing lock (L2), pull out connector (1) toward you. REMARK If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward you, push up portion A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) Insert it straight until it clicks.
Method for disconnecting slide lock type connector (FRAMATOME-24) 1.
Slide down lock (red) (L1).
00-56
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
2.
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
While pressing lock (L2), pull out connector (1). REMARK Lock (L2) is located behind connector (1) in the figure.
Method for connecting slide lock type connector (FRAMATOME-24) Insert it straight until it clicks.
PC210-10M0, PC210LC-10M0
00-57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL Method for disconnecting connector with lock to pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.
Method for connecting connector with lock to pull Insert the connector securely until it "clicks".
00-58
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH Method for disconnecting connector with lock to push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow. • 114 series
•
107 series
REMARK If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
Method for connecting connector with lock to push (BOSCH-3) Insert it straight until it clicks.
PC210-10M0, PC210LC-10M0
00-59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
00 INDEX AND FOREWORD
Method for disconnecting connector with lock to push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow.
Method for connecting connector with lock to push (AMP-3) Insert it straight until it clicks.
Method for disconnecting connector with lock to push (SUMITOMO-3) While pressing lock (E), pull out connector (5) in the direction of the arrow. REMARK Pull up the connector straight.
Method for connecting connector with lock to push (SUMITOMO-3) Insert it straight until it clicks.
Method for disconnecting connector with lock to push (SUMITOMO-4) While pressing lock (D), pull out connector (4) in the direction of the arrow.
Method for connecting connector with lock to push (SUMITOMO-4) Insert it straight until it clicks.
00-60
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE Method for disconnecting connector with housing to rotate Turn housing (H1) to the left, and pull it out. REMARK Housing (H1) is left on the wiring harness side.
Method for connecting connector with housing to rotate 1.
Insert the connector to the end while aligning its groove to the other.
2.
Turn housing (H1) clockwise until it clicks.
PC210-10M0, PC210LC-10M0
00-61
HOW TO READ ELECTRICAL WIRE CODE
00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electrical wire code is helpful in understanding the electrical circuit diagram. Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol. AEX
0.85 L
Type, symbol, and material of wire are shown in (Table 1). (Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on the diagram.) Indicates size of wire by nominal No. Sizes (Nominal Nos.) are shown in (Table 2). Indicates color of wire by color code. Color codes are shown in (Table 3).
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating. AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating. (Table 1) Type
Symbol
Low-voltage wire for automobile
AV
Thin-cover low-voltage wire for automobile
Insulator material
Temperature range (°C) in use
Example of use For large current wiring (nominal No. 5 and above)
General wiring
AVS Soft polyvinyl chloride
(Type 1) Thin-cover low-voltage wire for automobile
Conductor material
-30 to +60
Annealed copper for electric appliance
(nominal No. 3 and lower)
For mid- to small-size excavators
CAVS
(nominal No. 1.25 and lower)
(Type 2) Heat-resistant low-voltage wire for automobile
00-62
AEX
Heat-resistant crosslinked polyethylene
-50 to +110
General wiring for extremely cold weather specification Wiring at high-temperature place
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE
Dimensions
(Table 2) Nominal No.
Coating D
Conductor
0.5f
(0.5)
0.75f
(0.85)
1.25f
(1.25)
2f
2
3f
3
5
Number of strands
20
7
30
11
50
16
37
26
58
41
65
Diameter of strand
0.18
0.32
0.18
0.32
0.18
0.32
0.26
0.32
0.26
0.32
0.32
Cross-sectional area ( mm2)
0.51
0.56
0.76
0.88
1.27
1.29
1.96
2.09
3.08
3.30
5.23
d (approx.)
1.0
1.2
1.5
1.9
1.9
2.3
2.4
3.0
AVS
Standard
2.0
2.2
2.5
2.9
2.9
3.5
3.6
-
AV
Standard
-
-
-
-
-
-
-
4.6
AEX
Standard
2.0
2.2
2.7
3.0
3.1
-
3.8
4.6
Nominal No.
Coating D
Conductor
8
15
20
30
40
50
60
85
100
Number of strands
50
84
41
70
85
108
127
169
217
Diameter of strand
0.45
0.45
0.80
0.80
0.80
0.80
0.80
0.80
0.80
Cross-sectional area ( mm2)
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
d (approx.)
3.7
4.8
6.0
8.0
8.6
9.8
10.4
12.0
13.6
AVS
Standard
-
-
-
-
-
-
-
-
-
AV
Standard
5.5
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
AEX
Standard
5.3
7.0
8.2
10.8
11.4
13.0
13.6
16.0
17.6
Nominal No.
Conductor
0.5f
0.5
0.75f
0.85
1.25f
1.25
Number of strands
-
7
-
11
-
16
Diameter of strand
-
round compression
-
round compression
Cross-sectional area ( mm2)
-
0.56
-
0.88
-
1.29
d (approx.)
-
0.9
-
1.1
-
1.4
PC210-10M0, PC210LC-10M0
round compression
00-63
HOW TO READ ELECTRICAL WIRE CODE
Coating D
Nominal No. CAVS Standard
00 INDEX AND FOREWORD
0.5f
0.5
0.75f
0.85
1.25f
1.25
-
1.6
-
1.8
-
2.1
REMARK "f" of nominal No. denotes "flexible".
Color codes table (Table 3) Color Code
Color of wire
Color Code
Color of wire
B
Black
LgW
Light green and White
Br
Brown
LgY
Light green and Yellow
BrB
Brown and Black
LR
Blue and Red
BrR
Brown and Red
LW
Blue and White
BrW
Brown and White
LY
Blue and Yellow
BrY
Brown and Yellow
O
Orange
Ch
Charcoal
P
Pink
Dg
Dark green
R
Red
G
Green
RB
Red and Black
GB
Green and Black
RG
Red and Green
GL
Green and Blue
RL
Red and Blue
Gr
Gray
RW
Red and White
GR
Green and Red
RY
Red and Yellow
GW
Green and White
Sb
Sky Blue
GY
Green and Yellow
Y
Yellow
L
Blue
YB
Yellow and Black
LB
Blue and Black
YG
Yellow and Green
Lg
Light green
YL
Yellow and Blue
LgB
Light green and Black
YR
Yellow and Red
LgR
Light green and Red
YW
Yellow and White
REMARK In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example) GW indicates that the background is "Green" and marking is "White".
00-64
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
HOW TO READ ELECTRICAL WIRE CODE
Types of circuits and color codes Type of wire
AVS, AV, CAVS
AEX
Charge
R
WG
-
-
-
-
R
-
Ground
B
-
-
-
-
-
B
-
Start
R
-
-
-
-
-
R
-
Light
RW
RB
RY
RG
RL
-
O
-
Instrument
Y
YR
YB
YG
YL
YW
Y
Gr
Signal
G
GW
GR
GY
GB
GL
G
Br
L
LW
LR
LY
LB
-
L
-
Br
BrW
BrR
BrY
BrB
-
-
-
Lg
LgR
LgY
LgB
LgW
-
-
-
O
-
-
-
-
-
-
-
Gr
-
-
-
-
-
-
-
P
-
-
-
-
-
-
-
Sb
-
-
-
-
-
-
-
Dg
-
-
-
-
-
-
-
Ch
-
-
-
-
-
-
-
Type of circuit
Others
PC210-10M0, PC210LC-10M0
00-65
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
00 INDEX AND FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD The maintenance standard section shows the judgment criteria whether the equipment or parts should be replaced or can be reused when the machine is disassembled for the maintenance. The following terms are the descriptions of the judgment criteria.
Standard dimension and tolerance •
The finished dimension of a part is slightly different from one to another actually.
•
A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the part.
•
The dimension set as the standard is called the standard dimension and the allowable range of difference from this standard dimension is called "tolerance".
•
An indication example of a standard dimension and tolerance is shown in the following table. (The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side)
Example: Standard dimension
Tolerance -0.022
120
-0.126
•
The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/ lower limit of tolerance)." Example) 120 (-0.022/ -0.126)
•
Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is determined by the tolerance.
•
A dimension indication example of a shaft and hole is shown in the following table. (The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension
60
00-66
Tolerance Shaft
Hole
-0.030
+0.046
-0.076
0
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
Standard clearance and standard value •
The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance.
•
When some parts are repaired, the clearance is generally adjusted to the standard clearance.
•
The values indicating performance and function of new products or equivalent are called "standard value", which is indicated by a range or a target value.
•
When some parts are repaired, the value of performance/ function is set to the standard value.
Standard interference •
When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called "interference".
•
Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is "standard interference".
•
After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.
Repair limit and allowable value or allowable dimension •
The dimension of parts changes due to the wear or deformation while they are used. When the dimension changes exceeding certain value, parts cannot be used any longer. This value is called "repair limit".
•
If a part is worn to the repair limit, it must be replaced or repaired.
•
The performance and function of products lower while they are used. A value with which the product can be used without causing a problem is called "allowable value" or "allowable dimension".
•
A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgment must be made in consideration of the operating condition and customer's requirement.
Allowable clearance •
Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called "allowable clearance".
•
If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference •
The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called "allowable interference".
•
The allowable interference shows the repair limit of the part of smaller tolerance.
PC210-10M0, PC210LC-10M0
00-67
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
•
00 INDEX AND FOREWORD
The parts whose interferences are out of the allowable interference must be replaced or repaired.
00-68
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
STANDARD TIGHTENING TORQUE TABLE
STANDARD TIGHTENING TORQUE TABLE Table of tightening torque for bolts and nuts REMARK Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.
Thread diameter ( mm)
Width across flats ( mm) 10
6
(*2) 10 13
8
10
12
(*2) 12 17 (*1, *2) 14 19 (*1, *2) 17
14 16
22 24 (*1) 22
Tightening torque ( Nm { kgm} ) 11.8 to 14.7 {1.2 to 1.5}
27 to 34 {2.8 to 3.5}
59 to 74 {6 to 7.5}
98 to 123 {10 to 12.5} 153 to 190 {15.5 to 19.5} 235 to 285 {23.5 to 29.5}
18
27
320 to 400 {33 to 41}
20
30
455 to 565 {46.5 to 58}
22
32
610 to 765 {62.5 to 78}
24
36
785 to 980 {80 to 100}
27
41
1150 to 1440 {118 to 147}
30
46
1520 to 1910 {155 to 195}
33
50
1960 to 2450 {200 to 250}
36
55
2450 to 3040 {250 to 310}
39
60
2890 to 3630 {295 to 370}
*1: Split flange bolt *2: Flanged bolt REMARK Tighten the flanged bolt marked with "7" on the head as shown in the following to the tightening torque shown in the table below.
PC210-10M0, PC210LC-10M0
00-69
STANDARD TIGHTENING TORQUE TABLE
Thread diameter ( mm)
Width across flats ( mm)
00 INDEX AND FOREWORD
Tightening torque ( Nm { kgm} )
6
10
5.9 to 9.8 {0.6 to 1.0}
8
12
13.7 to 23.5 {1.4 to 2.4}
10
14
34.3 to 46.1 {3.5 to 4.7}
12
17
74.5 to 90.2 {7.6 to 9.2}
REMARK Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt Nominal size threads per inch
A
B
Tightening torque ( Nm { kgm} )
Tightening torque ( Nm { kgm} )
Range
Target
Range
Target
1/
4-20UNC
9.8 to 14.7 {1 to 1.5}
12.7 {1.3}
2.9 to 3.9 {0.3 to 0.4}
3.43 {0.35}
5/
16-18UNC
24.5 to 34.3 {2.5 to 3.5}
29.4 {3}
6.9 to 8.8 {0.7 to 0.9}
7.8 {0.8}
3/
8-16UNC
44.1 to 58.8 {4.5 to 6}
52.0 {5.3}
9.8 to 14.7 {1 to 1.5}
11.8 {1.2}
7/
16-14UNC
73.5 to 98.1 {7.5 to 10}
86.3 {8.8}
19.6 to 24.5 {2 to 2.5}
21.6 {2.2}
1/
2-13UNC
108 to 147 {11 to 15}
127 {13}
29.4 to 39.2 {3 to 4}
34.3 {3.5}
9/
16-12UNC
157 to 216 {16 to 22}
186 {19}
44.1 to 58.8 {4.5 to 6}
51.0 {5.2}
5/
8-11UNC
226 to 294 {23 to 30}
265 {27}
63.7 to 83.4 {6.5 to 8.5}
68.6 {7}
3/ -10UNC 4
392 to 530 {40 to 54}
461 {47}
108 to 147 {11 to 15}
127 {13}
637 to 853 {65 to 87}
745 {76}
177 to 235 {18 to 24}
206 {21}
7/
8-9UNC
00-70
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
STANDARD TIGHTENING TORQUE TABLE
Type of bolt Nominal size threads per inch
A
B
Tightening torque ( Nm { kgm} )
Tightening torque ( Nm { kgm} )
Range
Target
Range
Target
1-8UNC
883 to 1196 {90 to 122}
1040 {106}
245 to 333 {25 to 34}
284 {29}
11/8-7UNC
1187 to 1608 {121 to 164}
1393 {142}
333 to 451 {34 to 46}
392 {40}
11/4-7UNC
1598 to 2157 {163 to 220}
1873 {191}
451 to 608 {46 to 62}
530 {54}
11/2-6UNC
2354 to 3177 {240 to 324}
2765 {282}
657 to 892 {67 to 91}
775 {79}
REMARK Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise specified.
Type of bolt Nominal size threads per inch
A
B
Tightening torque ( Nm { kgm} )
Tightening torque ( Nm { kgm} )
Range
Target
Range
Target
1/
4-28UNF
14.7 to 19.6 {1.5 to 2}
17.7 {1.8}
3.9 to 4.9 {0.4 to 0.5}
4.41 {0.45}
5/
16-24UNF
34.3 to 39.2 {3.5 to 4}
34.3 {3.5}
7.8 to 9.8 {0.8 to 1}
8.8 {0.9}
3/
8-24UNF
53.9 to 68.6 {5.5 to 7}
61.8 {6.3}
14.7 to 19.6 {1.5 to 2}
16.7 {1.7}
7/
16-20UNF
83.4 to 108 {8.5 to 11}
96.1 {9.8}
24.5 to 29.4 {2.5 to 3}
26.5 {2.7}
1/
2-20UNF
127 to 167 {13 to 17}
147 {15}
34.3 to 49.0 {3.5 to 5}
41.2 {4.2}
9/
16-18UNF
186 to 245 {19 to 25}
216 {22}
49.0 to 68.6 {5 to 7}
58.8 {6}
5/
8-18UNF
255 to 343 {26 to 35}
294 {30}
73.5 to 98.1 {7.5 to 10}
83.4 {8.5}
3/
4-16UNF
441 to 598 {45 to 61}
520 {53}
127 to 167 {13 to 17}
147 {15}
716 to 961 {73 to 98}
843 {86}
196 to 265 {20 to 27}
226 {23}
1-14UNF
1020 to 1373 {104 to 140}
1196 {122}
284 to 382 {29 to 39}
333 {34}
11/8-12UNF
1353 to 1844 {138 to 188}
1598 {163}
382 to 520 {39 to 53}
451 {46}
11/4-12UNF
1804 to 2432 {184 to 248}
2118 {216}
510 to 686 {52 to 70}
598 {61}
11/2-12UNF
2707 to 3658 {276 to 373}
3177 {324}
765 to 1030 {78 to 105}
892 {91}
7/
8-14UNF
PC210-10M0, PC210LC-10M0
00-71
STANDARD TIGHTENING TORQUE TABLE
00 INDEX AND FOREWORD
Table of tightening torque for O-ring boss piping joints REMARK Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.
Nominal No.
Thread diameter ( mm)
02
14
-
18
03, 04
20
05, 06
24
10, 12
33
14
42
Width across flats ( mm)
Varies depending on type of connector.
Tightening torque ( Nm { kgm} ) Range
Target
35 to 63 {3.5 to 6.5}
44 {4.5}
59 to 98 {6.0 to 10.0}
78 {8.0}
84 to 132 {8.5 to 13.5}
103 {10.5}
128 to 186 {13.0 to 19.0}
157 {16.0}
363 to 480 {37.0 to 49.0}
422 {43.0}
746 to 1010 {76.0 to 103}
883 {90.0}
Table of tightening torque for O-ring boss plugs REMARK Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.
Nominal No.
00-72
Thread diam- Width across eter ( mm) flats ( mm)
Tightening torque ( Nm { kgm} ) Range
Target
08
8
14
5.88 to 8.82 {0.6 to 0.9}
7.35 {0.75}
10
10
17
9.8 to 12.74 {1.0 to 1.3}
11.27 {1.15}
12
12
19
14.7 to 19.6 {1.5 to 2.0}
17.64 {1.8}
14
14
22
19.6 to 24.5 {2.0 to 2.5}
22.54 {2.3}
16
16
24
24.5 to 34.3 {2.5 to 3.5}
29.4 {3.0}
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
Nominal No.
STANDARD TIGHTENING TORQUE TABLE
Tightening torque ( Nm { kgm} )
Thread diam- Width across eter ( mm) flats ( mm)
Range
Target
18
18
27
34.3 to 44.1 {3.5 to 4.5}
39.2 {4.0}
20
20
30
44.1 to 53.9 {4.5 to 5.5}
49.0 {5.0}
24
24
32
58.8 to 78.4 {6.0 to 8.0}
68.6 {7.0}
30
30
32
93.1 to 122.5 {9.5 to 12.5}
107.8 {11.0}
33
33
-
107.8 to 147.0 {11.0 to 15.0}
127.4 {13.0}
36
36
36
127.4 to 176.4 {13.0 to 18.0}
151.9 {15.5}
42
42
-
181.3 to 240.1 {18.5 to 24.5}
210.7 {21.5}
52
52
-
274.4 to 367.5 {28.0 to 37.5}
323.4 {33.0}
Table of tightening torque for hose (taper seal type and face seal type) REMARK • Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified. • The table is applied to the threaded portion coated with engine oil (wet threaded portion).
Nominal No. of hose
Width across flats ( mm)
Tightening torque ( Nm { kgm} )
Taper seal Thread size ( mm)
Face seal Nominal size - Thread root diameter( mm) threads per inch (reference)
Range
Target
34 to 54 {3.5 to 5.5}
44 {4.5}
-
34 to 63 {3.5 to 6.5}
44 {4.5}
14
22
54 to 93 {5.5 to 9.5}
74 {7.5}
-
24
59 to 98 {6.0 to 10.0}
78 {8.0}
18
-
-
04
27
84 to 132 {8.5 to 13.5}
103 {10.5}
22
13/ -16UN 16
20.6
05
32
128 to 186 {13.0 to 19.0}
157 {16.0}
24
1 -14UNS
25.4
06
36
177 to 245 {18.0 to 25.0}
216 {22.0}
30
13/16-12UN
30.2
(10)
41
177 to 245 {18.0 to 25.0}
216 {22.0}
33
-
-
(12)
46
197 to 294 {20.0 to 30.0}
245 {25.0}
36
-
-
(14)
55
246 to 343 {25.0 to 35.0}
294 {30.0}
42
-
-
02
03
19
PC210-10M0, PC210LC-10M0
9/
16-18UN
11/
16-16UN
14.3 17.5
00-73
STANDARD TIGHTENING TORQUE TABLE
00 INDEX AND FOREWORD
Table of tightening torque for face seal joints REMARK • The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine. • The table is applied to the threaded portion coated with engine oil (wet threaded portion). • Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.
Outside diameter of adequate pipe ( mm)
Width across flats ( mm)
8
Tightening torque ( Nm { kgm} )
Face seal Nominal size threads per inch
Thread root diameter( mm) (reference)
Range
Target
19
14 to 16 {1.4 to 1.6}
15 {1.5}
10
22
24 to 27 {2.4 to 2.7}
25.5 {2.6}
12
24 (27)
43 to 47 {4.4 to 4.8}
45 {4.6}
15 (16)
30 (32)
60 to 68 {6.1 to 6.8}
64 {6.5}
1 -14UNS
25.4
22 (20)
36
90 to 95 {9.2 to 9.7}
92.5 {9.4}
13/16-12UN
30.2
9/
16-18UN
14.3
11/ -16UN 16
17.5
13/
20.6
16-16UN
Tightening torque table for bolts and nuts on 102, 107 and 114 series engines REMARK Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified. Thread diameter ( mm)
Tightening torque ( Nm { kgm} )
6
10±2 {1.02±0.20}
8
24±4 {2.45±0.41}
10
43±6 {4.38±0.61}
12
77±12 {7.85±1.22}
14
-
Tightening torque table for 102, 107, and 114 series engines (joint bolts) REMARK Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified.
00-74
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
STANDARD TIGHTENING TORQUE TABLE
Thread diameter ( mm)
Tightening torque ( Nm { kgm} )
6
8±2 {0.81±0.20}
8
10±2 {1.02±0.20}
10
12±2 {1.22±0.20}
12
24±4 {2.45±0.41}
14
36±5 {3.67±0.51}
Tightening torque table for tapered screws on 102, 107, and 114 series engines (National taper pipe thread (NPT)) REMARK Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified. Material of female screw
In cast iron or steel
In aluminum
Nominal thread size
Tightening torque ( Nm { kgm} )
Tightening torque ( Nm { kgm} )
15±2 {1.53±0.20}
5±1 {0.51±0.10}
8
20±2 {2.04±0.20}
15±2 {1.53±0.20}
1/ 4
25±3 {2.55±0.31}
20±2 {2.04±0.20}
3/
8
35±4 {3.57±0.41}
25±3 {2.55±0.31}
2
55±6 {5.61±0.61}
35±4 {3.57±0.41}
4
75±8 {7.65±0.82}
45±5 {4.59±0.51}
1/
16
1/
1/ 3/
PC210-10M0, PC210LC-10M0
00-75
CONVERSION TABLE
00 INDEX AND FOREWORD
CONVERSION TABLE Method of using the conversion table The conversion table is provided to enable simple conversion of the numerical numbers between the different units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in. When converting 55 mm to in 1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A). 2.
Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3.
Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in 1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm. 2. Convert 55 mm to 2.165 in according to the preceding procedure. 3.
The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in (B) 1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
(C) (A)
50
1.969
2.008
2.017
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.847
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.780
3.819
3.858
3.898
mm to in 1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
00-76
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
CONVERSION TABLE
1 mm = 0.03937 in 0
1
2
3
4
5
6
7
8
9
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.847
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
kg to lb 1 kg = 2.2046 lb 0
1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
ℓ to U.S.Gal 1 ℓ = 0.2642 U.S.Gal 0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
ℓ to U.K.Gal 1 ℓ = 0.21997 U.K.Gal 0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
PC210-10M0, PC210LC-10M0
00-77
CONVERSION TABLE
00 INDEX AND FOREWORD
1 ℓ = 0.21997 U.K.Gal 0
1
2
3
4
5
6
7
8
9
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
kgm to lbft 1 kgm = 7.233 lbft 0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233 lb/in2 0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
00-78
PC210-10M0, PC210LC-10M0
00 INDEX AND FOREWORD
CONVERSION TABLE
1 kg/cm2 = 14.2233 lb/in2 0
1
2
3
4
5
6
7
8
9
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
Temperature Conversion of Fahrenheit to Celsius •
A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures in the center of the following table show the temperatures in both Fahrenheit and Celsius.
•
When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
•
When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right. 1 °C = 33.8 °F °C
°F
°C
°F
°C
°F
°C
°F
-40.4
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
177.8
-37.2
-35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
48
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
-28.3
-19
-2.2
-8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
PC210-10M0, PC210LC-10M0
00-79
CONVERSION TABLE
00 INDEX AND FOREWORD
1 °C = 33.8 °F °C
°F
°C
°F
°C
°F
°C
°F
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1
-15
5.0
-6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
-25.6
-14
6.8
-6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3
-10
14.0
-3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
-22.8
-9
15.8
-3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
-22.2
-8
17.6
-2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
-21.7
-7
19.4
-2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
-21.1
-6
21.2
-1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
-20.6
-5
23.0
-1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
-20.0
-4
24.8
-0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
-19.4
-3
26.6
0
32
89.6
19.4
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
-18.3
-1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
-17.8
0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
-17.2
1
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
-16.7
2
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
-16.1
3
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
-15.6
4
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
-15.0
5
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
-14.4
6
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
-13.9
7
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
8
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
9
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
00-80
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
PC210-10M0, PC210LC-10M0
01-1
CONTENTS
01 SPECIFICATION
CONTENTS ABBREVIATION LIST .................................................................................................................................... 01-3 SPECIFICATION............................................................................................................................................ 01-8 SPECIFICATION DRAWING................................................................................................................... 01-8 SPECIFICATION DRAWING: PC210-10M0 ..................................................................................... 01-8 SPECIFICATION DRAWING: PC210LC-10M0................................................................................. 01-9 WORKING RANGE DRAWINGS ...........................................................................................................01-11 WORKING RANGE DRAWINGS: PC210-10M0..............................................................................01-11 WORKING RANGE DRAWINGS: PC210LC-10M0 ........................................................................ 01-12 SPECIFICATION................................................................................................................................... 01-14 SPECIFICATION: PC210-10M0 ..................................................................................................... 01-14 SPECIFICATIONS: PC210LC-10M0 .............................................................................................. 01-16 WEIGHT TABLE ................................................................................................................................... 01-20 WEIGHT TABLE: PC210-10M0...................................................................................................... 01-20 WEIGHT TABLE: PC210LC-10M0 ................................................................................................. 01-21 FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE ....................................... 01-23
01-2
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
ABBREVIATION LIST
ABBREVIATION LIST •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
•
Abbreviations that are used in general society may not be included.
•
Special abbreviations that appear infrequently are noted in the text.
•
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
Steering
ARAC
Automatic Retarder Accelerator Control
Travel and brake
ARSC
Automatic Retarder Speed Control
Travel and brake (HD, HM)
(WA)
(HD, HM)
Travel and brake (HD, HM)
Explanation A function that releases the brakes when the tires skid (wheels stop rotating), and applies the brakes again when the wheels start to rotate. A function that automatically sets the idle speed. A function that uses a lever to perform the steering operations instead of a steering wheel. Moreover, the lever is used to shifts gear and changes direction (FORWARD, REVERSE). A function that automatically applies the retarder with a constant braking force when the accelerator pedal is released while the machine is traveling downhill. A function that automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when the accelerator pedal is released while the machine is traveling downhill.
ASR
Automatic Spin Regula- Travel and brake tor (HD, HM)
A function that automatically uses the optimum braking force to drive both wheels when the tires spin on soft ground.
ATT
Attachment
A device that can be fixed onto the standard machine in order to enable it to do different jobs.
BCV
Brake cooling oil control Brake valve (HD)
CAN
Controller Area Network
Communication and electronic control
One of communication standards that are used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve that is installed to KCCV ventilator. It is written as CDR valve and it is not used singly.
CLSS
Closed-center Load Sensing System
Hydraulic system
A system that simultaneously actuates multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
A function that maintains optimum fuel injection amount and fuel injection timing by engine controller electronically controlling supply pump, common rail, and injector.
CRI
Common Rail Injection
PC210-10M0, PC210LC-10M0
WORK EQUIPMENT
A valve that divides part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used.
01-3
ABBREVIATION LIST
01 SPECIFICATION
Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Travel Suspension System (WA)
A system that ensures smooth high-speed travel by absorbing vibration of machine during travel with spring effect of accumulator.
ECU
Electronic Control Unit
An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
A function that recirculates part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of NOx.
Equipment ManageMACHINE MONITOR ment Monitoring System
A system which enables data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor to be checked on the monitor.
EPC
Electromagnetic ProporHydraulic system tional Control
This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Cab and canopy Structure
EMMS
F-N-R
GPS
GNSS
Forward-Neutral-Reverse Global Positioning System
Electronic control system
Transmission (D, HD, WA, etc)
Electronic control system
Operation Communication (KOMTRAX, KOMTRAX Plus)
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
Explanation An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECU) A proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.
A structure that protects the operator's head from falling objects. ISO 3449 compliant Forward - Neutral - Reverse A system that uses satellites to determine the current location on the earth 1. A system that uses satellites such as GPS, GALILEO, etc. to determine location on the earth. A function which uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly, machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
Steering
HST
Hydrostatic Transmission
Transmission
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
IMA
01-4
Inlet Metering Actuator
(D Series)
(D, WA)
A hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears.
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
Abbreviation
IMU
Actual word spelled out
Inertial Measurement Unit
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
A device that detects the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV (+)
Inlet Metering Valve
Engine
A valve which is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
A mechanism that separates oil in blowby gas and send it back to the intake side for it to be burned again. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
Engine
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
A filter that captures soot in exhaust gas. It is built in to KDPF A catalyst that is used for purifying exhaust gas.
Engine
Komatsu Diesel ParticuEngine late Filter
It is built in to KDPF or used in combination with the muffler in some cases. A component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler. A function that recovers the driving force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle machine travels on the soft ground road.
Komatsu Traction Control System
Travel and brake
LCD
Liquid Crystal Display
MACHINE MONITOR
A display equipment such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic parts
It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
One of communication standards that are used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
One of communication standards that are used in the network on the machine
MAF
Mass Air Flow
Engine
This indicates engine intake air flow. Mass air flow sensor is described as MAF sensor in some cases.
MMS
Multimedia Messaging Service
Communication
A service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
NC
Normally Closed
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally closed if it is not actuated (it opens when it is actuated).
NO
Normally Open
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally open if it is not actuated (it closes when it is actuated).
KTCS
PC210-10M0, PC210LC-10M0
(HM)
01-5
ABBREVIATION LIST
Abbreviation OLSS PC
PCCS
Actual word spelled out Open-center Load Sensing System
01 SPECIFICATION
Purpose of use (major applicable machine (*1), or component/system) Hydraulic system
Pressure Compensation Hydraulic system Palm command control system
Steering (D Series)
Explanation A hydraulic system that can operate multiple actuators at the same time regardless of the load. A function used to correct oil pressure. A function that electronically controls the engine and transmission. It is done by a controller that instantly analyses data from each lever, pedal, and dial.
PCV
Pre-stroke Control Valve Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This system is used for controlling proportional pressure. It moves actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power train system
PTP
Power Tilt and power Pitch dozer
WORK EQUIPMENT
ROPS
Roll-Over Protective Structure
Hydraulic system Hydraulic system (D, PC, etc)
(D Series)
Cab and canopy
A piston type hydraulic pump and motor A mechanism that takes out the force for the work equipment separately from the travel. A function that hydraulically performs tilt operation and pitch operation of the bulldozer blade. A protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. ISO 3471 compliant
SCR
Selective Catalytic Reduction
Urea SCR system
An exhaust gas purifier using urea water to convert nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It Done also be mentioned as exhaust gas purification catalyst , or part of the of related devices.
Le Système internationUnit al d'unités
A universal unit system and "a single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
An actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
A solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
The turbocharger on which the cross-section area of the exhaust passage is made variable.
SI
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
01-6
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
ABBREVIATION LIST
List of abbreviations used in the circuit diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
PC210-10M0, PC210LC-10M0
01-7
SPECIFICATION DRAWING
01 SPECIFICATION
SPECIFICATION SPECIFICATION DRAWING SPECIFICATION DRAWING: PC210-10M0
Item
Unit
PC210-10M0
Machine weight
km
20200
Bucket capacity
m3
0.8
Engine model
-
Komatsu SAA6D107E-1 diesel engine
Rated horsepower •
SAE J1995 (gross)
•
ISO 14396
•
ISO 9249 /SAE J1349 (net)
kW/min-1 {HP/ rpm}
123 {165} /2000 {2000} 123 {165} /2000 {2000} 123 {165} /2000 {2000}
A
Overall length
mm
9550
B
Overall height (work equipment)
mm
3005
01-8
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
SPECIFICATION DRAWING
Item
Unit
PC210-10M0
C
Overall width
mm
2800
D
Shoe width
mm
600
E
Cab height
mm
3045
F
Tail swing radius
mm
2900
G
Overall length of the track
mm
4070
H
Distance between the tumbler centers
mm
3275
Minimum ground clearance
mm
440
Travel speed (Lo/Mi/Hi)
km/h
3.0/4.1/5.5
Continuous swing speed
min-1 {rpm}
12.4 {12.4}
REMARK The engine rated horsepower is shown in the net value and gross value. Gross is the rated horsepower measured on the basic engine unit while net is the value measured of an engine in the condition nearly the same as that when it is installed on a machine.
SPECIFICATION DRAWING: PC210LC-10M0
PC210-10M0, PC210LC-10M0
01-9
SPECIFICATION DRAWING
Item
01 SPECIFICATION
Unit
PC210LC-10M0
Machine weight
km
21400
Bucket capacity
m3
0.8
Engine model
-
Komatsu SAA6D107E-1 diesel engine
Rated horsepower •
SAE J1995 (gross)
•
ISO 14396
•
ISO 9249/SAE J1349 (net)
kW/min-1 {HP/ rpm}
123 {165} /2000 {2000} 123 {165} /2000 {2000} 123 {165} /2000 {2000}
A
Overall length
mm
9550
B
Overall height (work equpment)
mm
3005
C
Overall width
mm
3080
D
Shoe width
mm
700
E
Cab height
mm
3045
F
Tail swing radius
mm
2900
G
Overall length of the track
mm
4450
H
Distance between the tumbler centers
mm
3655
Minimum ground clearance
mm
440
Travel speed (Lo/Mi/Hi)
km/h
3.0/4.1/5.5
Continuous swing speed
min-1-1 {rpm}
12.4 {12.4}
REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine.
01-10
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
WORKING RANGE DRAWINGS
WORKING RANGE DRAWINGS WORKING RANGE DRAWINGS: PC210-10M0
Item
Unit
PC210-10M0
A
Maximum digging reach
mm
9860
B
Maximum digging depth
mm
6515
C
Maximum digging height
mm
10065
D
Maximum vertical wall digging depth
mm
5810
E
Maximum dumping height
mm
7160
PC210-10M0, PC210LC-10M0
01-11
WORKING RANGE DRAWINGS
Item
01 SPECIFICATION
Unit
PC210-10M0
F
Minimum dumping height
mm
2685
G
Maximum digging reach at ground level
mm
9680
WORKING RANGE DRAWINGS: PC210LC-10M0
Item
Unit
PC210LC-10M0
A
Maximum digging reach
mm
9860
B
Maximum digging depth
mm
6515
C
Maximum digging height
mm
10065
01-12
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
WORKING RANGE DRAWINGS
Item
Unit
PC210LC-10M0
D
Maximum vertical wall digging depth
mm
5810
E
Maximum dumping height
mm
7160
F
Minimum dumping height
mm
2685
G
Maximum digging reach at ground level
mm
9680
PC210-10M0, PC210LC-10M0
01-13
SPECIFICATION
01 SPECIFICATION
SPECIFICATION SPECIFICATION: PC210-10M0 Machine model
Unit
PC210-10M0
Bucket capacity
m3
0.8
Machine weight
kg
20200
Maximum digging depth
mm
6515
Maximum vertical wall digging depth
mm
5810
Maximum digging reach
mm
9860
Maximum digging reach at ground level
mm
9680
Maximum digging height
mm
10065
Maximum dumping height
mm
7160
Performance Working ranges
Maximum digging force (When one-touch power maximizing function is operated)
kN {kg}
138.3 {14200} (149.1 {15200})
min-1 {rpm}
12.4 {12.4}
Degree
25
km/h
3.0/4.1/5.5
Degree
35
kPa {kg/cm2}
46.3 {0.47}
Overall length
mm
9550
Overall width
mm
2800
Overall height (for transport) (*1)
mm
3045
Cab height
mm
3045
Ground clearance of upper structure bottom
mm
1085
Minimum ground clearance
mm
440
Tail swing radius
mm
2900
Minimum swing radius of work equipment
mm
2990
Maximum height at minimum swing radius of work equipment
mm
8010
Overall width of track
mm
2800
Overall length of the track
mm
4070
Distance between crawler centers
mm
2200
Distance between the tumbler centers
mm
3275
Machine cab height
mm
2095
Width of standard shoe
mm
600
-
SAA6D107E–1
Continuous swing speed Swing operation max. slope angle Travel speed (Lo/Mi/Hi) Gradeability Ground pressure (standard shoe) Dimensions
Engine Model
01-14
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
SPECIFICATION
Machine model Type Number of cylinders-bore x stroke Total piston displacement
Unit
PC210-10M0
-
4-cycle, water-cooled, in-line, vertical, and direct injection type with turbocharger and aircooled aftercooler
mm
6 - 107 x 124
ℓ {cc}
6.69 {6690}
Performance Rated horsepower •
SAE J1995 (gross)
•
ISO14396
•
ISO9249/SAE J1349 (net)
Maximum torque (net)
kW {HP}/ min-1 {rpm} Nm {kgm}/ min-1 {rpm}
123 {165} /2000 {2000} 123 {165} /2000 {2000} 123 {165} /2000 {2000} 731 {1500}/74.5 {1500}
Max. speed with no load •
When mounted on machine
•
As a bare engine
min-1 {rpm}
2060 2060
min-1 {rpm}
1050
g/kWh {g/HPh}
225 {167.8}
Starting motor
-
24 V, 4.5 kW
Alternator
-
24 V, 60 A
Battery(*2)
-
12 V, 88Ah × 2
Radiator type
-
S-ACoM, 3.5/2P
Min. speed with no load Min. fuel consumption ratio
*1: Including grouser height (26 mm) *2: The battery capacity (Ah) is shown in the 5-hour rate.
REMARK The engine rated horsepower is indicated in the net value and gross value. Gross is the rated horsepower measured on the basic engine unit while net is the value measured of an engine in the condition nearly the same as that when it is installed on a machine. Undercarriage Carrier roller
-
2 pieces on one side
Track roller
-
7 pieces on one side
Track shoe
-
Assembly type triple grouser shoe, 45 pieces on one side
-
Variable displacement piston type x 2 pieces
Hydraulic system Main pump Type x quantity Discharged volume Set pressure
ℓ/min
245 x 2
MPa {kg/cm2}
37.2 {380}
Control valve Type x quantity
-
6-spool type x 1 piece
Operating method
-
Hydraulically operated type
PC210-10M0, PC210LC-10M0
01-15
SPECIFICATION
01 SPECIFICATION
Machine model
Unit
PC210-10M0 Variable displacement piston type x 2 pieces
Travel motor
-
Swing motor
-
Fixed displacement piston type x 1 piece
-
(with safety valve and parking brake)
-
Double-acting piston
Type x quantity
(with safety valve and parking brake)
Boom cylinder Type Inside diameter of cylinder bore
mm
120
Diameter of piston rod
mm
85
Stroke
mm
1334.5
Max. distance between pins
mm
3204.5
Min. distance between pins
mm
1870
Arm cylinder (*3) Type
-
Double-acting piston
Inside diameter of cylinder bore
mm
135
Diameter of piston rod
mm
95
Stroke
mm
1490
Max. distance between pins
mm
3565
Min. distance between pins
mm
2075
Bucket cylinder Type
-
Double-acting piston
Inside diameter of cylinder bore
mm
115
Diameter of piston rod
mm
80
Stroke
mm
1120
Max. distance between pins
mm
2800
Min. distance between pins
mm
1680
Hydraulic tank
-
Box-shaped airtight type
Hydraulic oil filter
-
Tank return side
Hydraulic oil cooler
-
Air cooling type (thickness: 75)
*3: With cushions on head side and bottom side.
SPECIFICATIONS: PC210LC-10M0 Machine model
Unit
PC210LC-10M0
Bucket capacity
m3
0.8
Machine weight
kg
21400
Performance Working ranges
01-16
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
Machine model
SPECIFICATION
Unit
PC210LC-10M0
Maximum digging depth
mm
6515
Maximum vertical wall digging depth
mm
5810
Maximum digging reach
mm
9860
Maximum digging reach at ground level
mm
9680
Maximum digging height
mm
10065
Maximum dumping height
mm
7160
Maximum digging force (When one-touch power maximizing function is operated)
kN {kg}
138.3 {14200} (149.1 {15200})
min-1-1 {rpm}
12.4 {12.4}
Degree
25
km/h
3.0/4.1/5.5
Degree
35
kPa {kg/cm2}
38.0 {0.39}
Overall length
mm
9550
Overall width
mm
3080
Overall height (for transport) (*1)
mm
3045
Cab height
mm
3045
Ground clearance of upper structure bottom
mm
1085
Minimum ground clearance
mm
440
Tail swing radius
mm
2900
Minimum swing radius of work equipment
mm
2990
Maximum height at minimum swing radius of work equipment
mm
8010
Overall width of track
mm
3080
Overall length of the track
mm
4450
Distance between crawler centers
mm
2380
Distance between the tumbler centers
mm
3655
Machine cab height
mm
2095
Width of standard shoe
mm
700
Model
-
SAA6D107E–1
Type
-
4-cycle, water-cooled, in-line, vertical, and direct injection type with turbocharger and aircooled aftercooler
mm
6 - 107 x 124
ℓ {cc}
6.69 {6690}
Continuous swing speed Swing operation max. slope angle Travel speed (Lo/Mi/Hi) Gradeability Ground pressure (standard shoe) Dimensions
Engine
Number of cylinders-bore x stroke Total piston displacement Performance
PC210-10M0, PC210LC-10M0
01-17
SPECIFICATION
01 SPECIFICATION
Machine model
Unit
PC210LC-10M0
Rated horsepower •
SAE J1995 (gross)
•
ISO14396
•
ISO9249/SAE J1349 (net)
Maximum torque (net)
kW {HP}/ min-1-1 {rpm} Nm{kgm}/ min-1-1 {rpm}
123 {165} /2000 {2000} 123 {165} /2000 {2000} 123 {165} /2000 {2000} 731 {1500} / 74.5 {1500}
Max. speed with no load •
When mounted on machine
•
As a bare engine
min-1-1 {rpm}
2060 2060
min-1-1 {rpm}
1050
g /kWh {g/HPh}
225{167.8}
Starting motor
-
24 V, 4.5 kW
Alternator
-
24 V, 60 A
Battery(*2)
-
12 V, 88Ah x 2 pieces
Radiator type
-
S-ACoM, 3.5/2P
Min. speed with no load Min. fuel consumption ratio
*1: Includes grouser height (26 mm) *2: Battery capacity (Ah) indicates 5 hour rate.
REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine. Undercarriage Carrier roller
-
2 pieces on one side
Track roller
-
9 pieces on one side
Track shoe
-
Assembly type triple grouser shoe, 49 pieces on one side
-
Variable displacement piston type x 2 pieces
Hydraulic system Main pump Type x quantity Discharged volume Set pressure
ℓ/min
245 x 2
MPa {kg/cm2}
37.2 {380}
Control valve Type x quantity
-
6-spool type x 1 piece
Operating method
-
Hydraulically operated type
Travel motor
-
Type x quantity
Variable displacement piston type x 2 pieces (with safety valve and parking brake) Fixed displacement piston type x 1 piece (with safety valve and parking brake)
Boom cylinder
01-18
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
Machine model Type
SPECIFICATION
Unit -
PC210LC-10M0 Double-acting piston
Inside diameter of cylinder bore
mm
120
Diameter of piston rod
mm
85
Stroke
mm
1334.5
Max. distance between pins
mm
3204.5
Min. distance between pins
mm
1870
Arm cylinder (*3) Type
-
Double-acting piston
Inside diameter of cylinder bore
mm
135
Diameter of piston rod
mm
95
Stroke
mm
1490
Max. distance between pins
mm
3565
Min. distance between pins
mm
2075
Bucket cylinder Type
-
Double-acting piston
Inside diameter of cylinder bore
mm
115
Diameter of piston rod
mm
80
Stroke
mm
1120
Max. distance between pins
mm
2800
Min. distance between pins
mm
1680
Hydraulic tank
-
Box-shaped airtight type
Hydraulic oil filter
-
Tank return side
Hydraulic oil cooler
-
Air cooling type (75 thickness)
*3: With cushions on the head side and bottom side
PC210-10M0, PC210LC-10M0
01-19
WEIGHT TABLE
01 SPECIFICATION
WEIGHT TABLE WEIGHT TABLE: PC210-10M0 •
This weight table is for reference for handling the component or transporting them.
•
This weight table shows the dry weight. Unit: kg Item
PC210-10M0
Engine assembly
761
•
Engine
565
•
Damper
6
•
Main pump
190
Radiator and oil cooler assembly
140
Hydraulic tank and filter assembly
140
Fuel tank assembly
141
Revolving frame
1785
Operator cab (including head guard and front half guard)
480
Operator's seat
35
Counterweight
3920
Swing machinery
220
Control valve
231 51.5
Travel motor Center swivel joint Track frame assembly (excluding piping)
93 x 2 30 4145
•
Track frame
2230
•
Swing circle
267
•
Idler
101 x 2
•
Idler cushion
106 x 2
•
Carrier roller
13 x 4
•
Track roller
36 x 14
•
Final drive (including travel motor and sprocket)
339 x 2
Track shoe assembly Triple shoe (600 mm)
1215 x 2
Triple shoe (700 mm)
1405 x 2
Triple shoe (800 mm)
1530 x 2
Boom assembly
1520
Arm assembly
810
Bucket assembly
633
Boom cylinder assembly Arm cylinder assembly
01-20
176 x 2 228
PC210-10M0, PC210LC-10M0
01 SPECIFICATION
WEIGHT TABLE
Unit: kg Item
PC210-10M0
Bucket cylinder assembly
137
Bucket link (large) assembly
83
Bucket link (small) assembly
22 x 2
Boom foot pin
42
Boom cylinder bottom pin
8x2
Boom cylinder head pin
28
Arm cylinder bottom pin
10
Arm cylinder head pin
12
Boom and arm connecting pin
26
Bucket cylinder bottom pin
8
Bucket pin
20 x 2
Bucket link pin
13 x 2
WEIGHT TABLE: PC210LC-10M0 •
This weight table is for your reference when you handle or transport the components.
•
This weight table shows the dry weight. Unit: kg Item
PC210LC-10M0
Engine assembly
761
•
Engine
565
•
Damper
6
•
Main pump
190
Radiator and oil cooler assembly
140
Hydraulic tank and filter assembly
140
Fuel tank assembly
141
Revolving frame
1785
Operator cab (including head guard and front half guard)
480
Operator's seat
35
Counterweight
3920
Swing machinery
220
Control valve
231
Swing motor
51.5
Travel motor
93 x 2
Center swivel joint Track frame assembly (excluding piping)
30 4705
•
Track frame
2625
•
Swing circle
273
•
Idler
PC210-10M0, PC210LC-10M0
101 x 2
01-21
WEIGHT TABLE
01 SPECIFICATION
Unit: kg Item
PC210LC-10M0
•
Idler cushion
112 x 2
•
Carrier roller
13 x 4
•
Track roller
36 x 18
•
Final drive (including travel motor and sprocket)
339 x 2
Track shoe assembly Triple shoe (600 mm)
1325 x 2
Triple shoe (700 mm)
1530 x 2
Triple shoe (800 mm)
1670 x 2
Boom assembly
1520
Arm assembly
633
Bucket assembly
633
Boom cylinder assembly
176 x 2
Arm cylinder assembly
228
Bucket cylinder assembly
137
Bucket link (large) assembly
83
Bucket link (small) assembly
22 x 2
Boom foot pin
42
Boom cylinder bottom pin
8
Boom cylinder head pin
28
Arm cylinder bottom pin
10
Arm cylinder head pin
12
Boom and arm connecting pin
26
Bucket cylinder bottom pin
8
Bucket pin
20 x 2
Bucket link pin
13 x 2
01-22
PC210-10M0, PC210LC-10M0
FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE
01 SPECIFICATION
FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE Reservoir
Min
Max
Komatsu EOS0W30
-30
30
Komatsu EOS5W40
-25
40
Komatsu EO10W30-DH
-20
40
Komatsu EO15W40-DH
-15
50
Komatsu EO30DH
0
40
TO30
-30
50
TO10
-20
50
HO46-HM
-20
50
HO-M VK
-30
50
G2-T, G2-TE
-20
50
G2-LI
-20
50
AF-NAC
-30
50
-30
20
0
50
Engine oil (Note.1)
Engine oil pan Engine oil
Swing machinery Case Final drive case Damper case
Powertrain oil (Note.2) Power train oil
Hydraulic System
Hydraulic oil Hyper grease
Grease fitting
(Note.3) Lithium EP grease
Cooling system
Ambient temperature, degrees Celsius (°C)
Recommended Komatsu Fluids
Fluid type
Supercoolant (AF-NAC)(Note.4)
ASTM D975 No.1D S15
Fuel tank
ASTM D975 No.1D S500
Diesel fuel
ASTM D975 No.2D S15 ASTM D975 No.2D S500
ASTM: American Society of Testing and Material Reservoir
Specified capacity (Liter)
Refill capacity (Liter)
Liter
US gal
Liter
US gal
Engine oil pan
26.4
6.97
23.1
6.10
Swing machinery case
5.8
1.53
5.3
1.40
Final drive case (each)
3.5
0.92
3.3
0.87
Damper case
0.65
0.17
0.65
0.17
Hydraulic system
237
62.62
135
35.67
Cooling system
21.8
5.76
21.8
5.76
Fuel Tank
400
105.68
-
-
PC210-10M0, PC210LC-10M0
01-23
FUEL, COOLANT AND LUBRICANT TO MEET AMBIENT TEMPERATURE
01 SPECIFICATION
NOTICE Always use diesel oil for the fuel. To ensure good fuel consumption characteristics and exhaust gas characteristics, the engine mounted on this machine uses an electronically controlled high-pressure fuel injection device. This device requires high precision parts and lubrication, so if low viscosity fuel with low lubricating ability is used, the durability may drop remarkably. The ASTM diesel fuel recommended by Komatsu may contain 5 % or less of biofuel. The EN diesel fuel may contain 7 % or less of it. Use the fuel which is filled into the storage tank or the fuel tank of the machine as soon as possible. When the diesel fuel is changed to the one mixed with the biofuel, replace the fuel prefilter cartridge and the fuel main filter cartridge with new ones. REMARK Specified capacity means the total amount of oil including the oil in the tank and the piping. Refill capacity means the amount of oil needed to refill the system during inspection and maintenance. Note 1: HTHS (High Temperature High Shear Viscosity at 150 °C {302 °F} ) must be 3.5cP or more. Optimum oils are KOMATSU EOS0W30 and EOS5W40. Note 2: Power train oil has different properties from engine oil. Be sure to use the recommended oils. Note 3: Hyper grease (G2-T, G2-TE) has a high performance. When it is necessary to improve the lubricating ability of the grease in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended. Note 4: Non-Amine Engine Coolant (AF-NAC) 1. The coolant has the important function of preventing corrosion as well as preventing freezing. Even in the areas where freezing is not an issue, the use of coolant is essential. Komatsu machines are supplied with Non-Amine Engine Coolant (AF-NAC). Non-Amine Engine Coolant (AF-NAC) has excellent anti-corrosion, antifreeze and cooling properties and can be used continuously for 2 years or 4,000 hours. Non-Amine Engine Coolant (AF-NAC) is strongly recommended wherever available. 2. For the concentration of Non-Amine Engine Coolant (AF-NAC), see the Coolant density table. Non-Amine Engine Coolant (AF-NAC) is supplied in diluted state, so always fill up with it. (Never dilute it with ordinary water.) Coolant density table Min. atmospheric temperature Density(%)
01-24
℃
-10 or more
-15
-20
-25
-30
-35
-40
-45
-50
°F
14 or higher
5
-4
-13
-22
-31
-40
-49
-58
30
36
41
46
50
54
58
61
64
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
PC210-10M0, PC210LC-10M0
10-1
CONTENTS
10 STRUCTURE AND FUNCTION
CONTENTS ABBREVIATION LIST .................................................................................................................................... 10-5 BOOT-UP SYSTEM ..................................................................................................................................... 10-10 LAYOUT DRAWING OF BOOT-UP SYSTEM........................................................................................ 10-10 SYSTEM OPERATING LAMP SYSTEM ................................................................................................10-11 SYSTEM OPERATING LAMP SYSTEM DIAGRAM ........................................................................10-11 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM ................................................................10-11 OPERATION OF SYSTEM OPERATING LAMP..............................................................................10-11 BATTERY DISCONNECT SWITCH ...................................................................................................... 10-12 FUNCTION OF BATTERY DISCONNECT SWITCH ...................................................................... 10-12 OPERATION OF BATTERY DISCONNECT SWITCH .................................................................... 10-12 ENGINE SYSTEM ....................................................................................................................................... 10-13 LAYOUT DRAWING OF ENGINE SYSTEM .......................................................................................... 10-13 ENGINE CONTROL SYSTEM .............................................................................................................. 10-14 ENGINE CONTROL SYSTEM DRAWING ..................................................................................... 10-14 OPERATION OF ENGINE CONTROL SYSTEM ............................................................................ 10-14 AUTO-DECELERATION SYSTEM ........................................................................................................ 10-16 AUTO-DECELERATION SYSTEM DRAWING ............................................................................... 10-16 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................ 10-16 OPERATION OF AUTO-DECELERATION SYSTEM...................................................................... 10-17 ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................................................... 10-18 ENGINE AUTOMATIC WARM-UP SYSTEM DRAWING ................................................................ 10-18 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................... 10-19 OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM....................................................... 10-19 OVERHEAT PREVENTION SYSTEM ................................................................................................... 10-20 OVERHEAT PREVENTION SYSTEM DRAWING .......................................................................... 10-20 FUNCTION OF OVERHEAT PREVENTION SYSTEM ................................................................... 10-21 OPERATION OF OVERHEAT PREVENTION SYSTEM................................................................. 10-21 TURBOCHARGER PROTECTION SYSTEM ........................................................................................ 10-23 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM........................................................ 10-23 COOLING SYSTEM..................................................................................................................................... 10-24 LAYOUT DRAWING OF COOLING SYSTEM ....................................................................................... 10-24 SPECIFICATIONS OF COOLING SYSTEM................................................................................... 10-25 CONTROL SYSTEM.................................................................................................................................... 10-26 LAYOUT DRAWING OF CONTROL SYSTEM PARTS.......................................................................... 10-26 MACHINE MONITOR SYSTEM ............................................................................................................ 10-28 MACHINE MONITOR SYSTEM DIAGRAM.................................................................................... 10-28 FUNCTION OF MACHINE MONITOR SYSTEM ............................................................................ 10-28 KOMTRAX SYSTEM............................................................................................................................. 10-30 KOMTRAX SYSTEM DIAGRAM .................................................................................................... 10-30 FUNCTION OF KOMTRAX SYSTEM ............................................................................................ 10-30 CONTROL SYSTEM............................................................................................................................. 10-31 MACHINE MONITOR..................................................................................................................... 10-31 KOMTRAX TERMINAL .................................................................................................................. 10-42 PUMP CONTROLLER ................................................................................................................... 10-45 RESISTOR FOR PC-EPC VALVE .................................................................................................. 10-49 CAN TERMINATING RESISTOR ................................................................................................... 10-49 ENGINE CONTROLLER ................................................................................................................ 10-50 FUEL CONTROL DIAL .................................................................................................................. 10-54 HYDRAULIC SYSTEM................................................................................................................................. 10-55 LAYOUT DRAWING OF HYDRAULIC SYSTEM ................................................................................... 10-55 CLSS .................................................................................................................................................... 10-58 CLSS SYSTEM DIAGRAM ............................................................................................................ 10-58 FUNCTION OF CLSS .................................................................................................................... 10-59 PRESSURE COMPENSATION CONTROL.................................................................................... 10-76 ENGINE AND PUMP COMBINED CONTROL SYSTEM....................................................................... 10-77 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM .............................................. 10-77 10-2
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CONTENTS
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM....................................... 10-78 PUMP AND VALVE CONTROL SYSTEM ............................................................................................. 10-82 PUMP AND VALVE CONTROL SYSTEM DIAGRAM ..................................................................... 10-82 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM ............................................................. 10-83 COMPONENT PARTS OF HYDRAULIC SYSTEM ............................................................................... 10-85 HYDRAULIC TANK ........................................................................................................................ 10-85 MAIN PUMP................................................................................................................................... 10-87 CONTROL VALVE ........................................................................................................................10-107 WORK EQUIPMENT SYSTEM ...................................................................................................................10-153 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM .....................................................................10-153 ONE-TOUCH POWER MAXIMIZING SYSTEM ...................................................................................10-157 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM ...........................................................10-157 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM ...................................................10-158 PPC LOCK SYSTEM ...........................................................................................................................10-159 PPC LOCK SYSTEM DIAGRAM...................................................................................................10-159 FUNCTION OF PPC LOCK SYSTEM ...........................................................................................10-160 ATTACHMENT OIL FLOW ADJUSTER SYSTEM ................................................................................10-161 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM........................................................10-161 FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM ................................................10-162 WORK EQUIPMENT SYSTEM ............................................................................................................10-163 WORK EQUIPMENT AND SWING PPC VALVE ...........................................................................10-163 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) .........................................................10-167 2ND-LINE ATTACHMENT PPC VALVE.........................................................................................10-172 SOLENOID VALVE .......................................................................................................................10-176 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) ......................................10-178 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE).......................................10-180 PILOT CIRCUIT ACCUMULATOR ................................................................................................10-183 ATTACHMENT CIRCUIT ACCUMULATOR...................................................................................10-183 SWING SYSTEM ........................................................................................................................................10-186 LAYOUT DRAWING OF SWING SYSTEM ..........................................................................................10-186 SWING CONTROL SYSTEM DIAGRAM .............................................................................................10-188 FUNCTION OF SWING CONTROL SYSTEM...............................................................................10-188 SWING SYSTEM .................................................................................................................................10-192 SWING MOTOR ...........................................................................................................................10-192 SWING MACHINERY ...................................................................................................................10-201 SWING CIRCLE............................................................................................................................10-203 TRAVEL SYSTEM.......................................................................................................................................10-204 LAYOUT DRAWING OF TRAVEL SYSTEM .........................................................................................10-204 TRAVEL CONTROL SYSTEM DIAGRAM ............................................................................................10-206 FUNCTION OF TRAVEL CONTROL SYSTEM ....................................................................................10-207 TRAVEL SYSTEM................................................................................................................................10-208 TRAVEL MOTOR ..........................................................................................................................10-208 FINAL DRIVE................................................................................................................................10-219 TRAVEL PPC VALVE ....................................................................................................................10-220 CENTER SWIVEL JOINT..............................................................................................................10-225 FUNCTION OF SWING CIRCLE.................................................................................................................10-227 UNDERCARRIAGE AND FRAME...............................................................................................................10-228 LAYOUT DRAWING OF UNDERCARRIAG .........................................................................................10-228 SPECIFICATIONS OF UNDERCARRIAGE...................................................................................10-228 WORK EQUIPMENT...................................................................................................................................10-230 STRUCTURE OF WORK EQUIPMENT ...............................................................................................10-230 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...................................................................10-231 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM ..................................10-231 BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................................................10-232 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................10-232 CAB RELATED PARTS...............................................................................................................................10-233 ROPS CAB ..........................................................................................................................................10-233 STRUCTURE OF ROPS CAB.......................................................................................................10-233 PC210-10M0, PC210LC-10M0
10-3
CONTENTS
10 STRUCTURE AND FUNCTION
FUNCTION OF ROPS CAB ..........................................................................................................10-233 CAB MOUNT .......................................................................................................................................10-234 STRUCTURE OF CAB MOUNT....................................................................................................10-234 FUNCTION OF CAB MOUNT .......................................................................................................10-235 CAB TIPPING STOPPER ....................................................................................................................10-236 STRUCTURE OF CAB TIPPING STOPPER.................................................................................10-236 FUNCTION OF CAB TIPPING STOPPER ....................................................................................10-236
10-4
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ABBREVIATION LIST
ABBREVIATION LIST •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
•
Abbreviations that are used in general society may not be included.
•
Special abbreviations that appear infrequently are noted in the text.
•
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
Steering
ARAC
Automatic Retarder Accelerator Control
Travel and brake
ARSC
Automatic Retarder Speed Control
Travel and brake (HD, HM)
(WA)
(HD, HM)
Travel and brake (HD, HM)
Explanation A function that releases the brakes when the tires skid (wheels stop rotating), and applies the brakes again when the wheels start to rotate. A function that automatically sets the idle speed. A function that uses a lever to perform the steering operations instead of a steering wheel. Moreover, the lever is used to shifts gear and changes direction (FORWARD, REVERSE). A function that automatically applies the retarder with a constant braking force when the accelerator pedal is released while the machine is traveling downhill. A function that automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when the accelerator pedal is released while the machine is traveling downhill.
ASR
Automatic Spin Regula- Travel and brake tor (HD, HM)
A function that automatically uses the optimum braking force to drive both wheels when the tires spin on soft ground.
ATT
Attachment
A device that can be fixed onto the standard machine in order to enable it to do different jobs.
BCV
Brake cooling oil control Brake valve (HD)
CAN
Controller Area Network
Communication and electronic control
One of communication standards that are used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve that is installed to KCCV ventilator. It is written as CDR valve and it is not used singly.
CLSS
Closed-center Load Sensing System
Hydraulic system
A system that simultaneously actuates multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
A function that maintains optimum fuel injection amount and fuel injection timing by engine controller electronically controlling supply pump, common rail, and injector.
CRI
Common Rail Injection
PC210-10M0, PC210LC-10M0
WORK EQUIPMENT
A valve that divides part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used.
10-5
ABBREVIATION LIST
10 STRUCTURE AND FUNCTION
Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Travel Suspension System (WA)
A system that ensures smooth high-speed travel by absorbing vibration of machine during travel with spring effect of accumulator.
ECU
Electronic Control Unit
An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
A function that recirculates part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of NOx.
Equipment ManageMACHINE MONITOR ment Monitoring System
A system which enables data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor to be checked on the monitor.
EPC
Electromagnetic ProporHydraulic system tional Control
This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Cab and canopy Structure
EMMS
F-N-R
GPS
GNSS
Forward-Neutral-Reverse Global Positioning System
Electronic control system
Transmission (D, HD, WA, etc)
Electronic control system
Operation Communication (KOMTRAX, KOMTRAX Plus)
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
Explanation An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECU) A proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.
A structure that protects the operator's head from falling objects. ISO 3449 compliant Forward - Neutral - Reverse A system that uses satellites to determine the current location on the earth 1. A system that uses satellites such as GPS, GALILEO, etc. to determine location on the earth. A function which uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly, machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
Steering
HST
Hydrostatic Transmission
Transmission
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
IMA
10-6
Inlet Metering Actuator
(D Series)
(D, WA)
A hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears.
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Abbreviation
IMU
Actual word spelled out
Inertial Measurement Unit
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
A device that detects the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV (+)
Inlet Metering Valve
Engine
A valve which is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
A mechanism that separates oil in blowby gas and send it back to the intake side for it to be burned again. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
Engine
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
A filter that captures soot in exhaust gas. It is built in to KDPF A catalyst that is used for purifying exhaust gas.
Engine
Komatsu Diesel ParticuEngine late Filter
It is built in to KDPF or used in combination with the muffler in some cases. A component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler. A function that recovers the driving force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle machine travels on the soft ground road.
Komatsu Traction Control System
Travel and brake
LCD
Liquid Crystal Display
MACHINE MONITOR
A display equipment such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic parts
It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
One of communication standards that are used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
One of communication standards that are used in the network on the machine
MAF
Mass Air Flow
Engine
This indicates engine intake air flow. Mass air flow sensor is described as MAF sensor in some cases.
MMS
Multimedia Messaging Service
Communication
A service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
NC
Normally Closed
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally closed if it is not actuated (it opens when it is actuated).
NO
Normally Open
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally open if it is not actuated (it closes when it is actuated).
KTCS
PC210-10M0, PC210LC-10M0
(HM)
10-7
ABBREVIATION LIST
Abbreviation OLSS PC
PCCS
Actual word spelled out Open-center Load Sensing System
10 STRUCTURE AND FUNCTION
Purpose of use (major applicable machine (*1), or component/system) Hydraulic system
Pressure Compensation Hydraulic system Palm command control system
Steering (D Series)
Explanation A hydraulic system that can operate multiple actuators at the same time regardless of the load. A function used to correct oil pressure. A function that electronically controls the engine and transmission. It is done by a controller that instantly analyses data from each lever, pedal, and dial.
PCV
Pre-stroke Control Valve Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This system is used for controlling proportional pressure. It moves actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power train system
PTP
Power Tilt and power Pitch dozer
WORK EQUIPMENT
ROPS
Roll-Over Protective Structure
Hydraulic system Hydraulic system (D, PC, etc)
(D Series)
Cab and canopy
A piston type hydraulic pump and motor A mechanism that takes out the force for the work equipment separately from the travel. A function that hydraulically performs tilt operation and pitch operation of the bulldozer blade. A protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. ISO 3471 compliant
SCR
Selective Catalytic Reduction
Urea SCR system
An exhaust gas purifier using urea water to convert nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It Done also be mentioned as exhaust gas purification catalyst , or part of the of related devices.
Le Système internationUnit al d'unités
A universal unit system and "a single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
An actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
A solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
The turbocharger on which the cross-section area of the exhaust passage is made variable.
SI
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
10-8
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ABBREVIATION LIST
List of abbreviations used in the circuit diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
PC210-10M0, PC210LC-10M0
10-9
LAYOUT DRAWING OF BOOT-UP SYSTEM
10 STRUCTURE AND FUNCTION
BOOT-UP SYSTEM LAYOUT DRAWING OF BOOT-UP SYSTEM
1: Machine monitor
6: KOMTRAX terminal
2: Battery
8: System operating lamp (*1)
3: Fuse box
7: Battery disconnect switch (*1)
4: Engine controller
9: Fusible link
5: Pump controller *1: Some machine models or specifications cannot be equipped with these.
10-10
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SYSTEM OPERATING LAMP SYSTEM
SYSTEM OPERATING LAMP SYSTEM SYSTEM OPERATING LAMP SYSTEM DIAGRAM (If equipped)
1: Battery disconnect switch
6: Machine monitor
2: Battery
7: Engine controller
3: Fusible link
8: Pump controller
4: Fuse box
9: KOMTRAX terminal
5: System operating lamp
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (If equipped) The system operating lamp system is a system that indicates the operation state of each controller. Though the starting switch is turned to the OFF position to stop the engine, each controller sometimes continues to do processing and operates. When one of controllers operates, the lamp lights up. REMARK Do not operate the battery disconnect switch while the lamp lights up. For details, see "BATTERY DISCONNECT SWITCH".
OPERATION OF SYSTEM OPERATING LAMP (If equipped) The battery is connected to the (+) pole of the system operating lamp (LED: light-emitting diode) through a fuse. Each controller is connected to the (-) pole of the LED in parallel. Each controller provides an output of 0 V to the connecting pin of the LED while each controller operates. Each controller provides an output of 24 V to the connecting pin of the LED while each controller stops. For controllers connected to the (-) pole of the LED in parallel, when one of them at a minimum operates, the LED lights up. REMARK • Under the condition that an output of 24 V is provided to the connecting pin of the LED while each controller stops, current flows to the LED because of a small potential difference from the battery power supply, and the LED can light up dimly. • If the starting switch is in the OFF position, the KOMTRAX terminal can start. The terminal can continue to operate for approximately 1 hour depending on communication states. In this case, when the starting switch is turned to the ON position temporarily and then changed to the OFF position, the KOMTRAX terminal stops in a maximum of 6 min.
PC210-10M0, PC210LC-10M0
10-11
BATTERY DISCONNECT SWITCH
10 STRUCTURE AND FUNCTION
BATTERY DISCONNECT SWITCH (If equipped)
FUNCTION OF BATTERY DISCONNECT SWITCH (If equipped) The battery disconnect switch is a switch that connects or blocks the continuous power supply from the battery. When the battery disconnect switch is turned to the OFF position, all power supplies of the machine are interrupted. Turn the switch to the OFF position and pull out the key under the conditions below. •
When you store the machine for a long time (1 month or more)
•
When you do maintenance of or repair the electrical system
•
When you perform electrical welding
•
When you handle the battery
•
When you replace an electrical part such as a fuse
REMARK If the battery disconnect switch has been in the OFF position for a long period, the machine monitor and the clock of the radio can return to the initial state. Set them as needed again.
OPERATION OF BATTERY DISCONNECT SWITCH (If equipped) ○: OFF position. The power supply circuit is blocked. Pull out the key, and do maintenance of the machine. |: ON position. The power supply circuit is connected. You can start the engine of the machine. NOTICE • While the system operating lamp is lit, do not set the battery disconnect switch to the OFF position. You can lose the data in the controller, which could cause serious damage. • Do not turn the battery disconnect switch to the OFF position while the engine is running or immediately after the engine is stopped. If the battery disconnect switch is turned to the OFF position while the alternator is generating power, the generated current has nowhere to go. It leads to an over-voltage state and could cause serious damage to the electrical system including the electric devices and controllers.
10-12
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE SYSTEM LAYOUT DRAWING OF ENGINE SYSTEM
1: Auto-tensioner
6: Air cleaner
2: Alternator
7: Front engine mount
3: Starting motor
8: Engine controller
4: Engine oil filter
9: Damper
5: Vibration damper
10: Rear engine mount
PC210-10M0, PC210LC-10M0
10-13
ENGINE CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM DRAWING
1: Battery disconnect switch (*1)
11: Starting motor cut-off relay (for personal code)
2: Battery
12: Fuel control dial
3: Battery relay
13: Safety relay
4: Fusible link
14: Starting motor
5: Fuse box
15: Fuel supply pump
6: Starting switch
16: Sensors
7: Engine controller
17: Machine monitor
8: Lock lever
18: KOMTRAX terminal
9: PPC lock switch
19: Pump controller
10: Starting motor cut-off relay (for PPC lock) *1: Not available for some machine models and specifications.
OPERATION OF ENGINE CONTROL SYSTEM
10-14
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ENGINE CONTROL SYSTEM
Start engine The B terminal of the starting switch (6) is connected to the positive pole of the battery (2) through the fuse box (5). When the starting switch (6) is turned to ON position, the B terminal and BR terminal are connected, and the battery relay (3) is activated. When the battery relay (3) is activated, the battery power is supplied to the B terminal of the starting motor (14). When the starting switch (6) is turned to ON position, the B terminal and ACC terminal are also connected. The machine monitor (17), KOMTRAX terminal (18), and engine controller (7) that connected to the ACC terminal of the starting switch (6) are activated. When the engine controller (7) is activated, the fuel supply pump (15) operates to supply fuel. When the starting switch (6) is turned to START position, the B terminal and C terminal are connected. The C terminal of the starting switch (6) is connected to the C terminal of the starting motor (14) through the two starting motor cut-off relays (10) and (11). When the circuit is closed by the two starting motor cut-off relays (10) and (11) and the starting switch (6) is connected to the C terminal of the starting motor (14), the starting motor (14) is activated and the engine starts. The starting motor cut-off relay (11) for personal code is controlled by the machine monitor (17). The machine monitor (17) sends the current from the coil of the starting motor cut-off relay (11) by the command from the KOMTRAX terminal (18), and opens the circuit of the C terminal. In this state, the starting motor (14) is not activated even the starting switch (6) is turned to START position. The starting motor cut-off relay (10) for PPC lock opens and closes in response to the position of the lock lever (8). When the lock lever (8) is in FREE position, the current from the coil of the starting motor cut-off relay (10) is blocked, and the circuit of the C terminal opens. In this state, the starting motor (14) is not activated even the starting switch (6) is turned to START position.
Stop engine When the starting switch (6) is turned to OFF position, the B terminal and C terminal are disconnected, and the engine controller (7) stops the fuel supply pump (15). The engine stops as no fuel is supplied.
Engine speed control The engine controller (7) calculates the target speed of the engine from the signals of the fuel control dial (12) and pump controller (19), and sends the command to the fuel supply pump (15). The engine speed changes with the fuel quantity supplied from the fuel supply pump (15).
PC210-10M0, PC210LC-10M0
10-15
AUTO-DECELERATION SYSTEM
10 STRUCTURE AND FUNCTION
AUTO-DECELERATION SYSTEM AUTO-DECELERATION SYSTEM DRAWING 15
13 8
14 8c 8b
12 14
9
8a 14 11
7 5
14
6
14 10a 4
14
e f d 2 1 a
3
b
c G0000027
a: CAN signal
d: 1st throttle signal
b: Pressure sensor signal
e: Fuel supply pump control signal
c: Service pressure switch signal
f: Sensor signals
1: Pump controller
8b: Merge-divider valve
2: Engine controller
8c: Travel junction valve
3: Machine monitor
9: PPC lock solenoid valve
4: Fuel control dial
10: L.H. PPC valve (for arm and swing operation)
5: Fuel supply pump
11: Travel PPC valve
6: Sensors
12: R.H. PPC valve (for boom and bucket operation)
7: Main pump
13: 1st-line attachment PPC valve
8: Control valve
14: Pressure sensor
8a: Self-pressure reducing valve
15: Service pressure switch
FUNCTION OF AUTO-DECELERATION SYSTEM The auto-deceleration system automatically lowers the engine speed when all the control levers are set in NEUTRAL position. The auto-deceleration system decreases the fuel consumption and noise while the machine is not operated (such case that you wait for a dump truck).
10-16
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
AUTO-DECELERATION SYSTEM
OPERATION OF AUTO-DECELERATION SYSTEM A: All work equipment control levers are in NEUTRAL B: One of work equipment control lever is operated
Engine speed (rpm)
C: Engine speed which is set with the fuel control dial D: Control speed (approximately 1050 rpm) E: 4 seconds F: 2 seconds or below G: 1 seconds or below
Time (Sec.)
•
G0000002 When all control levers are in NEUTRAL position for 4 seconds or more while the engine runs at approximately 1050 rpm or more, the system deceases the engine speed to the control speed (approximately 1050 rpm).
•
The engine speed increases in a moment to the speed set with the fuel control dial when one of the control levers is operated.
PC210-10M0, PC210LC-10M0
10-17
ENGINE AUTOMATIC WARM-UP SYSTEM
10 STRUCTURE AND FUNCTION
ENGINE AUTOMATIC WARM-UP SYSTEM ENGINE AUTOMATIC WARM-UP SYSTEM DRAWING
a: Front pump PC-EPC valve drive signal
e: Hydraulic oil temperature signal
b: Rear pump PC-EPC valve drive signal
f: 1st throttle signal
c: GND (solenoid)
g: Fuel supply pump control signal
d: CAN signal
h: Sensor signals
1: Battery disconnect switch (*1)
16: Front pump
2: Battery
16a: Servo piston
3: Battery relay
16b: LS valve
4: Fusible link
16c: PC valve
5: Fuse box
17: Rear pump
6: Resistor for PC-EPC valve
17a: Servo piston
7: Pump controller
17b: LS valve
8: Engine controller
17c: PC valve
9: Machine monitor
18: Control valve
10: Air conditioner unit
18a: Self-pressure reducing valve
11: Pump secondary drive switch
18b: Merge-divider valve
12: Fuel control dial
18c: Travel junction valve
13: Fuel supply pump
19: Front pump PC-EPC valve
14: Sensors
20: Rear pump PC-EPC valve
15: Hydraulic oil temperature sensor *1: Not available for some machine models and specifications. 10-18
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ENGINE AUTOMATIC WARM-UP SYSTEM
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM The engine automatic warm-up system automatically starts the warm-up operation in response to the coolant temperature immediately after the engine is started. The operation mode automatically changes between "Heater warm-up" and "Normal warm-up" by the machine states (air conditioner usage, outside air temperature, coolant temperature, or such).
OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM Heater warm-up Operating condition
Activated
Condition to cancel
Activated when all of the conditions that follow are satisfied •
Machine specification: Air conditioner specification
•
Air conditioner blower: ON
•
Coolant temperature: Below 55 °C
•
→
Engine speed: 1300 rpm or more
→
Outside air temperature: Below 5 °C
Canceled when one of the conditions that follow is satisfied (Engine speed after cancellation: not specified) •
Coolant temperature: 60 °C or more
•
Outside air temperature: 10 °C or more
Normal warm-up Operating condition
Activated when one of the conditions for heater warm-up is not satisfied and all of the conditions that follow are satisfied •
Coolant temperature: Below 30 °C
•
Engine speed: 1200 rpm or below
Activated
Condition to cancel Canceled when one of the conditions that follow is satisfied (Engine speed after cancellation: not specified)
→
Engine speed: 1200 rpm
→
Automatic operation
Manual operation
•
Coolant temperature: 30 °C or more (*1)
•
Warm-up time: 10 minutes or more
Fuel control dial: Held for 3 seconds or more at 70% of full speed (Max.)
*1: When the coolant temperature becomes 20 °C or below, the automatic warm-up starts again.
PC210-10M0, PC210LC-10M0
10-19
OVERHEAT PREVENTION SYSTEM
10 STRUCTURE AND FUNCTION
OVERHEAT PREVENTION SYSTEM OVERHEAT PREVENTION SYSTEM DRAWING
a: Front pump PC-EPC valve drive signal
e: Hydraulic oil temperature signal
b: Rear pump PC-EPC valve drive signal
f: 1st throttle signal
c: GND (solenoid)
g: Fuel supply pump control signal
d: CAN signal
h: Sensor signals
1: Battery disconnect switch (*1)
16: Front pump
2: Battery
16a: Servo piston
3: Battery relay
16b: LS valve
4: Fusible link
16c: PC valve
5: Fuse box
17: Rear pump
6: Resistor for PC-EPC valve
17a: Servo piston
7: Pump controller
17b: LS valve
8: Engine controller
17c: PC valve
9: Machine monitor
18: Control valve
10: Air conditioner unit
18a: Self-pressure reducing valve
11: Pump secondary drive switch
18b: Merge-divider valve
12: Fuel control dial
18c: Travel junction valve
13: Fuel supply pump
19: Front pump PC-EPC valve
14: Sensors
20: Rear pump PC-EPC valve
15: Hydraulic oil temperature sensor *1: Not available for some machine models and specifications. 10-20
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
OVERHEAT PREVENTION SYSTEM
FUNCTION OF OVERHEAT PREVENTION SYSTEM The overheat prevention system monitors the coolant temperature and hydraulic oil temperature to prevent overheat of the engine and hydraulic component. It also lowers the pump capacity or engine speed to decrease the load if necessary.
OPERATION OF OVERHEAT PREVENTION SYSTEM Operating condition
Operation and remedy
Condition to cancel Hydraulic oil temperature: below 93 °C
Working mode: Travel
→
Hydraulic oil temperature: 95 °C or more
Engine speed: Kept as it is
Operation and remedy
Working mode: P, E, ATT-P, or ATT-E mode →
Pump flow rate: Throttled •
Hydraulic oil temperature: 100 °C or more
Operating condition
Lowers the pump absorption torque to decrease the engine load by the torque control signal.
Coolant temperature: below 100 °C →
•
→
Hydraulic oil temperature: 102 °C or more
Operating condition
Pump flow rate: Throttled •
Lowers the pump absorption torque to decrease the engine load by the torque control signal.
Coolant temperature: below 102 °C →
Hydraulic oil temperature: 102 °C or more
PC210-10M0, PC210LC-10M0
Hydraulic oil temperature: below 102 °C •
Operation and remedy
When above conditions are satisfied, it goes back to the state before operation. (automatic restoration) Condition to cancel
Coolant temperature: below 102 °C
Working mode: B mode
or
When above conditions are satisfied, it goes back to the state before operation. (automatic restoration) Condition to cancel
Engine speed: Kept as it is
or
Coolant temperature: 102 °C or more
Hydraulic oil temperature: below 100 °C
Operation and remedy
Working mode: P, E, ATT-P, or ATT-E mode
When above conditions are satisfied, it goes back to the state before operation. (automatic restoration) Condition to cancel
Engine speed: Kept as it is
or
Coolant temperature: 102 °C or more
•
Pump flow rate: Throttled
Operating condition
Coolant temperature: 100 °C or more
→
→
Engine speed: Kept as it is Pump flow rate: Throttled Alarm monitor: Lights up
→
Hydraulic oil temperature: below 102 °C •
When above conditions are satisfied, it goes back to the state before operation. (automatic restoration)
10-21
OVERHEAT PREVENTION SYSTEM
Operating condition
10 STRUCTURE AND FUNCTION
Operation and remedy
Condition to cancel Coolant temperature: below 105 °C
Working mode: All modes Coolant temperature: 105 °C or more or Hydraulic oil temperature: 105 °C or more
10-22
→
Engine speed: Low idle Alarm monitor: Lights up Alarm buzzer: Operates
Hydraulic oil temperature: below 105 °C →
Fuel control dial: Turn it back to low idle (MIN) position. •
When above conditions are satisfied, it goes back to the state before operation. (manual restoration)
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TURBOCHARGER PROTECTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM FUNCTION OF TURBOCHARGER PROTECTION SYSTEM The turbocharger protection system prevents the seizure of the turbocharger caused when lubrication is not sufficient immediately after the engine is started. The system monitors the engine oil pressure and controls the engine speed at low until the pressure becomes sufficient. REMARK While the engine oil pressure does not reach 50 kPa {0.51 kg/cm2}, the engine speed is set to approximately 1050 rpm. It takes approximately 20 seconds in maximum until the oil pressure becomes this value.
PC210-10M0, PC210LC-10M0
10-23
LAYOUT DRAWING OF COOLING SYSTEM
10 STRUCTURE AND FUNCTION
COOLING SYSTEM LAYOUT DRAWING OF COOLING SYSTEM
1: Capacitor opening and closing bracket
8: Fuel cooler (outlet)
2: Capacitor
9: Fuel cooler
3: Radiator
10: Fuel cooler (inlet)
4: Radiator (inlet)
11: Oil cooler (inlet)
5: Radiator cap
12: Reservoir tank
6: Aftercooler (outlet)
13: Aftercooler (inlet)
7: Oil cooler (outlet)
14: Shroud
10-24
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF COOLING SYSTEM
15: Aftercooler
18: Fan
16: Oil cooler
19: Radiator (outlet)
17: Fan guard
20: Radiator drain valve
SPECIFICATIONS OF COOLING SYSTEM Radiator Core type: S-ACoM Fin pitch: 3.5/2 mm Total heat dissipation area: 29.23 m2 Pressure valve cracking pressure: 0.05 MPa {0.5 kg/cm2} Vacuum valve cracking pressure: -0.005 MPa {-0.05 kg/cm2}
Oil cooler Core type: S-ACoM Fin pitch: 3.5/2 mm Total heat dissipation area: 20.82 m2
Aftercooler Core type: S-ACoM Fin pitch: 3.5/2 mm Total heat dissipation area: 11.41 m2
Fuel cooler Core type: Drawn cup Fin pitch: 4.0/2 mm Total heat dissipation area: 0.59 m2
PC210-10M0, PC210LC-10M0
10-25
LAYOUT DRAWING OF CONTROL SYSTEM PARTS
10 STRUCTURE AND FUNCTION
CONTROL SYSTEM LAYOUT DRAWING OF CONTROL SYSTEM PARTS
1: Engine controller
10-26
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF CONTROL SYSTEM PARTS
2: Machine monitor
6: Pump controller
3: Resistor for PC-EPC valve
7: KOMTRAX terminal
4: Communication antenna
8: CAN terminating resistor
5: GPS antenna
PC210-10M0, PC210LC-10M0
10-27
MACHINE MONITOR SYSTEM
10 STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM MACHINE MONITOR SYSTEM DIAGRAM
a: Power supply
d: Drive signal
b: CAN signal
e: Camera signal
c: Sensor signal and switch signal 1: Machine monitor
6: KOMTRAX terminal
2: Battery
7: Sensors and switches
3: Pump controller
8: Wiper motor and window washer motor
4: Engine controller
9: Camera (*1)
5: Air conditioner controller *1: Some machine models or specifications cannot be equipped with these.
FUNCTION OF MACHINE MONITOR SYSTEM The machine monitor system shows the condition of the machine to the operator. The machine monitor system quickly handles the signals from the sensors and switches installed on different parts of the machine and the information from the controller to show them on the machine monitor.
10-28
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM
Also, you can change the functions or operate the devices with the switches that are installed on the machine monitor. The information that is shown on the machine monitor is sorted as follows. •
Alarm when the machine has a trouble (caution lamp, failure code, etc)
•
Machine state (coolant temperature, hydraulic oil temperature, fuel level, etc.)
•
Camera image (machine with camera)
PC210-10M0, PC210LC-10M0
10-29
KOMTRAX SYSTEM
10 STRUCTURE AND FUNCTION
KOMTRAX SYSTEM KOMTRAX SYSTEM DIAGRAM
1: KOMTRAX terminal
3: Communication antenna
2: GPS antenna
FUNCTION OF KOMTRAX SYSTEM The KOMTRAX system is a system that does a check of various types of information on the machine remotely. The KOMTRAX terminal collects the information shown below to transmit it to the data server via wireless communication. •
Position information
•
Working information
•
Alarm and failure information
•
Fuel consumption information
•
Maintenance information
•
Machine working condition information
KOMTRAX administrators can use this information to supply different services to customers. The radio station for KOMTRAX needs to be established separately to start the KOMTRAX services.
10-30
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CONTROL SYSTEM
CONTROL SYSTEM MACHINE MONITOR FUNCTION OF MACHINE MONITOR
4
1 3 2
G0000030
1:070-18P
3:070-20P
2:070-12P
4:070-8P
The machine monitor has the monitor display function, the mode selection function, and the switch function of electrical components. An alarm buzzer is also built in. CPU (Central Processing Unit) is mounted inside. It handles, shows, and outputs information. The machine monitor consists of a liquid crystal display (LCD) and a switch section. The switch section consists of flat sheet switches. If there is a trouble in the machine monitor (main body), controller, or wiring of CAN signal, the machine monitor does not show correctly. REMARK • When the engine starts, the battery voltage can decrease suddenly by the ambient temperature and battery condition. In this case, the display can go off temporarily. But it is not a defect. • When the machine monitor is used continuously, blue bright spots can appear on the black background, but it is neither a failure nor a malfunction. Though blue bright spots can appear, the background color of the standard screen is blue or white. It is not a problem. (This is why the red, green, and blue primary colors are combined to represent the white color on the liquid crystal.) • For details of the items below, see the Operation and Maintenance Manual. •
Screen display
•
Switches
•
Guidance icons, function switches
INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR 070-18P [CM01] Pin No.
Signal name
Input and output signals
1
Continuous power supply (24 V)
Input
2
Continuous power supply (24 V)
Input
PC210-10M0, PC210LC-10M0
10-31
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
Pin No.
Signal name
Input and output signals
3
GND (continuous power supply)
-
4
GND (continuous power supply)
-
5
External starting signal
6
Starting motor cut-off relay (for personal code)
7
(*1)
8
System operating lamp
9
Lamp switch
Input
10
Starting switch (ACC)
Input
11
Starting switch (C)
Input
12
Preheating
Input
13
(*1)
-
14
GND (body analog signal)
-
15
Fuel level sensor
Input
16
Charge level (alternator terminal R)
Input
17
(*1)
-
18
(*1)
-
Input Output Input and output
*1: Do not connect these pins. Malfunctions or failures can occur. 070-12P [CM02] Pin No.
Signal name
Input and output signals
1
(*1)
-
2
Engine oil level sensor
Input
3
Radiator coolant level sensor
Input
4
Air cleaner clogging sensor
Input
5
Swing lock switch
Input
6
Quick coupler
Input
7
CAN (C) terminating resistor terminal
8
CAN (C)_H
Input and output
9
CAN (C)_L
Input and output
10
CAN (R) terminating resistor terminal
11
CAN (R)_H
Input and output
12
CAN (R)_L
Input and output
-
-
*1: Do not connect these pins. Malfunctions or failures can occur. 070-20P [CM03] Pin No.
10-32
Signal name
Input and output signals
1
(*1)
-
2
(*1)
-
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Pin No.
CONTROL SYSTEM
Input and output signals
Signal name
3
(*1)
-
4
(*1)
-
5
(*1)
-
6
(*1)
-
7
(*1)
-
8
(*1)
-
9
(*1)
-
10
(*1)
-
11
(*1)
-
12
(*1)
-
13
(*1)
-
14
(*1)
-
15
(*1)
-
16
(*1)
-
17
(*1)
-
18
(*1)
-
19
(*1)
-
20
(*1)
-
*1: Do not connect these pins. Malfunctions or failures can occur. 070-8P [CM04] Pin No.
Signal name
Input and output signals
1
Power supply for camera (8 V)
2
Camera NTSC signal 1
Input
3
Camera NTSC signal 2
Input
4
Camera NTSC signal 3
Input
5
GND (power supply for camera)
6
Normal image/mirror image selection (camera 2)
Output
7
Normal image/mirror image selection (camera 3)
Output
8
GND (shield)
PC210-10M0, PC210LC-10M0
Output
-
-
10-33
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
GAUGES AND METERS DISPLAYED ON MACHINE MONITOR Gauge
Display item
Range and method for display
Engine coolant temperature gauge (*1)
Hydraulic oil temperature gauge (*1)
Fuel gauge (*1)
Range
Temperature
Monitor background
W1
105 ℃
Red
W2
102 ℃
Red
W3
100 ℃
Blue
W4
85 ℃
Blue
W5
60 ℃
Blue
W6
30 ℃
White
Range
Temperature
Monitor background
H1
105 °C
Red
H2
102 °C
Red
H3
100 °C
Blue
H4
85 °C
Blue
H5
40 ℃
Blue
H6
20 ℃
White
Range
Quantity (%)
Monitor background
F1
289 ℓ
Blue
F2
245 ℓ
Blue
F3
200 ℓ
Blue
F4
100 ℓ
Blue
F5
60 ℓ
Blue
F6
41 ℓ
Red
Segment Green
1 to 8
Yellow
9, 10
ECO gauge (*2)
Service meter
Remarks Shows the applicable temperature range. An alarm buzzer sounds when the temperature exceeds 105 ℃. If the monitor background color is white, warm up the engine.
Shows the applicable temperature range. An alarm buzzer sounds when the temperature exceeds 105 ℃. If the monitor background color is white, warm up the engine.
Shows the applicable remaining level.
Load level This item shows instantaneous fuel consumption (average value of the fuel Light to consumption of every 3 seconds) in 10 medium levels. Heavy
00000.0 to 99999.9h
(Shown when Energy Saving Guidance -> Configurations -> ECO Gauge Display is set to ON on the user menu.) This item shows the accumulated time of engine operation (when the alternator generates power). (Press the F4 switch to change to clock display.)
Clock
10-34
•
12 hour display (AM/PM)
•
24 hour display
This item shows the time. (Press the F4 switch to change to service meter display.)
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Gauge
CONTROL SYSTEM
Display item
Fuel consumption gauge (*2)
Range and method for display •
1 day
•
Split Time
•
None
Remarks This item shows average fuel consumption. (You can change the display from "Energy Saving Guidance" -> "Configurations" ->" Average Fuel Consumption Display" on the user menu.)
*1: The gauge pointer could disappear if the gauge signal is not available where the CAN communication line has an open circuit. *2: (You can change the display from "Energy Saving Guidance" -> "Configurations" screen on the user menu.)
CAUTION LAMPS DISPLAYED ON MACHINE MONITOR Display range and method Symbol
Display item
Engine coolant temperature (*1)
Hydraulic oil temperature (*1)
Remaining fuel level (*1)
Range
Caution lamp display (background color) Lit (red)
L02
30 °C or above and less than 102 °C
Lit (blue)
-
Less than 30 °C
Lit (white)
-
If the background color of the caution lamp is white, perform warm-up operation of the engine.
102 °C or above
Lit (red)
L02
20 °C or above and less than 102 °C
Lit (blue)
-
The background color of the caution lamp changes according to the temperature detected.
Less than 20 °C
Lit (white)
-
Less than 41 ℓ
Lit (red)
-
41 ℓ or above
Lit (blue)
-
(Specified level or below)
Lit (yellow)
Normal
Not lit
PC210-10M0, PC210LC-10M0
The background color of the caution lamp changes according to the temperature detected. The alarm buzzer sounds when the temperature becomes 105 °Cor above.
The alarm buzzer sounds when the temperature becomes 105 °C or above. If the background color of the caution lamp is white, perform warm-up operation of the hydraulic component(s). The background color of the caution lamp changes according to the remaining fuel level.
The caution lamp lights up when L01(*3), L02 a failure is detected while engine is stopped. -
Charging failure Battery charge (*1)
Remarks
102 °C or above
Abnormal Radiator coolant level (*1)
Action level
(Below specified voltage)
Lit (red)
L03
Normal
Not lit
-
The caution lamp lights up, and alarm buzzer sounds when a failure is detected while engine is running.
10-35
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
Display range and method Symbol
Display item
Range
Caution lamp display (background color)
Action level
Abnormal Engine oil pressure (*1)
(Specified pressure or below)
Lit (red)
L03
Normal
Not lit
-
(Specified level or below)
Lit (yellow)
L01 (*3)
Normal
Not lit
-
(Specified pressure or above)
Lit (yellow)
L01 (*3)
Normal
Not lit
-
Abnormal
Lit (yellow)
L01
Normal
Not lit
-
Abnormal
Lit (yellow)
L01
Normal
Not lit
-
Abnormal Engine oil level (*1)
Abnormal Air cleaner clogging (*1)
Hydraulic oil filter clogging Hydraulic oil filter clogging (option)
Maintenance time
Machine system
Engine system
10-36
(Specified amount or more of water collected)
The caution lamp lights up, and alarm buzzer sounds when a failure is detected while engine is running. The caution lamp lights up when a failure is detected while engine is stopped.
The caution lamp lights up when a failure is detected while engine is running.
The caution lamp lights up when a failure is detected while engine is running. The caution lamp lights up when a failure is detected while engine is running. The caution lamp lights up when a failure is detected.
Abnormal Water separator (*1)
Remarks
Lit (red)
-
Normal
Not lit
-
When maintenance due time is over
Lit (red)
-
The display changes according to the time elapsed since the maintenance due time is over.
When maintenance notice time is over (*2)
Lit (yellow)
-
After you turn on the starting switch, the caution lamp lights up when the lighting-up conditions are satisfied and then goes out in 30 seconds.
When action level L04 or L03 is detected
Lit (red)
L04, L03
The caution lamp lights up when a failure is detected in the machine system.
When action level L01 is detected
Lit (yellow)
L01 (*3)
When the background color of the caution lamp is red, the alarm buzzer sounds.
When action level L04 or L03 is detected
Lit (red)
L04, L03
The caution lamp lights up when a failure is detected in the engine system.
When action level L01 is detected
Lit (yellow)
L01 (*3)
When the background color of the caution lamp is red, the alarm buzzer sounds.
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CONTROL SYSTEM
Display range and method Symbol
Display item
Hydraulic system
Fan control system
Engine overrun
Air conditioner system
Action level
Range
Caution lamp display (background color)
Action level
Remarks
When action level L04 or L03 is detected
Lit (red)
L04, L03
The caution lamp lights up when a failure is detected in the hydraulic system.
When action level L01 is detected
Lit (yellow)
L01 (*3)
When the background color of the caution lamp is red, the alarm buzzer sounds.
When action level L03 is detected
Lit (red)
L03
When action level L01 is detected
Lit (yellow)
L01(*3)
When the engine overruns
Lit (red)
L02
The caution lamp lights up when a failure is detected in the fan control system. When the background color of the caution lamp is red, the alarm buzzer sounds. The caution lamp lights up, and the alarm buzzer sounds when an engine overrun is detected. The caution lamp lights up when a failure is detected in the air conditioner system.
Abnormal air conditioner
Lit (yellow)
L01 (*3)
When action level L04 is detected
Lit (red)
L04
The caution lamp lights up when a failure is detected in the machine. When the background color of the caution lamp is red, the alarm buzzer sounds.
When action level L03 is detected
Lit (red)
L03
When action level L02 is detected
Lit (red)
L02
When action level L01 is detected
Lit (yellow)
L01 (*3)
*1: The item is included in the Check before starting items. The caution lamp lights up for 2 seconds after the starting switch is turned to ON position. If no failure is found, the monitor changes to the standard display. *2: The maintenance notice time can be changed on the Maintenance Mode Display Setting of service mode. *3: The caution lamp lights up for 2 seconds and then goes out.
PC210-10M0, PC210LC-10M0
10-37
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
PILOT LAMPS DISPLAYED ON MACHINE MONITOR Symbol
Display item
Range for display
Remarks
This function operates automat- This item shows the operation ically when temperature is low. state of preheating. Automatic pre- (The lamp is lit for approximateheating ly 30 seconds at maximum.) The lamp goes out after the engine is started. Elapsed time of preheating after operation Monitor display of the starting switch
Preheating
Manual preheating
0 to 30 seconds
Lit
30 to 40 seconds
Flashing
40 seconds or longer
Not lit
One-touch power maximizing switch
*
Lit
One-touch power maximizing
ON
(The lamp goes out in approximately 8.5 seconds, if held down.)
OFF
Not lit
Swing lock switch Swing lock
Monitor display
Swing parking This item displays the operation brake cancel Monitor display state of swing lock. switch
OFF
OFF
Not lit
ON
OFF
Lit
OFF
ON
Flashing
ON
ON
Flashing
INT: Intermittent operation Wiper
This item displays the operation state of the one-touch power maximizing function.
ON: Continuous operation
This item displays the operation state of the front window wiper.
Not lit: Stop
Air conditioner
Engine stop
Message (unread)
10-38
Not lit: OFF
This item displays the operation states of the air conditioner and the blower function.
Lit: ON
This item displays the operation state of the engine.
Lit: ON
Not lit: OFF
Lit: There is an unread message.
This item displays the state of receiving messages.
Not lit: No message
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Symbol
Display item Message (message that is not replied, already-read message)
CONTROL SYSTEM
Range for display Lit: There is a message that is read but not replied.
P: Heavy-duty operation E: Low fuel consumption operation L: Fine control operation B: Breaker operation ATT/P: 2-way attachment operation ATT/E: Low fuel 2-way attachment operation Lo: Low-speed travel Travel speed
This item displays the state of receiving messages.
Not lit: No message
Auto-decelera- Lit: ON tion Not lit: OFF
Working mode
Remarks
Mi: Middle-speed travel
This item displays the operation state of the auto-deceleration function. This item displays the working mode. In E mode, E0 to E3 are displayed. When ToolControl is ON, ATT/P, E, and the ATT number are displayed. This item displays the set mode of travel speed.
Hi: High-speed travel Idle stop guidance
ECO guidance
Hydraulic pressure relief event deterrence guidance
This item displays the support guidance for operation of the machine.
Economy mode recommended guidance Reduced engine speed recommended guidance Low fuel level guidance
OPERATOR MODE FUNCTION OF MACHINE MONITOR The information items in this mode are normally shown. The operator can show and set them by the operation of switches. (Display and setting of some items need special operation of switches.) For operating method of the operator mode functions, see the Operation and Maintenance Manual. For operating method of the Engine Start LockFunction, see Password setting and canceling manual. Items that you can select in the operator mode are as follows:
PC210-10M0, PC210LC-10M0
10-39
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
Category
Item
(*1)
A
Display pattern (*2) V W X Y Z
KOMATSU logo display
1
1 1 1 1
Password input display
2
-
-
-
-
Technician ID state display
3
-
2
-
-
Operator ID input display
4
-
3
-
-
Breaker mode check display
-
-
4
-
-
Check before starting display
5
2 5 2 2
Warning after check before starting display
-
-
-
3 -
Maintenance time warning display
-
-
-
- 3
Working mode and travel speed display
6
3 6 4 4
Standard screen display
7
4 7 5 5
End screen display Selection of auto-deceleration Selection of working mode Selection of travel speed Operation of alarm buzzer stop Operation of windshield wiper Operation of window washer Operation of air conditioner B
Operation of camera display Clock display and service meter display Confirmation of maintenance information User menu setting and display • Energy Saving Guidance •
Machine Setting
•
Maintenance
•
Monitor Setting
•
User Message (includes KOMTRAX messages for user)
ECO guidance display C
Alarm monitor display Action level display LCD (Liquid Crystal Display) check function
D
Service metercheck function Functions of usage limitation setting and change password
*1: The operator mode items are divided into the following categories. A: Displays shown from the turning-on (ON) of the starting switch until transition to the standard screen, and display(s) shown after the turning-off (OFF) of the starting switch. B: Display shown when the machine monitor switch is operated C: Display shown when conditions are satisfied 10-40
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CONTROL SYSTEM
D: Display shown when special switch operation(s) is required *2: Display sequence from when the starting switch is turned to ON position to when the standard screen appears changes in accordance with the settings and conditions of the machine as follows. V: When the engine start lock is active W: When the engine start lock is not active X: When the working mode at start is set to Breaker Mode (B) Y: When a trouble is found by the check before starting Z: When any maintenance item(s) of which due time is over is found
SERVICE MODE FUNCTION OF MACHINE MONITOR The contents of the service mode are not normally shown on the monitor. Specific switch operations by technicians allow the displays and settings of this function. The service mode functions are available for testing, adjusting, or troubleshooting. For operating method of the service mode functions, see "Service mode" in TESTING AND ADJUSTING. Items that you can select in the service mode are as follows: Pre-defined Monitoring Self-define Monitoring Abnormality Record
Mechanical Sys Abnormality Record Electrical Sys Abnormality Record
Maintenance Record Maintenance Mode Setting Phone Number Entry Default
Key-on Mode Unit With/Without Attachment Camera With/Without Eco mode Easy Setting With/Without Elec. Fuel Primer Pump With/Without Blow By Pressure Sensor Battery Disconnect Switch Setting
Diagnostic Tests
Cylinder Cutout Mode Operation
Adjustment
Pump Absorption Torque (F) Pump Absorption Torque (R) LS Differential Pressure Adjustment Travel Low Speed Att Flow Adjust in Combined Ope Calibrate F Pump Swash Plate Sensor Calibrate R Pump Swash Plate Sensor Fan Speed Mode Select Pump Calibration Matching Speed Check Pump Calibration: Matching Speed Calibration Pump Calibration: Restore to Default Setting
PC210-10M0, PC210LC-10M0
10-41
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
No-Injection Cranking KOMTRAX Settings
Terminal Status GPS & Communication State Modem Information
Service Message
KOMTRAX TERMINAL FUNCTION OF KOMTRAX TERMINAL 1
2
3
4
5
G0000318
1: GPS antenna connection part
4: Communication antenna connection
2: Machine harness connection (070-18P)
5: LED lamp display
3: Machine harness connection (070-12P) The KOMTRAX terminal is a device that transmits various pieces of machine information obtained from the network signals and input signals and also the GPS position information via wireless communication. Information is transmitted by the communication antenna. The condition of the KOMTRAX terminal can be checked on the KOMTRAX Settings on the service mode of the machine monitor. The KOMTRAX terminal cannot be used in countries or regions where there is no permission by law. The KOMTRAX terminal has LED lamps and 7-segment LED used for testing and troubleshooting on its display section. REMARK Each country or region has different communication method (communication company). The KOMTRAX terminal has built-in communication devices that are applicable to each country or region. To use the KOMTRAX terminal in a different country, authorization in the country where the machine is used is possibly required. For details, consult the person responsible for KOMTRAX at your local Komatsu distributor.
INPUT AND OUTPUT SIGNALS OF KOMTRAX TERMINAL 070-18P [CK01] Pin No.
Signal name
Input and output signals
1
(*1)
-
2
(*1)
-
3
(*1)
-
4
(*1)
-
5
(*1)
-
6
(*1)
-
10-42
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Pin No.
CONTROL SYSTEM
Signal name
Input and output signals
7
(*1)
-
8
(*1)
-
9
(*1)
-
10
CAN (C)_H
Input and output
11
CAN (C)_L
Input and output
12
(*1)
-
13
(*1)
-
14
External starting signal
Input and output
15
System operating lamp
Output
16
(*1)
-
17
(*1)
-
18
(*1)
-
*1: Do not connect these pins. The malfunctions or failures can occur.
PC210-10M0, PC210LC-10M0
10-43
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
070-12P [CK02] Pin No.
Signal name
Input and output signals
1
GND
-
2
GND
-
3
Starting switch (ACC)
Input
4
Alternator (terminal R)
Input
5
(*1)
6
Power supply
Input
7
Power supply
Input
8
(*1)
-
9
(*1)
-
10
(*1)
-
11
Starting switch (C)
12
(*1)
-
Input -
*1: Do not connect these pins. The malfunctions or failures can occur.
10-44
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CONTROL SYSTEM
PUMP CONTROLLER STRUCTURE OF PUMP CONTROLLER General view
1
2
G0000006
1: AMP-81P
2: AMP-40P
INPUT AND OUTPUT SIGNALS OF PUMP CONTROLLER AMP-81P[CN-CP01] Pin No.
Signal name
Input and output signals
1
Continuous power supply (24V)
Input
2
GND (continuous power supply)
Input
3
Window washer
4
Continuous power supply (24V)
Input
5
GND (continuous power supply)
Input
6
Sensor power supply (5V)
7
CAN_H(KOMNET/r)
PC210-10M0, PC210LC-10M0
Output
Output Input and output
10-45
CONTROL SYSTEM
Pin No.
10-46
10 STRUCTURE AND FUNCTION
Signal name
Input and output signals
8
Service pressure sensor
Input
9
Water in fuel
Input
10
(*1)
11
Pressure sensor (front pump)
Input
12
Pressure sensor (right swing)
Input
13
Pressure sensor (boom LOWER)
Input
14
Pressure sensor (arm IN)
Input
15
Pressure sensor (left travel reverse)
Input
16
(*1)
17
Additional hyd oil filter clog switch
Input
18
GND (analog signal)
Input
19
(*1)
20
Swing lock switch
Input
21
Model selection 3
Input
22
(*1)
-
23
(*1)
-
24
Starting switch ACC signal
25
(*1)
26
CAN_L (KOMNET/r)
27
(*1)
28
Hydraulic oil temperature sensor
29
(*1)
30
Pressure sensor (rear pump)
Input
31
Pressure sensor (left swing)
Input
32
Pressure sensor (boom RAISE)
Input
33
(*1)
34
Pressure sensor (left travel forward)
Input
35
Service oil pressure switch
Input
36
(*1)
-
37
(*1)
-
38
Fan speed sensor
Input
39
Swing parking brake cancel switch
Input
40
Model selection 2
Input
41
(*1)
42
One-touch power maximizing switch
Input
43
Starting switch ACC signal
Input
44
Pulse signal GND
Input
45
CAN_H (KOMNET/c)
Input and output
46
GND (analog signal)
Input
-
-
-
Input Input and output Input -
-
-
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Pin No.
CONTROL SYSTEM
Signal name
Input and output signals
47
(*1)
-
48
(*1)
-
49
Front pump swash plate sensor
Input
50
Pressure sensor (bucket DUMP)
Input
51
Pressure sensor (arm OUT)
Input
52
(*1)
53
Pressure sensor (right travel reverse)
Input
54
Quick coupler alarm switch
Input
55
Blowby pressure sensor
Input
56
Windshield wiper contact (W)
Input
57
Overload alarm switch
Input
58
Model selection 5
Input
59
Model selection 1
Input
60
(*1)
61
Starting switch C signal
Input
62
External starting signal
Input
63
Sensor power supply (5V)
64
CAN_L (KOMNET/c)
65
(*1)
-
66
(*1)
-
67
(*1)
-
68
Rear pump swash plate sensor
Input
69
Pressure sensor (bucket CURL)
Input
70
(*1)
-
71
(*1)
-
72
Pressure sensor (right travel forward)
73
(*1)
74
Hydraulic oil return filter clogging sensor
Input
75
Windshield wiper contact (P)
Input
76
Open limit switch (front window)
Input
77
Model selection 4
Input
78
(*1)
-
79
(*1)
-
80
Starting switch ACC signal
81
(*1)
-
-
Output Input and output
Input -
Input -
*1: Do not connect these pins. Malfunctions or failures can occur.
PC210-10M0, PC210LC-10M0
10-47
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
AMP-40P [CN-CP02] Pin No.
10-48
Signal name
Input and output signals
82
(*1)
-
83
(*1)
-
84
(*1)
-
85
Travel junction solenoid valve
Output
86
Attachment selector solenoid valve
Output
87
(*1)
88
LS-EPC valve
Output
89
Merge-divider EPC valve (LS)
Output
90
(*1)
-
91
(*1)
-
92
(*1)
-
93
Travel Hi/Lo selecting solenoid valve
Output
94
Swing pressure cut off solenoid valve
Output
95
(*1)
96
Front pump PC-EPC valve
Output
97
EPC valve (attachment flow adjustment)
Output
98
EPP drive relay
Output
99
Fan clutch solenoid
Output
100
System operating
Output
101
Swing parking brake solenoid valve
Output
102
(*1)
-
103
(*1)
-
104
Rear pump PC-EPC valve
105
(*1)
106
Swing stroke control solenoid valve
Output
107
Travel alarm
Output
108
Battery relay
Output
109
2-stage relief solenoid valve
Output
110
(*1)
-
111
(*1)
-
112
Merge-divider EPC valve (main)
Output
113
Variable back pressure solenoid valve
Output
114
Windshield wiper (-)
Output
115
GND (solenoid)
Input
116
Battery relay secondary power supply
Input
117
GND (solenoid)
Input
118
Solenoid power supply
Input
-
-
Output -
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CONTROL SYSTEM
Pin No.
Signal name
Input and output signals
119
Windshield wiper (+)
Output
120
GND (solenoid)
Input
121
Battery relay secondary power supply
Input
*1: Do not connect these pins. Malfunctions or failures can occur.
RESISTOR FOR PC-EPC VALVE FUNCTION OF PC-EPC VALVE RESISTOR 2
1
G0000279
1: Resistance
2: Connector
Current flows into the PC-EPC valve when the pump secondary drive switch is turned to the ON position. In this case, applicable current flows through the resistor for PC-EPC valve. REMARK • The resistance value is 20 Ω. • No current flows in normal operation. • If current flows, heat can be generated.
CAN TERMINATING RESISTOR CAN Abbreviation for Controller Area Network
FUNCTION OF CAN TERMINATING RESISTOR
1 A B
A
B C
C G0000221
PC210-10M0, PC210LC-10M0
10-49
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
1: Connector (with built-in resistor) The CAN terminating resistor makes CAN communications between controllers stable. It is connected to a resistor that is equally resistant to the surge impedance of the transmission path. This reduces the reflection of signals. The resistance value is 120 Ω. Without the CAN terminating resistor, you cannot operate the machine because a communication trouble occurs.
ENGINE CONTROLLER STRUCTURE OF ENGINE CONTROLLER
1: DRC60PIN
2: DRC50PIN
INPUT AND OUTPUT SIGNAL OF ENGINE CONTROLLER DRC60Pin [ECE01] Pin No.
10-50
Signal name
Input and output signals
1
(*1)
-
2
IMV(+)
3
Ambient pressure sensor
4
(*1)
-
5
(*1)
-
6
Datalink(-) (tool port)
7
(*1)
8
Datalink(-) (tool port)
9
(*1)
Output Input
Communication Communication -
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Pin No.
CONTROL SYSTEM
Signal name
Input and output signals
10
(*1)
-
11
(*1)
-
12
(*1)
-
13
(*1)
-
14
(*1)
-
15
Coolant temperature sensor
16
Sensor 5 V power supply
Power supply
17
Engine oil pressure switch
Input
18
(*1)
-
19
(*1)
-
20
(*1)
-
21
(*1)
-
22
(*1)
-
23
Charge temperature sensor
24
(*1)
25
Common rail pressure sensor
Input
26
BKUP sensor
Input
27
NE sensor
Input
28
(*1)
-
29
(*1)
-
30
(*1)
-
31
(*1)
-
32
IMV(-)
33
Sensor 5 V power supply
34
(*1)
-
35
(*1)
-
36
(*1)
-
37
Sensor 5 V power supply
38
GND
-
39
(*1)
-
40
(*1)
-
41
(*1)
-
42
(*1)
-
43
(*1)
-
44
Charge pressure sensor
45
Injector #1 (+)
Output
46
Injector #5 (+)
Output
47
GND
Ground/Shield/Return
48
GND
Ground/Shield/Return
PC210-10M0, PC210LC-10M0
Input
Input -
Ground/Shield/Return Power supply
Power supply
Input
10-51
CONTROL SYSTEM
Pin No.
10 STRUCTURE AND FUNCTION
Signal name
Input and output signals
49
(*1)
-
50
(*1)
-
51
Injector #2 (-)
Ground/Shield/Return
52
Injector #3 (-)
Ground/Shield/Return
53
Injector #1 (-)
Ground/Shield/Return
54
Injector #2 (+)
Output
55
Injector #3 (+)
Output
56
Injector #4 (+)
Output
57
Injector #6 (+)
Output
58
Injector #4 (-)
Ground/Shield/Return
59
Injector #6 (-)
Ground/Shield/Return
60
Injector #5 (-)
Ground/Shield/Return
DRC50Pin [ECE02] Pin No.
10-52
Signal name
Input and output signals
1
(*1)
-
2
(*1)
-
3
(*1)
-
4
(*1)
-
5
(*1)
-
6
(*1)
-
7
(*1)
-
8
(*1)
-
9
Throttle sensor
10
(*1)
-
11
(*1)
-
12
(*1)
-
13
(*1)
-
14
(*1)
-
15
(*1)
-
16
(*1)
-
17
(*1)
-
18
(*1)
-
19
(*1)
-
20
(*1)
-
21
(*1)
-
22
Sensor 5 V power supply
23
GND
24
(*1)
Input
Power supply Ground/Shield/Return -
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Pin No.
CONTROL SYSTEM
Signal name
Input and output signals
25
(*1)
-
26
(*1)
-
27
(*1)
-
28
(*1)
-
29
(*1)
-
30
(*1)
-
31
(*1)
-
32
(*1)
-
33
System operating lamp (-)
34
(*1)
-
35
(*1)
-
36
(*1)
-
37
(*1)
-
38
ACC (Key SW)
39
Intake air heater relay (+)
40
(*1)
41
Intake air heater relay (-)
42
(*1)
-
43
(*1)
-
44
(*1)
-
45
(*1)
-
46
Datalink(+)(KOMNET)
Communication
47
Datalink(+)(KOMNET)
Communication
48
(*1)
49
PWM Output(+)
50
(*1)
Ground/Shield/Return
Input Output Ground/Shield/Return
Output -
*1: Do not connect these pins. The malfunctions or failures can occur. DTP4P [ECE03] Pin No.
Signal name
1
Power GND
2
(*1)
3
Power supply (Continuously +24 V)
4
(*1)
Input and output signals Ground/Shield/Return Power supply -
*1: Do not connect these pins. The malfunctions or failures can occur.
PC210-10M0, PC210LC-10M0
10-53
CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
FUEL CONTROL DIAL STRUCTURE OF FUEL CONTROL DIAL General view and sectional view
1: Potentiometer
3: Knob
2: Spring
FUNCTION OF FUEL CONTROL DIAL You can operate the fuel control dial to adjust engine speed. When the dial is turned, the resistance value of the potentiometer changes, and signals are transmitted to the engine controller. If the voltage value of the potentiometer is abnormal (the hatched area in the graph), the engine controller sets the engine speed to low idle. Angle
Hi
Lo
Output voltage
10-54
G0000085
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF HYDRAULIC SYSTEM
HYDRAULIC SYSTEM LAYOUT DRAWING OF HYDRAULIC SYSTEM
1: Control valve
6: Merge-divider EPC valve (for main spool)
2: Hydraulic tank
7: Merge-divider EPC valve (for LS spool)
3: Solenoid valve
8: Variable back pressure solenoid valve
4: Pressure sensor (rear)
9: Travel junction solenoid valve
5: Pressure sensor (front)
10: 2-stage relief solenoid valve
PC210-10M0, PC210LC-10M0
10-55
LAYOUT DRAWING OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
11: LS-EPC valve
18: Pressure sensor (boom LOWER)
12: Front pump PC-EPC valve
19: Pressure sensor (RIGHT)
13: Front pump swash plate sensor
20: Pressure sensor (arm IN)
14: Rear pump swash plate sensor
21: Pressure sensor (bucket DUMP)
15: Main pump
22: Pressure sensor (boom RAISE)
16: Rear pump PC-EPC valve
23: Pressure sensor (LEFT)
17: Pressure sensor (bucket CURL)
24: Pressure sensor (arm OUT)
10-56
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF HYDRAULIC SYSTEM
Around the cab and floor
1: Machine monitor
7: Service pressure switch
2: Fuel control dial
8: Pressure sensor (right travel forward)
3: Pump controller
9: Pressure sensor (left travel forward)
4: One-touch power maximizing switch
10: Pressure sensor (left travel reverse)
5: Resistor for PC-EPC valve
11: Pressure sensor (right travel reverse)
6: Pump secondary drive switch
PC210-10M0, PC210LC-10M0
10-57
CLSS
10 STRUCTURE AND FUNCTION
CLSS CLSS Abbreviation for Closed-center Load Sensing System
CLSS SYSTEM DIAGRAM 1
PLS
PLS
2
3 4
4 5 5
6
6
7
7
PP
PP 10 9
9 8
8
G0000134
1: Actuator
6: PC valve
2: Control valve
7: LS valve
3: Merge-divider valve
8: Servo piston
4: Main relief valve
9: Pump
5: Unload valve
10: Engine
10-58
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
CLSS consists of the main pump, the control valve (2), and the actuator (1). The main pump consists of 2 (front and rear) variable capacity piston pumps (9). Each of the front pump and the rear pump has the PC valve (6), the LS valve (7), and the servo piston (8). When they are operated, a pump swash plate angle is changed to control discharged volume. The PC valve (6) (Power Constant) prevents the engine from being stopped because of a large load. The LS valve (7) (Load Sensing) increases or decreases the discharged volume of the pump depending on the stroke of control levers. The PC valve (6) is actually built in the servo piston (8). The control valve (2), the merge-divider valve (3), the main relief valve (4), and the unload valve (5) are incorporated into one unit.
FUNCTION OF CLSS CLSS is a system that controls a pump swash plate angle (pump discharged volume) by considering differential pressure between pump discharged pressure (PP) and LS pressure of the control valve outlet (PLS) (actuator load pressure). Differential pressure between pump discharged pressure (PP) and LS pressure of the control valve outlet (PLS) is called LS differential pressure (ΔPLS). LS differential pressure (∆PLS) = Pump discharged pressure (PP) - LS pressure (PLS) When LS differential pressure (∆PLS) is lower than the set pressure of the LS valve, CLSS operates so that pump discharged volume is increased. When LS differential pressure (∆PLS) is higher than the set pressure of the LS valve, CLSS operates so that pump discharged volume is reduced.
UNLOAD VALVE AND LS DIFFERENTIAL PRESSURE The unload valves mainly open and then discharge pressurized oil to the hydraulic tank when the control lever is in the NEUTRAL position. The pressure at this time is called unload pressure. When the control lever is operated, LS pressure (PLS) flows into the spring chambers of the unload valves and then acts on one of the unload valves. Pump discharged pressure (PP) acts on the other of the unload valves. When LS differential pressure (ΔPLS = PP - PLS) gets smaller than set pressure (spring force), the unload valves close.
When the control lever is in NEUTRAL Because pump discharged volume is at a minimum and the spool of the control valve is closed, the pressure of a pump circuit gradually increases. When the pressure of the pump circuit reaches the set pressure (spring force (F)) or above, the unload valve (2) opens and then discharges the pressurized oil from the pump to the hydraulic tank. At this time, the LS pressure (PLS) is discharged from the LS bypass valve (3) to the hydraulic tank. The LS pressure does not flow into the spring chamber of the unload valve (2). (0 MPa) Remark) The values in the figure show the pressure for PC200-10.
3 1
2
PP 3.9MPa
F + PLS 3.9MPa 0MPa G0000303
PC210-10M0, PC210LC-10M0
10-59
CLSS
10 STRUCTURE AND FUNCTION
When lever is operated (before relief) The spool of the control valve opens, and the LS pressure (PLS) flows into the spring chamber of the unload valve (2). At this time, the unload valve (2) closes because the LS differential pressure (ΔPLS) gets smaller than the set pressure (spring force (F)).
PLS 13MPa
1
2
PP 15MPa
F + PLS 3.9MPa 13MPa G0000304
When the control lever is stroked to the end (when relief) When the pump discharged pressure (PP) and the LS pressure (PLS) increase and then reach main relief pressure, the main relief valve (1) opens and then discharges the pressurized oil from the pump to the hydraulic tank. At this time, the LS pressure (PLS) flowing into the spring chamber of the unload valve (2) also becomes the main relief pressure. The unload valve (2) closes because the LS differential pressure (ΔPLS) gets smaller than the set pressure (spring force (F)).
2
1
PP 34.8MPa
F + PLS 3.9MPa 34.8MPa G0000305
LS VALVE AND LS DIFFERENTIAL PRESSURE The LS valve increases or decreases pump discharged volume so that LS differential pressure (ΔPLS = PP - PLS) becomes set pressure when the differential pressure changes. When the LS differential pressure (ΔPLS) increases, the LS valve reduces the discharged volume because the LS valve operates in the direction where a pump swash plate angle is decreased. When the LS differential pressure (ΔPLS) decreases, the LS valve increases the discharged volume because the LS valve operates in the direction where a pump swash plate angle is increased.
10-60
Decrease pump discharged volume
Increase pump discharged volume
PP PLS
LS-EPC pressure
Balanced G0000140
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
When the LS differential pressure (ΔPLS) becomes the set pressure, the LS valve is balanced. The pump swash plate does not move, which makes the discharged volume constant. The set pressure changes depending on the spring force of the LS valve and the pressure from the LS-EPC valve (LS set selector pressure). When the LS set selector pressure increases, the LS valve operates so that the set pressure is decreased.
Relationship with control lever Control lever
Hold half stroke
Spool
PP
Incline to full stroke
Spool opening varies according to lever operation
PLS
PLS: Set pressure
LS valve
Return to least stroke
PLS: Increase
PLS: Decrease
balanced Decrease pump discharged volume
Increase pump discharged volume
PLS balances at set pressure
G0000141
When the control lever is held in a half stroke position, the pump discharged pressure (PP) and LS pressure (PLS) are constant, and the LS differential pressure (ΔPLS) is equal to the set pressure. At this time, the LS valve is balanced. The pump swash plate does not move, which makes the discharged volume constant. When the control lever is operated, the opening area of the spool of the control valve is changed to increase or decrease the LS differential pressure (ΔPLS). When the control lever is returned to least stroke, the LS differential pressure (ΔPLS) increases. At this time, the LS valve reduces the discharged volume because the LS valve operates in the direction where a pump swash plate angle is decreased. The discharged volume is reduced, and the LS differential pressure (ΔPLS) decreases. When the decreased LS differential pressure (ΔPLS) balances at the set pressure, the LS valve returns to the balance state. When the control lever is inclined to full stroke, the LS differential pressure (ΔPLS) decreases. At this time, the LS valve increases the discharged volume because the LS valve operates in the direction where a pump swash
PC210-10M0, PC210LC-10M0
10-61
CLSS
10 STRUCTURE AND FUNCTION
Relationship with control lever spool opening area For example, the control lever is held in a half stroke position, and the spool of the control valve is fixed with an opening area. The flow rate passing through the opening area of the spool is in proportion to the square root of the differential pressure before or after spool (curve X in the figure).
Flow rate through spool
plate angle is increased. The discharged volume is increased, and the LS differential pressure (ΔPLS) increases. When the increased LS differential pressure (ΔPLS) balances at the set pressure, the LS valve returns to the balance state.
P0 (Set pressure)
Pump discharged pressure (PP) is the pressure before the flow Differential pressure before and after spool (MPa) G0001567 rate passes through the spool. LS pressure (PLS) is the pressure after the flow rate passes through the spool. PP and PLS flow into the LS valve. When the differential pressure (ΔPLS) reaches the set pressure (P0), the LS valve changes between the operation states where a pump swash plate angle is increased or decreased. Consequently, when the differential pressure before and after spool reaches the set pressure (P0), the LS valve is balanced to make a decision of the pump swash plate angle and pump discharged volume.
Relationship when control lever spool opening area chenges For example, the control lever is inclined to full stroke, and the opening area of the spool of the control valve is increased. The flow rate passing through the spool increases for the differential pressure before and after the same spool as much as the opening area was increased (curve Y in the figure).
Flow rate through spool
LS valve balanced position and pump discharged volume
P0 (Set pressure)
As described above, the LS valve is balanced when the differDifferential pressure before and after spool (MPa) ential pressure before and after spool reaches the set pressure (P0). The flow rate passing through the spool increases at the set pressure (P0). In this case, the pump discharged volume also increases.
G0001568
When the control lever is moved back, in contrast with the above, the flow rate passing through the spool decreases. In this case, the pump discharged volume also decreases.
For example, the control lever is held in a half stroke position, and the spool of the control valve is fixed with an opening area. When you operate the LS-EPC valve to reduce the set pressure of the LS valve from P0 to P1, the balance position of the LS valve changes as shown in the figure. Consequently, the flow rate passing through the spool decreases, and the pump discharged volume decreases.
10-62
Flow rate through spool
Relationship with LS-EPC valve
P1 (Set pressure) P0 (Set pressure)
Differential pressure before and after spool (MPa)
G0001569
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
PC VALVE AND PUMP ABSORPTION TORQUE When pump discharged pressure changes, the PC valve increases or decreases pump discharged volume so that pump absorption horsepower reaches a specified value.
PP
Increase pump discharged volume Spring
Decrease pump discharged volume
2 (Hard)
Spring 1 (Soft)
PC-EPC pressure
G0000142
Pump absorption horsepower ∝ Pump discharged pressure (P) x Pump discharged volume (Q) When the pump discharged pressure increases, the PC valve reduces the pump discharged volume by moving the servo piston in the direction where a pump swash plate angle is decreased. If the PC valve does not operate normally, the engine could stop due to the excessive pump absorption horsepower. The specified horsepower changes depending on the spring force of springs 1 and 2 and the pressure from the PC-EPC valve. When the pressure from the PC-EPC valve increases, the PC valve operates so that the specified horsepower is decreased.
When pump discharged pressure is low (A in P-Q diagram)
1 Max A
2
Q
3 4
5
6 P
7 G0000149
Because of low pump discharged pressure, the spring forces of springs (5) and (6) push the spool (4) of the PC valve to the left. The pressurized oil on the large diameter (right) side of the servo piston (2) is discharged. Consequently, the servo piston (2) moves to the right direction. The pump swash plate angle is increased, which results in the maximum pump discharged volume.
PC210-10M0, PC210LC-10M0
10-63
CLSS
10 STRUCTURE AND FUNCTION
When pump discharged pressure increases (B in P-Q diagram)
1
B
2
Q
3 4
5
6 P
7 G0000151
The force from increased pump discharged pressure becomes larger than the reaction forces of the springs (5) and (6). Thus, the spool (4) of the PC valve is pushed to the right. The pressurized oil is transmitted to the large diameter (right) side of the servo piston (2). Consequently, the servo piston (2) moves to the left direction. The pump swash plate angle is decreased, which reduces the pump discharged volume.
1
B
2
Q
3 4
5
6 P
7 G0000150
The servo piston (2) moves to the left direction. The forces of the springs (5) and (6), which push the spool (4) back to the left direction, act at the same time. The spool (4) stops at the position where the balance is achieved between the combined forces of the pump discharged pressure/the pressure from the PC-EPC valve (7) and the spring force of the springs (5) and (6) . The spool (4) reduces the oil pressure on the large diameter (right) side of the servo piston (2). Consequently, the servo piston (2) stops at the position where the force on the large diameter (right) side and the force on the small diameter (left) side of the servo piston (2) are balanced.
10-64
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
When pump discharged pressure increases further (C in P-Q diagram)
1
2
Q C
3 4 5
6 P
7 G0000152
When the pump discharged pressure further increases, the spring (6) cannot shrink because of the stopper of the follow up link (3). Only the spring (5) shrinks. Thus, only the force of the spring (5) reduces the pump swash plate angle (pump discharged volume). The P-Q diagram becomes the line graph as shown in the figure.
The PC-EPC valve increases or decreases the output pressure to the PC valve according to the command current from the pump controller. When the command current increases, the output pressure increases, and pump absorption horsepower and pump discharged volume decrease. The pump controller outputs the command current applicable for P, E, B, or L working modes.
Output pressure (P)
FUNCTION OF PC-EPC VALVE AND LS-EPC VALVE PC-EPC valve
Current (i) G0000046
LS-EPC valve The LS-EPC valve increases or decreases the output pressure (LS set selector pressure) to the LS valve according to the command current from the pump controller. When the command current increases, the LS set selector pressure increases, and the set pressure of the LS valve and the pump discharged volume decrease. When the command current does not flow from the pump controller, the LS set selector pressure does not flow from the LS-EPC valve. The set pressure of the LS valve reaches its peak.
Pump setting change function depending on working mode The pump controller outputs the command current applicable for each working mode to the PC-EPC valve. In P or ATT/P working mode, pump absorption torque reaches its peak, and the maximum output of the engine is used. In E, ATT/E, B, or L working mode, command current increases to reduce pump absorption torque. In
PC210-10M0, PC210LC-10M0
10-65
CLSS
10 STRUCTURE AND FUNCTION
each mode, the matching rotation speed of the engine changes, which causes a change in pump absorption horsepower. For details, see "Working mode selection function" in "FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM".
Cut-off function The cut-off function is a function that the pump controller increases command current for the PC-EPC valve to reduce pump discharged volume. Its objective is to suppress energy consumption during relief to get better fuel consumption. For details, see "Cut-off function" in "FUNCTION OF PUMP AND VALVE CONTROL SYSTEM".
LS set pressure change function with travel speed selector switch The pump controller increases or decreases the command current to the LS-EPC valve according to the travel speed selector switch (Hi, Mi, Lo). When travel speed is Hi, the command current does not flow. The LS-EPC valve does not output LS set selector pressure. Consequently, the set pressure of the LS valve reaches its peak.
For details, see "Control function when the machine travels" in "FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM".
Pump discharged volume (Q)
When travel speed is Mi or Lo, the command current increases. The LS-EPC valve reduces the set pressure of the LS valve. When the set pressure decreases, the supply of pump discharged volume starts at low LS differential pressure (ΔPLS) to get better ease of combined operation and fine controllability.
Lo Mi Hi
LS differential pressure ( PLS) G0000144
LS control function The LS-EPS valve changes the set pressure of the LS valve according to the operation state of the actuator. When the set pressure decreases, the supply of pump discharged volume starts at low LS differential pressure (ΔPLS) to get better ease of combined operation and fine controllability. For details, see "LS control function" in "FUNCTION OF PUMP AND VALVE CONTROL SYSTEM".
10-66
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
CONTROL OF PUMP SWASH PLATE ANGLE AND DISCHARGED VOLUME When control lever is in NEUTRAL 2
3 4 1
5
6
7
Min.
8 Max.
9
Max.
Min.
10 13
16
11 12
15
14 G0000135
1: PPC valve
PC210-10M0, PC210LC-10M0
2: Actuator
10-67
CLSS
10 STRUCTURE AND FUNCTION
3: Control valve
10: LS valve
4: Spool
11: PC valve
5: Main relief valve
12: PC-EPC valve
6: Unload valve
13: LS-EPC valve
7: LS bypass valve
14: Pump controller
8: Main pump
15: Self-pressure reducing valve
9: Servo piston
16: 2-stage relief solenoid valve
When the control lever is in the NEUTRAL position, the spool (4) closes. LS pressure (PLS) is discharged from the LS bypass valve (7) to the hydraulic tank, which results in 0 MPa. Because LS differential pressure (ΔPLS = PP - PLS) is large, the LS valve (10) transmits pressurized oil to the large diameter (right) side of the servo piston (9). Consequently, the servo piston (9) is pushed to the left, which results in the minimum pump swash plate angle and the minimum discharged volume. The pressurized oil discharged from the pump is discharged from the unload valve (6) to the hydraulic tank.
10-68
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
When balanced (when LS differential pressure (?PLS) and set pressure is balanced) 2
3 4 1
5
6
7
Min.
8 Max.
9
Max.
Min.
10 13
16
11 12
15
14 G0000136
PC210-10M0, PC210LC-10M0
10-69
CLSS
10 STRUCTURE AND FUNCTION
The LS differential pressure (ΔPLS) balances at the set pressure of the LS valve (10), which results in a balance state. The servo piston (9) does not move, and the pump swash plate angle and the discharged volume are constant. The set pressure, the discharged volume, and the pump absorption horsepower in the balance state increase or decrease according to the command current from the pump controller (14) to the PC-EPC valve (12) and the LS-EPC valve (13). When the command current increases, the set pressure, the discharged volume, and the pump absorption horsepower decrease.
10-70
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
When the control lever is moved to fine control postiio 2
3 4 1
5
6
7
Min.
8 Max.
9
Max.
Min.
10 13
16
11 12
15
14 G0000137
When the control lever is returned to the lifting position, the opening area of the spool (4) decreases. Pressure losses increase when the flow passes through the spool, and the LS differential pressure (ΔPLS) increases.
PC210-10M0, PC210LC-10M0
10-71
CLSS
10 STRUCTURE AND FUNCTION
The LS valve (10) transmits pressurized oil to the large diameter (right) side of the servo piston (9) so that the LS differential pressure (ΔPLS) is equal to the set pressure. Consequently, the servo piston (9) is pushed to the left, which reduces the pump swash plate angle and the discharged volume.
10-72
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
When the control lever is moved to the end 2
3 4 1
5
6
7
Min.
8 Max.
9
Max.
Min.
10 13
16
11 12
15
14 G0000138
When the control lever is moved to the full stroke position, the opening area of the spool (4) increases. Pressure losses decrease when the flow passes through the spool, and the LS differential pressure (ΔPLS) decreases.
PC210-10M0, PC210LC-10M0
10-73
CLSS
10 STRUCTURE AND FUNCTION
The pressurized oil is discharged from the large diameter (right) side of the servo piston (9) so that the LS differential pressure (ΔPLS) is equal to the set pressure. Consequently, the pump swash plate angle and the discharged volume increase.
10-74
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CLSS
When control lever is stroked to the end and cylinder is in stroke end position (when relief) 2
3 4 1
5
6
7
Min.
8 Max.
9
Max.
Min.
10 13
16
11 12
15
14 G0000139
The spool of the PC valve (11) moves to change a pump swash plate angle so that the force of the spring is balanced with the increased pump discharged pressure. PC210-10M0, PC210LC-10M0
10-75
CLSS
10 STRUCTURE AND FUNCTION
As the pump discharged pressure increases, the pump swash plate angle decreases, and the pump discharged volume decreases. When the pump discharged pressure reaches relief pressure, the main relief valve (5) opens and then discharges pressurized oil to the hydraulic tank to prevent the pressure higher than the relief pressure.
PRESSURE COMPENSATION CONTROL FUNCTION OF PRESSURE COMPENSATION CONTROL A: Heavy load mode
A
B: Low load mode
W
C: LS circuit
1
1
P: Difference in pressure between the inlet and output of the spool 1: Actuator
B W
C 2
2
3
3
2: Pressure compensation valve 3: Control lever
4 S1
S2
4: Spool
5
4
5: LS shuttle valve 6: Main pump 7: Servo piston
6
When multiple actuators (1) are operated at the same time, operation speed in proportion to the stroke of each control lever (3) is kept whether or not a load is high or low.
7
G0000306 The pressure compensation valve (2) is installed on the outlet of each spool (4) of the control valve. The flow rate to the lowload actuator (1) is reduced so that the highest LS pressure (PLS) is achieved. As a result, all differences in pressure (P) between the inlet and output of each spool (4) become the same. The flow rate in proportion to the stroke of the control lever (3) is kept.
Without the pressure compensation valve (2), the difference in pressure of the spool (4) is larger at lower load, which increases the flow rate. Thus, the operation speed in low load mode (B) is fast, which degrades simultaneous controllability.
A
B
W
W
1
1
3
3 4 4 S1
S2
6 7
G0000307
10-76
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ENGINE AND PUMP COMBINED CONTROL SYSTEM
ENGINE AND PUMP COMBINED CONTROL SYSTEM ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM
18 23
17
23c 23b 23a
30
20 19
12
11
29
22
21 13
19 14 21a
15 22a
21b
22b
19
21c
22c
19
l k j 8
19 28
27 19 24
9
26
e f g h d
10 3
2
25
4
5
6
7 c b a
1
g
i G0000016
a: Drive signal (front pump PC-EPC valve)
g: Oil pressure sensor signal
b: Drive signal (rear pump PC-EPC valve)
h: Signal (one-touch power maximizing switch)
c: GND (solenoid valve)
i: Signal (service pressure switch)
d: CAN signal
j: Throttle signal
e: Drive signal (LS-EPC valve)
k: Control signal (fuel supply pump)
f: Swash plate sensor signal
l: Sensor signals
1: Battery disconnect switch
9: Machine monitor
2: Battery
10: Pump secondary drive switch
3: Battery relay
11: Fuel control dial
4: Fusible link
12: Fuel supply pump
5: Fuse box
13: Sensors
6: Resistor for PC-EPC valve
14: Front pump swash plate sensor
7: Pump controller
15: Rear pump swash plate sensor
8: Engine controller
16: One-touch power maximizing switch
PC210-10M0, PC210LC-10M0
10-77
ENGINE AND PUMP COMBINED CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
17: Pressure sensor (front pump)
23: Control valve
18: Pressure sensor (rear pump)
23a: Self-pressure reducing valve
19: Oil pressure sensor
23b: Merge-divider valve
20: Pressure switch (service)
23c: Travel junction valve
21: Front pump
24: Front pump PC-EPC valve
21a: Servo piston
25: Rear pump PC-EPC valve
21b: LS valve
26: LS-EPC valve
21c: PC valve
27: L.H. PPC valve (for arm and swing operation)
22: Rear pump
28: Travel PPC valve
22a: Servo piston
29: R.H. PPC valve (for boom and bucket operation)
22b: LS valve
30: 1st-line attachment PPC valve
22c: PC valve
You can operate the working mode selector switch on the machine monitor to select the working mode. 6 working modes are provided: P, E, L, ATT-P, ATT-E, and B. You can select the most appropriate engine torque (T) and the pump absorption torque according to the work. When "Without Attachment" is selected at the initial setting of service mode, 4 modes of P, E, L and B are available.
•
The pump controller figures out the pump absorption upper limit torque corresponding to the pump absorption torque set for the working mode, the engine speed being set with the fuel control dial, and the actual engine speed. The pump is controlled so that the engine speed is kept around the matching point set in each mode when a heavy load is applied.
•
When the engine speed decreases, the pump absorption torque is reduced to prevent the engine from being stopped.
Engine speed (N)
G0000121
Engine horsepower (PW)
•
Engine torque (T)
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM Working mode selection function
G0000122
Pump discharged pressure (P)
Engine speed (N)
Pump discharged volume (Q)
10-78
G0000017
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ENGINE AND PUMP COMBINED CONTROL SYSTEM
P, ATT-P (during operation)
96.9 kW/1700 rpm {130 HP}
E, ATT-E (during operation)
84.5 kW/1700 rpm {113 HP}
•
In mode P, E, ATT-P, or ATT-E, the engine speed is always kept around the matching point set in each mode.
•
When the load is low, the engine operates in high speed range. As the load increases, the engine speed is decreased and the torque is increased to the matching point where the torque is balanced with the pump absorption upper limit torque (PT). ((1) in the graph)
•
If the load increases further, the engine speed also decreases further. ((2) in the graph)
•
The controller decreases pump absorption upper limit torque (PT) to reduce the load applied to the engine. ((3) in the graph)
•
As the load on the engine decreases, the engine speed increases. ((4) in the graph)
•
The controller increases pump absorption upper limit torque (PT) to keep the engine speed at around the matching point. ((5) in the graph)
•
The controller controls the engine so that the engine matching speed (Nm) is decreased when the load is light (low flow rate and low torque) to get better the fuel consumption. ((6) in the graph)
Engine speed (N)
Engine speed (N)
Pump discharged volume (Q)
PC210-10M0, PC210LC-10M0
G0000123
Engine horsepower (PW)
Matching point
G0000124
Pump discharged pressure (P)
Working mode
Engine torque (T)
Control method in mode P, E, ATT-P, and ATT-E
G0000018
10-79
ENGINE AND PUMP COMBINED CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
Partial output
B
80 %
L
75 %
Working mode
Matching point
B
77.2 kW/1655 rpm {104 HP}
L
73.6 kW/1650 rpm {99 HP}
•
In B mode or L mode, engine output is kept constant.
•
The controller controls pump absorption upper limit torque (PT) so that the engine torque is kept constant along the equal engine horsepower curve.
Engine speed (N)
G0000019
Engine horsepower (PW)
Working mode
Engine torque (T)
Control method in mode B and L
G0000020
Pump discharged pressure (P)
Engine speed (N)
Pump discharged volume (Q)
G0000021
Control function when the machine travels •
The engine speed (N) increases during the travel in P or ATT-P mode.
•
The engine speed increases during the travel in E, ATT-E, or B mode. At that time, the engine speed is the same as that in P or ATT-P mode. The pump absorption torque is lower than that in P or ATT-P mode.
•
When the machine travels in L mode, the working mode is kept as it is, and the engine speed (N) is kept as it is but the pump absorption torque increases.
10-80
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ENGINE AND PUMP COMBINED CONTROL SYSTEM
The pump secondary drive switch (1) enables the machine to temporarily operate with absorption torque equivalent to E mode for the time when an abnormality occurs in the controller, the main pump does not operate normally. Only the sensor of the PC-EPC valve senses the oil pressure because constant current flows from the battery to the PC-EPC valve at this time. REMARK The pump secondary drive switch (1) is an alternative type. Action level L03 appears on the display if the machine is operated with this switch at emergency (a) position while the machine is normal.
a: Emergency (when abnormal)
PC210-10M0, PC210LC-10M0
Pump discharged pressure (P)
Control function when the pump secondary drive switch is in "ON" position
Pump discharged volume (Q)
G0000024
b: Normal (when normal)
10-81
PUMP AND VALVE CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
PUMP AND VALVE CONTROL SYSTEM PUMP AND VALVE CONTROL SYSTEM DIAGRAM
18 18e
25
18d 18d
18c 18b 18a
26
12
24
16
17
14 16a
15 17a
16b
17b
16c
17c
23
13 22
11
m n l 8 19
20
f e
21
d 9
10 3
2
4
5
7
g h i j k
c b a
6
1 G0000025
b: Drive signal (rear pump PC-EPC valve)
h: Drive signal (merge-divider EPC valve (for LS spool))
c: GND (solenoid valve)
i: Drive signal (travel junction solenoid valve)
d: CAN signal
j: Drive signal (2-stage relief solenoid valve)
e: Drive signal (LS-EPC valve)
k: Drive signal (variable back pressure solenoid valve)
f: Swash plate sensor signal
l: Throttle signal
g: Drive signal (merge-divider EPC valve (for main spool))
m: Signal (fuel supply pump)
1: Battery disconnect switch
7: Pump controller
2: Battery
8: Engine controller
3: Battery relay
9: Machine monitor
4: Fusible link
10: Pump secondary drive switch
5: Fuse box
11: Fuel control dial
6: Resistor for PC-EPC valve
12: Fuel supply pump
a: Drive signal (front pump PC-EPC valve)
10-82
n: Sensor signals
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
PUMP AND VALVE CONTROL SYSTEM
13: Sensors
18b: Merge-divider valve
14: Front pump swash plate sensor
18c: Travel junction valve
15: Rear pump swash plate sensor
18d: Main relief valve
16: Front pump
18e: Variable back pressure valve
16a: Servo piston
19: Front pump PC-EPC valve
16b: LS valve
20: Rear pump PC-EPC valve
16c: PC valve
21: LS-EPC valve
17: Rear pump
22: Merge-divider EPC valve (for main spool)
17a: Servo piston
23: Merge-divider EPC valve (for LS spool)
17b: LS valve
24: Travel junction solenoid valve
17c: PC valve
25: 2-stage relief solenoid valve
18: Control valve
26: Variable back pressure solenoid valve
18a: Self-pressure reducing valve
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM LS control function The LS control function is a function that changes the selector point for pump discharged volume (LS set differential pressure (DLS)) according to the operation state of work equipment (quantity of load) to get better ease of combined operation and fine controllability. Output pressure (EPC pressure) from the LS-EPC valve to the LS valve changes depending on the command current from the pump controller. B: EPC pressure = 1.8 MPa (18 kg/cm2)
Pump discharged volume (Q)
A: 0 MPa (0 kg/cm2)
LS set differential pressure (△PLS) G0000008
Cut-off function The cut-off function is a function that reduces the discharged volume during pump relief by increasing PC-EPC current to get better fuel consumption. When the Certain conditions are satisfied, the cut-off function operates. •
When working in E mode.（Excluding traveling operation and swinging operation）
•
When the one-touch power maximizing function is disabled
•
When the swing lock switch is OFF
•
When the discharged pressure of the main pump is 27.9 MPa (285 kg/cm2 ) or above
PC210-10M0, PC210LC-10M0
10-83
PUMP AND VALVE CONTROL SYSTEM
10 STRUCTURE AND FUNCTION
PC-EPC current (J)
A: PC-EPC current when the cut-off function operates
Pump discharged pressure (P) G0000009
2-stage relief function The 2-stage relief function is a function that temporarily increases the digging force of work equipment by increasing the relief pressure of the main valve. Operation of the 2-stage relief function •
When the machine travels
•
When the swing lock switch is ON
•
At boom LOWER
•
When the one-touch power maximizing function is operated
•
In L mode
Relief pressure 34.8 MPa (355 kg/cm2) ↓ 37.2 MPa (388 kg/cm2)
Variable back pressure function The variable back pressure function is a function that changes the set pressure of the back pressure valve according to the operating state of the machine to get better fuel consumption. Operating condition
Setting of back pressure valve
During swinging or travel
High-pressure set
During swinging or travel
Low-pressure set
10-84
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM HYDRAULIC TANK STRUCTURE OF HYDRAULIC TANK General view and sectional view
1: Sight gauge
5: Filter element
2: Oil filler cap
6: Strainer
3: Hydraulic tank
7: Bypass valve
4: Suction strainer
SPECIFICATIONS OF HYDRAULIC TANK Hydraulic tank capacity: 190 ℓ Hydraulic tank refill capacity: 135 ℓ Pressure valve (this valve is installed inside the cap). Bypass valve set pressure: 0.25 ± 0.05 MPa {2.5 ± 0.5 kg/cm2} Relief cracking pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2 or below}
PC210-10M0, PC210LC-10M0
10-85
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
Suction cracking pressure: 2.0 kPa or below {0.02 kg/cm2 or below} Bypass valve set pressure: 250 ± 50 kPa {2.5 ± 0.5 kg/cm2}
HYDRAULIC TANK OIL FILLER CAP STRUCTURE OF HYDRAULIC TANK OIL FILLER CAP Sectional view 1: Bottom plate 2: Gasket 3: Spring
FUNCTION OF HYDRAULIC TANK OIL FILLER CAP The oil filler cap is a cap that releases the pressure in the hydraulic tank to prevent the pressure in the tank from increasing when that pressure exceeds the set pressure. The pressure in the hydraulic tank increases when the oil level or temperature increases. (Pressure valve set pressure: 16.7 ± 6.9 kPa {0.17 ± 0.07 kg/cm2})
HYDRAULIC TANK BREATHER STRUCTURE OF HYDRAULIC TANK BREATHER Sectional view 1: Nut 2: Cover 3: Filter element 4: Case 5: Valve assembly 6: Body
FUNCTION OF HYDRAULIC TANK BREATHER The breather is a function that takes ambient pressure into the hydraulic tank to prevent negative pressure. Negative pressure is generated if the oil level in the hydraulic tank decreases because the hydraulic tank is pressurized and airtight. (Set pressure of intake valve: 2.0 kPa or below {0.02 kg/cm2 or below})
10-86
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
MAIN PUMP STRUCTURE OF MAIN PUMP General view
G0033460
PC210-10M0, PC210LC-10M0
10-87
COMPONENT PARTS OF HYDRAULIC SYSTEM
IMF: Front pump PC mode selector current IMR: Rear pump PC mode selector current ISIG: LS set pressure selector current PAF: Discharge port (front pump)
10 STRUCTURE AND FUNCTION
PFC: Pressure pickup port (front pump discharged pressure) PLSF: Pressure pickup port (front pump load pressure)
PAR: Discharge port (rear pump)
PLSFC: Pressure pickup port (front pump load pressure)
PBF: Input port (front pump pressure)
PLSR: Input port (rear pump load pressure)
PD3R: Air bleeder
PLSRC: Pressure pickup port (rear pump load pressure)
PD1R: Case drain port PD2F: Drain plug PD2R: Drain plug
PMF: Pressure pickup port (front pump PC mode selector pressure)
PENF: Pressure pickup port (front pump control pressure)
PMR: Pressure pickup port (rear pump PC mode selector pressure)
PENR: Pressure pickup port (rear pump control pressure)
PRC: Pressure pickup port (rear pump discharged pressure)
PEPC: Input port (EPC source pressure)
PS: Intake port (pump)
PEPB: Pressure pickup port (EPC source pressure)
PSIG: Pressure pickup port (LS set selector pressure)
1: Front pump
7: Rear pump swash plate sensor
2: Rear pump
8: Front pump LS valve
3: LS-EPC valve
9: Rear pump LS valve
4: Front pump PC-EPC valve
10: Front pump swash plate sensor
5: Rear pump PC-EPC valve
11: Front pump PC valve
6: Rear pump PC valve
10-88
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
Sectional view
G0033461
a: Spline 1: Front shaft
9: End cap
2: Cradle
10: Rear shaft
3: Front case
11: Rear case
4: Rocker cam
12: PC valve
5: Shoe
13: Servo piston
6: Piston
14: Slider
7: Cylinder block
15: Bearing
8: Valve plate
16: LS valve
PC210-10M0, PC210LC-10M0
10-89
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
SPECIFICATIONS OF MAIN PUMP Model: HPV125 + 125 Type: Variable displacement piston type Theoretical discharged volume: 125 + 125 cm3/rev Set pressure: 34.8 MPa {355 kg/cm2}
FUNCTION OF MAIN PUMP The main pump is a pump that converts the rotation movement by the engine to the fluid movement of hydraulic oil. The main pump consists 2 flexible capacity piston pumps connected in series that have the same dimensions, structure, and functions. The discharged pressure and the actuator load pressure corresponding to each pump are transmitted to that pump. The flow rates of the pumps are controlled in consideration of the difference in the discharged pressure and the actuator load pressure, depending on a load or the operation of the lever.
OPERATION OF MAIN PUMP
G0033462
The shaft (1) is supported in the case (3) by the bearing (15). In each cylinder of the cylinder block (7), the piston (6) is set, and it can slide in the axial direction. The shoe (5) is connected to the end of the piston (6) on a sphere plane so that the shoe can rock. The shoe (5) is connected so that it can rock in contact with the plane of the rocker cam (4). The cylinder block (7) is connected to the shaft (1) through the spline (a). When the shaft (1) rotates, the cylinder block (7), the piston (6), and the shoe (5) rotate together. 10-90
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
The rocker cam (4) is installed so that it rocks on the cylindrical surface (B) of the cradle (2) fixed to the case (3). The angle between the vertical axis of the flat surface (A) of the rocker cam (4) and the axis of the shaft (1) is called a swash plate angle (b). The swash plate angle does not become 0. Thus, when the cylinder block (7) rotates, the piston (6) does reciprocation in the cylinder through the shoe (5). When the piston (6) is pulled by the cylinder block (7), hydraulic oil is sucked. When the piston (6) is pushed by the cylinder block (7), hydraulic oil is discharged. The swash plate angle of the rocker cam (4) changes through the slider (14) by the reciprocation linear motion of the servo piston (13). The back and forth distance of the piston (6) changes in response to the swash plate angle. The piston (6) of the cylinder block (7) and the opposite end are connected to rotate relatively to the valve plate (8) fixed to the case (3). The valve plate (8) has holes parallel with the positions of the cylinder block (7) where hydraulic oil is sucked and discharged. These holes are connected to the intake port and discharge port of the end cap (9), respectively.
MAIN PUMP LS VALVE LS Abbreviation for Load Sensing
PC210-10M0, PC210LC-10M0
10-91
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
STRUCTURE OF MAIN PUMP LS VALVE Sectional view 1
PA
3
2
PSIG
PDP
PLL
4
PLP
PP
5
6
7
PLS
8
G0000269
PA: Pump port
PP: Pump port
PDP: Pump drain port
PPL: Input port (control pressure)
PLP: Output port (LS control pressure)
PSIG: Input port (LS set selector pressure)
PLS: Input port (LS pressure) 1: Sleeve
5: Seat
2: Piston
6: Sleeve
3: Spool
7: Plug
4: Spring
8: Lock nut
The LS valve is a valve that controls pump discharged volume (Q) by sensing pump discharged pressure (PP) and LS pressure of the control valve outlet (PLS). The figure shows the relationship between the pump discharged volume (Q) and the LS differential pressure (ΔPLS) that indicates the difference between the pump discharged pressure (PP) and the LS pressure.
Pump discharged volume (Q)
FUNCTION OF MAIN PUMP LS VALVE
The LS set selector pressure (PSIG) from the LS-EPC valve LS set differential pressure (△PLS) (proportional solenoid valve) is transmitted to the LS valve. The G0000008 LS set selector pressure (PSIG) changes depending on the quantity of the LS set pressure selector current (ISIG) applied to the LS-EPC valve. When the LS set selector pressure (PSIG) transmitted to the LS valve changes, the selector point for pump discharged volume (Q) changes. When the LS set pressure selector current (ISIG) is small, the selector point for pump discharged volume (Q) is at high LS differential pressure, as shown in the line A of the figure. When the LS set pressure selector current (ISIG) is large, the selector point for pump discharged volume (Q) is at low LS differential pressure, as shown in the line B of the figure.
OPERATION OF MAIN PUMP LS VALVE The force of the spring (4), the force from LS-EPC valve pressure (PSIG), the force from pump discharged pressure (PP), and the force from LS pressure (PLS) act on the spool (3) of the LS valve. When the output pressure from the LS-EPC valve (PSIG) is subtracted from the force of the spring (4), the obtained force becomes LS set pressure. When the force from the LS set pressure is balanced with the force from LS differential pressure 10-92
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
(ΔPLS), the position of the spool (3) is specified, and the hydraulic pressure transmitted to the servo piston (9) is changed.
When control valve is in neutral position
PT
LS-EPC valve PSIG
PP
PLS
Controller Control valve
Main pump
D C
Selfpressure reducing valve
H 3
4
PC valve
K Large diameter
J 9
Small diameter
Minimum direction G0000078
When the control valve is in the NEUTRAL position, the LS circuit is connected to the drain circuit. The LS pressure (PLS) transmitted to the LS valve becomes approximately 0. On the other hand, because the pump discharged pressure (PP) from the unload valve is transmitted to the port (H), the spool (3) moves to the right, and the port (C) is connected to the port (D). The pump discharged pressure (PP) is transmitted from the port (D) to the port (K) on the large diameter side of the servo piston (9). The pump discharged pressure (PP) is applied to the port (J) on the small diameter side of the servo piston (9). The piston moves to the right depending on a difference in the area receiving the pressure, which results in the minimum pump discharged volume.
PC210-10M0, PC210LC-10M0
10-93
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
When LS differential pressure is low
PT
LS-EPC valve PSIG
PP
PLS
Controller Control valve
Main pump
D
Selfpressure reducing valve
3
E
PC valve J
K Large diameter
9
Small diameter
Maximum direction G0000079
When the LS differential pressure (ΔPLS) is temporarily smaller than the LS set pressure because the opening area of the control valve increases, the spool (3) moves to the left. When the spool (3) moves, the port (D) is connected to the port (E). The port (K) on the large diameter side of the servo piston (9) is connected to the tank through the PC valve. The pump pressure (PP) is applied to the port (J) on the small diameter side of the servo piston (9). The servo piston (9) moves to the left to increase the pump discharged volume.
10-94
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When LS differential pressure is high
PT
LS-EPC valve PSIG
PP
PLS
Controller Control valve
Main pump
D
Selfpressure reducing valve
C
3
PC valve K Large diameter
J
9
Small diameter
Minimum direction G0000080
When the LS differential pressure (ΔPLS) is temporarily larger than the LS set pressure because the opening area of the control valve decreases, the spool (3) moves to the right. When the spool (3) moves, the port (C) is connected to the port (D). The pump discharged pressure (PP) is applied to the port (K) on the large diameter side of the servo piston (9). The pump discharged pressure (PP) is applied to the port (J) on the small diameter side of the servo piston (9). The servo piston (9) moves to the right depending on a difference in the area receiving the pressure, and the pump discharged volume is reduced.
PC210-10M0, PC210LC-10M0
10-95
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
When LS differential pressure is balanced with LS set pressure
LS-EPC valve
PT PSIG
PP
PLS
Controller Control valve
Main pump
D
Selfpressure reducing valve
C
3
E
PC valve
A0
PEN A1 Large diameter
Small diameter
K
9 G0000081
When the LS differential pressure (ΔPLS) is equal to the LS set pressure in the normal state of machine operation, the spool (3) stops at the position where the force is balanced. At this time, the port (D) is connected to the port (C) and the port (E). Some of the pump discharged pressure (PP) transmitted from the port (C) flows into the tank through the port (E) and the PC valve. The reduced pressure (PEN) is transmitted to the port (K) of the servo piston (9). The servo piston (9) stops at the position where the ratio between the area receiving the pressure on the large diameter side and the area receiving the pressure on the small diameter side (A0:A1) is equal to the ratio between the load performance on the small diameter side and the load performance on the large diameter side (PP:PEN). The pump discharged volume is kept constant.
10-96
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
MAIN PUMP PC VALVE STRUCTURE OF MAIN PUMP PC VALVE Sectional view 1
2
PM
3
PA
PLL
PA2
4
5
6
PA2
PDP 10
11
7
8 PA 9
G0000102
PA: Pump port
PM: Mode selector pressure pilot port
PA2: Pump pressure pilot port
PPL: Control pressure output port (to LS valve)
PDP: Drain port 1: Plug
7: Cover
2: Servo piston assembly
8: Wiring
3: Piston
9: Seat
4: Spool
10: Spring
5: Retainer
11: Spring
6: Seat
The PC valve is a valve that controls pump discharged volume so that pump absorption horsepower does not exceed engine horse power. The relationship between the average discharged pressure of the front pump and the rear pump, that is, (PP1 + PP2)/2, and pump discharged volume (Q) is shown in the figure. The PC valve decreases the pump discharged volume when the load is increased during work and the pump discharged pressure rises. The PC valve increases the pump discharged volume when the pump discharged pressure decreases. When the load increases and the engine speed is about decreasing, the PC valve reduces the pump discharged volume to prevent the engine speed from decreasing.
Pump discharged volume (Q)
FUNCTION OF MAIN PUMP PC VALVE Command current (X): Small Command current (X): Medium Command current (X): Large
Average of pump discharged pressures (PP1+PP2)/2
G0000161
The control of the pump discharged volume by the PC valve has higher priority than the control by the LS valve. Though the LS valve tries to increase the pump discharged volume when the stroke of lever operation is increased at high pump discharged pressure, the PC valve does not flow the discharged volume at the rate exceeding a specified rate, depending on discharged pressure. The command current (X) from the pump controller flows into the PC-EPC valve (proportional solenoid valve). The output pressure corresponding to the command current (X) is supplied to the PC valve. When the command current (X) applied to the PC-EPC valve is large, the pump absorption horsepower is reduced. When the engine speed decreases below a specified value at an increased load, the command current (X) increases according to PC210-10M0, PC210LC-10M0
10-97
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
the decreased engine speed, and the PC valve reduces the pump discharged volume. The pump controller adjusts the quantity of the command current (X) to control the pump discharged volume, and operates to get the correct engine speed.
OPERATION OF MAIN PUMP PC VALVE Action of PC-EPC valve solenoid
Control valve PP2
PP1
When port B and C are connected
PT
C
B M A
E C
LS valve
PT
C
B R
D When port C and D are connected
G
Q
P Large diameter
B
C
3 2 4 J
P R 10
9
Small diameter
11
Maximum direction
Pump controller
OFF
Pump secondary drive switch
PC-EPC valve
ON Self-pressure reducing valve
Resistor
Q
X
12 G0000154
The push force caused by the spring (10) and (11) to the spool (4) acts leftward. The push force caused by the self-pump pressure (PP1), other pump pressure (PP2) and the pilot pressure of PC-EPC valve solenoid (12) to the spool (4) acts rightward. The balance of these 4 forces determines the position of the spool (4) and the pressure of the port (C) that is output to the LS valve. •
Contents of work (lever operation)
•
Selection of working mode
•
Engine speed setting value and actual engine speed
REMARK The other pump pressure indicates the pressure of the pump on the other side. If the pressure is the front pump pressure, it indicates the rear pump pressure. If the pressure is the rear pump pressure, it indicates the front pump pressure.
10-98
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
Operation of spring Spring forces (10) and (11) of the PC valve is determined by the position of the spool (4). When the spool (4) moves to the right, the springs (10) and (11) are compressed. When the spool (4) moves further to the right, the seat (9) is fixed at the spring chamber, and the spring (11) is not compressed one more. After that,only the spring (4) is compressed. On the other hand, the position of the servo piston (2) is determined by the swash plate angle. When the servo piston is balanced, the servo piston (2) and the spool (4) are on the relatively same position as shown in the figure. Thus, when the spool (4) is balanced, the force of springs (1) and (11) is determined finally by the swash plate angle.
(1) When actuator load is small and pump pressures (PP1) and (PP2) are low
Control valve PP2
PP1
When port B and C are connected
PT
C
B M A
E LS valve
PT
C
B
C R
D G
When port C and D are connected
Q
P Large diameter
B
C
3 2 4 J
P R 10
9
Small diameter
11
Maximum direction
Pump controller
OFF
Pump secondary drive switch
PC-EPC valve
ON Self-pressure reducing valve
Resistor
Q
X
12 G0000154
The port (C) of the PC valve is connected to the port (E) of the LS valve. The self pressure (PP1) goes into the small diameter side of the piston of the servo piston (2) and the port (B). The other pump pressure (PP2) goes into the port (A). When the pump pressures (PP1) and (PP2) are low, the spool (4) is relatively at left against the servo piston (2). The port (C) is connected to the port (D), and the pressure goes into the LS valve becomes the drain pressure (PT). (See the view P). When the port (E) and the port (G) of the LS valve are connected, the pressure goes from the port (J) to the large diameter side of the piston becomes the drain pressure (PT). The servo piston (2) moves to the left, and the pump discharge pressure increases. As the servo piston (2) moves to the left, the springs (10) and (11) are expanded, and the reaction force of the springs are weakened. When the spool (4) moves relatively to the right against the servo piston (2), the port (C) and the port (D) are disconnected, and the PC210-10M0, PC210LC-10M0
10-99
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
discharge port (B) of the pump is connected to the port (C). (See the view R, view Q) The pressure of the port (C) increases and the piston large-diameter side pressure of the piston increases, the servo piston (2) stops moving to the left. The servo piston (2) stops when the push force of the pressure (PP1), (PP2) acting on the spool (4), the push force from the PC-EPC valve, and the forces of the spring (10) and (11) are balanced.
(2) When actuator load is large and pump pressures (PP1) and (PP2) are high
Control valve PP2
PP1
PT
B
M A
E C
LS valve
B
C
D G
P Large diameter
2 3 4
P
10
Small diameter
11
J Minimum direction
Pump controller
OFF
Pump secondary drive switch
PC-EPC valve
ON Self-pressure reducing valve
Resistor
X G0000155
When the load is large, and the pump discharge pressures (PP1) and (PP2) are high, the push force which pushes the spool (4) to the right increases. The spool (4) is at the position where the port (B) and the port (C) is connected (See view P). The pump pressure (PP1) passes through the port (C), and flows into the inlet port (E) of the LS valve. If the port (E) and the port (G) of the LS valve are connected, this pressure enters from the port (J) to the large-diameter side, and the servo piston (2) moves to the direction (right) to lower the swash plate angle. When the servo piston (2) moves to the right, the spool (4) moves relatively to the left relative against the servo piston (2). Thus, for the port (c) and the port (d) to be connected, a portion of the pressure oil from the port (B) goes back to the tank via the port (C) from the port (d). As the pressure of the port (C) decreases, the pressure on the large diameter side decreases. At this position, the servo piston (2) and the spool (4) are relatively balanced.
10-100
PC210-10M0, PC210LC-10M0
COMPONENT PARTS OF HYDRAULIC SYSTEM
The position relationship of the pump pressure average (PP1 + PP2)/2 and the servo piston (2) is a polygonal line. This is because the spring (10) and (11) are two-stage springs. The relationship of the pump pressure average (PP1 + PP2)/2 and the pump discharged pressure (Q) are as shown in the figure that follow.
Pump discharged volume (Q)
10 STRUCTURE AND FUNCTION
Average of pump discharged pressures (PP1+PP2)/2
When the command current (X) increase, the relationship of the pump pressure average (PP1 + PP2)/2 and the pump discharged pressure (Q) moves from (A) to (B) in response to the push force from the PC-EPC valve.
Pump discharged volume (Q)
G0000043
B (Command current (X): Large)
A (Command current (X): Small)
Average of pump discharged pressures (PP1+PP2)/2
G0000044
When the pump secondary drive switch is turned on, the current (X) that flows to the PC-EPC solenoid (12) is constant. Thus, the relationship (C) of the pump pressure average (PP1 + PP2)/2 and the pump discharged pressure (Q) is fixed. The power to move the work equipment to some extent without lowering the engine speed is ensured.
Pump discharged volume (Q)
(3) When the pump secondary drive switch is turned on due to failure in pump controller A (Command current (X): Small) B (Command current (X): Large) C (Pump secondary drive switch: ON)
Average of pump discharged pressures (PP1+PP2)/2
G0000045
MAIN PUMP LS-EPC VALVE LS Abbreviation for Load Sensing
EPC Abbreviation for Electromagnetic Proportional Control
PC210-10M0, PC210LC-10M0
10-101
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
STRUCTURE OF MAIN PUMP LS-EPC VALVE General view and sectional view 1
B-B 2
C
3 A B
B
T 7
6
5
4
A-A C: To the LS valve
A P G0000258
T: To the hydraulic tank
P: From the self-pressure reducing valve 1: Connector
5: Spool
2: Coil
6: Rod
3: Body
7: Plunger
4: Spring
FUNCTION OF MAIN PUMP LS-EPC VALVE Upon receiving the signal current (i) from the pump controller, the LS-EPC valve supplies the EPC output pressure in proportion to that signal current to the LS valve.
10-102
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
OPERATION OF MAIN PUMP LS-EPC VALVE Pump when signal current from controller does not flow (coil de-energized) When the signal current does not flow from the pump controller to the EPC valve, the coil (2) is de-energized. The spool (5) is pushed to the left by the spring (4). The path from the port (P) to the port (C) is closed by the spool (5), the pressurized oil from the self-pressure reducing valve does not flow to the LS valve, The pressurized oil from the LS valve flows from the port (C) through the port (T) to the tank.
LS valve
5
2
4
C
T P
Self-pressure reducing valve
Pump G0000117
When signal current from pump controller is low (coil energized) When a small signal current flows from the pump controller to the EPC valve, the coil (2) is energized and the thrust force to the right is generated in the plunger (7). When the plunger (7) pushes the spool (5) to the right through the rod (6), the pressurized oil from the port (P) flows through the opening of the spool (5) to the port (C). When the pressure of the port (C) increases, the force acting on the face of the spool (5) and the reaction force of the spring (4) becomes larger than the thrust force of the plunger (7). The spool (5) is pushed to the left, ports (P) and port (c) are blocked, ports (c) and port (T) are connected, and the pressure of the port (c) stops increasing. The spool (5) moves to the position where the thrust force of the plunger (7), the pressure of the port (C), and the reaction force of the spring (4) are balanced. The circuit pressure between the EPC valve and the LS valve is controlled proportionally to the magnitude of the signal current.
LS valve
5
2
4
C
T P
7
6
Self-pressure reducing valve
Pump G0000118
PC210-10M0, PC210LC-10M0
10-103
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
When signal current from pump controller is maximum (coil energized) When the maximum signal current flows from the pump controller to the EPC valve, the coil (2) is energized, and the thrust force of the plunger (7) becomes maximum. The plunger (7) pushes the spool (5) through the rod (6) to the right. The pressurized oil from the port (P) flows through the opening of the spool (5) to the port (C) maximum. Thus, the circuit pressure between the EPC valve and LS valve becomes maximum. The port (T) is closed, and the pressurized oil from the LS valve does not flow to the tank.
LS valve
5
2
C
T P
7
6
Self-pressure reducing valve
Pump G0000119
MAIN PUMP PC-EPC VALVE PC Abbreviation for Pressure Compensation
EPC Abbreviation for Electromagnetic Proportional Control
10-104
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
STRUCTURE OF MAIN PUMP PC-EPC VALVE General view and sectional view 1
B-B 2
C
3 A B
B
T 7
6
5
4
A-A C: To the PC valve
A P G0000258
T: To the hydraulic tank
P: From the self-pressure reducing valve 1: Connector
5: Spool
2: Coil
6: Rod
3: Body
7: Plunger
4: Spring
FUNCTION OF MAIN PUMP PC-EPC VALVE Upon receiving the signal current (i) from the pump controller, the PC-EPC valve supplies the EPC output pressure in proportion to that signal current to the PC valve.
PC210-10M0, PC210LC-10M0
10-105
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
Operation of main pump PC-EPC valve Pump When signal current from controller does not flow (coil de-energized) When the signal current does not flow from the pump controller to the EPC valve, the coil (2) is de-energized. The spool (5) is pushed to the left by the spring (4). The path from the port (P) to the port (C) is closed by the spool (5), and the pressure oil from the self-pressure reducing valve does not flow to the PC valve. The pressure oil from the PC valve flows from the port (C) to the tank through the port (T).
PC valve
5
2
4
C
T P
Self-pressure reducing valve
Pump G0000127
When signal current from pump controller is low (coil energized) When a small signal current flows from the pump controller to the EPC valve, the coil (2) is energized and the thrust force to the right is generated in the plunger (7). When the plunger (7) presses the spool (5) to the right through the rod (6), the pressure oil from the port (P) flows through the opening of the spool (5) to the port (C). When the pressure of the port (C) increases, the force acting on the face of the spool (5) and the reaction force of the spring (4) are larger than the thrust force of the plunger (7). The spool (5) is pushed to the left, ports (P) and port (c) are blocked, and ports (c) and port (T) are connected. The pressure of the port (C) stops increasing.
PC valve
5
2
4
C
T
The spool (5) moves, and the thrust force of the plunger (7), the pressure of the port (C), and the reaction force of the spring (4) are balanced.
P
7
6
Self-pressure reducing valve
Pump G0000128
10-106
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When signal current from pump controller is maximum (coil energized) When the signal current from pump controller to the EPC valve is maximum, the coil (2) is energized, and the thrust force of the plunger (7) becomes maximum. The plunger (7) pushes the spool (5) through the rod (6) to the right. The pressurized oil from the port (P) flows through the opening of the spool (5) to the port (C) maximum. Thus, the circuit pressure between the EPC valve and PC valve becomes maximum. The port (T) is closed, and the pressurized oil from the PC valve does not flow to the tank.
PC valve
5
2
C
T P
7
6
Self-pressure reducing valve
Pump G0000129
CONTROL VALVE STRUCTURE OF CONTROL VALVE The control valve consists of the integrated 6-spool valve and the service valve. The merge-divider valve, the variable back pressure valve, and the boom hydraulic drift prevention valve are installed on the control valve. These valves are formed in one unit with connecting bolts, and the paths are connected inside. The control valve has 1 spool by work equipment. The structure of a 7-spool valve is shown.
PC210-10M0, PC210LC-10M0
10-107
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
General view
A1: To the bucket cylinder head
A3: To the boom cylinder bottom
A2: To the L.H. travel motor
A4: To the swing motor
10-108
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
A5: To the R.H. travel motor
A6: To the arm cylinder head
A-1: To the attachment
P12: From the left work equipment PPC valve (arm IN)
ATT: From the attachment
P-1: From the right attachment PPC valve
B1: To the bucket cylinder bottom
P-2: From the right attachment PPC valve
B2: To the L.H. travel motor
PLS1: To the rear pump LS valve
B3: To the boom cylinder head
PLS2: To the front pump LS valve
B4: To the swing motor
PLSC: Pressure pickup port (LS pressure)
B5: To the R.H. travel motor
PP1: From the rear pump
B6: To the arm cylinder bottom
PP2: From the front pump
B-1: To the attachment
PP1S: Output port (rear pump pressure sensor)
BP1: From the LS select solenoid valve
PPC: Pressure pickup port (pilot source pressure)
BP5: From the attachment selector solenoid valve
PP2S: Output port (front pump pressure sensor)
C: To the oil cooler
PPS2: To the front pump LS valve
P1: From the right work equipment PPC valve (bucket DUMP)
PR: To the solenoid valve, PPC valve, and EPC valve
P2: From the right work equipment PPC valve (bucket CURL)
Psw: From the swing stroke control solenoid valve
P3: From the travel PPC valve (left travel REVERSE) P4: From the travel PPC valve (left travel FORWARD) P5: From the right work equipment PPC valve (boom RAISE)
PST: From the travel junction solenoid valve PX1: From the 2-stage relief solenoid valve PX2: From the 2-stage relief solenoid valve T: To the tank T1: To the tank
P6: From the right work equipment PPC valve (boom LOWER)
TS: To the tank
P7: From the left work equipment PPC valve (RIGHT)
IS1: Drive signal (merge-divider EPC valve (for main spool))
P8: From the left work equipment PPC valve (LEFT) P9: From the travel PPC valve (right travel REVERSE) P10: From the travel PPC valve (right travel FORWARD) P11: From the left work equipment PPC valve (arm OUT)
TSW: From the swing motor
IS2: Drive signal (merge-divider EPC valve (for LS spool)) IS3: Drive signal (variable back pressure solenoid valve)
1: Variable back pressure valve
7: Service valve
2: Variable back pressure solenoid valve
8: Cover A
3: Merge-divider EPC valve (for LS spool)
9: 7-spool valve
4: Merge-divider EPC valve (for main spool)
10: Arm quick return valve
5: Arm hydraulic drift prevention valve (if equipped)
11: Cover B
6: Boom hydraulic drift prevention valve
12: Merge-divider valve
PC210-10M0, PC210LC-10M0
10-109
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
Sectional views (A-A, B-B)
1: Pressure compensation valve (arm OUT)
5: Pressure compensation valve (left travel REVERSE)
2: Pressure compensation valve (right travel REVERSE)
6: Pressure compensation valve (bucket DUMP)
3: Pressure compensation valve (RIGHT)
7: Pressure compensation valve (service)
4: Pressure compensation valve (boom RAISE)
8: Pressure compensation valve (bucket CURL)
10-110
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
9: Pressure compensation valve (left travel FORWARD)
16: Main relief valve
10: Pressure compensation valve (boom LOWER)
18: Spool (bucket)
11: Pressure compensation valve (LEFT)
19: Spool (left travel)
12: Pressure compensation valve (right travel FORWARD)
20: Spool (boom)
13: Pressure compensation valve (arm IN) 14: Main relief valve 15: Unload valve
PC210-10M0, PC210LC-10M0
17: Spool (service)
21: Spool (swing) 22: Spool (right travel) 23: Spool (arm)
10-111
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
Sectional views (C-C, D-D)
1: Suction valve (arm OUT)
6: Suction safety valve (service)
2: Suction valve (right travel REVERSE)
7: 2-stage suction safety valve (service)
3: Suction valve (boom RAISE)
8: Suction safety valve (bucket CURL)
4: Suction valve (left travel REVERSE)
9: Suction valve (left travel FORWARD)
5: Suction safety valve (bucket DUMP)
10: Suction safety valve (boom LOWER)
10-112
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
11: Suction valve (right travel FORWARD)
16: LS shuttle valve (boom)
12: Suction safety valve (arm IN)
17: LS shuttle valve (left travel)
13: LS shuttle valve (arm)
18: LS shuttle valve (bucket)
14: LS shuttle valve (right travel)
19: LS shuttle valve (service)
15: LS select valve
20: LS check valve
Sectional views (E-E, F-F, G-G, H-H, AM-AM)
1: Unload valve 2: Safety valve for hydraulic drift prevention valve (boom RAISE and arm OUT) 3: Main relief valve 4: Variable back pressure valve PC210-10M0, PC210LC-10M0
10-113
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
Arm valve 5: LS shuttle valve 6: Arm quick return valve 7: Pressure compensation valve (arm IN) 8: Spool 9: Suction safety valve (arm IN) 10: Cooler check valve 11: Check valve (for regeneration circuit) 12: Suction valve (arm OUT) 13: Pressure compensation valve (arm OUT)
Right travel valve 14: LS shuttle valve 15: Pressure compensation valve (FORWARD) 16: Spool 17: Suction valve (FORWARD) 18: Suction valve (REVERSE) 19: Pressure compensation valve (REVERSE)
Swing valve 20: LS select valve 21: Pressure compensation valve (left) 22: Spool 23: Pressure compensation valve (right)
10-114
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
Sectional views (J-J, L-L, K-K, M-M)
1: Return spring 2: Merge-divider valve (for LS) 3: Valve (sequence valve) 4: Spring (sequence valve) 5: Merge-divider valve (main) 6: Return spring
Boom valve 7: Boom hydraulic drift prevention valve 8: LS shuttle valve PC210-10M0, PC210LC-10M0
10-115
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
9: Pressure compensation valve (lower) 10: Spool 11: Suction safety valve (LOWER) 12: Check valve (for regeneration circuit) 13: Suction valve (RAISE) 14: Pressure compensation valve (RAISE)
Left travel valve 15: Merge-divider valve (travel junction valve) 16: Return spring 17: LS shuttle valve 18: Pressure compensation valve (FORWARD) 19: Spool 20: Suction valve (FORWARD) 21: Suction valve (REVERSE) 22: Pressure compensation valve (REVERSE)
Bucket valve 23: LS shuttle valve 24: Pressure compensation valve (bucket CURL) 25: Spool 26: Suction safety valve (bucket CURL) 27: Suction safety valve (bucket DUMP) 28: Pressure compensation valve (bucket DUMP)
10-116
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
Sectional views (N-N, AB-AB, AC-AC, AE-AE)
1: LS shuttle valve
5: Suction safety valve
2: Pressure compensation valve
6: Unload valve
3: Spool
7: Main relief valve
4: 2-stage suction safety valve
8: LS bypass plug
PC210-10M0, PC210LC-10M0
10-117
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT DIAGRAMS OF CONTROL VALVE AND NAMES OF VALVES
G0033599
1: Arm valve 10-118
2: Right travel valve PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
3: Swing valve
18: Check valve (for arm regeneration circuit)
4: Boom valve
19: Merge-divider EPC valve (for LS spool)
5: Left travel valve
20: Merge-divider EPC valve (for main spool)
6: Bucket valve
21: LS shuttle valve
7: Service valve
22: LS bypass plug
8: Arm valve spool (CURL/push)
23: LS select valve
9: Right travel valve spool (FORWARD/REVERSE)
24: Merge-divider valve
10: Swing valve spool (LEFT/RIGHT)
25: Arm quick return valve
11: Boom valve spool (LOWER/RAISE)
26: Arm hydraulic drift prevention valve (if equipped)
12: Left travel valve spool (FORWARD/REVERSE)
27: Self-pressure reducing valve
13: Bucket valve spool (dozing/dump)
28: Travel junction valve
14: Service spool
29: Variable back pressure valve
15: Pressure compensation valve
30: Variable back pressure solenoid valve
16: Suction valve
31: Cooler check valve
17: Check valve (for boom regeneration circuit)
32: Boom hydraulic drift prevention valve
33: Main relief valve (boom, left travel, bucket, and attachment) Set pressure: 35.4 MPa {360.5 kg/cm2} Digging force up: 38.0 MPa {387 kg/cm2} 34: Main relief valve (arm, right travel, and swing) Set pressure: 35.4 MPa {360.5 kg/cm2} Digging force up: 38.0 MPa {387 kg/cm2} 35: Unload valve (boom, left travel, bucket, and attachment) Cracking pressure: 2.5 MPa {26 kg/cm2} 36: Unload valve (arm, right travel, and swing) Cracking pressure: 2.5 MPa {26 kg/cm2} 37: Suction safety valve Set pressure: 24.5 MPa {250 kg/cm2} 38: Suction safety valve Set pressure: 38.9 MPa {397 kg/cm2} 39: Suction safety valve Set pressure: 31.4 MPa {320 kg/cm2} 40: 2-stage suction safety valve 1st stage set pressure: 24.5 MPa {250 kg/cm2} 2nd stage set pressure: 20.1 MPa {205 kg/cm2} 41: Safety valve for hydraulic drift prevention valve Set pressure: 38.9 MPa {397 kg/cm2}
PRESSURE COMPENSATION VALVE OF CONTROL VALVE FUNCTION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE The pressure compensation valve is provided for each actuator. It is installed between the spool of the control valve and the actuator. When the load applied to one of actuators increases during combined operations, the large quantity of oil from the pump tries to flow into a low-load actuator. PC210-10M0, PC210LC-10M0
10-119
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
The pressure compensation valve compensates the flow rate to a high-load actuator by reducing the flow rate to the low-load actuator. The pressure compensation valve prevents the backflow of hydraulic oil as a load check valve.
OPERATION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE When load pressure is lower than that of other work equipment during combined operation, or when compensated
F
5 D
C
From LS shuttle valve for other work equipment
2
3 B
E
Upstream pressure of pressure compensation valve (for spool meter-in downstream)
4
A Spool meter-in upstream pressure
1
1: Main pump
4: Spring
2: Valve
5: LS shuttle valve
3: Shuttle valve When the load pressure of the port (C) is lower than the load pressure of the other work equipment, the maximum LS pressure of the other work equipment flows from the port (F) to the port (D) via the LS shuttle valve (5). The ball in the shuttle valve of the pressure compensation valve is pushed to the right. The spring chamber (E) and the port (D) are connected. By the LS pressure from the port (D), the shuttle valve (3) moves to the right. The shuttle valve (3) pushes the valve (2) and moves for the port (B) and the port (C) to be closed in the right direction by the LS pressure from the port (D). The spool meter-in downstream pressure of the port (B) is controlled by the LS pressure of the port (D), and is equal to the maximum LS pressure of the other work equipment. The spool meter-in upstream pressure of the port (A) is a pump pressure, and the spool meter-in differential pressure = upstream pressure (port (A))-downstream pressure (port (B)) is equal in all sections. The pump flow rate is divided to the ratio of the meter in opening area.
10-120
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When load pressure is higher than other actuator in combined operation, in single operation, or at maximum load pressure
5 D
C
2
3 B E 4
1
A
If load pressure of the port (C) is higher than the LS pressure of the port (D), the ball in the shuttle valve (3) of the pressure compensation valve moves to the left. The spring chamber (E) and the port (C) are connected. The pressure oil from the pump passes through the port (A) to the port (B), overcomes the force of the spring (4), and the valve (2) pushes the shuttle valve (3) to the left. The opening of the port (B) and the port (C) expands
PC210-10M0, PC210LC-10M0
10-121
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE FUNCTION OF SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE Shuttle valve From LS circuit Orifice
To Actuator
A1
A2 Spool meter-in downstream pressure
G0000073
The dividing condition of the pump flow rate varies with the surface area ratio of (A1) and (A2) for the pressure compensation valve. The surface area ratio is equal to (A2)/(A1). •
When the surface area ratio is 1, the spool meter-in downstream pressure is equal to the maximum load pressure, and the pump flow rate is divided corresponding with the opening area ratio of the main spool.
•
When the surface area ratio is 1 or above, the spool meter-in downstream pressure is higher than the maximum load pressure, and the pump flow is divided at the rate lower than the surface area ratio of the main spool.
•
When the surface area ratio is 1 or below, the spool meter-in downstream pressure is lower than the maximum load pressure, and the pump flow rate is divided at the rate larger than the surface area ratio of the main spool.
10-122
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF CONTROL VALVE OPERATION OF SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF CONTROL VALVE When holding pressure in port (A) exceeds LS pressure in port (C)
2
A
3
C
B 4
Z
Z
1 1: Main pump
3: Shuttle valve
2: Valve
4: Pressure compensation valve
The ball in the shuttle valve is pushed to the right by the holding pressure in the port (A), and the circuit between the port (A) and the port (C) is blocked. The holding pressure in the port (A) is transmitted to the spring chamber (B), and the shuttle valve (3) pushes the valve (2) to the left.
INTRODUCTION OF LS PRESSURE IN CONTROL VALVE LS Abbreviation for Load Sensing
PC210-10M0, PC210LC-10M0
10-123
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
FUNCTION OF INTRODUCTION OF LS PRESSURE IN CONTROL VALVE
7
B
4
3
Upstream pressure of pressure compensation valve (Spool metet-in downstream pressure) A d
6
a
5
c
2
1 G0000071
1: Main pump
5: Check valve
2: Main spool
6: LS circuit
3: Pressure compensation valve
7: LS shuttle valve
4: Valve The pressurized oil in the port (A) (upstream pressure of the pressure compensation valve) flows into the port (c) through the introduction hole (a) inside the main spool (2). The pressurized oil pushes and opens the check valve (5) to flow from the derivation hole (d) to the port (B). Some of the pressurized oil through the introduction hole (a) is transmitted as LS pressure to the LS shuttle valve (7) through the LS circuit (6). The LS pressure is used as the source pressure for closing the unload valve operating the control lever, as the operating pressure when the pressure compensation valve is compensated, and as the pressure for controlling the pump.
LS BYPASS PLUG OF CONTROL VALVE LS Abbreviation for Load Sensing
10-124
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
FUNCTION OF LS BYPASS PLUG OF CONTROL VALVE D
E
$
F
*
1: Main pump
4: LS shuttle valve
2: Main spool
5: LS bypass plug
3: Pressure compensation valve
6: LS circuit
The LS bypass plug is installed on the LS circuit (6) and connected to the drain circuit through the path (a) and the orifice (b). The LS bypass plug releases the remaining pressure in the LS circuit (6). The LS bypass plug prevents the rapid change in the oil pressure by slowing down the speed of the rise in the LS pressure.
BOOM REGENERATION CIRCUIT OF CONTROL VALVE FUNCTION OF BOOM REGENERATION CIRCUIT OF CONTROL VALVE The boom regeneration circuit is a circuit that merges some of the returning flow rate on the bottom in the circuit on the head at boom LOWER. When the flow rate on the head increases, the flow rate transmitted from the pump is reduced to restrict energy consumption.
PC210-10M0, PC210LC-10M0
10-125
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF BOOM REGENERATION CIRCUIT OF CONTROL VALVE When the cylinder head pressure is lower than the bottom pressure (when hydraulic drift, etc.)
RAISE
LOWER
E A
7
3
3
2
5
B
6
C
1
D
4 G0000047
1: Main pump
5: Suction valve
2: Boom valve spool
6: Check valve
3: Pressure compensation valve
7: LS shuttle valve
4: Suction safety valve When the head pressure (E) in the boom cylinder is lower than the bottom pressure (A), some of the pressurized oil (A) from the cylinder bottom flows to the drain circuit (B) from the notch of the boom valve spool (2). The remaining oil flows to the regeneration circuit (C), pushes and opens the check valve (6), and flows to the circuit (E) on the head through (D). The flow rate from the main pump (1) is merged in the circuit (E) on the head.
10-126
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When the cylinder head pressure is higher than the bottom pressure (when digging, etc.)
RAISE LOWER
A
E
6
C G0000048
When the head pressure (E) in the boom cylinder is higher than the bottom pressure (A), the check valve (6) is closed by the pressure (E) on the head and by the spring inside the check valve (6). The circuit (C) where the oil flows from the head to the bottom is blocked.
ARM REGENERATION CIRCUIT OF CONTROL VALVE FUNCTION OF ARM REGENERATION CIRCUIT OF CONTROL VALVE The arm regeneration circuit is a circuit that merges some of the returning flow rate on the head in the circuit on the bottom at arm IN. When the flow rate on the bottom increases, the cylinder speed increases.
PC210-10M0, PC210LC-10M0
10-127
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF ARM REGENERATION CIRCUIT OF CONTROL VALVE When cylinder head pressure is higher than bottom pressure (When arm IN operation is performed)
IN OUT E A
7
3
3
2
5
B
6
C
1
D
4 G0000049
1: Main pump
5: Suction valve
2: Arm valve spool
6: Check valve
3: Pressure compensation valve
7: LS shuttle valve
4: Suction safety valve When the head pressure (A) in the arm cylinder is higher than the bottom pressure (E), some of the pressurized oil (A) from the cylinder head flows to the drain circuit (B) from the notch of the arm valve spool (2). The remaining oil flows to the regeneration circuit (C), pushes and opens the check valve (6), and flows to the circuit (E) on the head through (D). The flow rate from the main pump (1) is merged in the circuit (E), and cylinder speed increases.
10-128
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When cylinder head pressure is lower than bottom pressure
IN OUT E A
6
C G0000050
When the head pressure (A) in the arm cylinder is lower than the bottom pressure (E), the check valve (6) is closed by the pressure (E) on the bottom and by the spring inside the check valve (6). The circuit (C) where the oil flows from the head to the bottom is blocked.
MERGE-DIVIDER VALVE OF CONTROL VALVE FUNCTION OF MERGE-DIVIDER VALVE OF CONTROL VALVE The merge-divider valve is a valve that merges or divides the pressurized oil discharged from 2 (front and rear) pumps. When merged, the pressurized oil discharged from the 2 pumps flows into all control valves. When divided, the pressurized oil discharged from each pump flows into its corresponding control valve. The merge-divider valve also merges or divides the LS circuits of the front and rear pumps. The pressurized oil supplied from the mergedivider EPC valve is used to merge or divide the pressurized oil from the front and rear pumps.
PC210-10M0, PC210LC-10M0
10-129
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF MERGE-DIVIDER VALVE OF CONTROL VALVE When merge-divider valve selector signals (IS1) and (IS2) are OFF (when merged) Connected
IS2
Connected Front pump side
5
8
OFF
IS1
OFF
Rear pump side
A
B
C
D
3
4 7
6 10
9
1
2 E
F
To control valve To control valve
P1
(Rear pump)
P2
(Front pump) G0000147
1: Main spool
6: LS circuit (rear pump side)
2: Spring
7: LS circuit (rear pump side)
3: LS spool
8: LS circuit (front pump side)
4: Spring
9: Merge-divider EPC valve (to select the main spool)
5: LS circuit (front pump side)
10: Merge-divider EPC valve (to select the LS spool)
When there is no selecting signal (IS1) and (IS2) of the merge-divider valve, the output pressure from the merge-divider EPC valves (9) and (10) is zero. The main spool (1) is pressed to the right by the spring (2) and the ports (E) and (F) are connected. The pressure oils (P1) and (P2) discharged from the 2 pumps are joined by the ports (E) and (F) and sent to each demanding control valve. The LS spool (3) is pressed to the right by the spring (4) and the ports (A) and (D) are connected, and ports (B) and (C) are connected. The LS circuits of the front pump side and the rear pump side are connected. The LS pressure which flows from the spool of each control valve to the LS circuit flows to all pressure compensation valves.
10-130
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When merge-divider valve selector signals (IS1) and (IS2) are ON (when divided)
IS2
Connected
8
ON
Rear pump side
Front pump side
5
IS1
ON
A
B
C
D
3
4 7
6 10
9
1
2 E
F
To control valve To control valve
P1
(Rear pump)
P2
(Front pump) G0000148
When there is selecting signal (IS1) and (IS2) of the merge-divider valve, the pressure oil from merge-divider EPC valves (9) and (10) are sent to the spools (1) and (3). The main spool (1) is moved to the left by the pressure oil from the merge-divider EPC valve (9), and the port (E) and (F) are blocked. The pressure oils (P1) and (P2) discharged from the 2 pumps flow to each demanding control valve. •
P1 pressure (rear pup side): To bucket, left travel, boom
•
P2 pressure (front pump side): To swing, right travel, arm
The LS spool (3) moves to the left by pressure oil from the merge-divider EPC valve (10), the ports (a) and (C) are connected, and others are separated (ports (B) and (D) are connected inside the control valve). The LS circuit on the front pump side and rear pump side is blocked. The LS pressure led from the spool of each control valve to the LS circuit flows to the pressure compensation valve of the front pump side and the rear pump side.
LS SEPARATION VALVE OF CONTROL VALVE LS Abbreviation for Load Sensing
PC210-10M0, PC210LC-10M0
10-131
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
FUNCTION OF LS SEPARATION VALVE OF CONTROL VALVE The figure shows the simultaneous operation of boom RAISE, swing, and right travel.
4 BP
3
1
2 B
A
uONv
5 P1 6 P2
8
7
P3 9
G0000145
1: Valve
6: Right travel valve spool
2: Spring
7: Arm valve spool
3: Piston
8: LS shuttle valve
4: Piston
9: LS circuit
5: Swing valve spool The LS separation valve is a valve that prevents the high LS pressure caused by the swing driving from flowing into the LS circuit of work equipment at the combined operations of swing and boom RAISE. If the high LS pressure flows into the LS circuit without being processed, pump discharged pressure increases. Then, the PC valve tries to reduce pump discharged volume. The LS separation valve prevents a reduction in the pump discharged volume by separating the LS pressure caused by the swing driving so that the lifting speed of the boom is not late. The LS separation valve operates when the pilot pressure of boom RAISE is supplied.
10-132
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
OPERATION OF LS SEPARATION VALVE OF CONTROL VALVE When boom RAISE operation is not performed The pilot pressure of boom RAISE (BP) is not supplied to the LS separation valve. The piston (3) is pushed to the left by the force of the spring (2). At swing operation, the swing LS pressure (P1) through the swing spool flows into the port (A). The swing LS pressure (P1) pushes the valve (1) to the left, and the port (A) is connected to the port (B). The swing LS pressure (P1) flows from the port (A) to the LS shuttle valve through the port (B).
4
3
2
B
1
BP “OFF”
A
P1
To LS shuttle valve
4
3
2
B
1
A
P1
BP “ON”
To LS shuttle valve G0000146
When the combined operations of the swing and the boom RAISE are operated The pilot pressure (BP) is supplied from the boom RAISE PPC circuit. The pilot pressure (BP) moves the piston (3) to the right against the force of the spring (2). The valve (1) moves to the right to block the port (A) and the port (B). The swing LS pressure (P1) does not flow into the LS shuttle valve. Though the swing LS pressure (P1) increases, it does not affect other LS circuits.
SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE FUNCTION OF SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE The self-pressure reducing valve is a valve that reduces the discharged pressure of the main pump to output it as constant pressure. Reduced pressurized oil is supplied as the control pressure of the PPC valve, the solenoid valve, and the EPC valve, etc.
PC210-10M0, PC210LC-10M0
10-133
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE P2: From the front pump PR: To the solenoid valve, PPC valve, and EPC valve PP: To the control valve A2: To the merge-divider valve TS: To the drain circuit
When the engine is stopped Since the poppet (4) is pushed to the seat by the spring (3), the circuit between the port (PR) and the port (TS) is closed. A2
Since the spool (6) is pushed to the left by the spring (5), the circuit between the port (P2) and the port (TS) is closed.
Merge-divider valve
1
2
Since the valve (1) is pushed to the left by the spring (2), the circuit between the port (P2) and the port (A2) is closed. P2
TS
PR
6
5
4
3
PPC valve G0033520
10-134
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When load pressure (A2) is lower than self-pressure reducing valve output pressure (PR) The spring (2) and the pressure (PR) apply a force to the valve (1) in the direction where the circuit between the port (P2) and the port (A2) is closed. When the pressure in the port (P2) increases, the valve (1) is balanced based on the formula (Pressure P2 x φd area = Force of the spring (2) + Pressure PR x φd area). The valve (1) adjusts the opening between the port (P2) and the port (A2) so that the pressure (P2) is kept to the constant pressure higher than or equal to the pressure (PR). When the pressure (PR) reaches the set pressure or above, the poppet (4) opens. The pressurized oil flows from the port (PR) to the orifice (a) in the spool (6), and then flows into the drain port (TS) through the opening of the poppet (4). The differential pressure is made between the upstream side and downstream side of the orifice (a), and the spool (6) moves to the direction where the opening between the port (P2) and the port (PR) is closed. The pressure (P2) is reduced and kept constant according to the area of the opening at this time, and it is supplied as the pressure (PR).
A2
Merge-divider valve
d
1
2
P2
TS
PR
6
a
5
4
PPC valve G0033521
When load pressure (A2) is higher than self-pressure reducing valve output pressure (PR) The load pressure (A2) is increased by the operation of digging, etc., and the pressure (P2) also increases. The valve (1) moves to the right based on the formula (Pressure P2 x φd area > Force of the spring (2) + Pressure PR x φd area). The opening between the port (P2) and the port (A2) reaches its peak. When the pressure (PR) reaches the set pressure or above, the poppet (4) opens. The pressurized oil flows from the port (PR) to the orifice (a) in the spool (6), and then flows into the drain port (TS) through the opening of the poppet (4). The differential pressure is made between the upstream side and downstream side of the orifice (a), and the spool (6) moves in the direction where the opening between the port (P2) and the port (PR) is closed. The pressure (P2) is reduced and kept constant according to the area of the opening at this time, and it is supplied as the pressure (PR).
A2
Merge-divider valve
d
1
2
P2
TS
PR
a
6
5
4
PPC valve G0033522
PC210-10M0, PC210LC-10M0
10-135
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
TRAVEL JUNCTION VALVE OF CONTROL VALVE FUNCTION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE The travel junction valve is a valve that connects the right and left travel paths when the travel lever is in the straight travel position. The equal oil flow is supplied to the right and left travel motors to keep straight travel performance. The travel junction valve blocks the right and left travel paths when the travel lever is in the steering operation position. Independent oil flows are supplied to the right and left travel motors to keep steering performance. The travel paths are connected or blocked by the pilot pressure from the travel junction solenoid valve.
10-136
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
OPERATION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE When pilot pressure (PST) is cut off (travel circuits are connected to each other)
Pilot pressure
L.H. travel valve
PTL
Controller
Travel junction solenoid valve
㹋 PST PTR
1
2
Pilot pressure
R.H. travel valve
G0000108
When the pilot pressure (PST) from the travel junction solenoid valve is not output, the spool (2) of the travel junction valve is pushed to the left by the reaction force of the spring (1). The circuit between the port (PTL) and the port (PTR) is connected.
PC210-10M0, PC210LC-10M0
10-137
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
When there is a difference between the flow rates supplied to the right and left travel motors, the flow rate corresponding to the differential pressure is compensated from the port at higher pressure to the port at lower pressure through the travel junction valve. The equal oil flow is supplied to the right and left travel motors.
When pilot pressure (PST) is supplied (travel circuits independent from each other)
Pilot pressure
L.H. travel valve
PTL
Controller
Travel junction solenoid valve
M PST PTR
2 1
Pilot pressure
R.H. travel valve G0000055
10-138
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When the pilot pressure (PST) from the travel junction solenoid valve is output, the spool (2) of the travel junction valve pushes and compresses the spring (1), and moves to the right. The circuit between the port (PTL) and the port (PTR) is blocked. Independent oil flows are supplied to the right and left travel motors.
TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE FUNCTION OF TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE The function of the travel PPC shuttle valve of the control valve is a function that limits the spool stroke of the control valve of work equipment to get better the controllability of the work equipment that is climbing a steep slope. The function acts on the operation below. •
Boom RAISE
•
Arm IN
•
Arm OUT
•
Bucket CURL
•
Bucket DUMP
The strokes of spools of booms, arms, and buckets are limited by the pilot pressure from the travel PPC valve. The pilot pressure flows into the circuit inside the control valve.
PC210-10M0, PC210LC-10M0
10-139
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE When travel lever is in NEUTRAL
5
3
4
6
R.H. travel valve Travel PPC valve
st0
Boom RAISE PPC pressure
a
2
1
Boom valve G0000056
The pressurized oil in the signal chamber (a) (for limiting spool stroke) flows through the orifices (5) and (6) of the pistons (3) and (4) in the spring case (travel), and flows into the tank through the travel PPC valve. At boom RAISE (arm IN, arm OUT, bucket CURL, or bucket DUMP) operation, the spool (1) moves to the left until it hits the end surface of the spring case (2) (stroke quantity: st0).
10-140
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When travel lever is operated
5
7
3
4
6
R.H. travel REVERSE PPC valve
R.H. travel valve
Travel PPC valve
st2 st1
a 8 2
1
Boom valve G0000057
At right travel REVERSE (or FORWARD) operation, the pilot pressure from the travel PPC valve pushes the spool (7) to the left (or right). When the spool (7) pushes the piston (3), the orifice (5) is closed, and the drain circuits of the signal chamber (a) and the travel PPC valve are blocked. The pilot pressure from the travel PPC valve flows into the signal chamber (a) through the orifice (6) of the piston (4), and acts on the left end surface of the piston (8). The piston (8) is pushed to the right. At boom RAISE (arm IN, arm OUT, bucket CURL, or bucket DUMP) operation, the spool (1) moves to the left. The maximum stroke quantity of the spool (1) is limited as much as the piston (8) moved to the right (st2) (stroke quantity: st1 = st0 - st2). The flow rate supplied to the cylinder is limited to prevent drastically late travel speed.
PC210-10M0, PC210LC-10M0
10-141
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
SWING STROKE CONTROL VALVE OF CONTROL VALVE FUNCTION OF SWING STROKE CONTROL VALVE OF CONTROL VALVE The function of the swing stroke control valve is a function that controls the flow rate to the swing motor by limiting the spool stroke of the swing operation valve in E adjustment mode. It keeps the speed of work equipment in combined operations. The swing spool stroke is limited by the output pressure from the swing stroke control solenoid valve.
OPRATION OF SWING STROKE CONTROL VALVE OF CONTROL VALVE When swing stroke limit solenoid valve is OFF
2
1
St0
Swing LEFT PPC pressure Controller
a Swing spool stroke control solenoid valve
3
a
4
When the controller does not supply output signals to the swing stroke control solenoid valve, the output pressure from the swing stroke control solenoid valve is connected to the tank. The output port of the swing stroke control solenoid valve is connected to the signal chamber (a) of the swing valve (for limiting spool stroke). Thus, the pressurized oil in the signal chamber (a) flows into the tank through the swing stroke control solenoid valve. When swing left PPC pressure is input without the pilot pressure (Psw) output from the swing stroke control solenoid valve, the swing spool (1) moves until it hits the end surface of the spring case (2) (stroke quantity: St0). The pistons (3) and (4) do not control the stroke of the swing spool (1).
10-142
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When swing stroke limit solenoid valve is ON (E mode adjustment function)
St1 St2
2
1
Swing LEFT PPC pressure Controller
a
3
4
a
Swing spool stroke control solenoid valve
When the pilot pressure (Psw) is output from the swing stroke control solenoid valve, the pilot pressure (Psw) is input from the swing spring case (2) to the signal chamber (a) through the valve to move the swing stroke control pistons (3) and (4). The piston (3) moves to the right, and the piston (4) moves to the left. At swing left operation at this time, the spool (1) moves to the left by the swing left PPC pressure. The maximum stroke quantity of the spool (1) is limited as much as the piston (3) moved to the right (St2) (St1 = St0 - St2). The flow rate supplied to the swing motor is limited as much as the stroke quantity of the spool was limited. Thus, the flow rate to other work equipment is kept to prevent the late travel speed of work equipment. (This also applies to swing right operation.)
BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE FUNCTION OF BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE The boom hydraulic drift prevention valve is a valve that prevents the lowering of work equipment, which is caused by the pressurized oil in the cylinder bottom of the boom leaked from the spool of the control valve when the work equipment control lever is not used for boom operation.
PC210-10M0, PC210LC-10M0
10-143
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE When raising boom
Boom cylinder Boom drift prevention valve
4
5
d1 d2
S
1
Boom RAISE PPC pressure
At boom RAISE, the pressurized oil from the control valve acts in the left direction to the area (S) whose outside diameter is the diameter (d1) of the poppet (5) and inside diameter is the seat diameter (d2). This force compresses the spring (4) and moves the poppet (5) to the left. The pressurized oil from the control valve flows to the cylinder bottom through the opening of the poppet (5).
10-144
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When boom is in NEUTRAL
Boom cylinder Boom drift prevention valve
2
4
5
d1
d2
S
T
When the boom is in the NEUTRAL position, the pilot piston (2) closes. The pressurized oil in the poppet (5) does not flow into the drain port (T). The holding pressure in the cylinder bottom acts in the right direction to the area (S) formed by the difference between the outside diameter (d1) of the poppet (5) and the seat diameter (d2). This force and the reaction force of the spring (4) move the poppet (5) to the right. The circuit from the cylinder bottom to the control valve is blocked. The pressure in the cylinder bottom is kept.
PC210-10M0, PC210LC-10M0
10-145
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
When lowering boom
Boom cylinder Boom drift prevention valve
c
2
b
5
B
A
T Boom LOWER PPC pressure
At boom LOWER, the pilot pressure from the PPC valve pushes the pilot piston (2). The pressurized oil in the cylinder bottom flows from the orifice (c) to the drain port (T) through the orifice (a) and the chamber (b). The chamber (b) is connected to the drain port (T), and the pressure in the chamber (b) decreases. When the pressure in the chamber (b) decreases below the pressure in the port (B), the poppet (5) opens. The pressurized oil from the port (B) flows into the port (A) through the opening of the poppet (5).
10-146
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
SAFETY VALVE FOR HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE OPERATION OF SAFETY VALVE FOR HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE When abnormally high pressure is generated
B
1a
Boom valve
2
1b
Arm valve
PC210-10M0, PC210LC-10M0
10-147
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
When the boom is not operated, if abnormally high pressure occurs on the boom side of the cylinder because of an external force, the pressurized oil in the port (B) pushes and opens the check valve (1a). The safety valve (2) releases the high pressure. When the arm hydraulic drift prevention valve (if equipped) is installed, the pressurized oil on the boom side of the boom cylinder or the pressurized oil on the head side of the arm cylinder, which is higher, pushes and opens the check valve (6) or (6A). The safety valve (3) releases the high pressure.
ARM QUICK RETURN VALVE OF CONTROL VALVE FUNCTION OF ARM QUICK RETURN VALVE OF CONTROL VALVE At arm OUT operation, a large quantity of oil is returned from the cylinder bottom. Some of the returned oil is directly discharged to the tank through an arm quick return valve. Because the total quantity of the returned oil does not flow through the control valve, pressure losses caused by oil pressure can be reduced. The arm quick return valve is installed on the bottom port of the arm control valve.
OPERATION OF ARM QUICK RETURN VALVE OF CONTROL VALVE When the arm OUT operation is performed T
T
A
2
a
B
T
b
c
1
A-A d2
A
A S2
d1
S1
Arm OUT PPC pressure
At arm OUT operation, the PPC pressure from the arm OUT pushes the pilot piston (1). The pressurized oil in the chamber (b) inside the valve flows into the drain port (T) through the orifice (c). The pressurized oil on the cylinder bottom side flows from the orifice (c) to the drain port (T) through the orifice (a) and the chamber (b). The chamber (b) is connected to the drain port (T), and the pressure in the chamber (b) decreases. The 10-148
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
pressure in the chamber (b) acts in the left direction to the area (S1) of the valve (2). The reaction force of the spring also acts in the left direction to the valve (2). The pressure in the port (A) acts in the right direction to the area (S2) of the valve (2). When the pressure in the chamber (b) decreases below the pressure in the port (A), the force in the right direction to the valve (2) gets larger than the force in the left direction. The valve (2) moves to the right. The pressurized oil flows from the port (A) to the port (B). Some of the pressurized oil on the cylinder bottom side is directly discharged from the port (B) to the tank.
When arm is in NEUTRAL 7
7
$
D
%
7
E
F
$$
G
$
G
$
6
6
7
*
When the Arm OUT position is returned to the NEUTRAL position, the PPC pressure is blocked. The pilot piston (1) closes, and the pressurized oil does not flow from the orifice (c). The holding pressure on the bottom side of the arm cylinder transmitted from the orifice (a) to the chamber (b) is kept by the pilot piston (1) and acts in the left direction to the area (S1) of the valve (2). The same quantity of holding pressure acts in the right direction to the area (S2) of the valve (2). The reaction force of the spring (3) acts in the left direction to the valve (2). Because the force in the left direction to the valve (2) gets larger than the force in the right direction, the valve (2) moves to the left. The port (A) and the port (B) are blocked.
VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE FUNCTION OF VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE The variable back pressure valve is a valve that applies back pressure to the drain circuit of the control valve in order to prevent cavitation which is caused by the negative pressure of each actuator (motor, cylinder, etc.). The back pressure is decreased to reduce output losses for operation other than travel operation and swing operation.
PC210-10M0, PC210LC-10M0
10-149
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE When the engine is stopped No pressurized oil is supplied from the main pump to the selfpressure reducing valve (1). No pressurized oil is supplied from the variable back pressure solenoid valve (3) to the spring chamber (C) of the variable back pressure valve (4). The valve (6) is pushed to the right by the reaction force of the spring (5). The drain circuit (A) of the control valve is connected to the port (T) through the orifice (b) of the valve (6). %
65 6 24
+5
D
#
/ )
When engine is in operation (swing or travel operation) The pressurized oil (PR) from the self-pressure reducing valve (1) is supplied to the variable back pressure solenoid valve (3). At swing or travel operation, the drive signal (IS3) to the variable back pressure solenoid valve (3) is OFF. The pressurized oil (PR) flows to the spring chamber (C) of the variable back pressure valve (4) through the variable back pressure solenoid valve (3). The pressurized oil (PR) in the spring chamber (C) acts on the left end surface (area of Φd) of the valve (6) and pushes the valve (6) to the right together with the reaction force of the spring (5). The pressure (PA) in the drain circuit (A) of the control valve acts on the right end surface (area of Φd1) of the valve (6) and pushes the valve (6) to the left. The valve (6) stops at the position where the force in the left direction is balanced with the force in the right direction. At this time, the back pressure (PA) is represented in the formula below. PA = (Area of ϕd x Pressure (PR) + Reaction force of the spring (5))/Area of ϕd1 The flow rate from the drain circuit (A) of the control valve to the port (T) is adjusted. The back pressure (PA) is adjusted to the set pressure of the variable back pressure valve (4).
G &
3$
76 7 ,6
35
$
G
0 *
10-150
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
COMPONENT PARTS OF HYDRAULIC SYSTEM
When engine is in operation (other than swing and travel operations) The pressurized oil (PR) from the self-pressure reducing valve (1) is supplied to the variable back pressure solenoid valve (3). At operation other than swing or travel operation, the drive signal (IS3) to the variable back pressure solenoid valve (3) is ON. The pressurized oil (PR) transmitted to the spring chamber (C) of the variable back pressure valve (4) is returned to the tank through the variable back pressure solenoid valve (3). The reaction force of the spring (5) pushes the valve (6) to the right. The pressure (PA) in the drain circuit (A) of the control valve acts on the right end surface (area of Φd1) of the valve (6) and pushes the valve (6) to the left. The valve (6) stops at the position where the force in the left direction is balanced with the force in the right direction. At this time, the back pressure (PA) is represented in the formula below.
%
2#
PA = Reaction force of the spring (5)/Area of Φd1 The flow rate from the drain circuit (A) of the control valve to the port (T) is adjusted. The back pressure (PA) is adjusted to the set pressure of the variable back pressure valve (4).
65 6 +5
24
#
F
/ )
MAIN RELIEF VALVE OF CONTROL VALVE FUNCTION OF MAIN RELIEF VALVE OF CONTROL VALVE
1: Spring
2: Poppet
The main relief valve is a valve that can change set pressure at 2 stages. The pilot pressure from the 2-stage relief solenoid valve changes the set pressure. When the pilot pressure is connected to the tank, the set pressure depends on the installation load of the spring (1). When the pilot pressure is applied, the set pressure is obtained by the addition of the force of the spring (1) to the force of the pilot pressure (P1) applied to the diameter of receiving pressure (d1).
PC210-10M0, PC210LC-10M0
10-151
COMPONENT PARTS OF HYDRAULIC SYSTEM
10 STRUCTURE AND FUNCTION
2-STAGE SUCTION SAFETY VALVE OF CONTROL VALVE FUNCTION OF 2-STAGE SUCTION SAFETY VALVE OF CONTROL VALVE Port (B) of service valve
1: Spring
3: Spring
2: Piston
4: Holder
The 2-stage suction safety valve is a valve that can change set pressure at 2 stages. The pilot pressure from the attachment selector solenoid valve changes the set pressure. When the pilot pressure is connected to the hydraulic tank, the set pressure depends on the installation load of the spring (1). When the pilot pressure is applied, the installation load of the spring (1) decreases, and the set pressure decreases.
OPERATION OF 2-STAGE SUCTION SAFETY VALVE OF CONTROL VALVE When pilot pressure (P) is connected to tank (high pressure setting) Because the pilot pressure from the attachment selector solenoid valve is connected to the tank, the piston (2) is pushed to the left by the reaction force of the spring (3). Thus, the installation load of the spring (1) reaches its peak, which results in high pressure set.
%
3
'
& *
When pilot pressure (P) is supplied (low pressure setting) The pilot pressure from the attachment selector solenoid valve is supplied to the part (A) through the path (B). The pilot pressure acts on the receiving pressure diameter (d1-d2) of the piston. The piston (2) is pushed against the spring (3) until it hits the holder (4). When the piston (2) moves, the installation load of the spring (1) decreases, which results in low pressure set. The pressurized oil caused by the stroke of the piston (2) is drained through the path (C) and the chamber (D).
10-152
#
$
2
F F &
% )
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
WORK EQUIPMENT SYSTEM LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM Chassis part
1: Bucket cylinder
3: Boom cylinder
2: Arm cylinder
PC210-10M0, PC210LC-10M0
10-153
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
4: Attachment circuit selector valve (for low pressure side) (*1)
10: Pressure sensor (front pump)
5: Accumulator (attachment circuit, for low pressure side) (*1)
12: Pressure sensor (rear pump)
6: Fuel supply pump 7: Engine controller 8: Accumulator (attachment circuit, for high pressure side) (*1)
11: Control valve 13: Accumulator (pilot circuit) 14: Rear pump PC-EPC valve 15: Front pump PC-EPC valve 16: Main pump
9: Solenoid valve *1: Machines ready for installation of attachment
10-154
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
Around cab and floor
1: Machine monitor
5: Left PPC valve (for arm and swing operation)
2: Right PPC valve (for boom and bucket operation)
6: Lock lever
3: Fuel control dial
7: PPC lock switch
4: One-touch power maximizing switch
8: Resistor for PC-EPC valve
12: Service pressure switch (*1)
9: Pump secondary drive switch
13: 1st-line attachment PPC valve (*1)
10: Swing parking brake cancel switch
14: EPC valve (for attachment flow adjustment) (*1)
11: Pump controller
15: Pressure sensor (right travel forward)
PC210-10M0, PC210LC-10M0
10-155
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
16: Travel PPC valve
18: Pressure sensor (left travel reverse)
17: Pressure sensor (left travel forward)
19: Pressure sensor (right travel reverse)
*1: Machines ready for installation of attachment
10-156
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ONE-TOUCH POWER MAXIMIZING SYSTEM
ONE-TOUCH POWER MAXIMIZING SYSTEM ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM
a: Front pump PC-EPC valve drive signal
f: Pressure sensor signal
b: Rear pump PC-EPC valve drive signal
g: One-touch power maximizing switch signal
c: GND (solenoid valve)
h: Throttle signal
d: CAN signal
i: Fuel supply pump control signal
e: 2-stage relief solenoid valve drive signal
j: Sensor signals
1: Battery disconnect switch
16: Pressure sensor (rear pump)
2: Battery
17: Front pump
3: Battery relay
17a: Servo piston
4: Fusible link
17b: LS valve
5: Fuse box
17c: PC valve
6: Resistor for PC-EPC valve
18: Rear pump
7: Pump controller
18a: Servo piston
8: Engine controller
18b: LS valve
9: Machine monitor
18c: PC valve
10: Pump secondary drive switch
19: Control valve
11: Fuel control dial
19a: Self-pressure reducing valve
12: Fuel supply pump
19b: Merge-divider valve
13: Sensors
19c: Travel junction valve
14: One-touch power maximizing switch
19d: Main relief valve
15: Pressure sensor (front pump)
20: Front pump PC-EPC valve
PC210-10M0, PC210LC-10M0
10-157
ONE-TOUCH POWER MAXIMIZING SYSTEM
21: Rear pump PC-EPC valve
10 STRUCTURE AND FUNCTION
23: L.H. PPC valve (for arm and swing operation)
22: 2-stage relief solenoid valve
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM The function of the one-touch power maximizing system is a function that temporarily increases the digging force of work equipment. It operates in P, E, ATT/P, or ATT/E mode. While the one-touch power maximizing switch (1) of the L.H. work equipment control lever is pressed, the function increases the maximum digging force of the work equipment by increasing the relief pressure of the main relief valve. When the switch is kept pressed, this function is canceled automatically in approximately 8.5 seconds. When the one-touch power maximizing system is operated, each element of the machine is set as follows: Each element Engine and pump combined control Relief pressure of the main relief valve
Setting Matching at rated horsepower point 34.8 MPa {355 kg/cm2} ↓ 37.2 MPa {380 kg/cm2}
Cut-off function of the main pump
10-158
Canceled
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
PPC LOCK SYSTEM
PPC LOCK SYSTEM PPC Abbreviation for Proportional Pressure Control
PPC LOCK SYSTEM DIAGRAM
a: PPC lock switch signal
e: PPC lock solenoid valve monitor signal
b: PPC lock switch signal
f: Pressure sensor signal
c: Lock lever automatic lock cancel switch signal
g: Pressure switch (service) signal
d: PPC lock relay drive signal 1: Battery disconnect switch
12: Control valve
2: Battery
12a: Merge-divider valve
3: Battery relay
12b: Self-pressure reducing valve
4: Fusible link
13: Main pump
5: Fuse box
14: Lock lever automatic lock cancel switch
6: Starting switch
15: L.H. PPC valve (for arm and swing operation)
7: Lock lever
16: Travel PPC valve
8: PPC lock switch
17: R.H. PPC valve (for boom and bucket operation)
9: Pump controller
18: 1st-line attachment PPC valve
10: PPC lock relay
19: Pressure sensor
11: PPC lock solenoid valve
20: Pressure switch (service)
PC210-10M0, PC210LC-10M0
10-159
PPC LOCK SYSTEM
10 STRUCTURE AND FUNCTION
FUNCTION OF PPC LOCK SYSTEM The function of the PPC lock system is a function that blocks the pilot pressure to each PPC valve for work equipment, travel, and attachment to prevent the operation of work equipment and the machine when the lock lever is in the lock position. When the lock lever is inclined to the lock position, the PPC lock switch is turned OFF, and the current to the PPC lock solenoid valve is blocked. The PPC lock solenoid valve blocks the pilot pressure to each PPC valve. Consequently, though the control lever or the pedal is operated, the work equipment and the machine do not operate.
10-160
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ATTACHMENT OIL FLOW ADJUSTER SYSTEM
ATTACHMENT OIL FLOW ADJUSTER SYSTEM ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM (Machines ready for installation of attachment)
a: Front pump PC-EPC valve drive signal
f: EPC valve (attachment flow adjustment) drive signal
b: Rear pump PC-EPC valve drive signal
g: Pressure switch (service) signal
c: GND (solenoid valve)
h: Throttle signal
d: CAN signal
i: Fuel supply pump control signal
e: Drive signal of the attachment circuit selector solenoid valve
j: Sensor signals
1: Battery disconnect switch
15: Front pump
2: Battery
15a: Servo piston
3: Battery relay
15b: LS valve
4: Fusible link
15c: PC valve
5: Fuse box
16: Rear pump
6: Resistor for PC-EPC valve
16a: Servo piston
7: Pump controller
16b: LS valve
8: Engine controller
16c: PC valve
9: Machine monitor
17: Control valve
10: Pump secondary drive switch
17a: Self-pressure reducing valve
11: Fuel control dial
17b: Merge-divider valve
12: Fuel supply pump
17c: Travel junction valve
13: Sensors
18: Attachment circuit selector solenoid valve
14: Pressure switch (service)
19: PPC lock solenoid valve
PC210-10M0, PC210LC-10M0
10-161
ATTACHMENT OIL FLOW ADJUSTER SYSTEM
10 STRUCTURE AND FUNCTION
20: EPC valve (attachment flow adjustment)
25: Attachment
21: Front pump PC-EPC valve
26: Accumulator (attachment circuit, for high pressure)
22: Rear pump PC-EPC valve
27: Accumulator (attachment circuit, for low pressure)
23: Attachment circuit selector valve (for high pressure)
28: 1st-line attachment PPC valve
24: Attachment circuit selector valve (for low pressure)
FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM The function of the oil flow adjuster system for attachment is a function that adjusts the flow rate supplied to the attachment when the attachment control pedal is pressed to full stroke. You can use the machine monitor to set the flow rate. For details, see the Operation and Maintenance Manual. Because the attachment circuit changes depending on each working mode, the operation of the attachment changes as shown in the table below.
10-162
Working mode
Operation of attachment
ATT/P, ATT/E
Double-acting
B
Single-acting
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
WORK EQUIPMENT SYSTEM WORK EQUIPMENT AND SWING PPC VALVE PPC Abbreviation for Proportional Pressure Control
FUNCTION OF WORK EQUIPMENT AND SWING PPC VALVE General view
A
C
C
A
B
Z
E
E
D
D
B
P
P2
P3
T
P4
P1
Z G0000217
L.H. work equipment control lever P: From the self-pressure reducing valve P1: To the control valve (arm OUT port) PC210-10M0, PC210LC-10M0
10-163
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
P2: To the control valve (arm IN port) P3: To the control valve (swing LEFT port) P4: To the control valve (swing RIGHT port) T: To the hydraulic tank
R.H. work equipment control lever P: From the self-pressure reducing valve P1: To the control valve (boom LOWER port) P2: To the control valve (boom RAISE port) P3: To the control valve (bucket CURL port) P4: To the control valve (bucket DUMP port) T: To the hydraulic tank
10-164
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
Sectional view
4 3 5 2 6 7
1 A-A
8
C-C
9
D-D
B-B E-E G0000218
1: Spool
6: Plate
2: Piston
7: Retainer
3: Disc
8: Body
4: Nut (for connecting lever)
9: Filter
5: Joint
PC210-10M0, PC210LC-10M0
10-165
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE When it is in neutral When the control lever in the NEUTRAL position, the pressureadjusting hole (f1) of the spool (6) is disconnected to the pump pressure chamber (PP) and connected to the drain chamber (D). Thus, the pressurized oil in the port (A) and the pressurized oil in the port (B) flow into the drain chamber (D).
D
f1
f2
T P
Self-pressure reducing valve
6 A
PP
P1
P2
Control valve
6
B
G0000036
During fine control (when control lever is operated) When the control lever is operated, the disc (1) pushes down the spool (6) through the piston (2), the retainer (3), and the metering spring (5). The pressure-adjusting hole (f1) is disconnected to the drain chamber (D) and connected to the pump pressure chamber (PP). The pilot pressure is supplied from the self-pressure reducing valve to the port (A) and pushes the spool of the control valve. The oil returning from the port (B) flows into the drain chamber (D) through the pressure-adjusting hole (f2). When the pressure in the port (P1) increases, the spool (6) is pushed back. The pressure-adjusting hole (f1) is connected to the drain chamber (D). The pressurized oil in the port (P1) flows into the drain chamber (D), and the pressure decreases. The spool (6) moves to the position where the force of the metering spring (5) is balanced with the pressure in the port (P1). The pressure-adjusting hole (f1) is positioned at the midpoint between the drain chamber (D) and the pump pressure chamber (PP). Thus, the metering spring (5) deflects and the pressure in the port (P1) increases in proportion to the stroke of the lever.
1 2 3
D
5 T
f1 P
Self-pressure reducing valve
6
f2
P1
PP
P2
7 A
Control valve
B
G0000037
10-166
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
During fine control (when control lever is released) When the control lever is returned to the original position, the spool (6) is pushed up by the force of the centering spring (4) and the pressure in the port (P1). The pressure-adjusting hole (f1) is connected to the drain chamber (D), and the pressure in the port (A) decreases. The spool of the control valve is returned back, and the pressurized oil flows from the drain chamber (D) to the port (B) through the pressure-adjusting hole (f2). If the pressure decreases too much, the force of the metering spring (5) pushes down the spool. The pressure-adjusting hole (f1) is connected to the pump pressure chamber (PP). The pressurized oil is supplied to the port (P1) until the pressure corresponding to the travel of the control lever is reached.
4 5
D
f1
T P
f2 Self-pressure reducing valve
6 A
P1
PP
P2
Control valve
B
G0000038
When the lever is stroked to the end When the control lever is inclined to full stroke, the disc (1) pushes down the spool (6) through the piston (2) and the retainer (3). The pressure-adjusting hole (f1) is disconnected to the drain chamber (D) and connected to the pump pressure chamber (PP). The pilot pressure is supplied from the selfpressure reducing valve to the port (A) and pushes the spool of the control valve. The oil returning from the port (B) flows into the drain chamber (D) through the pressure-adjusting hole (f2).
1 2
3 D f1
T P
f2 Self-pressure reducing valve
6 A
P1
PP
P2
Control valve
B
G0000039
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) (Machines ready for installation of attachment)
PPC Abbreviation for Proportional Pressure Control
EPC Abbreviation for Electromagnetic Proportional Control
PC210-10M0, PC210LC-10M0
10-167
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
STRUCTURE OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) General view and sectional view
A
7
P
A
T
P2
P1 3
2
4 5
1 A-A
6 G0000125
P: From the self-pressure reducing valve 10-168
P1: To the control valve (service valve 1 port) PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
P2: To the control valve (service valve 1 port)
T: To the hydraulic tank
1: Spool
5: Retainer
2: Piston
6: Body
3: Lever
7: EPC valve
4: Plate
ATTACHMENT OIL FLOW ADJUSTER EPC VALVE (Machines ready for installation of attachment)
EPC Abbreviation for Electromagnetic Proportional Control
PC210-10M0, PC210LC-10M0
10-169
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
STRUCTURE OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE General view and sectional view
A
A
7
P
6
5
4
A-A
3
C
T
2
1 G0000278
P: From the self-pressure reducing valve
T: To the hydraulic tank
C: To the PPC valve (R.H. attachment) 1: Body
5: Plunger
2: Spool
6: Push pin
3: Spring
7: Connector
4: Coil
10-170
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE
Output pressure (P)
When the signal current (i) from the controller is received, the EPC output pressure in proportion to the magnitude of current is generated.
Current (i) G0000195
OPERATION OF ATTACHMENT OIL FLOW ADJUSTER EPC VALVE When signal current does not flow (coil de-energized) When the signal current from the controller does not flow into the EPC valve, the coil (4) is de-energized. The spool (2) is pushed to the right by the spring (3). The pressurized oil from the self-pressure reducing valve is blocked. The pressurized oil from the control valve flows into the hydraulic tank through the port (C) and the port (T).
Control valve
3 C
T
4
P
2
Self pressure reducing valve
G0033702
When signal current is minute (coil is energized) >
PC210-10M0, PC210LC-10M0
10-171
WORK EQUIPMENT SYSTEM
When the minute signal current flows from the controller to the EPC valve, the coil (4) is energized, and the thrust force to the left is generated in the plunger (5). The push pin (3) pushes the spool (1) to the left, and the port (P) is connected to the port (C). Thus, the pressurized oil flows from the self-pressure reducing valve to the control valve. When the pressure in the port (C) increases, the force acting on the surface (a) of the spool (2) and the reaction force of the spring (3) become larger than the thrust force of the plunger (5). Then, the spool (2) is pushed to the right. Thus, the pressurized oil from the self-pressure reducing valve is blocked. The spool (1) moves so that the pressure in the port (C) and the reaction force of the spring (3) are balanced with the thrust force of the plunger (5). The circuit pressure between the EPC valve and the control valve is controlled in proportion to the quantity of signal current.
10 STRUCTURE AND FUNCTION
Control valve
3
a
C
T
5 4
6
P
2
Self pressure reducing valve
G0033703
When signal current is maximum (coil is energized) When the signal current is at the maximum, the thrust force of the plunger (5) reaches its peak in proportion to the current. The spool (1) is pushed to the left by the push pin (3), and the port (P) is connected to the port (C). The circuit pressure between the EPC valve and the control valve reaches its peak.
Control valve
C
T
5 4
6
P
2
Self pressure reducing valve
G0033704
2ND-LINE ATTACHMENT PPC VALVE (Machines ready for installation of attachment)
PPC Abbreviation for Proportional Pressure Control
10-172
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
STRUCTURE OF 2ND-LINE ATTACHMENT PPC VALVE General view and sectional view A
T
P A
P1 3
P2
2
4 5
6
1 A-A G0000011
P: From the self-pressure reducing valve
P2: To the control valve (service valve 2 port)
P1: To the control valve (service valve 2 port)
T: To the hydraulic tank
1: Spool
4: Plate
2: Piston
5: Retainer
3: Lever
6: Body
PC210-10M0, PC210LC-10M0
10-173
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF 2ND-LINE ATTACHMENT PPC VALVE When it is in neutral When the control pedal is in the NEUTRAL position, the pressure-adjusting hole (f1) of the spool (6) is disconnected to the pump pressure chamber (PP) and connected to the drain chamber (D). Thus, the pressurized oil in the port (A) and the pressurized oil in the port (B) flow into the drain chamber (D).
D T
f1
P
6 Self-pressure reducing valve
P2
P1
PP A
Control valve
B
G0000093
During fine control (when control pedal is operated) When the control pedal is operated, the lever (1) pushes down the spool (6) through the piston (2), the retainer (3), and the metering spring (5). The pressure-adjusting hole (f1) is disconnected to the drain chamber (D) and connected to the pump pressure chamber (PP). The pilot pressure is supplied from the self-pressure reducing valve to the port (A) and pushes the spool of the control valve. The oil returning from the port (B) flows into the drain chamber (D) through the pressure-adjusting hole (f2). When the pressure in the port (P1) increases, the spool (6) is pushed back. The pressure-adjusting hole (f1) is connected to the drain chamber (D). The pressurized oil in the port (P1) flows into the drain chamber (D), and the pressure decreases. The spool (6) moves to the position where the force of the metering spring (5) is balanced with the pressure in the port (P1). The pressure-adjusting hole (f1) is positioned at the midpoint between the drain chamber (D) and the pump pressure chamber (PP). Thus, the metering spring (5) deflects and the pressure in the port (P1) increases in proportion to the stroke of the lever.
1 2
3
D T
5 f2
f1
P
6
P1
Self-pressure reducing valve
P2
PP
A
Control valve
B G0000192
10-174
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
During fine control (when control pedal is released) When the control pedal is returned to the original position, the spool (6) is pushed up by the force of the centering spring (4) and the pressure in the port (P1). The pressure-adjusting hole (f1) is connected to the drain chamber (D), and the pressure in the port (A) decreases. The spool of the control valve is turned back, and the pressurized oil flows from the drain chamber (D) to the port (B) through the pressure-adjusting hole (f2). If the pressure decreases too much, the force of the metering spring (5) pushes down the spool. The pressure-adjusting hole (f1) is connected to the pump pressure chamber (PP). The pressurized oil is supplied to the port (P1) until the pressure corresponding to the control pedal stroke is reached.
4
D T
5 P
f1 f2 6
Self-pressure reducing valve
P2
P1
PP
A
B
Control valve
G0000193
When the lever is stroked to the end When the control pedal is inclined to full stroke, the lever (1) pushes down the spool (6) through the piston (2) and the retainer (3). The pressure-adjusting hole (f1) is disconnected to the drain chamber (D) and connected to the pump pressure chamber (PP). The pilot pressure is supplied from the selfpressure reducing valve to the port (A) and pushes the spool of the control valve. The oil returning from the port (B) flows into the drain chamber (D) through the pressure-adjusting hole (f2).
1 2
3
D T P
f1 f2 6
P1
Self-pressure reducing valve
P2
PP
A
Control valve
B G0000194
PC210-10M0, PC210LC-10M0
10-175
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
SOLENOID VALVE STRUCTURE OF SOLENOID VALVE General view and sectional view The below is a drawing for machines ready for installation of attachment.
G0033684
10-176
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
P1: From self-pressure reducing valve
ACC: To accumulator (pilot circuit)
A1: To PPC valve
A6: To 2-stage swing relief valve
A2: To control valve (port (PX1), (PX2))
A7: To swing stroke control solenoid valve
A3: To swing motor (port (B)) A4: To travel motor (port (P))
A8: To attachment circuit selector valve (for machines ready for installation of attachment)
A5: To control valve (port (PST))
T: To hydraulic tank
1: PPC lock solenoid valve
6: 2-stage swing relief solenoid valve
2: 2-stage relief solenoid valve
7: Swing stroke control solenoid valve
3: Swing parking brake solenoid valve
8: Attachment circuit selector solenoid valve (for machines ready for installation of attachment)
4: Travel speed increase solenoid valve 5: Travel junction solenoid valve
Solenoid valve 9: Valve spool 10: Sleeve 11: Block 12: Plug
Check valve 13: Plug 14: Plunger
OPERATION OF SOLENOID VALVE AND CHECK VALVE When the solenoid valve is de-energized (circuit is blocked) When the coil (1) is de-energized without current flowing into the coil (1), the spool (2) is pushed to the left by the spring (3).
$
The port (P) and the port (A) are blocked at this time, and the pressurized oil from the self-pressure reducing valve does not flow into the actuator. The port (A) is connected to the port (T). The pressurized oil from the actuator is discharged to the hydraulic tank.
7
3 *
When the solenoid valve is energized (circuit is interconnected) When the coil (1) is energized with current flowing into the coil (1), the spool (2) is pushed to the right by the push pin (4).
$
The port (P) and the port (A) are connected at this time, and the pressurized oil from the self-pressure reducing valve flows into the actuator. The port (A) and the port (T) are blocked. The pressurized oil from the actuator does not flow into the hydraulic tank.
7
3 *
PC210-10M0, PC210LC-10M0
10-177
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
Check valve The check valve is positioned between the port (PCC) and the port (P). The plunger (1) is pushed to the right by the pressurized oil from the port (P) while the engine is running. Thus, the port (ACC) and the port (P) are connected.
2
When the engine stops, the plunger (1) is pushed to the left by the spring (2), as shown in the figure. The port (ACC) and the port (P) are blocked at this time, and the pressure accumulated in the accumulator (pilot circuit) is kept. #%% )
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) (Machines ready for installation of attachment)
STRUCTURE OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) Sectional view 1
ACC
TS
P1
ATT G0000216
PI: From the attachment circuit selector solenoid valve
ATT: To the attachment
ACC: To the accumulator (attachment circuit, for high pressure)
TS: To the hydraulic tank
1: Spool
FUNCTION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) The function of the attachment circuit selector valve (for high pressure) is a function that connects or blocks the accumulator (attachment circuit for high pressure) and the attachment circuit, depending on the pilot pressure from the attachment circuit selector solenoid valve. When the attachment other than a breaker is installed, the accumulator and the attachment circuit are blocked. When the breaker is installed, the accumulator and the attachment circuit are connected.
10-178
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
OPERATION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) When attachment other than breaker is installed The spool (1) is pushed to the left by the spring (2), and the port (ACC) and the port (ATT) are blocked. Accumulator
Attachment selector solenoid valve
1
2
ACC
PI
TS
ATT
Attachment
Control valve G0000014
PC210-10M0, PC210LC-10M0
10-179
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
When breaker is installed The pilot pressure from the attachment circuit selector solenoid valve flows through the port (PI). This pressure pushes the spool (1) to the right, and the port (ACC) and the port (ATT) are connected.
Accumulator
Attachment selector solenoid valve
1
2
ACC
PI
TS
ATT
Breaker
Control valve G0000015
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) (Machines ready for installation of attachment)
10-180
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
STRUCTURE OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) General view and sectional view
PI: From the attachment selector solenoid valve
ATT: To the attachment
V: To the port of the control valve (service valve)
T: To the hydraulic tank
ACC: To the accumulator (attachment circuit, for low pressure)
TS: To the hydraulic tank
1: Spool
FUNCTION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) The function of the attachment circuit selector valve (for low pressure) is a function that specifies whether one of attachment ports is connected to the control valve or to the hydraulic tank. This is specified by the pilot pressure from the attachment circuit selector solenoid valve. In ATT/P or ATT/E working mode (when the attachment other than the breaker is installed), one of attachment ports is connected to the circuit leading to the control valve to deal with double-acting attachment.
PC210-10M0, PC210LC-10M0
10-181
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
In B working mode (when the breaker is installed), one of attachment ports is connected to the circuit leading to the hydraulic tank to deal with single-acting attachment. The port (T) is connected to the port (ACC). The accumulator is installed on the port (ACC), and pulsation is absorbed when the breaker is operated.
OPERATION OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) When attachment other than breaker is installed The spool (1) is pushed to the left by the spring (2). The port (ATT) is disconnected to the port (T) and connected to the port (V). Pressurized oil can be transmitted from the 2 directions of the control valve to the attachment.
Attachment
Attachment selector solenoid valve
1
2
ATT
PI
TS
V
T
Control valve G0000065
When breaker is installed The spool (1) is pushed to the right by the pilot pressure from the attachment circuit selector solenoid valve. The port (ATT) is disconnected to the port (V) and connected to the port (T). The pressurized oil discharged from the attachment flows into the hydraulic tank.
Breaker
Attachment selector solenoid valve
1
2
ATT
PI
TS
V
T
Control valve G0000066
10-182
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
PILOT CIRCUIT ACCUMULATOR STRUCTURE OF PILOT CIRCUIT ACCUMULATOR General view and sectional view 1
2 3 4 5
6 G0000208
1: Gas plug
4: Holder
2: Shell
5: Bladder
3: Poppet
6: Oil port
SPECIFICATIONS OF PILOT CIRCUIT ACCUMULATOR Gas used: Nitrogen gas Quantity of gas 300 cc Sealed gas pressure: 1.18 MPa {12 kg/cm2} (at a temperature of 80 ℃) Maximum pressure used: 4.91 MPa {50 kg/cm2}
FUNCTION OF PILOT CIRCUIT ACCUMULATOR The function of the accumulator (pilot circuit) is a function that accumulates the pressure for operating the control valve as pilot pressure. Though the engine is stopped, the pressure from the accumulator can operate the spool of the control valve to lower work equipment under the conditions below. •
15 seconds or fewer after the engine is stopped
•
The starting switch is in the ON position.
•
The lock lever is in the free position.
ATTACHMENT CIRCUIT ACCUMULATOR (Machines ready for installation of attachment)
PC210-10M0, PC210LC-10M0
10-183
WORK EQUIPMENT SYSTEM
10 STRUCTURE AND FUNCTION
STRUCTURE OF ATTACHMENT CIRCUIT ACCUMULATOR Structure of accumulator(Attachment circuit) (for high pressure) 1: Cap 2: Core 3: Gas port 4: Bladder 5: Shell 6: Valve 7: Oil port
G0033685
Structure of accumulator(Attachment circuit) (for low pressure) 1: Cap 2: Gas port 3: Shell 4: Oil port
G0033686
SPECIFICATIONS OF ATTACHMENT CIRCUIT ACCUMULATOR Specifications of accumulator (Attachment circuit) (for high pressure) Gas used: Nitrogen gas Gas quantity: 1000cc Charged gas pressure: 8.83MPa{90kg/cm2} (at 20 °C) Maximum operating pressure: 29.4MPa {300kg/cm2}
Specifications of accumulator (Attachment circuit) (for low pressure) Gas used: Nitrogen gas Gas quantity: 1000cc Charged gas pressure: 0.24MPa{2.4kg/cm2} (at 20 °C) Maximum operating pressure: 19.6MPa {200kg/cm2}
10-184
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
REMARK For testing and charging the gas pressure, see TESTING AND ADJUSTING, "TEST AND CHARGE ACCUMULATOR GAS PRESSURE FOR ATTACHMENT PIPING".
PC210-10M0, PC210LC-10M0
10-185
LAYOUT DRAWING OF SWING SYSTEM
10 STRUCTURE AND FUNCTION
SWING SYSTEM LAYOUT DRAWING OF SWING SYSTEM
1: Swing circle
6: Swing parking brake solenoid valve
2: Swing machinery
7: 2-stage swing relief solenoid valve
3: Swing motor
8: Pressure sensor (left swing)
4: Main pump
9: Pressure sensor (right swing)
5: Control valve
10-186
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF SWING SYSTEM
10: Machine monitor
13: Pump controller
11: Swing lock switch
14: Swing parking brake cancel switch
12: Left PPC valve
PC210-10M0, PC210LC-10M0
10-187
SWING CONTROL SYSTEM DIAGRAM
10 STRUCTURE AND FUNCTION
SWING CONTROL SYSTEM DIAGRAM
a: Swing parking brake cancel switch signal
e: 2-stage swing relief solenoid valve drive signal
b: Swing parking brake solenoid valve drive signal
f: Pressure sensor signal
c: CAN signal
g: Pressure switch (service) signal
d: Swing lock switch signal 1: Battery disconnect switch
13: Control valve
2: Battery
13a: Self-pressure reducing valve
3: Battery relay
13b: Merge-divider valve
4: Fusible link
13c: Travel junction valve
5: Fuse box
14: Swing motor
6: Swing parking brake cancel switch
14a: 2-stage swing relief valve
7: Swing lock switch
15: Swing parking brake solenoid valve
8: Pump controller
16: 2-stage swing relief solenoid valve
9: Machine monitor
17: L.H. PPC valve (for arm and swing operation)
10: Service oil pressure switch
18: R.H. PPC valve (for boom and bucket operation)
11: Pressure sensor (service)
19: 1st-line attachment PPC valve
12: Main pump
FUNCTION OF SWING CONTROL SYSTEM Swing lock and swing parking brake function Swing lock system (manual type) allows the operator to lock the swing operation at any position by setting the swing lock switch to ON position. The swing parking brake (automatic) is interlocked with the swing operation to prevent operator’s failure to lock the swing system or hydraulic drift on slopes.
10-188
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
Swing lock switch
Swing lock pilot lamp
OFF
SWING CONTROL SYSTEM DIAGRAM
Function
Swing parking brake
Not lit
Action When you set the right and left control levers or the attachment control pedal to NEUTRAL, the swing parking brake operates in approximately 5 seconds. (See the figure.) When you operate the right and left control levers or the attachment control pedal, the swing parking brake is canceled, allowing free swing operation. The swing parking brake is activated to lock the swing operation.
Lit
Swing lock
Even if you operate the right and left control levers to swing, the swing parking brake still operates, preventing swing operation.
A: Right and left control levers or attachment control pedal is operated (swing parking brake is canceled). B: Right and left control levers or attachment control pedal is in NEUTRAL.
Swing parking brake solenoid valve
C: Swing parking brake is activated.
Swing pressure sensor
ON
D: Approximately 5 seconds
Energized
Deenergized Time
G0000004
Swing parking brake cancel function If abnormal controller or other problem prevents the swing operation, turn the swing parking brake cancel switch (2) to CANCEL position (a) to enable swing operation. k
When the swing parking brake is canceled, be careful when you stop the swing operation on a slope. A hydraulic drift may occur.
Swing parking brake cancel switch Swing lock switch Swing parking brake
Cancel (when controller is abnormal)
Normal (when controller is normal)
ON
OFF
ON
OFF
Activated
Canceled
Activated
Activated
REMARK When the swing lock switch is ON, the swing parking brake is activated even if you turn the switch (2) to CANCEL position (a). The swing parking brake cancel switch (2) is alternate type. When you turn the switch (2) to CANCEL position (a), the swing lock pilot lamp flashes on the machine monitor.
PC210-10M0, PC210LC-10M0
10-189
SWING CONTROL SYSTEM DIAGRAM
10 STRUCTURE AND FUNCTION
a: Cancel (under abnormal condition)
b: Normal (under normal condition)
Quick warm-up function When you turn the swing lock switch (1) to ON, the cut-off function is canceled, and the main relief pressure increases. Start the operation of the work equipment with the main relief pressure high. It makes the hydraulic oil temperature rise quickly, and the warm-up time shortened. Operating condition
Main relief pressure 34.8 MPa {355 kg/cm2}
Swing lock switch: ON
↓ 37.2 MPa {380 kg/cm2}
2-stage swing relief function This function reduces the relief flow rate by changing the set pressure of the 2-stage swing relief valve to improve the fuel consumption. A decrease in the relief flow rate improves the fuel consumption. Operating condition During swing acceleration (except repeating an abrupt swing)
10-190
Relief flow rate 180 ℓ/min ↓ 70 ℓ/min
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SWING CONTROL SYSTEM DIAGRAM
The set pressure of the 2-stage swing relief valve changes depending on the pilot pressure. When the pilot pressure is cut off (A), low-pressure setting is achieved, and the relief flow rate is 180 ℓ/min (Q1). On the other hand, when the pilot pressure is supplied (B), high-pressure setting is achieved, and the relief flow rate is 70 ℓ/min (Q2). P: Relief pressure 28.4 MPa {290 kg/cm2}
Flow rate (Q)
Relationship between set pressure and flow rate
Set pressure (P)
G0000109
The graph shows the relationship between flow rate (C) required for swing operation and time. The difference in flow rate between low-pressure setting (A) and high-pressure setting (B) is the loss reduction area (Z) that contributes to fuel consumption improvement.
Flow rate (Q)
Characteristics of 2-stage swing relief valve
Time (Sec.) G0000032
PC210-10M0, PC210LC-10M0
10-191
SWING SYSTEM
10 STRUCTURE AND FUNCTION
SWING SYSTEM SWING MOTOR STRUCTURE OF SWING MOTOR General view
G0033447
MA: From control valve (swing LEFT port)
S: From control valve (variable back pressure valve)
MB: From control valve (swing RIGHT port)
T: To hydraulic tank
B: From swing parking brake solenoid valve
PI: From 2-stage swing relief solenoid valve
1: Reverse prevention valve
2: 2-stage swing relief valve
10-192
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SWING SYSTEM
Sectional views (A-A, B-B, C-C, D-D)
G0033448
1: Brake spring
9: Piston
2: Drive shaft
10: Cylinder block
3: Spacer
11: Valve plate
4: Case
12: Center shaft
5: Disc
13: Center spring
6: Plate
14: Suction valve
7: Brake piston
15: Shuttle valve
8: Housing
SPECIFICATIONS OF SWING MOTOR Type: KMF125ABE-6 Theoretical displacement: 125 cm3/rev 2-stage swing relief pressure: 28.4 MPa {290 kg/cm2} 2-stage swing relief flow rate (low-pressure setting): 180 ℓ/min 2-stage swing relief flow rate (high-pressure setting): 70 ℓ/min Rated speed: 1706 rpm PC210-10M0, PC210LC-10M0
10-193
SWING SYSTEM
10 STRUCTURE AND FUNCTION
Brake releasing pressure: 1.6±0.4 MPa {16±4 kg/cm2}
FUNCTION OF SWING MOTOR The swing motor converts the fluid movement of hydraulic oil into mechanical rotation movement. The rotation movement of the swing motor is transmitted to the swing machinery and then becomes the power to swing the upper structure.
SWING PARKING BRAKE OF SWING MOTOR OPERATION OF SWING PARKING BRAKE OF SWING MOTOR When swing parking brake is in operation (when solenoid valve is de-energized) When the swing parking brake solenoid valve (5) is de-energized, the pressurized oil in the brake chamber (a) is discharged into the hydraulic tank through the port (B). The brake spring (1) pushes down the brake piston (2) against the disc (3) and plate (4), and the brake is activated.
T Self pressure reducing valve
De-energized
Hydraulic pump
Swing brake solenoid valve
1 7 B 5 6
G0033449
10-194
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SWING SYSTEM
When swing parking brake is released (when solenoid valve is energized) When the swing parking brake solenoid valve (5) is energized, the pressurized oil from the self-pressure reducing valve flows into the brake chamber (a) through the port (B). The pressurized oil in the brake chamber (a) pushes up the brake piston (2) against the brake spring (1). Then, the disc (3) and plate (4) separate from each other, and the brake is released.
Self pressure reducing valve
Hydraulic pump
Energized
Swing brake solenoid valve
1 7 B
a 5 6
G0033450
SUCTION VALVE, SHUTTLE VALVE, AND 2-STAGE SWING RELIEF VALVE OF SWING MOTOR FUNCTION OF SUCTION VALVE, SHUTTLE VALVE, AND 2-STAGE SWING RELIEF VALVE OF SWING MOTOR This function prevents damage to the motor by letting any abnormal pressure escape from the outlet circuit of the motor. When the swing operation is stopped, the control valve closes the outlet circuit, but the motor is rotated by inertial force. When the motor rotates, the pressure in the outlet circuit increases, resulting in damage to the motor.
PC210-10M0, PC210LC-10M0
10-195
SWING SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF SUCTION VALVE, SHUTTLE VALVE, AND 2-STAGE SWING RELIEF VALVE OF SWING MOTOR When starting swing When you operate the control lever to RIGHT, the pressurized oil from the pump flows into the port (MA) through the control valve (6). When the pressure in the port (MA) increases, starting torque is generated, and the motor starts rotating. The pressurized oil from the motor’s outlet returns to the hydraulic tank through the port (MB) and the control valve (6).
Self pressure reducing valve
Energized
7
Hydraulic pump
During swing acceleration, the pilot pressure from the 2-stage swing relief solenoid valve (7) is applied to the port (PI), reducing the relief flow rate.
From port S
PI
1 2 3 C
MB
4
MA
5
6
G0033451
When stopping swing When you operate the control lever to the NEUTRAL position, the pump stops supplying the pressurized oil to the port (MA). Since the control valve (6) closes the return circuit to the hydraulic tank, the pressure in the port (MB), the motor’s outlet, increases. At this time, rotational resistance occurs in the motor, and the brake starts working.
Self pressure reducing valve
De-energized
Hydraulic pump
When the pressure in the port (MB) exceeds that in the port (MA), it pushes the shuttle valve (4). The port (MB) connects to the chamber (a). High braking torque acts on the motor, and the motor stops.
From port S
1
The pressure in the chamber (a) becomes equal to or more than the relief pressure. Then, the oil is discharged from the 2stage swing relief valve (1) into the hydraulic tank through the port (S). While the 2-stage swing relief valve (1) is in operation, relieved pressurized oil and pressurized oil from port (S) are supplied to port (MA) through suction valve (3). As a result, the occurrence of cavitation in the port (MA) is prevented.
3 C
MB
4
10-196
MA
6
G0033452
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SWING SYSTEM
2-STAGE SWING RELIEF VALVE OF SWING MOTOR STRUCTURE OF 2-STAGE SWING RELIEF VALVE OF SWING MOTOR Sectional view
G0033453
1: Valve seat
5: Rod
2: Valve
6: Spring
3: Piston
7: Piston
4: Spring
FUNCTION OF 2-STAGE SWING RELIEF VALVE OF SWING MOTOR The 2-stage swing relief valve controls the relief flow rate by changing the load at installed height of the spring (4). The load at installed height of the spring (4) changes by receiving the pilot pressure from the 2-stage swing relief solenoid valve.
Relationship between set pressure and flow rate A: When pilot pressure is blocked (low-pressure setting) B: When pilot pressure is supplied (high-pressure setting) Q1: 180 ℓ/min Q2: 70 ℓ/min P: 28.4 MPa {290 kg/cm2}
OPERATION OF 2-STAGE SWING RELIEF VALVE OF SWING MOTOR When pilot pressure (PI) is cut off (low pressure setting) The pilot pressure from the 2-stage swing relief solenoid valve is blocked. When the pressure becomes equal to or more than the set pressure, the valve (2) is pushed to the right to discharge the oil.
When pilot pressure (PI) is supplied (high pressure setting) During swing acceleration, the pilot pressure (PI) from the 2-stage swing relief solenoid valve acts on the pressure receiving area (d2 - d1). The pilot pressure (PI) moves the piston (7) to the left by the distance (a) against the spring (4). The set pressure for opening of the valve (2) increases by the compression of the spring (4). Thus, the relief flow rate becomes lower than the value in the low-pressure setting.
PC210-10M0, PC210LC-10M0
10-197
SWING SYSTEM
10 STRUCTURE AND FUNCTION
SWING MOTOR REVERSE PREVENTION VALVE STRUCTURE OF SWING MOTOR REVERSE PREVENTION VALVE General view and sectional view
G0033455
MA: From control valve (swing LEFT port)
T1: To hydraulic tank
MB: From control valve (swing RIGHT port)
T2: To hydraulic tank
1: Valve body
5: Spool (MB side)
2: Spool (MA side)
6: Spring (MB side)
3: Spring (MA side)
7: Plug (MB side)
4: Plug (MA side) 10-198
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SWING SYSTEM
FUNCTION OF SWING MOTOR REVERSE PREVENTION VALVE The reverse prevention valve reduces the swing back of a structure that occurs when the swing is stopped. The factors causing the swing back of a structure are as follows. •
Inertia of a structure
•
Backlash and rigidity of the machinery system
•
Compressibility of hydraulic oil
A swing back reduction prevents cargo from falling and improves positioning performance, which is effective in shortening the cycle time.
Figure to explain effect With reversal prevention valve Without reversal prevention valve
Reversal pressure
Pressure MA
Closed pressure
Pressure MB
Reversal pressure
1st reversal 2nd reversal
Motor speed
Start
Brake
Reversal
Time G0000076
After the motor rotation is stopped, the motor starts rotating in the reverse direction by the closed pressure generated in the port (MB). At this time, reverse pressure occurs in the port (MA), rotating the motor further in the reverse direction. The rotation speed during the reverse rotation decreases by using the reverse prevention valve to release the reverse pressure to the drain circuit. The amount of swing back with the use of reverse prevention valve becomes less than that without the use of reverse prevention valve.
PC210-10M0, PC210LC-10M0
10-199
SWING SYSTEM
10 STRUCTURE AND FUNCTION
OPERATION OF SWING MOTOR REVERSE PREVENTION VALVE When brake pressure occurs in port (MB) When the swing is stopped, the pressure (MB) is supplied into the chamber (d) through the cut-out portion (g). The spring (6) is compressed by the circle area difference of the spool (5) (diameter D1 > diameter D2) to move the spool (5) to the left. Then, the port (MB) and the chamber (e) are connected. Since the pressure (MA) is equal to or less than the set pressure of the spring (3), the spool (2) does not move. The pressurized oil is trapped. As a result, the braking force is secured.
e
6 5
3
2
T
D1 d g
D2
b
T
Swing motor MB
MA
Control valve
G0000033
When reverse pressure on motor occurs in port (MA) The motor rotates in reverse by the closed pressure generated in the port (MB) (first reverse rotation). Reverse pressure is generated at the port (MA). The pressure (MA) is supplied to the chamber (a). The spring (3) is compressed by the circle area difference of the spool (2) (diameter D3 > diameter D4) to move the spool (2) to the right. The port (MA) and the chamber (b) are connected. The port (b) and the port (f) are connected through the drilled hole (h) of the spool (5). Through this passage, the reverse pressure in the port (MA) is released to the port (T). This prevents the occurrence of the second reverse rotation.
a D3
D4 T
b h
5
T
f
2
3
Swing motor MB
MA
Control valve
G0000034
10-200
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SWING SYSTEM
SWING MACHINERY STRUCTURE OF SWING MACHINERY General view and sectional view
PC210-10M0, PC210LC-10M0
10-201
SWING SYSTEM
10 STRUCTURE AND FUNCTION
1: Swing pinion (quantity of teeth: 13)
9: No. 1 sun gear (quantity of teeth: 19)
2: No. 2 planetary carrier
10: Ring gear (quantity of teeth: 65, 64)
3: No. 2 sun gear (quantity of teeth: 20)
No. 1 ring gear (quantity of teeth: 65)
4: No. 2 planetary gear (quantity of teeth: 21)
No. 2 ring gear (quantity of teeth: 64)
5: No. 1 planetary carrier
11: Swing machinery case
6: No. 1 planetary gear (quantity of teeth: 22)
12: Oil level gauge
7: Swing motor
13: Oil filler pipe
8: Breather
14: Drain plug
SPECIFICATIONS OF SWING MACHINERY Reduction ratio: ((19+65)/19) X ((20+64)/20) = 18.568 Swing reduction ratio: 18.568 X (-(96/13)) = -137.118 Swing speed: 1717 rpm
FUNCTION OF SWING MACHINERY The swing machinery decreases the speed of the swing motor, and transmits applicable rotation force to the swing circle. The rotation force from the swing motor is decreased by the 2-speed type of planetary mechanism and output to the swing pinion. The No. 1 planetary consists of the sun gear (9), planetary gear (6), planetary carrier (5), and ring gear (10). The No. 2 planetary consists of the sun gear (3), planetary gear (4), planetary carrier (2), and ring gear (10). The ring gear (10) is fixed to the swing machinery case (11). The No. 1 planetary carrier (5) is connected to the No. 2 sun gear (3) by the spline. The No. 2 planetary carrier (2) is connected to the swing pinion (1) by the spline.
10-202
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
SWING SYSTEM
SWING CIRCLE STRUCTURE OF SWING CIRCLE General view and sectional view
a: Position of inner race soft zone mark (S)
b: Position of outer race soft zone
1: Greasing port of swing circle bearing
4: Ball
2: Greasing port of swing circle pinion
5: Outer race
3: Inner race (quantity of teeth: 96)
6: Seal
SPECIFICATIONS OF SWING CIRCLE Reduction ratio: 96/13 = 7.385 Grease: G2-LI Quantity of grease: 14.6 ℓ
PC210-10M0, PC210LC-10M0
10-203
LAYOUT DRAWING OF TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM LAYOUT DRAWING OF TRAVEL SYSTEM
1: Control valve
8: Center swivel joint
2: Main pump
9: Pressure sensor (front pump)
3: Fuel supply pump
10: Pressure sensor (rear pump)
4: Engine controller
11: Travel junction solenoid valve
5: Final drive
12: Travel speed increase solenoid valve
6: Travel alarm
13: LS-EPC valve
7: Travel motor
10-204
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF TRAVEL SYSTEM
14: Machine monitor
19: Pressure sensor (right travel forward)
15: Fuel control dial
20: Travel PPC valve
16: Pump controller
21: Pressure sensor (left travel forward)
17: Travel lever
22: Pressure sensor (left travel reverse)
18: Pressure sensor (right travel reverse)
PC210-10M0, PC210LC-10M0
10-205
TRAVEL CONTROL SYSTEM DIAGRAM
10 STRUCTURE AND FUNCTION
TRAVEL CONTROL SYSTEM DIAGRAM
a: Pressure sensor signal
g: Pressure sensor signal
b: CAN signal
h: Travel alarm activation signal
c: LS-EPC
i: Throttle signal
d: GND (solenoid valve)
j: Fuel supply pump control signal
e: Travel junction solenoid valve drive signal
k: Various sensor signals
f: Travel speed increase solenoid valve drive signal 1: Pump controller
12: Rear pump
2: Engine controller
12a: Servo piston
3: Machine monitor
12b: LS valve
4: Fuel control dial
12c: PC valve
5: Fuel supply pump
13: Control valve
6: Various sensors
13a: Self-pressure reducing valve
7: Pressure sensor (front pump)
13b: Merge-divider valve
8: Pressure sensor (rear pump)
13c: Travel junction valve
9: Pressure sensor
14: Travel motor
10: Travel alarm
15: Travel speed increase solenoid valve
11: Front pump
16: Travel junction solenoid valve
11a: Servo piston
17: LS-EPC valve
11b: LS valve
18: Travel PPC valve
11c: PC valve
10-206
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
FUNCTION OF TRAVEL CONTROL SYSTEM
FUNCTION OF TRAVEL CONTROL SYSTEM Travel speed selector function Manual gear shift of travel speed Operating the travel speed selector switch changes the travel motor capacity, allowing for the change in travel speed. You can change the travel speed in three levels, Lo, Mi. and Hi. Travel speed selector switch
Lo (Low speed)
Mi (Medium speed)
Hi (High speed)
Flow rate of travel motor
65%
90%
100%
Capacity of travel motor
Maximum
Maximum
Minimum
P/ATT-P/B
3.0 km/h
4.1 km/h
5.5 km/h
E/ATT-E
2.7 km/h
4.1 km/h
5.5 km/h
L
3.0 km/h
3.7 km/h
5.0 km/h
Travel speed
Automatic gear shift of travel speed Gear shift by engine speed When the engine speed is set to 1500 rpm or lower with the fuel control dial, the travel speed of the machine traveling at High speed level automatically changes to Mi. But, the travel speed of the machine traveling at Mi speed level does not change to Hi.
Gear shift by pump discharged pressure When the machine traveling at Hi speed level is under increased load (pump discharged pressure: 33.3 MPa {340 kg/cm2} or more) for 0.5 seconds or more, the travel motor capacity changes. The travel motor capacity becomes the maximum, and the travel speed changes to the specified value of Lo. But, the travel speed selector switch stays in the Hi position. When the machine is under reduced load (pump discharged pressure: 19.6 MPa {200kg/cm2} or less) for 0.5 seconds or more after the automatic gear shift, the travel motor capacity changes automatically. The travel motor capacity becomes the minimum, and the travel speed changes to the specified value of Hi. A: 14.7 MPa {150 kg/cm2} C: 0.5 seconds or more D: 0.5 seconds or more
Travel speed
B: 19.6 MPa {200 kg/cm2}
Pump discharged pressure
G0000005
Pump control function when the machine travels For details, see "ENGINE AND PUMP COMBINED CONTROL SYSTEM".
Travel junction function When you operate the travel lever, this function judges whether the operation is for straight travel or for steering by detecting the pilot pressure. Straight travel operation sets the R.H. and L.H. travel motors to almost the same flow rate by sending signals to the travel junction solenoid valve. This is to prevent travel deviation and improve the straight travel performance. Steering operation sets the R.H. and L.H. travel motors to different flow rates by blocking signals to the travel junction solenoid valve. This is to improve the travel performance during steering.
PC210-10M0, PC210LC-10M0
10-207
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM TRAVEL MOTOR STRUCTURE OF TRAVEL MOTOR General view
G0033443
L.H. travel motor PA: From control valve (left travel forward port) PB: From control valve (left travel reverse port)
R.H. travel motor PA: From control valve (right travel reverse port) PB: From control valve (right travel forward port)
Common to R.H. and L.H. travel motors P: From travel speed increase solenoid valve T: To hydraulic tank B: Brake releasing pressure pickup port MA: Oil pressure pickup port 10-208
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
MB: Oil pressure pickup port
Sectional views (A-A, B-B, C-C, D-D, E-E, F-F)
G0033444
1: Regulator piston PC210-10M0, PC210LC-10M0
2: Motor case 10-209
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
3: Regulator valve
12: Cylinder block
4: Safety valve
13: Valve plate
5: Check valve
14: Counterbalance valve
6: Rocker cam
15: Ring
7: Retainer guide
16: Brake piston
8: Output shaft
17: Plate
9: Pin
18: Disc
10: Retainer
19: Ball retainer
11: Piston
SPECIFICATIONS OF TRAVEL MOTOR Model: HMV120 Theoretical displacement (Min.): 82 cm3/rev Theoretical displacement (Max.): 106.2 cm3/rev Rated pressure: 37.3 MPa {380 kg/cm2} Rated rotation speed (at Min. displacement): 2565 rpm Rated rotation speed (at Max. displacement): 1315 rpm Brake releasing pressure: 1.18 MPa {12 kg/cm2} Travel speed selector pressure: 0.78 MPa {8.0 kg/cm2}
FUNCTION OF TRAVEL MOTOR The travel motor converts the fluid movement of hydraulic oil into mechanical rotation movement. The rotation movement of the travel motor is transmitted to the final drive and then becomes the power to drive the machine.
10-210
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
MOTOR PORTION OF TRAVEL MOTOR OPERATION OF MOTOR PART OF TRAVEL MOTOR During high-speed travel (motor swash plate angle is minimum)
6
a
1
P De-energized
b
Travel valve
5
4
3
c
Self-pressure reducing valve
2
M
G0000105
The displacement of the motor varies as the angle of the rocker cam (1) changes. The regulator piston (5) determines the angle of rocker cam (1) by the actions of travel speed increase solenoid valve (6) and regulator valve (2). When the travel speed increase solenoid valve (6) is de-energized, the port (P) connects to the tank. Then, the spring (3) moves the regulator valve (2) to the right. The hydraulic oil in the regulator piston (5) is discharged into the motor case through the orifice (c) of the regulator valve (2). The dead center (a) of the rocker cam (1) is eccentric to the point (b) at which a combined force of piston thrust is applied. The combined force of piston thrust acts as a moment to tilt the rocker cam (1) to the direction of the maximum swash plate angle. Hydraulic oil supplied by the travel valve pushes out the piston (4), tilting the rocker cam (1) to the direction of maximum swash plate angle. The displacement of the motor becomes the maximum. Since one rotation of the motor requires more hydraulic oil, the motor rotates at lower speeds.
PC210-10M0, PC210LC-10M0
10-211
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
During high-speed travel (motor swash plate angle is minimum)
6
1
P Energized
Travel valve
5
d
Self-pressure reducing valve
2
M
G0000106
When the travel speed increase solenoid valve (6) is energized, pilot pressure flows from the self-pressure reducing valve to the port (P). This pressure flow pushes the regulator valve (2) to the left. Some of the hydraulic oil supplied from the control valve flows into the regulator piston (5) through the passage (d) of the regulator valve (2). Then, the regulator piston (5) moves to the right, and the swash plate angle of the rocker cam (1) becomes smaller. The displacement of the motor becomes the minimum. Since one rotation of the motor requires less hydraulic oil, the motor rotates at higher speeds.
10-212
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
TRAVEL MOTOR PARKING BRAKE OPERATION OF TRAVEL MOTOR PARKING BRAKE Release parking brake (when the machine starts travel)
1
Travel valve
M 6
5
4
3
a
2
G0000107
The parking brake stops the rotation of the motor by the press force of the spring (6) onto the plate (4) and the disk (5). When you operate the travel lever, pressurized oil from the control valve moves the spool (1) of the counterbalance valve. Then, the pressurized oil is introduced into the chamber (a). The pressurized oil in the camber (a) moves the brake piston (3) to the left against the spring (6). The press force of the spring (6) is lost. As a result, the plate (4) and disc (5) separate from each other, and the parking brake is released.
PC210-10M0, PC210LC-10M0
10-213
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
Operate parking brake (when the machine stops travel)
1
Travel valve
M 6
5
4
3
b a
2
G0000160
When the travel lever is in NEUTRAL, the hydraulic oil in the chamber (a) is discharged from the orifice (b) of the brake piston (3) into the case. The spring (6) moves the brake piston (3) to the right, pushing down the plate (4) and the disc (5). Then, the parking brake is activated. The pressurized oil in the chamber (a) passes through the throttle of the slow return valve (2) into the control valve. It stops flowing when the spool (1) returns to the NEUTRAL position. This oil flow delays the activation of the parking brake until after the machine is stopped.
10-214
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
COUNTERBALANCE VALVE OF TRAVEL MOTOR FUNCTION OF COUNTERBALANCE VALVE OF TRAVEL MOTOR The counterbalance valve prevents the machine from running away by the motor rotation caused by an external force. When the machine drives downhill, the motor rotates by the machine’s own weight. In this case, more hydraulic oil than the control valve supplies is discharged. The counterbalance valve adjusts the throttle of the outlet pipe line according to the oil pressure on the inlet side.
OPERATION OF COUNTERBALANCE VALVE OF TRAVEL MOTOR During travel flat ground or uphill ground When you operate the travel lever, the pressurized oil from the control valve flows into the port (PA). The pressurized oil pushes the suction safety valve (1) and flows from the inlet port (MA) to the outlet port (MB). Since the outlet circuit is closed by the suction safety valve (3) and the spool (2), the pressure on the inlet side increases.
Travel valve PA
PB
3
1
MA
2
MB
G0000074
The pressurized oil on the inlet side flows from the orifices (B) and (C) of the spool (2) into the chamber (A). When the pressure in the chamber (A) rises above the selector pressure of the counterbalance valve, the spool (2) moves to the right. The outlet port (MB) and the port (PB) are connected through the outlet passage (D), and the motor rotates.
Travel valve PA
PB
A
2
MA
B
C
MB
D
G0000110
PC210-10M0, PC210LC-10M0
10-215
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
When driving the machine on a downhill When the machine drives downhill, the motor is rotated by an external force, and the pressure on the inlet side decreases. The pressure in the chamber (A) decreases through the orifices (B) and (C). The pressure in the chamber (A) drops below the selector pressure of the counterbalance valve. Then, the reaction force of the spring (4) returns the spool (2) to the left, throttling the outlet passage (D). The pressure on the outlet side increases, and rotating resistance is generated in the motor. The spool (2) moves to a position where the machine’s own weight force and the inlet-side pressure are balanced with the outlet port (MB) pressure. By throttling the outlet passage (D), the travel speed of the machine can be adjusted according to the discharged volume of the pump.
Travel valve PA
PB
4
A
MA
2 B
MB
D
C D
G0000075
SUCTION SAFETY VALVE OF TRAVEL MOTOR SPECIFICATIONS OF SUCTION SAFETY VALVE OF TRAVEL MOTOR Set pressure: 27.5 MPa {280 kg/cm2}
FUNCTION OF SUCTION SAFETY VALVE OF TRAVEL MOTOR During a transition to travel stop or when driving downhill, even if the circuit is closed, the motor rotates by an external force. As a result, the pressure in the outlet circuit becomes high. The suction safety valve lets the hydraulic oil escape from the outlet side to the inlet side to avoid an excessively high-pressure condition.
10-216
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
OPERATION OF SUCTION SAFETY VALVE OF TRAVEL MOTOR When machine stops travel or travel downhill Returning of the travel lever to NEUTRAL blocks the pressurized oil from the travel valve, reducing pressure inside the port (PA) and the chamber (A). The pressure in the chamber (A) drops below the switching pressure of the counterbalance valve. Then, the reaction force of the spring (3) moves the spool (2) to the left, throttling the outlet passage (C).
Travel valve
C
1 PA
Since the motor continues to rotate because of inertial force, the pressure on the outlet side increases. The outlet-side pressurized oil pushes the check valve (4) and passes through the cut-out portion (B) of spool (2) into the suction safety valve (1).
PB
3
A
MA
2
MB
B
4
G0000111
When the pressure becomes equal to or more than the set pressure of the suction safety valve (1), the poppet (5) opens. Then, the pressurized oil flows into the circuit on the inlet side. As a result, the pressure on the outlet side decreases.
1
5
MB
MA G0000112
PC210-10M0, PC210LC-10M0
10-217
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
When machine starts traveling or normal travel When you operate the travel lever, the pressurized oil from the travel valve moves the spool (2) to the right, opening the outlet passage (C). The pressurized oil flows from the outlet port (MB) into the port (PB), rotating the motor. The pressurized oil on the inlet side pushes the check valve (6) and flows into the orifice (D). Since the pressurized oil is throttled at the orifice (D), the differential pressure between the inlet side and the outlet side increases. As a result, the traction force becomes larger.
C
Travel valve PA
2
PB
MA
6
MB
D
G0000113
10-218
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
FINAL DRIVE STRUCTURE OF FINAL DRIVE General view and sectional view
1: Level plug
4: No. 1 sun gear (quantity of teeth: 12)
2: No. 1 planetary gear (quantity of teeth: 52)
5: No. 2 sun gear (quantity of teeth: 17)
3: Drain plug
6: No. 1 planetary carrier
PC210-10M0, PC210LC-10M0
10-219
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
7: Cover
11: Hub
8: Ring gear
12: Sprocket
No. 1 ring gear (quantity of teeth: 117)
13: Floating seal
No. 2 ring gear (quantity of teeth: 75)
14: Travel motor
9: No. 2 planetary carrier
15: No. 2 planetary gear (quantity of teeth: 28)
10: Ring nut
SPECIFICATIONS OF FINAL DRIVE Reduction ratio: -((12+117)/12) X ((17+75)/17) + 1 = -57.177
FUNCTION OF FINAL DRIVE The final drive decreases the speed of the travel motor, and transmits applicable rotation force to the track. The rotation force from the track is decreased by the 2-speed type of planetary mechanism and output from the sprocket (12) installed to the hub (11). The No. 1 planetary consists of the sun gear (4), planetary gear (2), planetary carrier (6), and ring gear (8). The No. 2 planetary consists of the sun gear (5), planetary gear (15), planetary carrier (9), and ring gear (8). The No. 2 planetary carrier (9) is fixed to the travel motor (14) by the spline. The No. 1 planetary carrier (6) is connected to the No. 2 sun gear (5) by the spline. The ring gear (8) is connected to the sprocket (12) through the hub (11).
TRAVEL PPC VALVE PPC Abbreviation for Proportional Pressure Control
10-220
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
STRUCTURE OF TRAVEL PPC VALVE General view
A
A
C
Z
T
D
D
P2S
C P1S
P2
P1
P4
P3
P P3S Z
P4S G0000299
P: From self-pressure reducing valve
T: To hydraulic tank
P1: To control valve (left travel reverse port)
P1S: Pressure sensor port
P2: To control valve (left travel forward port)
P2S: Pressure sensor port
P3: To control valve (right travel reverse port)
P3S: Pressure sensor port
P4: To control valve (right travel forward port)
P4S: Pressure sensor port
PC210-10M0, PC210LC-10M0
10-221
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
Sectional view
6
C-C
A-A 2
3 1
4
B
B 5
D-D
B-B G0000300
1: Plate
4: Seal
2: Case
5: Spool
3: Piston
6: Damper
10-222
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
OPERATION OF TRAVEL PPC VALVE When it is in neutral When the travel lever is in NEUTRAL, the passage from the adjustment hole (f1) of spool (6) to the pump pressure chamber (PP) is blocked. The hole connects to the drain chamber (D). Thus, the pressurized oil in the ports (A) and (B) flows into the drain chamber (D). D f1 T P
6 Self-pressure reducing valve
P1
A
PP
P2
Control valve
B
G0000087
During fine control (when travel lever is operated) When you operate the travel lever, the lever (1) pushes down the spool (6) through the piston (2), retainer (3), and metering spring (5). As the passage from the adjustment hole (f1) to the drain chamber (D) is blocked, the hole connects to the pump pressure chamber (PP). The pilot pressure is supplied from the self-pressure reducing valve to the port (A), pushing the spool of the control valve. The oil returning from the port (B) flows into the drain chamber (D) through the adjustment hole (f2). As the spool (6) is pushed back when the pressure in the port (P1) increases, the adjustment hole (f1) connects to the drain chamber (D). The pressurized oil in the port (P1) flows into the drain chamber (D), and the pressure decreases. The spool (6) moves to a position where the force of the metering spring (5) is balanced with the pressure of the port (P1). The adjustment hole (f1) is at the midpoint between the drain chamber (D) and the pump pressure chamber (PP). Thus, the metering spring (5) is deflected in proportion to the lever stroke. The pressure in the port (P1) also increases proportionately.
1 2 3
D f2
5 f1
T P
6 Self-pressure reducing valve
PP P1
A
P2
Control valve
7 B
G0000088
PC210-10M0, PC210LC-10M0
10-223
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
During fine control (when travel lever is released) When returning the travel lever, the spool (6) is pushed up by the force of the centering spring (4) and the port (P1) pressure. The adjustment hole (f1) connects to the drain chamber (D), and the pressure in the port (A) decreases. The spool of the control valve returns to its original position. The pressurized oil in the drain chamber (D) passes through the adjustment hole (f2) into the port (B). If the pressure decreases too much, the force of the metering spring (5) pushes the spool down. Then ,the adjustment hole (f1) connects to the pump pressure chamber (PP). Pressurized oil is supplied to the port (P1) until the pressure becomes proportional to the travel lever stroke.
4
D
5 f1
T P
f2
6 Self-pressure reducing valve
PP P1
A
P2
Control valve
B
G0000089
When the lever is stroked to the end When you operate the travel lever to the stroke end, the lever (1) pushes down the spool (6) through the piston (2) and the retainer (3). As the passage from the adjustment hole (f1) to the drain chamber (D) is blocked, the hole connects to the pump pressure chamber (PP). The pilot pressure is supplied from the self-pressure reducing valve to the port (A), pushing the spool of the control valve. The oil returning from the port (B) flows into the drain chamber (D) through the adjustment hole (f2).
1 2
D
3 T
f1 P
f2
6 PP
Self-pressure reducing valve
P1
A
P2
Control valve
B
G0000090
10-224
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
TRAVEL SYSTEM
CENTER SWIVEL JOINT STRUCTURE OF CENTER SWIVEL JOINT General view and sectional view
*
A1: To L.H. travel motor (Port PB)
D1: To R.H. travel motor (Port PB)
A2: From control valve (left travel forward port)
D2: From control valve (right travel reverse port)
B1: To L.H. travel motor (Port PA)
E1: To R.H./L.H. travel motor (port P)
B2: From control valve (right travel reverse port)
E2: From travel speed increase solenoid valve
C1: To R.H. travel motor (Port PA)
DR1: From R.H./L.H. travel motor (port T)
C2: From control valve (right travel forward port)
DR2: To hydraulic tank
1: Cover
5: Oil seal
2: Slipper seal
6: Cover
3: Rotor
7: Shaft
4: Dust seal
8: O-ring
FUNCTION OF CENTER SWIVEL JOINT The center swivel joint prevents the hoses and the tubes from twisting during swing operation. The main pump of the upper structure supplies pressurized oil to the travel motor of the undercarriage through the center swivel PC210-10M0, PC210LC-10M0
10-225
TRAVEL SYSTEM
10 STRUCTURE AND FUNCTION
joint. The center swivel joint is installed to the undercarriage. The shaft rotates in conjunction with the upper structure. As there is a groove in 360 degrees of the rotor, pressurized oil can be supplied to the travel motor even during swing operation.
10-226
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
FUNCTION OF SWING CIRCLE
FUNCTION OF SWING CIRCLE The internal gear of the inner race (3) is engaged with the swing pinion of the swing machinery. When the swing machinery rotates along the inner race (3) fixed to the undercarriage, the outer race (5) fixed to the upper structure rotates at the same time. The upper structure swings in response to the rotation of the swing machinery. The ball (4) between the inner race (3) and outer race (5) lets the upper structure swing smoothly.
PC210-10M0, PC210LC-10M0
10-227
LAYOUT DRAWING OF UNDERCARRIAG
10 STRUCTURE AND FUNCTION
UNDERCARRIAGE AND FRAME LAYOUT DRAWING OF UNDERCARRIAG
1: Front guard
6: Track roller
2: Track frame
7: Center guard
3: Track shoe
8: Idler cushion
4: Carrier roller
9: Idler
5: Final drive
SPECIFICATIONS OF UNDERCARRIAGE Number of track rollers (one side) PC210-10M0: 7 pieces PC210LC-10M0: 9 pieces
Standard shoe PC210-10M0 Shoe width: 600 mm 10-228
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
LAYOUT DRAWING OF UNDERCARRIAG
Link pitch: 190 mm Number of shoes (each side): 45 pieces
PC210LC-10M0 Shoe width: 600 mm Link pitch: 190 mm Number of shoes (each side): 49 pieces
PC210-10M0, PC210LC-10M0
10-229
STRUCTURE OF WORK EQUIPMENT
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT STRUCTURE OF WORK EQUIPMENT General view
5
7 6 3 4 2
1
G0000276
1: Bucket
5: Arm cylinder
2: Bucket link
6: Boom
3: Bucket cylinder
7: Boom cylinder
4: Arm
10-230
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM Steel shim You can adjust the clearance in the horizontal (right and left) direction of the work equipment by inserting shim(s) in the joint of the work equipment. Depending on the required adjustment amount of clearance, insert shim(s) in the joint on either right or left side.
G0000266
Plastic shim The use of plastic shim(s) has two purposes: to reduce clearance in the work equipment’s horizontal direction and to prevent a creak and scuffing caused by rubbing of the joint’s iron end surfaces. Combination use of bushings that help to extend lubrication interval and plastic shims prevents creaking due to lack of grease and extends the lubrication interval. To prevent the iron end surfaces of the joint from contacting each other, plastic shim(s) is inserted between all contact faces.
PC210-10M0, PC210LC-10M0
G0000097
10-231
BUCKET CLEARANCE ADJUSTMENT SHIM
10 STRUCTURE AND FUNCTION
BUCKET CLEARANCE ADJUSTMENT SHIM FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM Steel shim Split-type iron shims are used for the joint of the arm and the bucket. Insert shims in the joint to adjust the clearance. This split-type shims allow readjustment of clearance without removing the fastening bolts.
10-232
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
ROPS CAB
CAB RELATED PARTS ROPS CAB ROPS Abbreviation for Roll-Over Protective Structure
STRUCTURE OF ROPS CAB General view
1: Front window
5: Radio antenna
2: Windshield wiper
6: Door
3: Ceiling window
7: Mirror
4: KOMTRAX GPS antenna
FUNCTION OF ROPS CAB The ROPS cab protects the operator who wears the seat belt not to be crushed when the machine rolls over.
PC210-10M0, PC210LC-10M0
10-233
CAB MOUNT
10 STRUCTURE AND FUNCTION
CAB MOUNT STRUCTURE OF CAB MOUNT General view
1: Cab mount (front)
3: Bent claw (installed)
2: Cab mount (rear)
Structure The cab mount secures the cab and revolving frame at 4 places (front, rear, left, and right). The type of cab mount varies by the location as shown in the identification table below.
10-234
Location of damper
Bent claw
Text color of identification mark
Front left
Done
Yellow
Front right
Done
Yellow
Rear left
Done
Pink
Rear right
Done
Pink
PC210-10M0, PC210LC-10M0
10 STRUCTURE AND FUNCTION
CAB MOUNT
FUNCTION OF CAB MOUNT The oil sealed type cab mount absorbs the machine vibration for operator's comfort. 1: Silicone oil 2: Coil spring
PC210-10M0, PC210LC-10M0
10-235
CAB TIPPING STOPPER
10 STRUCTURE AND FUNCTION
CAB TIPPING STOPPER STRUCTURE OF CAB TIPPING STOPPER General view
1: Bolt
3: Lock plate
2: Lock plate bolt
4: Stopper plate
FUNCTION OF CAB TIPPING STOPPER The cab tipping stopper (1 piece) is installed at the rear part and it secures the cab against the machine body for the time when the machine tips over. 1: Cab 2: Stopper plate 3: Revolving frame
10-236
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
PC210-10M0, PC210LC-10M0
20-1
CONTENTS
20 STANDARD VALUE TABLE
CONTENTS ABBREVIATION LIST .................................................................................................................................... 20-3 STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-8 STANDARD VALUE TABLE FOR ENGINE: PC210-10M0 ...................................................................... 20-8 STANDARD VALUE TABLE FOR MACHINE: PC210-10M0.................................................................. 20-12 STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0 ................................................................ 20-26 STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0 ............................................................. 20-30 MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE .................................... 20-44
20-2
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
ABBREVIATION LIST
ABBREVIATION LIST •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
•
Abbreviations that are used in general society may not be included.
•
Special abbreviations that appear infrequently are noted in the text.
•
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
Steering
ARAC
Automatic Retarder Accelerator Control
Travel and brake
ARSC
Automatic Retarder Speed Control
Travel and brake (HD, HM)
(WA)
(HD, HM)
Travel and brake (HD, HM)
Explanation A function that releases the brakes when the tires skid (wheels stop rotating), and applies the brakes again when the wheels start to rotate. A function that automatically sets the idle speed. A function that uses a lever to perform the steering operations instead of a steering wheel. Moreover, the lever is used to shifts gear and changes direction (FORWARD, REVERSE). A function that automatically applies the retarder with a constant braking force when the accelerator pedal is released while the machine is traveling downhill. A function that automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when the accelerator pedal is released while the machine is traveling downhill.
ASR
Automatic Spin Regula- Travel and brake tor (HD, HM)
A function that automatically uses the optimum braking force to drive both wheels when the tires spin on soft ground.
ATT
Attachment
A device that can be fixed onto the standard machine in order to enable it to do different jobs.
BCV
Brake cooling oil control Brake valve (HD)
CAN
Controller Area Network
Communication and electronic control
One of communication standards that are used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve that is installed to KCCV ventilator. It is written as CDR valve and it is not used singly.
CLSS
Closed-center Load Sensing System
Hydraulic system
A system that simultaneously actuates multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
A function that maintains optimum fuel injection amount and fuel injection timing by engine controller electronically controlling supply pump, common rail, and injector.
CRI
Common Rail Injection
PC210-10M0, PC210LC-10M0
WORK EQUIPMENT
A valve that divides part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used.
20-3
ABBREVIATION LIST
20 STANDARD VALUE TABLE
Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Travel Suspension System (WA)
A system that ensures smooth high-speed travel by absorbing vibration of machine during travel with spring effect of accumulator.
ECU
Electronic Control Unit
An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
A function that recirculates part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of NOx.
Equipment ManageMACHINE MONITOR ment Monitoring System
A system which enables data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor to be checked on the monitor.
EPC
Electromagnetic ProporHydraulic system tional Control
This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Cab and canopy Structure
EMMS
F-N-R
GPS
GNSS
Forward-Neutral-Reverse Global Positioning System
Electronic control system
Transmission (D, HD, WA, etc)
Electronic control system
Operation Communication (KOMTRAX, KOMTRAX Plus)
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
Explanation An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECU) A proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.
A structure that protects the operator's head from falling objects. ISO 3449 compliant Forward - Neutral - Reverse A system that uses satellites to determine the current location on the earth 1. A system that uses satellites such as GPS, GALILEO, etc. to determine location on the earth. A function which uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly, machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
Steering
HST
Hydrostatic Transmission
Transmission
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
IMA
20-4
Inlet Metering Actuator
(D Series)
(D, WA)
A hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears.
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Abbreviation
IMU
Actual word spelled out
Inertial Measurement Unit
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
A device that detects the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV (+)
Inlet Metering Valve
Engine
A valve which is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
A mechanism that separates oil in blowby gas and send it back to the intake side for it to be burned again. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
Engine
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
A filter that captures soot in exhaust gas. It is built in to KDPF A catalyst that is used for purifying exhaust gas.
Engine
Komatsu Diesel ParticuEngine late Filter
It is built in to KDPF or used in combination with the muffler in some cases. A component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler. A function that recovers the driving force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle machine travels on the soft ground road.
Komatsu Traction Control System
Travel and brake
LCD
Liquid Crystal Display
MACHINE MONITOR
A display equipment such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic parts
It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
One of communication standards that are used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
One of communication standards that are used in the network on the machine
MAF
Mass Air Flow
Engine
This indicates engine intake air flow. Mass air flow sensor is described as MAF sensor in some cases.
MMS
Multimedia Messaging Service
Communication
A service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
NC
Normally Closed
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally closed if it is not actuated (it opens when it is actuated).
NO
Normally Open
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally open if it is not actuated (it closes when it is actuated).
KTCS
PC210-10M0, PC210LC-10M0
(HM)
20-5
ABBREVIATION LIST
Abbreviation OLSS PC
PCCS
Actual word spelled out Open-center Load Sensing System
20 STANDARD VALUE TABLE
Purpose of use (major applicable machine (*1), or component/system) Hydraulic system
Pressure Compensation Hydraulic system Palm command control system
Steering (D Series)
Explanation A hydraulic system that can operate multiple actuators at the same time regardless of the load. A function used to correct oil pressure. A function that electronically controls the engine and transmission. It is done by a controller that instantly analyses data from each lever, pedal, and dial.
PCV
Pre-stroke Control Valve Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This system is used for controlling proportional pressure. It moves actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power train system
PTP
Power Tilt and power Pitch dozer
WORK EQUIPMENT
ROPS
Roll-Over Protective Structure
Hydraulic system Hydraulic system (D, PC, etc)
(D Series)
Cab and canopy
A piston type hydraulic pump and motor A mechanism that takes out the force for the work equipment separately from the travel. A function that hydraulically performs tilt operation and pitch operation of the bulldozer blade. A protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. ISO 3471 compliant
SCR
Selective Catalytic Reduction
Urea SCR system
An exhaust gas purifier using urea water to convert nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It Done also be mentioned as exhaust gas purification catalyst , or part of the of related devices.
Le Système internationUnit al d'unités
A universal unit system and "a single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
An actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
A solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
The turbocharger on which the cross-section area of the exhaust passage is made variable.
SI
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
20-6
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
ABBREVIATION LIST
List of abbreviations used in the circuit diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
PC210-10M0, PC210LC-10M0
20-7
STANDARD VALUE TABLE FOR ENGINE: PC210-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE STANDARD VALUE TABLE FOR ENGINE: PC210-10M0 Engine - SAA6D107E-1 Performance Item
Engine speed at high idle
Engine speed at low idle
Test condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P mode
•
Fuel control dial: MAX (High idle) position
•
Control lever and control pedal: NEUTRAL
•
Auto-deceleration: OFF
•
Swing lock switch: ON
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P mode
•
Fuel control dial: MIN (Low idle) position
•
Control lever and control pedal: NEUTRAL
Unit
Standard value for new machine
Repair limit
rpm
1780 to 1920
1780 to 1920
rpm
1000 to 1100
1000 to 1100
Unit
Standard value for new machine
Repair limit
Min. 133
Min. 103
{Min. 1,000}
{Min. 775}
Min. 120
Min. 90
{Min. 900}
{Min. 675}
Air intake and exhaust system Item
Test condition •
Boost pressure
20-8
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P mode
•
Fuel control dial: MAX (High idle) position
•
Swing lock switch: ON
•
When oil pressure is relieved in arm IN circuit and one-touch power maximizing is activated
Turbocharger outlet pressure
kPa Intake manifold pressure
{mmHg}
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
Exhaust gas color
STANDARD VALUE TABLE FOR ENGINE: PC210-10M0
Test condition •
Engine coolant temperature: 60 to 100 °C
•
Fuel control dial: MAX (High idle) position
•
After holding 5 seconds while the oil pressure is relieved in arm IN circuit
•
Swing lock ON
•
Without pressure cutoff
•
Engine coolant temperature: Normal temperature
Valve clearance
Engine outlet (tail pipe outlet)
Unit
Standard value for new machine
Repair limit
Bosch index
Max. 1.5
Max. 1.5
0.25
0.152 to 0.381
0.51
0.381 to 0.762
Unit
Standard value for new machine
Repair limit
MPa
Min. 2.41
Min. 1.69
{kg/cm2}
{Min. 24.6}
{Min. 17.2}
kPa
Max. 0.98
Max. 1.96
{mmH2O}
{Max. 100}
{Max. 200}
Intake side Exhaust side
mm
Main body Item Compression pressure
Blowby pressure
Test condition •
Engine oil temperature: 40 to 60 °C
•
At no-injection cranking
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Fuel control dial: MAX (High idle) position
•
Swing lock switch: ON
•
When oil pressure is relieved in arm IN circuit and one-touch power maximizing is activated
PC210-10M0, PC210LC-10M0
20-9
STANDARD VALUE TABLE FOR ENGINE: PC210-10M0
Item
Test condition •
•
•
• Fuel pressure •
• •
•
Engine coolant temperature: 60 to 100 °C
Engine coolant temperature: 60 to 100 °C
Fuel control dial: MIN (Low idle) position
Fuel control dial: MAX (High idle) position
Pressure difference between inlet side At cranking and outlet side of the fuel main filter Engine coolant temperature: 60 to 100 °C
Fuel control dial: MIN (Low idle) position
Pressure in the return circuit
At cranking
Engine coolant temperature: 60 to 100 °C
Fuel control dial: MAX (High idle) position
Pressure in the negative pressure circuit
Return volume from the supply pump
Fuel control dial: MIN (Low idle) position
At cranking
500 to 1300
500 to 1300
{5.1 to 13.3}
{5.1 to 13.3}
304 to 1109
304 to 1109
{3.1 to 11.3}
{3.1 to 11.3} Max. 81 {Max. 0.83}
Max. 81
Max. 81
{Max. 0.83}
{Max. 0.83}
Max. 18.6
Max. 18.6
{Max. 0.19}
{Max. 0.19}
Max. 18.6
Max. 18.6
{Max. 0.19}
{Max. 0.19}
kPa
Max. -50.7
Max. -40.5
{mmHg}
{Max. -380}
{Max. -305}
Min. 70
Min. 70
Max. 575
Max. 575
Max. 575
Max. 575
Max. 8
Max. 8
Max. 5 drops
Max. 5 drops
Max. 150
Max. 150
Max. 45
Max. 45
kPa {kg/cm2}
mℓ
Fuel control dial: MIN (Low idle) position
Fuel control diReturn volume from the in- al: MIN (Low idle) position jector
Repair limit
Max. 81
At cranking Leakage from the pressure limiter
Standard value for new machine
{Max. 0.83}
At cranking
At cranking
20-10
Unit
Pressure in the low pressure circuit (inlet At cranking side of the fuel main filter)
Discharge volume of the supply pump
Fuel discharged volume, return volume, and leakage
20 STANDARD VALUE TABLE
-
mℓ
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE: PC210-10M0
Lubrication system Item
Test condition •
Engine Oil Pressure
Engine coolant temperature: 60 to 100 °C
•
Auto-deceleration: OFF
•
Working mode: P mode
•
Engine oil EO10W30-DH
Standard value for new machine
Repair limit
Min. 0.29
Min. 0.25
{Min. 3.0}
{Min. 2.5}
Min. 0.10
Min. 0.07
{Min. 1.0}
{Min. 0.7}
°C
80 to 110
Max. 120
Unit
Standard value for new machine
Repair limit
mm
6.3 to 8.7
6.3 to 8.7
Unit
Fuel control dial: MAX (High idle) position
MPa Fuel control dial: MIN (Low idle) position
{kg/cm2}
EO15W40-DH EOS0W30-DH EOS5W40-DH Engine Oil Temperature
All rotation area (in the oil pan)
Cooling system Item Belt tension of air conditioner compressor
Test condition •
Middle of the compressor pulley and fan pulley
•
Deflection when it is pushed with a finger with 60N {6.2 kg}
PC210-10M0, PC210LC-10M0
20-11
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0 Engine - SAA6D107E-1 Engine Speed Item
Engine speed at 2 pump relief
Engine speed at 2 pump relief and when onetouch power maximizing is enabled
Engine speed when auto-deceleration is actuated
20-12
Test condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Swing lock switch: ON
•
Arm IN relief
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Arm IN relief+one-touch power maximizing switch is ON
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: ON
•
Control lever and control pedal: NEUTRAL
Unit
Standard value for new machine
Repair limit
rpm
1600 to 1800
1600 to 1800
rpm
1850 to 2050
1850 to 2050
rpm
950 to 1150
950 to 1150
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Stroke of the control valve spool Unit
Standard value for new machine
Repair limit
RAISE side
mm
11.0 to 12.0
11.0 to 12.0
LOWER side
mm
9.0 to 10.0
9.0 to 10.0
Arm IN side
mm
11.0 to 12.0
11.0 to 12.0
Arm OUT side
mm
9.0 to 10.0
9.0 to 10.0
Bucket CURL side
mm
9.0 to 10.0
9.0 to 10.0
Bucket DUMP side
mm
9.0 to 10.0
9.0 to 10.0
Swing RIGHT side
mm
9.0 to 10.0
9.0 to 10.0
Swing LEFT side
mm
9.0 to 10.0
9.0 to 10.0
Travel FORWARD side
mm
9.0 to 10.0
9.0 to 10.0
Travel REVERSE side
mm
9.0 to 10.0
9.0 to 10.0
Unit
Standard value for new machine
Repair limit
Stroke of the R.H. control lever (boom side)
mm
75 to 95
75 to 95
Stroke of the L.H. control lever (arm side)
mm
75 to 95
75 to 95
mm
75 to 95
75 to 95
mm
75 to 95
75 to 95
mm
103 to 127
103 to 127
Play of the R.H. control lever and L.H. control lever
mm
Max. 15
Max. 20
Stroke of the travel control lever
mm
Max. 20
Max. 25
Item
Test condition
Stroke of the boom valve spool Stroke of the arm valve spool Stroke of the boom valve spool
•
Engine: Stopped
•
Measuring posture: See "CONTROL VALVE" of "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE"
Stroke of the swing valve spool
Stroke of the travel valve spool
Stroke and play of the lever Item
Stroke of the R.H. control lever (bucket side) Stroke of the L.H. control lever (swing side) Stroke of the travel control lever
Test condition
•
Engine: Stopped
•
Measuring position: Center of the lever grip
•
From the neutral position to the stroke end (excludes the play)
PC210-10M0, PC210LC-10M0
20-13
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
20 STANDARD VALUE TABLE
Operating force of the control lever and travel pedal Item
Test condition
Operating force of the R.H. control lever (boom side) Operating force of the L.H. Control lever (arm side) Operating force of the R.H. control lever (bucket side) Operating force of the L.H. control lever (swing side)
Unit
N {kg}
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Control lever measurement position: Center of the lever grip
•
Control pedal measurement position: tip of the pedal
•
From neutral position to the stroke end
N {kg}
N {kg}
N {kg}
Operating force of the travel lever
N {kg}
Operating force of the travel pedal
N {kg}
Standard value for new machine
Repair limit
11.8 to 19.6
Max. 24.5
{1.2 to 2.0}
{Max. 2.5}
11.8 to 19.6
Max. 24.5
{1.2 to 2.0}
{Max. 2.5}
9.8 to 15.6
Max. 21.6
{1.0 to 1.6}
{Max. 2.2}
9.8 to 15.6
Max. 21.6
{1.0 to 1.6}
{Max. 2.2}
18.6 to 30.4
Max. 39.2
{1.9 to 3.1}
{Max. 4.0}
55.9 to 93.1
Max. 107.6
{5.7 to 9.5}
{Max. 11}
Standard value for new machine
Repair limit
Oil pressure of work equipment, swing, and travel Item
Unload pressure (PFC, PRC)
20-14
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Control lever and control pedal: NEUTRAL
Unit
MPa
2.5 to 4.5
2.5 to 4.5
{kg/cm2}
{26 to 46}
{26 to 46}
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Test condition
•
When onetouch power maximizing is Hydraulic oil temper- activated
ature: 45 to 55 °C •
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Swing lock switch: OFF
Bucket relief pressure (PFC、 PRC)
Swing relief pressure (PFC、 PRC)
Travel relief pressure (PFC、 PRC)
Control circuit oil pressure
Repair limit
33.8 to 35.8
33.3 to 36.3
{345 to 365}
{340 to 370}
36.3 to 38.3
35.8 to 38.8
{370 to 390}
{365 to 396}
33.8 to 35.8
33.3 to 36.3
{345 to 365}
{340 to 370}
36.3 to 38.3
35.8 to 38.8
{370 to 390}
{365 to 396}
33.8 to 35.8
33.3 to 36.3
{345 to 365}
{340 to 370}
36.3 to 38.3
35.8 to 38.8
{370 to 390}
{365 to 396}
MPa
27.9 to 30.9
{kg/cm2}
{285 to 315}
27.4 to 31.4 {280 to 320}
MPa
36.7 to 39.7
36.2 to 40.2
{kg/cm2}
{375 to 405}
{370 to 410}
MPa
2.93 to 3.43
2.75 to 3.43
{kg/cm2}
{30 to 35}
{28 to 35}
At normal relief
Boom relief pressure (PFC、 PRC)
Arm relief pressure (PFC、 PRC)
Standard value for new machine
Unit
{kg/cm2}
At normal relief When onetouch power maximizing is activated
MPa {kg/cm2}
At normal relief When onetouch power maximizing is activated
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Swing lock switch: ON
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Control lever and control pedal: NEUTRAL
PC210-10M0, PC210LC-10M0
MPa
MPa {kg/cm2}
20-15
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Item
Test condition
• • PC valve outlet pressure (PFC-PENF, PRC-ENR)
Fuel control dial: MAX (High idle) position Working mode: P mode
•
Swing lock switch: ON Arm IN relief
Servo piston inlet pressure Rear pump discharged pressure
Hydraulic oil temper- Fuel control dial: MIN (Low ature: 45 to 55 °C
PC-EPC valve outlet pressure
•
Working mode: P mode
(PMF, PMR)
•
Control lever and control pedal: NEUTRAL
(PFC-PLSFC, PRC-PLSRC)
LS valve outlet pressure (Servo piston inlet pressure) (PFC-PENF, PRC-PENR)
Fuel control dial: MAX (High idle) position
Hydraulic oil temper- Control lever and control ature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Hi
•
Run the track on one side idle off the ground
•
Hydraulic oil temper- Control lever and control ature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
36.1 to 38.8
36.1 to 39.7
{368 to 395}
{368 to 405}
Above value x Approximately
Above value x Approximately
MPa
0.6
0.6
{kg/cm2}
36.1 to 38.8
36.1 to 39.7
{368 to 395}
{368 to 405}
Above value x Approximately
Above value x Approximately
0.6
0.6
Approximately 2.6
Approximately 2.6
{Approximately 26}
{Approximately 26}
MPa {kg/cm2}
pedal: NEUTRAL
Approximately 1.0
Approximately 1.0
{Approximately 10}
{Approximately 10}
2.5 to 4.5
2.5 to 4.6
{26 to 46}
{26 to 46}
1.66 to 1.81
1.66 to 1.81
{17 to 18.5}
{17 to 18.5}
Approximately the same as the pump discharged pressure
Approximately the same as the pump discharged pressure
Above value x Approximately
Above value x Approximately
0.6
0.6
MPa {kg/cm2} Travel lever: Half stroke
pedal: NEUTRAL
Travel lever: Run the track on one Half stroke
side idle off the ground
20-16
idle) position
•
•
Repair limit
Servo piston inlet pressure
•
LS differential pressure
Standard value for new machine
Unit
Front pump Hydraulic oil temper- discharged pressure ature: 45 to 55 °C
•
•
20 STANDARD VALUE TABLE
MPa {kg/cm2}
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
LS-EPC valve outlet pressure
Test condition •
Hydraulic oil temper- Travel speed: ature: 45 to 55 °C Lo
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
(PSIG)
Solenoid valve outlet pressure
PPC valve outlet pressure
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Travel speed: Hi
Hydraulic oil temper- OFF (de-enerature: 45 to 55 °C gized) ON (energized)
•
Hydraulic oil temper- Control lever and control ature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position Working mode: P mode
{Approximately 25}
{Approximately 25}
Approximately 0.7
Approximately 0.7
{Approximately 7}
{Approximately 7}
0
0
{0}
{0}
{kg/cm2}
•
•
Repair limit
MPa
Travel lever: Fine control
Fuel control dial: MAX (High idle) position
Standard value for new machine
Approximately 2.45 Approximately 2.45
Travel speed: Mi
•
•
Unit
pedal: NEUTRAL
Control lever and control pedal: Full stroke
0
0
MPa
{0}
{0}
{kg/cm2}
Approximately 2.9
Approximately 2.9
{Approximately 30}
{Approximately 30}
0
0
{0}
{0}
MPa {kg/cm2}
Approximately the Approximately the same as the control same as the control circuit oil pressure circuit oil pressure
Swing Item
Overrun when stopping swing
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
Unit
° (angle)
Standard value for new machine
Repair limit
Max. 100
Max. 130
• How much angle swing circle is displaced from the original position when it stops after one swing
PC210-10M0, PC210LC-10M0
20-17
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Item
Time required from the start position of the swing
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
20 STANDARD VALUE TABLE
Standard value for new machine
Repair limit
2.8 to 3.4
Max. 3.7
4.0 to 4.8
Max. 5.5
Second
21.7 to 26.7
Max. 30
mm
0
0
ℓ/min
Max. 5
Max. 10
Unit 90°
180°
Second
Time required from the start position of the swing to 90 degrees and 180 degrees positions
Time required for swing
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
The time it takes to swing 5 times after swinging 1 time
Hydraulic drift of swing
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine is stopped
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 2".
Mark the inner race and outer race of the swing circle with a measurement posture. Displacement after 5 minutes
Oil leakage from swing motor
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Swing lock switch: ON
Oil leakage from swing motor at relief
20-18
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Travel Item
Travel speed (Required time, engine is at idle, and track is off the ground)
Standard value for new machine
Repair limit
Lo
44.6 to 54.9
44.6 to 58.8
Mi
33.7 to 41.3
33.7 to 45.3
Hi
26.6 to 29.4
26.6 to 31.4
Lo
20.9 to 25.7
20.9 to 26.9
Mi
14.5 to 19.5
14.5 to 20.5
12.0 to 14.0
12.0 to 15.0
Max. 150
Max. 250
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 1".
Unit
Second
The time it takes to run the track 5 times after it is run once •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 2".
Travel speed (Required time, the machine actually travels)
Second Hi
(The time it takes to travel 20 m after a 10 m run on the flat ground)
Deviation while the machine travels
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Lo
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 2".
mm
Deviation while the machine travels 20 m after a 10 m run on the flat ground((x) of "TRAVEL 3")
PC210-10M0, PC210LC-10M0
20-19
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Item
Hydraulic drift while the machine travels
Oil leakage from the travel motor
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Engine is stopped
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 4".
•
Hydraulic drift 5 minutes after the measurement posture
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Lock the sprocket with a pin
20 STANDARD VALUE TABLE
Unit
Standard value for new machine
Repair limit
mm
0
0
ℓ/min
Max. 13.6
Max. 27.2
Unit
Standard value for new machine
Repair limit
Max. 600
Max. 900
Max. 18
Max. 27
Max. 160
Max. 240
Max. 40
Max. 58
Oil leakage from the travel motor at relief
Hydraulic drift of work equipment Item Hydraulic drift measured at tooth tip (all work equipment) Retract quantity of the boom cylinder Extract quantity of the arm cylinder
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Flat ground
•
Rated load or the bucket is filled with sand (0.8 m3: 1440 kg)
•
Engine is stopped
•
Control lever: NEUTRAL
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 1."
Retract quantity of the bucket cyl- Amount of movement of 15 minutes while it inder is measured every five minutes from the measurement position
20-20
mm
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Work equipment speed Item
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 2."
Boom speed (Required time)
Unit RAISE
LOWER
Second
Standard value for new machine
Repair limit
2.9 to 3.7
Max. 4.7
2.1 to 2.7
Max. 3.7
3.1 to 3.9
Max. 4.5
2.4 to 3.0
Max. 3.5
Required time to operate from RAISE stroke end to LOWER the bucket to the ground
Arm speed (Required time)
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 3."
Arm IN
Arm OUT
Second
Required time to operate from arm OUT stroke end to arm IN stroke end
PC210-10M0, PC210LC-10M0
20-21
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Item
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 4."
Bucket speed (Required time)
20 STANDARD VALUE TABLE
Standard value for new machine
Repair limit
2.1 to 2.7
Max. 3.3
1.6 to 2.1
Max. 2.7
Unit
Standard value for new machine
Repair limit
Second
Max. 1.0
Max. 1.2
Unit Bucket CURL
Bucket DUMP
Second
Required time to operate from bucket DUMP stroke end to bucket CURL stroke end
Time lag of work equipment control Item
Boom time lag
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 5."
Set the boom to the maximum RAISE position. Required time to operate the boom from the time when the work equipment is lowered to the ground and until the time when the machine front is lifted off.
20-22
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 6."
Arm time lag
Unit
Standard value for new machine
Repair limit
Second
Max. 2.0
Max. 2.8
Second
Max. 1.0
Max. 3.6
Unit
Standard value for new machine
Repair limit
Max. 4.5
Max. 20
Max. 10
Max. 50
Set the arm to the maximum arm OUT position, then operate it to the arm IN side. Stop the arm at the vertical position. Required time from the time when the arm is operated again and until the time when the arm starts move off. •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 7."
Bucket time lag
Set the bucket at the maximum DUMP position, and operate it to the bucket CURL side. Stop the bucket at the vertical position. Required time from the time when the bucket is operated again and until the time when the bucket starts move off
Oil leakage volume Item Oil leakage from the cylinder
Test condition •
Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) Oil leakage from position the center swivel Oil leakage at relief from the cylinder to be joint measured, or travel motor
PC210-10M0, PC210LC-10M0
cc/min
20-23
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
20 STANDARD VALUE TABLE
Pump performance Item
Travel deviation at combined operation of work equipment and travel.
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Lo
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 2".
Unit
Standard value for new machine
Repair limit
mm
Max. 200
Max. 220
1.15 to 1.55
0.72 to 1.98
3.15 to 3.55
2.72 to 3.98
Deviation while the machine travels 20 m after a 10 m run on the flat ground((x) of "TRAVEL 3") •
Voltage of the pump swash plate sensor
Required time to start the boom RAISE and swing (PC oil flow control characteristic)
Hydraulic oil temper- When the control lever is in ature: 45 to 55 °C NEUTRAL
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Hi
•
Travel operation: Turn the track on one side idle off the ground
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Rated load or the bucket is filled with sand (0.8 m3: 1440 kg)
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 8."
When the track is running off the ground (full stroke)
V
Second
3.8 to 4.6 (Reference value)
Required time to reach the 90 degrees point of swing while the boom is raised
20-24
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
STANDARD VALUE TABLE FOR MACHINE: PC210-10M0
Test condition
Pump discharged volume (performance)
Unit
•
Pump speed: 1750 rpm
•
PC-EPC current value: 440 mA
•
Discharged pressure of the test pump (MPa{kg/cm2}): P1
•
Discharged pressure of the another pump (MPa{kg/cm2}): P2
•
Average discharged pressure of the pumps (MPa{kg/cm2}): Pp=(P1+P2)/2
ℓ/min
Standard value for new machine
Repair limit
Q
Q
(See the graph)
(See the graph)
300
Pump discharged volume Q(ℓ/min)
250
200
Upper limit (ref.) 150
Lower limit 100
50
0
50
100
150
200
Average of pump discharged pressure
250
300
350
400
Pp=(P1+P2)/2 (MPa{kg/cm2}) G0002027
•
Measure the discharged pressure of pumps (P1) and (P2) at near the average discharged pressure.
•
Avoid the measurement near the point where the graph bends because the error is large.
•
When the engine speed cannot be set to the specified speed by the fuel control dial, calculate the pump discharge amount of the specified speed based on the engine speed and pump discharge amount at the time of measurement.
PC210-10M0, PC210LC-10M0
20-25
STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0 Engine - SAA6D107E-1 Performance Item
Engine speed at high idle
Engine speed at low idle
Test condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P mode
•
Fuel control dial: MAX (High idle) position
•
Control lever and control pedal: NEUTRAL
•
Auto-deceleration: OFF
•
Swing lock switch: ON
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P mode
•
Fuel control dial: MIN (Low idle) position
•
Control lever and control pedal: NEUTRAL
Unit
Standard value for new machine
Repair limit
rpm
1780 to 1920
1780 to 1920
rpm
1000 to 1100
1000 to 1100
Unit
Standard value for new machine
Repair limit
Min. 133
Min. 103
{Min. 1,000}
{Min. 775}
Min. 120
Min. 90
{Min. 900}
{Min. 675}
Air intake and exhaust system Item
Test condition •
Boost pressure
20-26
Engine coolant temperature: 60 to 100 °C
Turbocharger outlet pressure Intake mani-
•
Hydraulic oil temper- fold pressure ature: 45 to 55 °C
•
Working mode: P mode
•
Fuel control dial: MAX (High idle) position
•
Swing lock switch: ON
•
When oil pressure is relieved in arm IN circuit and one-touch power maximizing is activated
kPa {mmHg}
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Unit
Standard value for new machine
Repair limit
Bosch index
Max. 1.5
Max. 1.5
0.25
0.152 to 0.381
0.51
0.381 to 0.762
Unit
Standard value for new machine
Repair limit
Engine oil temperature: 40 to 60 °C
MPa
Min. 2.41
Min. 1.69
•
When no-injection cranking is done
{kg/cm2}
{Min. 24.6}
{Min. 17.2}
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P mode
•
Auto-deceleration: OFF
kPa
Max. 0.98
Max. 1.96
•
Fuel control dial: MAX (High idle) position
{mmH2O}
{Max. 100}
{Max. 200}
•
Swing lock switch: ON
•
When oil pressure is relieved in arm IN circuit and one-touch power maximizing is activated
Item
Exhaust gas color
STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0
Test condition •
Engine coolant temperature: 60 to 100 °C
•
Fuel control dial: MAX (High idle) position
•
After holding 5 seconds while the oil pressure is relieved in arm IN circuit
•
Swing lock ON
•
Without pressure cutoff
•
Engine coolant temperature: Normal temperature
Valve clearance
Engine outlet (tail pipe outlet)
Intake side Exhaust side
mm
Main body Item Compression pressure
Blowby pressure
Test condition •
PC210-10M0, PC210LC-10M0
20-27
STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0
Item
Test condition •
•
•
• Fuel pressure •
• •
•
Engine coolant temperature: 60 to 100 °C
20 STANDARD VALUE TABLE
Unit
Fuel control dial: MAX (High idle) position
Pressure in the low pressure circuit (inlet At cranking side of the fuel main filter) Engine coolant temperature: 60 to 100 °C
Fuel control dial: MAX (High idle) position
Pressure difference between inlet side At cranking and outlet side of the fuel main filter Engine coolant temperature: 60 to 100 °C
Fuel control dial: MAX (High idle) position
Pressure in the return circuit
At cranking
Engine coolant temperature: 60 to 100 °C
Fuel control dial: MAX (High Pressure in the neg- idle) position
Standard value for new machine
Repair limit
500 to 1300
500 to 1300
{5.1 to 13.3}
{5.1 to 13.3}
304 to 1109
304 to 1109
{3.1 to 11.3}
{3.1 to 11.3}
Max. 81
Max. 81
{Max. 0.83}
{Max. 0.83}
Max. 81
Max. 81
{Max. 0.83}
{Max. 0.83}
Max. 18.6
Max. 18.6
{Max. 0.19}
{Max. 0.19}
Max. 18.6
Max. 18.6
{Max. 0.19}
{Max. 0.19}
kPa
Max. -50.7
Max. -40.5
{mmHg}
{Max. -380}
{Max. -305}
Min. 70
Min. 70
Max. 575
Max. 575
Max. 575
Max. 575
Max. 8
Max. 8
Max. 5 drops
Max. 5 drops
Max. 150
Max. 150
Max. 45
Max. 45
kPa {kg/cm2}
ative pressure circuit Discharge volume of the supply pump Return volume from the supply pump Fuel discharged volume, return volume, and leakage
At cranking Fuel control dial: MIN (Low idle) position
Leakage from the pressure limiter
Fuel control dial: MIN (Low idle) position At cranking
Fuel control diReturn volume from the in- al: MIN (Low idle) position jector At cranking
20-28
mℓ
At cranking
-
mℓ
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE: PC210LC-10M0
Lubrication system Item
Test condition •
Engine Oil Pressure
Engine coolant temperature: 60 to 100 °C
•
Auto-deceleration: OFF
•
Working mode: P mode
•
Engine oil EO10W30-DH
Standard value for new machine
Repair limit
Min. 0.29
Min. 0.25
{Min. 3.0}
{Min. 2.5}
Min. 0.10
Min. 0.07
{Min. 1.0}
{Min. 0.7}
°C
80 to 110
Max. 120
Unit
Standard value for new machine
Repair limit
mm
6.3 to 8.7
6.3 to 8.7
Unit
Fuel control dial: MAX (High idle) position
MPa Fuel control dial: MIN (Low idle) position
{kg/cm2}
EO15W40-DH EOS0W30-DH EOS5W40-DH Engine Oil Temperature
Full speed range (in oil pan)
Cooling system Item Belt tension of air conditioner compressor
Test condition •
Middle of the compressor pulley and fan pulley
•
Deflection when it is pushed with a finger with 60N {6.2 kg}
PC210-10M0, PC210LC-10M0
20-29
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0 Engine - SAA6D107E-1 Engine Speed Item
Engine speed at 2 pump relief
Engine speed at 2 pump relief and when onetouch power maximizing is enabled
Engine speed when auto-deceleration is actuated
20-30
Test condition •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Swing lock switch: ON
•
Arm IN relief
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Arm IN relief+one-touch power maximizing switch is ON
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: ON
•
Control lever and control pedal: NEUTRAL
Unit
Standard value for new machine
Repair limit
rpm
1600 to 1800
1600 to 1800
rpm
1850 to 2050
1850 to 2050
rpm
950 to 1150
950 to 1150
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Stroke of the control valve spool Unit
Standard value for new machine
Repair limit
RAISE side
mm
11.0 to 12.0
11.0 to 12.0
LOWER side
mm
9.0 to 10.0
9.0 to 10.0
Arm IN side
mm
11.0 to 12.0
11.0 to 12.0
Arm OUT side
mm
9.0 to 10.0
9.0 to 10.0
Arm IN side
mm
9.0 to 10.0
9.0 to 10.0
Arm OUT side
mm
9.0 to 10.0
9.0 to 10.0
Swing RIGHT side
mm
9.0 to 10.0
9.0 to 10.0
Swing LEFT side
mm
9.0 to 10.0
9.0 to 10.0
Travel FORWARD side
mm
9.0 to 10.0
9.0 to 10.0
Travel REVERSE side
mm
9.0 to 10.0
9.0 to 10.0
Unit
Standard value for new machine
Repair limit
Stroke of the R.H. control lever (boom side)
mm
75 to 95
75 to 95
Stroke of the L.H. control lever (arm side)
mm
75 to 95
75 to 95
mm
75 to 95
75 to 95
mm
75 to 95
75 to 95
mm
103 to 127
103 to 127
Play of the R.H. control lever and L.H. control lever
mm
Max. 15
Max. 20
Stroke of the travel control lever
mm
Max. 20
Max. 25
Item
Test condition
Stroke of the boom valve spool Stroke of the arm valve spool Stroke of the boom valve spool
•
Engine: Stopped
•
Measuring posture: See "CONTROL VALVE" of "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE"
Stroke of the swing valve spool
Stroke of the travel valve spool
Stroke and play of the lever Item
Stroke of the R.H. control lever (bucket side) Stroke of the L.H. control lever (swing side) Stroke of the travel control lever
Test condition
•
Engine: Stopped
•
Measuring position: Center of the lever grip
•
From the neutral position to the stroke end (excludes the play)
PC210-10M0, PC210LC-10M0
20-31
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
20 STANDARD VALUE TABLE
Operating force of the control lever and travel pedal Item
Test condition
Operating force of the R.H. control lever (boom side) Operating force of the L.H. Control lever (arm side) Operating force of the R.H. control lever (bucket side) Operating force of the L.H. control lever (swing side)
Unit
N {kg}
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Control lever measurement position: Center of the lever grip
•
Control pedal measurement position: tip of the pedal
•
From neutral position to the stroke end
N {kg}
N {kg}
N {kg}
Operating force of the travel lever
N {kg}
Operating force of the travel pedal
N {kg}
Standard value for new machine
Repair limit
11.8 to 19.6
Max. 24.5
{1.2 to 2.0}
{Max. 2.5}
11.8 to 19.6
Max. 24.5
{1.2 to 2.0}
{Max. 2.5}
9.8 to 15.6
Max. 21.6
{1.0 to 1.6}
{Max. 2.2}
9.8 to 15.6
Max. 21.6
{1.0 to 1.6}
{Max. 2.2}
18.6 to 30.4
Max. 39.2
{1.9 to 3.1}
{Max. 4.0}
55.9 to 93.1
Max. 107.6
{5.7 to 9.5}
{Max. 11}
Standard value for new machine
Repair limit
Oil pressure of work equipment, swing, and travel Item
Unload pressure (PFC, PRC)
20-32
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Control lever and control pedal: NEUTRAL
Unit
MPa
2.5 to 4.5
2.5 to 4.5
{kg/cm2}
{26 to 46}
{26 to 46}
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Test condition
•
When onetouch power maximizing is Hydraulic oil temper- activated
ature: 45 to 55 °C •
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Swing lock switch: OFF
Bucket relief pressure (PFC、 PRC)
Swing relief pressure (PFC、 PRC)
Travel relief pressure (PFC、 PRC)
Control circuit oil pressure
Repair limit
33.8 to 35.8
33.3 to 36.3
{345 to 365}
{340 to 370}
36.3 to 38.3
35.8 to 38.8
{370 to 390}
{365 to 396}
33.8 to 35.8
33.3 to 36.3
{345 to 365}
{340 to 370}
36.3 to 38.3
35.8 to 38.8
{370 to 390}
{365 to 396}
33.8 to 35.8
33.3 to 36.3
{345 to 365}
{340 to 370}
36.3 to 38.3
35.8 to 38.8
{370 to 390}
{365 to 396}
MPa
27.9 to 30.9
{kg/cm2}
{285 to 315}
27.4 to 31.4 {280 to 320}
MPa
36.7 to 39.7
36.2 to 40.2
{kg/cm2}
{375 to 405}
{370 to 410}
MPa
2.93 to 3.43
2.75 to 3.43
{kg/cm2}
{30 to 35}
{28 to 35}
At normal relief
Boom relief pressure (PFC、 PRC)
Arm relief pressure (PFC、 PRC)
Standard value for new machine
Unit
{kg/cm2}
At normal relief When onetouch power maximizing is activated
MPa {kg/cm2}
At normal relief When onetouch power maximizing is activated
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Swing lock switch: ON
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
•
Control lever and control pedal: NEUTRAL
PC210-10M0, PC210LC-10M0
MPa
MPa {kg/cm2}
20-33
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Item
Test condition
• • PC valve outlet pressure (PFC-PENF, PRC-ENR)
Fuel control dial: MAX (High idle) position Working mode: P mode
•
Swing lock switch: ON Arm IN relief
Servo piston inlet pressure Rear pump discharged pressure
Hydraulic oil temper- Fuel control dial: MIN (Low ature: 45 to 55 °C
PC-EPC valve outlet pressure
•
Working mode: P mode
(PMF, PMR)
•
Control lever and control pedal: NEUTRAL
(PFC-PLSFC, PRC-PLSRC)
LS valve outlet pressure (Servo piston inlet pressure) (PFC-PENF, PRC-PENR)
Fuel control dial: MAX (High idle) position
Hydraulic oil temper- Control lever and control ature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Hi
•
Run the track on one side idle off the ground
•
Hydraulic oil temper- Control lever and control ature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
36.1 to 38.8
36.1 to 39.7
{368 to 395}
{368 to 405}
Above value x Approximately
Above value x Approximately
MPa
0.6
0.6
{kg/cm2}
36.1 to 38.8
36.1 to 39.7
{368 to 395}
{368 to 405}
Above value x Approximately
Above value x Approximately
0.6
0.6
Approximately 2.6
Approximately 2.6
{Approximately 26}
{Approximately 26}
MPa {kg/cm2}
pedal: NEUTRAL
Approximately 1.0
Approximately 1.0
{Approximately 10}
{Approximately 10}
2.5 to 4.5
2.5 to 4.5
{26 to 46}
{26 to 46}
1.66 to 1.81
1.66 to 1.81
{17 to 18.5}
{17 to 18.5}
Approximately the same as the pump discharged pressure
Approximately the same as the pump discharged pressure
Above value x Approximately
Above value x Approximately
0.6
0.6
MPa {kg/cm2} Travel lever: Half stroke
pedal: NEUTRAL
Travel lever: Run the track on one Half stroke
side idle off the ground
20-34
idle) position
•
•
Repair limit
Servo piston inlet pressure
•
LS differential pressure
Standard value for new machine
Unit
Front pump Hydraulic oil temper- discharged pressure ature: 45 to 55 °C
•
•
20 STANDARD VALUE TABLE
MPa {kg/cm2}
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
LS-EPC valve outlet pressure
Test condition •
Hydraulic oil temper- Travel speed: ature: 45 to 55 °C Lo
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Auto-deceleration: OFF
(PSIG)
Solenoid valve outlet pressure
PPC valve outlet pressure
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Travel speed: Hi
Hydraulic oil temper- OFF (de-enerature: 45 to 55 °C gized) ON (energized)
•
Hydraulic oil temper- Control lever and control ature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position Working mode: P mode
{Approximately 25}
{Approximately 25}
Approximately 0.7
Approximately 0.7
{Approximately 7}
{Approximately 7}
0
0
{0}
{0}
{kg/cm2}
•
•
Repair limit
MPa
Travel lever: Fine control
Fuel control dial: MAX (High idle) position
Standard value for new machine
Approximately 2.45 Approximately 2.45
Travel speed: Mi
•
•
Unit
pedal: NEUTRAL
Control lever and control pedal: Full stroke
0
0
MPa
{0}
{0}
{kg/cm2}
Approximately 2.9
Approximately 2.9
{Approximately 30}
{Approximately 30}
0
0
{0}
{0}
MPa {kg/cm2}
Approximately the Approximately the same as the control same as the control circuit oil pressure circuit oil pressure
Swing Item
Overrun when stopping swing
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
Unit
° (angle)
Standard value for new machine
Repair limit
Max. 100
Max. 130
How much angle swing circle is displaced from the original position when it stops after one swing
PC210-10M0, PC210LC-10M0
20-35
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Item
Time required from the start position of the swing
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
20 STANDARD VALUE TABLE
Standard value for new machine
Repair limit
2.8 to 3.4
Max. 3.7
4.0 to 4.8
Max. 5.5
Second
21.7 to 26.7
Max. 30
mm
0
0
ℓ/min
Max. 5
Max. 10
Unit 90°
180°
Second
Time required from the start position of the swing to 90 degrees and 180 degrees positions
Time required for swing
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
•
The time it takes to swing 5 times after swinging 1 time
Time required from the start position of the swing to 90 degrees and 180 degrees positions
Hydraulic drift of swing
•
Hydraulic oil temperature: 45 to 55 °C
•
Engine is stopped
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 2".
Mark the inner race and outer race of the swing circle with a measurement posture. Displacement after 5 minutes
Oil leakage from swing motor
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Swing lock switch: ON
Oil leakage from swing motor at relief
20-36
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Travel Item
Travel speed (Required time, engine is at idle, and track is off the ground)
Standard value for new machine
Repair limit
Lo
48.6 to 59.8
48.6 to 63.8
Mi
36.7 to 44.9
36.7 to 48.9
Hi
28.9 to 32.1
28.9 to 34.1
Lo
20.9 to 25.7
20.9 to 26.7
Mi
14.5 to 19.5
14.5 to 20.5
12.0 to 14.0
12.0 to 15.0
Max. 150
Max. 250
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 1".
Unit
Second
The time it takes to run the track 5 times after it is run once •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 2".
Travel speed (Required time, the machine actually travels)
Second Hi
(The time it takes to travel 20 m after a 10 m run on the flat ground)
Deviation while the machine travels
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Lo
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 2".
mm
Deviation while the machine travels 20 m after a 10 m run on the flat ground((x) of "TRAVEL 3")
PC210-10M0, PC210LC-10M0
20-37
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Item
Hydraulic drift while the machine travels
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Engine is stopped
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 4".
20 STANDARD VALUE TABLE
Unit
Standard value for new machine
Repair limit
mm
0
0
ℓ/min
Max. 13.6
Max. 27.2
Unit
Standard value for new machine
Repair limit
Max. 600
Max. 900
Max. 18
Max. 27
Max. 160
Max. 240
Max. 40
Max. 58
Hydraulic drift 5 minutes after the measurement posture
Oil leakage from the travel motor
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Lock the sprocket with a pin
Oil leakage from the travel motor at relief
Hydraulic drift of work equipment Item Hydraulic drift measured at tooth tip (all work equipment) Retract quantity of the boom cylinder Extract quantity of the arm cylinder
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Flat ground
•
Rated load or the bucket is filled with sand (0.8 m3: 1440 kg)
•
Engine is stopped
•
Control lever: NEUTRAL
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 1."
Retract quantity of the bucket cyl- Amount of movement of 15 minutes while it inder is measured every five minutes from the measurement position
20-38
mm
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Work equipment speed Item
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 2."
Boom speed (Required time)
Unit RAISE
LOWER
Second
Standard value for new machine
Repair limit
2.9 to 3.7
Max. 4.7
2.1 to 2.7
Max. 3.7
3.1 to 3.9
Max. 4.5
2.4 to 3.0
Max. 3.5
Required time to operate from RAISE stroke end to LOWER the bucket to the ground
Arm speed (Required time)
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 3."
Arm IN
Arm OUT
Second
Required time to operate from arm OUT stroke end to arm IN stroke end
PC210-10M0, PC210LC-10M0
20-39
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Item
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 4."
Bucket speed (Required time)
20 STANDARD VALUE TABLE
Standard value for new machine
Repair limit
2.1 to 2.7
Max. 3.3
1.6 to 2.1
Max. 2.7
Unit
Standard value for new machine
Repair limit
Second
Max. 1.0
Max. 1.2
Unit Bucket CURL
Bucket DUMP
Second
Required time to operate from bucket DUMP stroke end to bucket CURL stroke end
Time lag of work equipment control Item
Boom time lag
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 5."
Set the boom to the maximum RAISE position. Required time to operate the boom from the time when the work equipment is lowered to the ground and until the time when the machine front is lifted off
20-40
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 6."
Arm time lag
Unit
Standard value for new machine
Repair limit
Second
Max. 2.0
Max. 2.8
Second
Max. 1.0
Max. 3.6
Unit
Standard value for new machine
Repair limit
Max. 4.5
Max. 20
Max. 10
Max. 50
Set the arm to the maximum arm OUT position, then operate it to the arm IN side. Stop the arm at the vertical position. Required time from the time when the arm is operated again and until the time when the arm starts move off •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MIN (Low idle) position
•
Working mode: P mode
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 7."
Bucket time lag
Set the bucket at the maximum DUMP position, and operate it to the bucket CURL side. Stop the bucket at the vertical position. Required time from the time when the bucket is operated again and until the time when the bucket starts move off
Oil leakage volume Item Oil leakage from the cylinder
Test condition •
Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) Oil leakage from position the center swivel Leakage from the cylinder to be measured joint or travel motor at relief
PC210-10M0, PC210LC-10M0
cc/min
20-41
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
20 STANDARD VALUE TABLE
Pump performance Item
Travel deviation at combined operation of work equipment and travel.
Test condition •
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Lo
•
Measuring posture See:"MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 2".
Unit
Standard value for new machine
Repair limit
mm
Max. 200
Max. 220
1.15 to 1.55
0.72 to 1.98
3.15 to 3.55
2.72 to 3.98
Deviation while the machine travels 20 m after a 10 m run on the flat ground((x) of "TRAVEL 3") •
Voltage of the pump swash plate sensor
Required time to start the boom RAISE and swing (PC oil flow control characteristic)
Hydraulic oil temper- When the control lever is in ature: 45 to 55 °C NEUTRAL
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Travel speed: Hi
•
Travel operation: Turn the track on one side idle off the ground
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P mode
•
Rated load or the bucket is filled with sand (0.8 m3: 1440 kg)
•
Measuring posture: See "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "WORK EQUIPMENT 8."
When the track is running off the ground (full stroke)
V
Second
3.8 to 4.6 (Reference value)
Required time to reach the 90 degrees point of swing while the boom is raised
20-42
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
Item
STANDARD VALUE TABLE FOR MACHINE: PC210LC-10M0
Test condition
Pump discharged volume (performance)
Unit
•
Pump speed: 1750 rpm
•
PC-EPC current value: 440 mA
•
Discharged pressure of the test pump (MPa{kg/cm2}): P1
•
Discharged pressure of the another pump (MPa{kg/cm2}): P2
•
Average discharged pressure of the pumps (MPa{kg/cm2}): Pp=(P1+P2)/2
ℓ/min
Standard value for new machine
Repair limit
Q
Q
(See the graph)
(See the graph)
300
Pump discharged volume Q(ℓ/min)
250
200
Upper limit (ref.) 150
Lower limit 100
50
0
50
100
150
200
Average of pump discharged pressure
250
300
350
400
Pp=(P1+P2)/2 (MPa{kg/cm2}) G0002027
•
Measure the discharged pressure of pumps (P1) and (P2) at near the average discharged pressure.
•
Avoid the measurement near the point where the graph bends because the error is large.
•
When the engine speed cannot be set to the specified speed by the fuel control dial, calculate the pump discharge amount of the specified speed based on the engine speed and pump discharge amount at the time of measurement.
PC210-10M0, PC210LC-10M0
20-43
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE
20 STANDARD VALUE TABLE
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE Control valve Spool stroke
G0002024
Swing 1 •
Amount of overrun when stopping swing
•
Time required from swing start position
•
Time required for swing
G0002025
Swing 2 Hydraulic drift of swing
15°
G0002026
Travel 1 Travel speed (required time, idling)
Travel 2 •
Travel speed (required time, actual travel)
•
Travel deviation
45r
G0002028
20-44
PC210-10M0, PC210LC-10M0
20 STANDARD VALUE TABLE
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE
Travel 3
20m
Travel deviation
X 10m G0002029
Travel 4 Hydraulic drift of travel
12°
G0002030
Work equipment 1 Hydraulic drift of work equipment
G0002031
Work equipment 2 Boom speed (required time)
G0002032
Work equipment 3 Arm speed (required time)
G0002033
PC210-10M0, PC210LC-10M0
20-45
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE
20 STANDARD VALUE TABLE
Work equipment 4 Bucket speed (required time)
G0002034
Work equipment 5 Boom time lag
G0002035
Work equipment 6 Arm time lag
G0002036
Work equipment 7 Bucket time lag
G0002037
Work equipment 8 Time required for boom RAISE and swing start (PC flow control characteristics)
G0002038
20-46
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
PC210-10M0, PC210LC-10M0
30-1
CONTENTS
30 TESTING AND ADJUSTING
CONTENTS ABBREVIATION LIST .................................................................................................................................... 30-5 RELATED INFORMATION ON TESTING AND ADJUSTING ....................................................................... 30-10 TOOLS FOR TESTING AND ADJUSTING............................................................................................ 30-10 SKETCH OF TOOLS FOR TESTING AND ADJUSTING ...................................................................... 30-15 ENGINE AND COOLING SYSTEM.............................................................................................................. 30-17 TEST ENGINE SPEED ......................................................................................................................... 30-17 TEST ENGINE HIGH IDLE SPEED ............................................................................................... 30-17 Test engine low idle speed ............................................................................................................. 30-17 TEST ENGINE SPEED AT 2 PUMPS RELIEF ............................................................................... 30-17 Test engine speed at 2 pumps relief and one-touch power maximizing .......................................... 30-18 TEST ENGINE SPEED WITH AUTO-DECELERATION ................................................................. 30-18 Test boost pressure............................................................................................................................... 30-20 TEST BOOST PRESSURE ON MACHINE MONITOR................................................................... 30-20 TEST BOOST PRESSURE BY TESTING TOOL ........................................................................... 30-21 TEST EXHAUST GAS COLOR ............................................................................................................. 30-23 Test exhaust gas color by handy smoke checker ........................................................................... 30-23 TEST EXHAUST GAS COLOR BY SMOKE METER ..................................................................... 30-24 Test and adjust valve clearance ............................................................................................................ 30-26 TEST VALVE CLEARANCE ........................................................................................................... 30-26 Adjust valve clearance ................................................................................................................... 30-27 TEST COMPRESSION PRESSURE..................................................................................................... 30-29 TEST COMPRESSION PRESSURE.............................................................................................. 30-29 TEST BLOWBY PRESSURE ................................................................................................................ 30-32 TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT))................................................................................................................................ 30-32 Test blowby pressure (machine without blowby pressure sensor) .................................................. 30-33 TEST ENGINE OIL PRESSURE ........................................................................................................... 30-35 TEST ENGINE OIL PRESSURE .................................................................................................... 30-35 Test fuel pressure.................................................................................................................................. 30-37 TEST FUEL PRESSURE ............................................................................................................... 30-38 Test fuel discharged volume, return rate, and leakage .......................................................................... 30-44 TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-45 BLEED AIR FROM FUEL SYSTEM ...................................................................................................... 30-50 Bleed air from fuel system.............................................................................................................. 30-50 Test fuel system for leakage.................................................................................................................. 30-52 Test fuel circuit for leakage............................................................................................................. 30-52 CYLINDER CUT-OUT MODE OPERATION .......................................................................................... 30-54 NO-INJECTION CRANKING OPERATION ........................................................................................... 30-55 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ........................................ 30-56 CHECK AIR CONDITIONER COMPRESSOR BELT...................................................................... 30-56 ADJUST AIR CONDITIONER COMPRESSOR BELT .................................................................... 30-56 POWER TRAIN............................................................................................................................................ 30-58 Test swing circle bearing clearance....................................................................................................... 30-58 Test swing circle bearing clearance................................................................................................ 30-58 UNDERCARRIAGE AND FRAME................................................................................................................ 30-59 Test and adjust track shoe tension ........................................................................................................ 30-59 Test track shoe tension .................................................................................................................. 30-59 Adjust track shoe tension ............................................................................................................... 30-59 HYDRAULIC SYSTEM................................................................................................................................. 30-61 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.................................................... 30-61 RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK .................................................. 30-61 Release remaining pressure in hydraulic cylinder circuit ................................................................ 30-61 Release remaining pressure for machines without anti-drop valve ................................................. 30-61 Release remaining pressure for machines with boom anti-drop valve ............................................ 30-61 Release remaining pressure from swing motor circuit ................................................................... 30-63 RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT...................................... 30-63 30-2
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
CONTENTS
Test and adjust oil pressure in work equipment, swing, and travel circuits............................................. 30-64 Test oil pressure in work equipment, swing, and travel circuits....................................................... 30-64 Adjust oil pressure in work equipment, swing, and travel circuits ................................................... 30-71 TEST OIL PRESSURE OF CONTROL CIRCUIT .................................................................................. 30-74 Test oil pressure of control circuit .................................................................................................. 30-74 Test and adjust oil pressure in pump PC control circuit ......................................................................... 30-76 Test PC valve outlet pressure (servo piston inlet pressure) ............................................................ 30-76 TEST PC-EPC VALVE OUTLET PRESSURE ................................................................................ 30-77 Adjust oil pressure in pump PC control circuit ................................................................................ 30-79 Test and adjust oil pressure in pump LS control circuit .......................................................................... 30-80 Test LS differential pressure with machine monitor......................................................................... 30-80 Test LS differential pressure by testing tool .................................................................................... 30-82 Test LS valve outlet pressure (servo piston inlet pressure)............................................................. 30-84 Test LS-EPC valve outlet pressure................................................................................................. 30-85 Adjust LS valve .............................................................................................................................. 30-86 Test outlet pressure of solenoid valve ................................................................................................... 30-88 Test outlet pressure of solenoid valve ............................................................................................ 30-88 OPERATING CONDITION OF SOLENOID VALVE ........................................................................ 30-90 Test PPC valve outlet pressure ............................................................................................................. 30-92 Test outlet pressure of PPC valve with machine monitor ............................................................... 30-92 TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL................................................ 30-93 Adjust play of work equipment and swing PPC valve ............................................................................ 30-95 Adjust play of work equipment and swing PPC valve ..................................................................... 30-95 TesTest pump swash plate sensor......................................................................................................... 30-96 Test pump swash plate sensor ....................................................................................................... 30-96 Test parts causing hydraulic drift in work equipment ............................................................................. 30-97 Test parts causing hydraulic drift of boom cylinder and bucket cylinder .......................................... 30-97 Test parts causing hydraulic drift of arm cylinder ............................................................................ 30-97 Test parts causing hydraulic drift of boom hydraulic drift prevention valve...................................... 30-98 Test parts causing hydraulic drift of PPC valve............................................................................... 30-98 Test oil leakage ..................................................................................................................................... 30-99 TEST OIL LEAKAGE FROM BOOM CYLINDER ........................................................................... 30-99 TEST OIL LEAKAGE FROM ARM CYLINDER .............................................................................30-100 TEST OIL LEAKAGE FROM BUCKET CYLINDER .......................................................................30-101 Test oil leakage from swing motor .................................................................................................30-101 Test oil leakage from travel motor..................................................................................................30-102 Bleed air from hydraulic system ...........................................................................................................30-104 Bleed air from main pump .............................................................................................................30-105 BLEED AIR FROM CYLINDER .....................................................................................................30-106 BLEED AIR FROM SWING MOTOR.............................................................................................30-107 BLEED AIR FROM TRAVEL MOTOR ...........................................................................................30-107 CAB RELATED PARTS...............................................................................................................................30-109 Test cab tipping stopper .......................................................................................................................30-109 Test cab tipping stopper ................................................................................................................30-109 ADJUST MIRRORS .............................................................................................................................30-110 ADJUST MACHINE LEFT FRONT MIRROR (A)...........................................................................30-110 Adjust regular position of machine left front mirror (A)................................................................... 30-111 ADJUST MACHINE RIGHT FRONT MIRROR (B) ........................................................................30-112 ADJUST REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)...............................30-112 ADJUST MACHINE RIGHT SIDE MIRROR (C) ............................................................................30-113 ELECTRICAL SYSTEM ..............................................................................................................................30-115 SETTING AND OPERATION OF MACHINE MONITOR.......................................................................30-115 OPERATOR MODE ......................................................................................................................30-119 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN ............................30-119 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN .................................30-119 CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY).........................................................30-120 CHECK FUNCTION OF SERVICE METER ..................................................................................30-120 SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD.....................................30-120 PC210-10M0, PC210LC-10M0
30-3
CONTENTS
30 TESTING AND ADJUSTING
SERVICE MODE...........................................................................................................................30-123 Operation of service mode ............................................................................................................30-123 Check pre-defined monitoring information.....................................................................................30-124 CHECK MONITORING INFORMATION ........................................................................................30-128 ABNORMALITY RECORD MENU.................................................................................................30-136 CHECK MAINTENANCE RECORD ..............................................................................................30-139 MAINTENANCE MODE SETTING ................................................................................................30-141 Phone number entry setting ..........................................................................................................30-145 DEFAULT SETTING MENU ..........................................................................................................30-146 TESTING MENU...........................................................................................................................30-154 ADJUSTMENT MENU ..................................................................................................................30-156 NO-INJECTION CRANKING OPERATION ...................................................................................30-173 KOMTRAX SETTINGS MENU ......................................................................................................30-175 Display service message ..............................................................................................................30-177 START UP KOMTRAX TERMINAL ......................................................................................................30-178 Adjust rearview camera angle ..............................................................................................................30-182 ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-182 ENGINE CONTROLLER VOLTAGE CIRCUIT .....................................................................................30-184 TEST DIODES .....................................................................................................................................30-185 TEST DIODES BY DIGITAL TESTER ...........................................................................................30-185 TEST DIODES BY ANALOG TESTER..........................................................................................30-185 Pm-CLINIC .................................................................................................................................................30-186 PM CLINIC SERVICE ..........................................................................................................................30-186 PM CLINIC CHECK SHEET: PC210-10M0 ...................................................................................30-189 PM CLINIC CHECK SHEET: PC210LC-10M0...............................................................................30-197
30-4
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
ABBREVIATION LIST
ABBREVIATION LIST •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
•
Abbreviations that are used in general society may not be included.
•
Special abbreviations that appear infrequently are noted in the text.
•
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
Steering
ARAC
Automatic Retarder Accelerator Control
Travel and brake
ARSC
Automatic Retarder Speed Control
Travel and brake (HD, HM)
(WA)
(HD, HM)
Travel and brake (HD, HM)
Explanation A function that releases the brakes when the tires skid (wheels stop rotating), and applies the brakes again when the wheels start to rotate. A function that automatically sets the idle speed. A function that uses a lever to perform the steering operations instead of a steering wheel. Moreover, the lever is used to shifts gear and changes direction (FORWARD, REVERSE). A function that automatically applies the retarder with a constant braking force when the accelerator pedal is released while the machine is traveling downhill. A function that automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when the accelerator pedal is released while the machine is traveling downhill.
ASR
Automatic Spin Regula- Travel and brake tor (HD, HM)
A function that automatically uses the optimum braking force to drive both wheels when the tires spin on soft ground.
ATT
Attachment
A device that can be fixed onto the standard machine in order to enable it to do different jobs.
BCV
Brake cooling oil control Brake valve (HD)
CAN
Controller Area Network
Communication and electronic control
One of communication standards that are used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve that is installed to KCCV ventilator. It is written as CDR valve and it is not used singly.
CLSS
Closed-center Load Sensing System
Hydraulic system
A system that simultaneously actuates multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
A function that maintains optimum fuel injection amount and fuel injection timing by engine controller electronically controlling supply pump, common rail, and injector.
CRI
Common Rail Injection
PC210-10M0, PC210LC-10M0
WORK EQUIPMENT
A valve that divides part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used.
30-5
ABBREVIATION LIST
30 TESTING AND ADJUSTING
Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Travel Suspension System (WA)
A system that ensures smooth high-speed travel by absorbing vibration of machine during travel with spring effect of accumulator.
ECU
Electronic Control Unit
An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
A function that recirculates part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of NOx.
Equipment ManageMACHINE MONITOR ment Monitoring System
A system which enables data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor to be checked on the monitor.
EPC
Electromagnetic ProporHydraulic system tional Control
This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Cab and canopy Structure
EMMS
F-N-R
GPS
GNSS
Forward-Neutral-Reverse Global Positioning System
Electronic control system
Transmission (D, HD, WA, etc)
Electronic control system
Operation Communication (KOMTRAX, KOMTRAX Plus)
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
Explanation An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECU) A proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.
A structure that protects the operator's head from falling objects. ISO 3449 compliant Forward - Neutral - Reverse A system that uses satellites to determine the current location on the earth 1. A system that uses satellites such as GPS, GALILEO, etc. to determine location on the earth. A function which uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly, machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
Steering
HST
Hydrostatic Transmission
Transmission
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
IMA
30-6
Inlet Metering Actuator
(D Series)
(D, WA)
A hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears.
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Abbreviation
IMU
Actual word spelled out
Inertial Measurement Unit
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
A device that detects the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV (+)
Inlet Metering Valve
Engine
A valve which is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
A mechanism that separates oil in blowby gas and send it back to the intake side for it to be burned again. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
Engine
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
A filter that captures soot in exhaust gas. It is built in to KDPF A catalyst that is used for purifying exhaust gas.
Engine
Komatsu Diesel ParticuEngine late Filter
It is built in to KDPF or used in combination with the muffler in some cases. A component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler. A function that recovers the driving force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle machine travels on the soft ground road.
Komatsu Traction Control System
Travel and brake
LCD
Liquid Crystal Display
MACHINE MONITOR
A display equipment such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic parts
It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
One of communication standards that are used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
One of communication standards that are used in the network on the machine
MAF
Mass Air Flow
Engine
This indicates engine intake air flow. Mass air flow sensor is described as MAF sensor in some cases.
MMS
Multimedia Messaging Service
Communication
A service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
NC
Normally Closed
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally closed if it is not actuated (it opens when it is actuated).
NO
Normally Open
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally open if it is not actuated (it closes when it is actuated).
KTCS
PC210-10M0, PC210LC-10M0
(HM)
30-7
ABBREVIATION LIST
Abbreviation OLSS PC
PCCS
Actual word spelled out Open-center Load Sensing System
30 TESTING AND ADJUSTING
Purpose of use (major applicable machine (*1), or component/system) Hydraulic system
Pressure Compensation Hydraulic system Palm command control system
Steering (D Series)
Explanation A hydraulic system that can operate multiple actuators at the same time regardless of the load. A function used to correct oil pressure. A function that electronically controls the engine and transmission. It is done by a controller that instantly analyses data from each lever, pedal, and dial.
PCV
Pre-stroke Control Valve Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This system is used for controlling proportional pressure. It moves actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power train system
PTP
Power Tilt and power Pitch dozer
WORK EQUIPMENT
ROPS
Roll-Over Protective Structure
Hydraulic system Hydraulic system (D, PC, etc)
(D Series)
Cab and canopy
A piston type hydraulic pump and motor A mechanism that takes out the force for the work equipment separately from the travel. A function that hydraulically performs tilt operation and pitch operation of the bulldozer blade. A protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. ISO 3471 compliant
SCR
Selective Catalytic Reduction
Urea SCR system
An exhaust gas purifier using urea water to convert nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It Done also be mentioned as exhaust gas purification catalyst , or part of the of related devices.
Le Système internationUnit al d'unités
A universal unit system and "a single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
An actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
A solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
The turbocharger on which the cross-section area of the exhaust passage is made variable.
SI
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
30-8
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
ABBREVIATION LIST
List of abbreviations used in the circuit diagrams Abbreviation
Actual word spelled out
A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
PC210-10M0, PC210LC-10M0
30-9
TOOLS FOR TESTING AND ADJUSTING
30 TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING TOOLS TO TEST BOOST PRESSURE Symbol
A
B
Part number
Part name
Q'ty
Remarks
-
799-201-2202
Boost gauge kit
1
1
799-101-5160
Nipple
1
Size: R1/8
2
799-401-2311
Gauge
1
Pressure range: -101 to 200 kPa {-760 to 1500 mmHg}
3
799-401-2610
Hose
1
-
799-401-2301
Pm kit
1
1
790-261-1130
Coupling
1
TOOLS TO TEST EXHAUST GAS COLOR Symbol
Part number
A
799-201-9002
Handy smoke checker
1
B
Commercially available
Smoke meter
1
Filter paper
1
C
Commercially available
Part name
Q'ty
Remarks Bosch index: 0 to 9
TOOLS TO TEST VALVE CLEARANCE Symbol
Part number
Part name
Q'ty
A
795-799-1131
Gear
1
B
Commercially available
Feeler gauge
1
Remarks
TOOLS TO TEST COMPRESSION PRESSURE Symbol
Part number
A
795-502-1590
Gauge assembly
1
B
795-790-4411
Adapter
1
C
6754-11-3130
Gasket
1
D
Commercially available
Hose
1
E
Commercially available
Container
1
F
Commercially available
Insulating tape
1
30-10
Part name
Q'ty
Remarks Pressure range: 0 to 7 MPa
Internal diameter: 15 mm
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
TOOLS TO TEST BLOWBY PRESSURE Symbol
A
Part number
Part name
Q'ty
-
799-201-1506
Blowby checker
1
1
799-201-1591
Gauge
1
2
799-201-1511
Tool
1
3
799-201-1450
Adapter
1
Remarks
Pressure range: 0 to 10 MPa
TOOLS TO TEST ENGINE OIL PRESSURE Symbol
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5160
Nipple
1
Size: R1/8
B
799-401-2320
Gauge
1
Pressure range: 0 to 1 MPa
C
795-790-4430
Adapter
1
Size: R1/8
D
6215-81-9710
O-ring
1
A
TOOLS TO TEST FUEL PRESSURE Symbol
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5160
Nipple
2
Size: R1/8
2
799-101-5140
Gauge
1
Pressure range: 0 to 2.5 MPa
B
795-790-4430
Adapter
2
C
6215-81-9710
O-ring
2
D
795-790-5110
Screw
1
E
799-401-2320
Gauge
1
F
795-790-5120
Screw
1
-
799-201-2202
Boost gauge kit
1
1
799-101-5160
Nipple
1
Size: R1/8
2
799-401-2311
Gauge
1
Pressure range: -101 to 200 kPa {-760 to 1500 mmHg}
A
G
Pressure range: 0 to 1 MPa
TOOLS TO TEST FUEL DISCHARGE, RETURN AND LEAKAGE Symbol
Part number
Part name
A
799-790-4700
Tester kit
1
B
6164-81-5790
Joint
1
C
07005-01212
Washer
1
D
6754-71-5340
Connector
1
E
6754-71-5350
Washer
1
F
Commercially available
Measuring cylinder
1
G
Commercially available
Stopwatch
1
H
Commercially available
Hose
1
PC210-10M0, PC210LC-10M0
Q'ty
Remarks
Internal diameter: Approx. 14mm
30-11
TOOLS FOR TESTING AND ADJUSTING
Symbol
Part number
J
Commercially available
Part name Hose
30 TESTING AND ADJUSTING
Q'ty 1
Remarks Internal diameter: Approx. 7mm
TOOLS TO TEST FUEL CIRCUIT FOR LEAKAGE Symbol
Part number
A
Commercially available
Part name Developer for dye penetrant (color checker)
Q'ty
Remarks
1
TOOLS TO TEST SWING CIRCLE BEARING CLEARANCE Symbol
Part number
A
Commercially available
Part name Dial gauge
Q'ty
Remarks
1
TOOLS TO TEST TRACK TENSION Symbol
Part number
A
Commercially available
Part name Wooden block
Q'ty
Remarks
1
TOOLS TO TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS Symbol
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5110
Gauge
1
Pressure range: 0 to 60 MPa
2
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
2
Size: M10 x 1.25 mm
D
07002-11023
O-ring
2
E
Commercially available
Plate
1
Size: 250 x 260 x 32
F
Commercially available
Pin
1
Size: φ 200 x 80
A
TOOLS TO TEST ADJUST CONTROL CIRCUIT OIL PRESSURE Symbol
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
2
Size: M10 x 1.25 mm
D
07002-11023
O-ring
2
A
TOOLS TO TEST ADJUST PUMP PC CONTROL CIRCUIT OIL PRESSURE Symbol
A
30-12
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5110
Gauge
1
Pressure range: 0 to 60 MPa
2
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
Symbol
Part number
Part name
Q'ty
Remarks
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
4
Size: M10 x 1.25 mm
D
07002-11023
O-ring
4
TOOLS TO TEST ADJUST PUMP LS CONTROL CIRCUIT OIL PRESSURE Symbol
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5110
Gauge
1
Pressure range: 0 to 60 MPa
2
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
4
Size: M10 x 1.25 mm
D
07002-11023
O-ring
4
E
799-401-2701
Differential pressure gauge
1
Pressure range: 0 to 50 MPa
F
796T-440-1101
Sensor adapter
1
Pressure range: 0 to 50 MPa
A
TOOLS TO TEST SOLENOID VALVE OUTLET PRESSURE Symbol
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799-401-3200
Adapter
1
Size: 03
A
TOOLS TO TEST PPC VALVE OUTLET PRESSURE Symbol
Part number
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
1
Size: 02
D
07002-11023
O-ring
1
Size: 03
A
TOOLS TO TEST PPC VALVE OUTLET PRESSURE Symbol
Part number
A
07376-70315
Part name Plug
Q'ty 1
Remarks Size: 03
TOOLS TO TEST OIL LEAKAGE Symbol
Part number
A
Commercially available
Part name Measuring cylinder
PC210-10M0, PC210LC-10M0
Q'ty
Remarks
1
30-13
TOOLS FOR TESTING AND ADJUSTING
Symbol
Part number
B
07379-00640
Flange
2
Size: 06
C
07376-70522
Plug
2
Size: 05
D
07376-70422
Plug
1
Size: 04
E
Commercially available
Plate
1
Size: 250 x 260 x 32
F
Commercially available
Pin
1
Size: φ 200 x 80
30-14
Part name
30 TESTING AND ADJUSTING
Q'ty
Remarks
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING Note: Komatsu accepts no responsibilities whatsoever for special tools that are fabricated based on these drawings. Sensor adapter
Nipple
PC210-10M0, PC210LC-10M0
30-15
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
30 TESTING AND ADJUSTING
Adapter
Plug
30-16
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TEST ENGINE SPEED
ENGINE AND COOLING SYSTEM TEST ENGINE SPEED Test engine speed. For details, see the procedure below.
k
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to the LOCK position, and then stop the engine.
For standard values, see STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR ENGINE and STANDARD VALUE TABLE FOR MACHINE.
TEST ENGINE HIGH IDLE SPEED 1.
Start the engine.
2.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display items that follow by "Pre-defined Monitoring(01/11)", or "Monitoring Selection Menu". Monitoring code: 01002 "Engine Speed" Monitoring code: 04107"Coolant Temperature" Monitoring code: 04401"Hydraulic Oil Temperature"
3.
Set the coolant temperature and hydraulic oil temperature to be in the testing condition. •
Coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
4.
Set the working mode to P mode.
5.
Set the auto-deceleration function to be OFF.
6.
Turn the swing lock switch to ON position.
7.
Turn the fuel control dial to MAX (High idle) position.
8.
Check the engine speed when control levers and control pedals are in NEUTRAL position.
Test engine low idle speed 1.
Start the engine.
2.
Display the items below on "Pre-defined Monitoring (01/11)" or from "Monitoring Selection Menu". See "SETTING AND OPERATION OF MACHINE MONITOR". Monitoring code: 01002 "Engine Speed" Monitoring code: 04107 "Coolant Temperature" Monitoring code: 04401 "Hydraulic Oil Temperature"
3.
Set the engine coolant temperature and the hydraulic oil temperature so that they are in the testing condition range. •
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 ℃
4.
Set the working mode to P mode.
5.
Turn the fuel control dial to the MIN (low idle) position.
6.
Test the engine speed when the control lever and the control pedal are in the NEUTRAL position.
TEST ENGINE SPEED AT 2 PUMPS RELIEF 1.
Start the engine.
PC210-10M0, PC210LC-10M0
30-17
TEST ENGINE SPEED
2.
30 TESTING AND ADJUSTING
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display items that follow by "Pre-defined Monitoring(01/11)", or "Monitoring Selection Menu". Monitoring code: 01002"Engine Speed" Monitoring code: 04107"Coolant Temperature" Monitoring code: 04401"Hydraulic Oil Temperature"
3.
Set the coolant temperature and hydraulic oil temperature to be in the test condition. •
Coolant Temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55°C
4.
Set the working mode to P mode.
5.
Disable the auto-deceleration function.
6.
Set the swing lock switch to ON position.
7.
Turn the fuel control dial to MAX (High idle) position.
8.
Set the lock lever to FREE position.
9.
Operate the control lever, and test the engine speed when relieve the oil pressure in the arm IN circuit.
Test engine speed at 2 pumps relief and one-touch power maximizing 1.
Start the engine.
2.
Display the items below on "Pre-defined Monitoring (01/11)" or from "Monitoring Selection Menu". See "SETTING AND OPERATION OF MACHINE MONITOR". Monitoring code: 01002 "Engine Speed" Monitoring code: 04107 "Coolant Temperature" Monitoring code: 04401 "Hydraulic Oil Temperature"
3.
Set the engine coolant temperature and the hydraulic oil temperature so that they are in the testing condition range. •
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 ℃
4.
Set the working mode to P mode.
5.
Turn off the auto-deceleration.
6.
Turn the fuel control dial to MAX (High idle) position.
7.
Move the lock lever to FREE position.
8.
Operate the control lever to relieve the oil pressure in the arm IN circuit and do the one-touch power maximizing operation, and test the engine speed. When the switch is kept pressed, the one-touch power maximizing function is canceled automatically in approximately 8.5 seconds. Test the engine speed while this function is active.
TEST ENGINE SPEED WITH AUTO-DECELERATION 1.
Start the engine.
30-18
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
2.
TEST ENGINE SPEED
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display items that follow by "Pre-defined Monitoring(01/11)", or "Monitoring Selection Menu". Monitoring code: 01002 "Engine Speed" Monitoring code: 04107"Coolant Temperature" Monitoring code: 04401"Hydraulic Oil Temperature"
3.
Set the coolant temperature and hydraulic oil temperature to be in the testing condition. •
Coolant temperature: 60 to 100 °C
4.
Set the working mode to P mode.
5.
Enable the auto-decelerator.
6.
Set the fuel control dial to MIN (Low idle) position.
7.
Set the lock lever to FREE position.
8.
Set control levers and control pedals in NEUTRAL position, and check the engine speed when auto-decelerator is activated. REMARK Auto-decelerator is activated when the control lever and control pedal are in NEUTRAL position for 4 seconds or more, and the engine speed is decreased.
PC210-10M0, PC210LC-10M0
30-19
Test boost pressure
30 TESTING AND ADJUSTING
Test boost pressure Test boost pressure according to the procedure below. Check that no abnormality occurs in boost piping. TOOLS TO TEST BOOST PRESSURE Symbol
A
B k k
Part number
Part name
Q'ty
Remarks
-
799-201-2202
Boost gauge kit
1
1
799-101-5160
Nipple
1
Size: R1/8
2
799-401-2311
Gauge
1
Pressure range: -101 to 200 kPa {-760 to 1500 mmHg}
3
799-401-2610
Hose
1
-
799-401-2301
Pm kit
1
1
790-261-1130
Coupling
1
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
For standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
TEST BOOST PRESSURE ON MACHINE MONITOR 1.
Start the engine.
2.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(01/11)".
3.
Set the coolant temperature and hydraulic oil temperature to be in the testing condition. •
Coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
30-20
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
4.
Test boost pressure
Display the monitoring item that follow by "Pre-defined Monitoring (03/11)", or "Monitoring Selection Menu". Monitoring code: 37400"Ambient Pressure" Monitoring code: 36500"Charge Pressure" REMARK • Charge pressure is displayed in absolute pressure on the monitor screen. • See the air intake manifold pressure value for the boost pressure.
5.
Set the working mode to P mode.
6.
Set the auto-deceleration function to be OFF.
7.
Turn the swing lock switch to ON position.
8.
Turn the fuel control dial to MAX (High idle) position.
9.
Set the lock lever to FREE position.
10. Operate the control lever, and test the boost pressure when one-touch power maximizing is actuated while oil pressure in arm IN circuit is relieved. One-touch power maximizing is automatically canceled in 8.5 seconds, even when the switch is kept pushed. Test the pressure while the one-touch power maximizing function is in operation.
TEST BOOST PRESSURE BY TESTING TOOL Install the tools to test 1. Open the engine hood. 2.
Remove the boost pressure pickup plug (1).
PC210-10M0, PC210LC-10M0
30-21
Test boost pressure
3.
Install the nipple A1 of boost gauge kit A, and connect the hose A3 and gauge A2.
4.
Start the engine.
5.
Set the engine speed at medium or higher by adjusting the fuel control dial.
6.
Drain oil from the hose A3.
30 TESTING AND ADJUSTING
Put the connection part of the hose A3 into the gauge A2 halfway to open the self-seal on the hose side again and again, and the oil will be drained. If the oil stays in the hose A3, the gauge A2 will not move. Be sure to drain oil. REMARK If the Pm kit B is available, use the oil draining coupling B in it.
Setting of test condition 7. See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(01/11)". 8. Set the coolant temperature and hydraulic oil temperature to be in the testing condition. •
Coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
9.
Set the working mode to P mode. 10. Set the auto-deceleration function to be OFF. 11. Turn the swing lock switch to ON position. 12. Turn the fuel control dial to MAX (High idle) position. Test procedure 13. Set the lock lever to FREE position. 14. Operate the control lever, and test the boost pressure when one-touch power maximizing is actuated while oil pressure in arm IN circuit is relieved. REMARK • One-touch power maximizing is automatically canceled in 8.5 seconds, even when the switch is kept pushed. Test the pressure while the one-touch power maximizing function is in operation. • See the turbocharger outlet pressure value for the boost pressure. Restoration 1. Stop the engine. k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the nipple A1.
3.
Install the pickup plug (1), and put it back to the initial position. Testing plug (1): 2.0 to 3.9Nm {0.2 to 0.39kgm}
30-22
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TEST EXHAUST GAS COLOR
TEST EXHAUST GAS COLOR Obey the procedure that follows when you test the exhaust gas color. TOOLS TO TEST EXHAUST GAS COLOR Symbol
Part number
A
799-201-9002
Handy smoke checker
1
B
Commercially available
Smoke meter
1
Filter paper
1
C k k
Commercially available
Part name
Q'ty
Remarks Bosch index: 0 to 9
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
If an air source and an electric power source are not available in the field, use the handy smoke checker A. When you record the official data, use the smoke meter B. For standard values, see "STANDAR VALUE TABLESTANDARD VALUE TABLE FOR ENGINE".
Test exhaust gas color by handy smoke checker Installing testing tools 1. Fit a sheet of filter paper to the handy smoke checker A. 2.
Insert the exhaust gas intake pipe of the handy smoke checker A into the tail tube (4). Insert the handy smoke checker A so that its end is at the center of the piping, and it is in parallel with the piping.
Setting measurement conditions 3. Start the engine. 4.
Select "Pre-defined Monitoring (01/11)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
5.
Set the engine coolant temperature and the hydraulic oil temperature so that it is in the testing condition range.
6.
•
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 ℃
Turn off the auto-deceleration.
PC210-10M0, PC210LC-10M0
30-23
TEST EXHAUST GAS COLOR
7.
30 TESTING AND ADJUSTING
Turn the fuel control dial to MAX (High idle) position.
Doing diagnostic tests 8. Move the lock lever to FREE position. 9.
Operate the control lever to relieve the oil pressure in the arm IN circuit, and keep the situation for 5 seconds.
10. Collect the exhaust gas to the filter paper by operating the handle of the handy smoke checker A. Collecting time: 1.4±0.2 seconds 11. Remove the filter paper and compare it with the attached scale for judgment. Restoring the machine 1. Stop the engine. k
2.
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
Remove the handy smoke checker A.
TEST EXHAUST GAS COLOR BY SMOKE METER 1.
Put the probe B1 of the smoke meter B into the tail pipe (4). Put the probe B1 for its tip to be at the center of the piping, and to be in parallel with the piping.
2.
Set the smoke meter B for testing. For the operation procedure of the smoke meter B, see Operation manual of the smoke meter B.
Setting of test condition 3. Start the engine. 4.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(01/11)".
5.
Set the coolant temperature and hydraulic oil temperature to be in the testing condition. •
Coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
6.
Set the auto-deceleration function to be OFF.
7.
Turn the fuel control dial to MAX (High idle) position.
Test procedure 8. Set the lock lever to FREE position. 9.
Operate the control lever, relieve the oil pressure in the arm IN circuit, hold it 5 seconds.
10. Operate the smoke meter B, collect the exhaust gas to the filter paper. 30-24
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TEST EXHAUST GAS COLOR
11. Place the filter paper that collected the exhaust gas on the clean filter paper (at least 10 sheets) in the filter paper holder and read the indicated value. Restoration 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
PC210-10M0, PC210LC-10M0
30-25
Test and adjust valve clearance
30 TESTING AND ADJUSTING
Test and adjust valve clearance Test and adjust valve clearance according to the procedure below. TOOLS TO TEST VALVE CLEARANCE Symbol
Part number
A
795-799-1131
Gear
1
B
Commercially available
Feeler gauge
1
k k k
Part name
Q'ty
Remarks
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Make sure that the system operation lamp is not lit, set the battery disconnect switch to the OFF position, and remove the key. (Only for machines with battery disconnect switch) Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
For standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
TEST VALVE CLEARANCE Preparing diagnostic tests in advance 1. Remove the cylinder head cover (1). See DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL INJECTOR ASSEMBLY".
2.
Remove the undercovers (2), (3), and (4).
3.
Remove the plug (5) on the starting motor, and insert the gear A into the position shown in the figure.
4.
Rotate the crankshaft clockwise with the gear A. Align the wide slit (b) (its width is the same as the ring of the speed sensor) to the top surface of the protrusion (a) of the front cover.
30-26
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust valve clearance
REMARK • The top surface of the protrusion (a) is in the wide slit (b) when you see it from the air conditioner compressor side. • Two yellow marks, one is on the top of the protrusion (a) and the other is in the wide slit (b), can be matched each other.
k
If the crankshaft is adjusted as described above, piston No.1 or No. 6 does not come to the compression top dead center (TDC) position.
Setting measurement conditions 5. Set the engine coolant temperature, and make sure it is in the testing condition range. Engine coolant temperature: Normal temperature Doing diagnostic tests 6. Test the valve clearance by confirming the movement of the rocker arm (11) of the No. 1 cylinder. Insert the feeler gauge B into the clearance between the rocker arm (11) and the crosshead (12) to check the valve clearance.
7.
•
If you can move the rocker arm of air intake side (IN) with the hand by the valve clearance amount, check the valve clearance marked with ○ in the valve layout drawing.
•
If you can move the rocker arm of exhaust side (EX) with the hand by the valve clearance amount, check the valve clearance marked with ● in the valve layout drawing.
Rotate the crankshaft in the normal direction by 1 turn and test other valve clearances. For the alignment procedure, see Step 4. in "Preparing diagnostic tests in advance".
Restoring the machine 1. Remove the gear A, and install the plate (5) and the plug (6) on the starting motor. 2.
Install the undercovers (2), (3), and (4).
3.
Restore the machine. See DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL INJECTOR ASSEMBLY".
Adjust valve clearance Adjust valve clearance according to the procedure below, if necessary. PC210-10M0, PC210LC-10M0
30-27
Test and adjust valve clearance
1.
Loosen the lock nut (10) with the adjustment screw (9) fixed.
2.
Insert the feeler gauge B in the clearance between the rocker arm (11) and the crosshead (12), and adjust the valve clearance with the adjustment screw (9).
30 TESTING AND ADJUSTING
Turn the adjustment screw (9) until the inserted feeler gauge B can move lightly. 3.
With the adjustment screw (9) fixed, tighten the lock nut (10). Lock nut (10): 24±4 Nm {2.45±0.41 kgm} Tighten the lock nut (10), and check the valve clearance again.
Restore the machine. See "Test valve clearance".
30-28
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TEST COMPRESSION PRESSURE
TEST COMPRESSION PRESSURE Obey the procedures that follow to test the fuel pressure. Check that the airtightness in the cylinder is correct. Do this test in the temperature condition as follows. • Coolant Temperature: 40 to 60 °C Start the engine to raise the temperature before you start the actual test. TOOLS TO TEST COMPRESSION PRESSURE Symbol
Part number
A
795-502-1590
Gauge assembly
1
B
795-790-4411
Adapter
1
C
6754-11-3130
Gasket
1
D
Commercially available
Hose
1
E
Commercially available
Container
1
F
Commercially available
Insulating tape
1
k k k k
Part name
Q'ty
Remarks Pressure range: 0 to 7 MPa
Internal diameter: 15 mm
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Check that the system operating lamp is not lit. Turn the battery disconnect switch to the OFF position, and remove the key. Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Sufficiently use caution not to become entangled with rotating parts or not to become caught in movable portions.
For the test conditions and standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
TEST COMPRESSION PRESSURE Removing the injector assembly 1. Set the cylinders to be tested to the compression top dead center. See DISASSEMBLY AND ASSEMBLY, "Test and adjust valve clearance". 2. Remove the injector assembly. See DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL INJECTOR ASSEMBLY". 3. Install the hose D on the common rail side of the disconnected part of the high-pressure piping (1). REMARK Fuel flows out from the disconnected part of the high-pressure piping when compression pressure is measured. Set the container E so that it receives the fuel flowing out from the outlet of the hose D. 4.
The harness of the injector is removed from the terminals (2). Wrap the insulating tape F around the terminals (2) for insulation to keep them from contact with each other.
PC210-10M0, PC210LC-10M0
30-29
TEST COMPRESSION PRESSURE
30 TESTING AND ADJUSTING
Install the adapter 5. Install the gasket C to the end of the adapter B, and insert it into the mounting portion of the injector. 6. Use the holder (3) on the injector side and install the adapter B tightly. Tighten the mounting bolt (3) on the injector side alternately. Holder (3) mounting bolt (2 pieces): 8±0.8 Nm {0.82±0.08 kgm}
Install the parts which is necessary for cranking 7. Install the crossheads (5) and the rocker arm assembly (4). Rocker arm assembly (4) mounting bolt (2 pieces): 36±5 Nm {3.67±0.51 kgm} 8.
Check that the valve clearance is in the range of the standard value by referring to "Test and adjust valve clearance". Adjust the valve clearance if it is out of range.
Install the gauge assembly 9. Connect the gauge assembly A to the adapter B. REMARK If a small amount of oil is applied to the connecting parts of gauge assembly A and adapter B, air will not leak easily.
Set with the machine monitor 10. Turn the battery disconnect switch to ON position. 11. Turn the starting switch to the ON position. 12. To set "No-Injection Cranking" on the "Service Menu" screen, see "SETTING AND OPERATION OF MACHINE MONITOR ". k
It is dangerous if no-injection cranking mode is not selected because engine will start. Be sure to set it.
*
Doing diagnostic tests 13. Turn the starting switch to the START position, and measure the compression pressure when the engine is cranked by the starting motor. Read the compression pressure when the pointer of the gauge becomes stable. NOTICE Do not crank the engine continuously for 20 seconds or more to protect the starting motor. Restoring the machine
30-30
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TEST COMPRESSION PRESSURE
1.
Turn the starting switch to the OFF position. Make sure that the system operating lamp goes off, set the battery disconnect switch to the OFF position for only the machine with the switch, and pull out the key. (if this is installed to the machine)
2.
Remove the gauge assembly A from the adapter B.
3.
Remove the crossheads (5) and the rocker arm assembly (4).
4.
Remove the adapter B from the mounting part of the injector.
5.
Remove the hose D on the common rail side of the disconnected part of the high-pressure piping (1).
6.
Install the injector assembly, and restore the machine. See DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL INJECTOR ASSEMBLY".
PC210-10M0, PC210LC-10M0
30-31
TEST BLOWBY PRESSURE
30 TESTING AND ADJUSTING
TEST BLOWBY PRESSURE Obey the procedures that follow to test the blowby pressure. Make sure that there is no problem for the blowby gas pressure released from the cylinder block (crankcase). TOOLS TO TEST BLOWBY PRESSURE Symbol
A
k k
Part number
Part name
Q'ty
-
799-201-1506
Blowby checker
1
1
799-201-1591
Gauge
1
2
799-201-1511
Tool
1
3
799-201-1450
Adapter
1
Remarks
Pressure range: 0 to 10 MPa
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
For the test conditions and standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT)) 1.
Start the engine.
2.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(03/11)".
3.
Set the engine coolant temperature and the hydraulic oil temperature so that it is within the testing condition range.
4.
Select and display the monitoring item that follow by "Predefined Monitoring (03/11)", or "Monitoring Selection Menu". Monitoring code: 42803"Blowby Pressure"
5.
Set the working mode to ("Power Mode").
6.
Turn the swing lock switch to ON position. REMARK If the swing lock switch is turned on, the main relief valve is set for high-pressure relief.
7.
Turn the fuel control dial to MAX (High idle) position.
8.
Test the blowby pressure when the pressure is relieved at arm IN and one-touch power maximizing is applied. Read the blowby pressure when the pointer of the gauge is stabilized. For standard values, see STANDARD VALUE TABLE,"STANDARD VALUE TABLE FOR ENGINE".
30-32
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TEST BLOWBY PRESSURE
If the measure value of the blowby pressure exceeds the standard value, the clogging of the throttle part (1) is considered. Do testing and cleaning, and measure it again.
After you complete the test, remove the test tools and make the machine to the original state.
Test blowby pressure (machine without blowby pressure sensor) Installing testing tools 1. Remove the undercover of the hydraulic pump. 2.
Install the tool A2 and the adapter A3 of the blowby checker A to the breather hose (1).
3.
Connect the gauge A1, and fix it with the clamp (3). Clamp (3): 4.4±0.49 Nm {0.45±0.05 kgm}
Setting measurement conditions 4. Start the engine. 5.
Select "Pre-defined Monitoring (01/11)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
6.
Set the engine coolant temperature and the hydraulic oil temperature so that they are in the testing condition range. •
Engine coolant temperature: 60 to 100 ℃
PC210-10M0, PC210LC-10M0
30-33
TEST BLOWBY PRESSURE
•
30 TESTING AND ADJUSTING
Hydraulic oil temperature: 45 to 55 °C
7.
Set the working mode to P mode.
8.
Turn off the auto-deceleration.
9.
Turn the swing lock switch to the ON position.
10. Turn the fuel control dial to MAX (High idle) position. Doing diagnostic tests 11. Move the lock lever to FREE position. 12. Operate the control lever to relieve the oil pressure in the arm IN circuit. Then, test blowby pressure when the one-touch power maximizing operation is done. Read the blowby pressure when the pointer of gauge is stabilized. For standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE". When the switch is kept pressed, the one-touch power maximizing function is canceled automatically in approximately 8.5 seconds. Test the engine speed while this function is active. Restoring the machine 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the gauge A1, the tool A2, and the adapter A3.
3.
Remove the plug B.
4.
Remove the cap C.
30-34
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
TEST ENGINE OIL PRESSURE
TEST ENGINE OIL PRESSURE Obey the procedures that follow to test the engine oil pressure. TOOLS TO TEST ENGINE OIL PRESSURE Symbol
k
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5160
Nipple
1
Size: R1/8
B
799-401-2320
Gauge
1
Pressure range: 0 to 1 MPa
C
795-790-4430
Adapter
1
Size: R1/8
D
6215-81-9710
O-ring
1
A
k
Part number
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
For the test conditions and standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
TEST ENGINE OIL PRESSURE Install the tools to test 1. Open the cover on the right side of the machine. 2.
Remove the engine oil pressure pickup plug (1) on the upper part of the engine oil filter.
3.
Install the adapter C or D to the nipple A1 of hydraulic tester A.
PC210-10M0, PC210LC-10M0
30-35
TEST ENGINE OIL PRESSURE
4.
30 TESTING AND ADJUSTING
Install the adapter C, and connect it to the gauge B.
Setting measurement conditions 5. Start the engine. 6.
See "SETTING AND OPERATION OF MACHINE MONITOR", and select "Pre-defined Monitoring (01/11)" to show it.
7.
Set the engine coolant temperature, and make sure it is in the testing condition range. •
Engine coolant temperature: 60 to 100 °C
8.
Set the working mode to P mode.
9.
Turn off the auto-deceleration.
Doing diagnostic tests 10. Test the engine oil pressure when the fuel control dial is in the MIN (low idle) and MAX (high idle) positions. Restoring the machine 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the gauge B, the nipple A1, and the adapter C.
3.
Install the testing plug (1) for the engine oil pressure, and make the machine to the original position.
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test fuel pressure
Test fuel pressure Test fuel pressure according to the procedure below. Check that no abnormality occurs in circuits where fuel is supplied or returned. TOOLS TO TEST FUEL PRESSURE Symbol
k k k
k
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5160
Nipple
2
Size: R1/8
2
799-101-5140
Gauge
1
Pressure range: 0 to 2.5 MPa
B
795-790-4430
Adapter
2
C
6215-81-9710
O-ring
2
D
795-790-5110
Screw
1
E
799-401-2320
Gauge
1
F
795-790-5120
Screw
1
-
799-201-2202
Boost gauge kit
1
1
799-101-5160
Nipple
1
Size: R1/8
2
799-401-2311
Gauge
1
Pressure range: -101 to 200 kPa {-760 to 1500 mmHg}
A
G
Part number
Pressure range: 0 to 1 MPa
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. Do not measure the pressure in the high-pressure circuit from the supply pump through the common rail to the injector. The pressure is very high and dangerous. Measure the pressure only in the low pressure circuit from the feed pump through the fuel main filter to the supply pump, and return circuit between supply pump, common rail, injector and fuel tank. Do not remove or install the testing device for fuel system immediately after the engine is stopped. There is remaining pressure in the circuit. Wait for the remaining pressure in the fuel circuit to be released for at least 30 seconds after stopping the engine.
PC210-10M0, PC210LC-10M0
30-37
Test fuel pressure
30 TESTING AND ADJUSTING
For measurement conditions and standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
A: Low-pressure circuit measuring position (fuel main filter inlet)
C: Return circuit measuring position (return from the supply pump)
B: Low-pressure circuit measuring position (fuel main filter outlet)
D: Negative pressure circuit measuring position (supply pump inlet)
TEST FUEL PRESSURE Test low-pressure circuit (fuel main filter inlet) Installing testing tools 1. Open the cover on the right side of the machine.
30-38
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
2.
Remove the fuel pressure pickup plug (2) on the inlet of the fuel main filter (1).
3.
Install the adapter B. Insert the O-ring C into the mounting portion.
Test fuel pressure
Adapter B: 32±4 Nm {3.26±0.41 kgm} 4.
Install the nipple A1 of the hydraulic tester A, and connect it to the gauge A2.
Setting measurement conditions 5. Start the engine. 6.
Select and show "Pre-defined Monitoring" (01/11). For details, see "SETTING AND OPERATION OF MACHINE MONITOR".
Check procedure 7. Test the pressure when the fuel control dial is set in the MAX (high idle) position. NOTICE If the engine cannot be started, you can do diagnostic tests while cranking the engine by using the starting motor. Do not crank the engine continuously for 20 seconds or more to protect the starting motor. Restoring the machine PC210-10M0, PC210LC-10M0
30-39
Test fuel pressure
1.
30 TESTING AND ADJUSTING
Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the gauge A2, the nipple A1, the adapter B, and the O-ring C.
3.
Install the fuel pressure pickup plug (2), and restore the machine. Pickup plug (2): 32±4 Nm {3.26±0.41 kgm}
Testing of low-pressure circuit (pressure difference) Installing testing tools 1. Open the cover on the right side of the machine. 2.
Remove the fuel pressure pickup plugs (2) and (3) on the inlet and the outlet of the fuel main filter (1).
3.
Install the adapter B to both. Insert the O-ring C into the mounting portion. Adapter B: 32±4 Nm {3.26±0.41 kgm}
4.
Install the nipples A1 of the hydraulic tester A to the respective adapters, and connect them to the gauge A2.
30-40
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test fuel pressure
Setting measurement conditions 5. Start the engine. 6.
Select and show "Pre-defined Monitoring" (01/11). For details, see "SETTING AND OPERATION OF MACHINE MONITOR".
Doing diagnostic tests 7. Measure the pressure when the fuel control dial is set in the MAX (high idle) position, and get the difference in pressure between the inlet and the outlet of the fuel main filter. NOTICE If the engine cannot be started, you can do diagnostic tests while cranking the engine by using the starting motor. Do not crank the engine continuously for 20 seconds or more to protect the starting motor. REMARK If the difference in pressure exceeds the standard value, the fuel main filter clogging is considered. Replace the fuel main filter, and test it again. Restoring the machine 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the gauge A2, the nipple A1, the adapter B, and the O-ring C.
3.
Install the fuel pressure pickup plugs (2) and (3), and restore the machine. Pickup plugs (2) and (3): 32±4 Nm {3.26±0.41 kgm}
Testing return circuit Installing testing tools 1. Open the engine hood. 2.
Remove the joint bolt (2) of the return hose between the supply pump and the fuel cooler.
PC210-10M0, PC210LC-10M0
30-41
Test fuel pressure
3.
30 TESTING AND ADJUSTING
Install the screw D. Insert the seal washer into the mounting portion. Screw D: 19.6 to 29.4 Nm {2 to 3 kgm}
4.
Install the nipple A1 of the hydraulic tester A, and connect it to the gauge E.
Setting measurement conditions 5. Start the engine. 6.
Select and show "Pre-defined Monitoring" (01/11). For details, see "SETTING AND OPERATION OF MACHINE MONITOR".
Check procedure 7. Test the pressure when the fuel control dial is set in the MAX (high idle) position. NOTICE If the engine cannot be started, you can do diagnostic tests while cranking the engine by using the starting motor. Do not crank the engine continuously for 20 seconds or more to protect the starting motor. Restoring the machine 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the gauge E, the nipple A1, and the screw D.
3.
Install the joint bolt (2), and restore the machine. Joint bolt (2): 19.6 to 29.4 Nm {2 to 3 kgm}
Testing negative pressure circuit Installing testing tools 1. Open the engine hood.
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
2.
Remove the joint bolt (3) of the supply hose between the fuel prefilter and the supply pump.
3.
Install the screw F. Insert the seal washer into the mounting portion.
Test fuel pressure
Screw F: 25.4 to 34.3 Nm {2.59 to 3.5 kgm} 4.
Install the nipple G1 of the boost gauge kit G, and connect it to the gauge G2.
Setting measurement conditions 5. Start the engine. 6.
Select and show "Pre-defined Monitoring" (01/11). For details, see "SETTING AND OPERATION OF MACHINE MONITOR".
Doing diagnostic tests 7. Test the pressure when the fuel control dial is set in the MAX (high idle) position. Restoring the machine 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the gauge G2, the nipple G1, and the screw F.
3.
Install the joint bolt (3), and restore the machine. Joint bolt (3): 25.4 to 34.3 Nm {2.59 to 3.5 kgm}
PC210-10M0, PC210LC-10M0
30-43
Test fuel discharged volume, return rate, and leakage
30 TESTING AND ADJUSTING
Test fuel discharged volume, return rate, and leakage Test the fuel discharged volume from the supply pump to the common rail, the return rate from the supply pump and the injector, and the leakage from the pressure limiter, according to the procedure below. TOOLS TO TEST FUEL DISCHARGE, RETURN AND LEAKAGE Symbol
Part number
A
799-790-4700
Tester kit
1
B
6164-81-5790
Joint
1
C
07005-01212
Washer
1
D
6754-71-5340
Connector
1
E
6754-71-5350
Washer
1
F
Commercially available
Measuring cylinder
1
G
Commercially available
Stopwatch
1
H
Commercially available
Hose
1
Internal diameter: Approx. 14mm
J
Commercially available
Hose
1
Internal diameter: Approx. 7mm
k k k
Part name
Q'ty
Remarks
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. Do not remove or install the testing device for fuel system immediately after the engine is stopped. There is the pressure that remains in the circuit. Wait for the pressure that remains in the fuel circuit to be released for at least 30 seconds after stopping the engine.
For measurement conditions and standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
30-44
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test fuel discharged volume, return rate, and leakage
A: Measuring position of supply pump discharged volume
C: Measuring position of the leakage from the pressure limiter
B: Measuring position of the return rate from the supply pump
D: Measuring position of the return rate from the injector
TEST FUEL DISCHARGE, RETURN AND LEAKAGE TEST SUPPLY PUMP DISCHARGED VOLUME Install the tools to test 1. Open the engine hood. 2.
Loosen the clamp (2) of the tube on the discharge side of the supply pump, and disconnect the tube (1).
3.
Install the testing hose H to the nipple on the discharge side of the supply pump.
PC210-10M0, PC210LC-10M0
30-45
Test fuel discharged volume, return rate, and leakage
30 TESTING AND ADJUSTING
REMARK • Fix the hose with the wire for the hose not to come off. • Adjust the route for the testing hose not to slack, and insert the tip of the hose into tray.
Check procedure 4. Crank the engine for 30 seconds, and test the discharged volume with measuring cylinder F. REMARK Adjust the route for the testing hose not to slack, and insert the tip of the hose into tray. NOTICE Do not crank the engine more than 20 seconds for cases other than this testing in order to protect the starting motor. Discharged volume of the supply pump is normal if it is in the standard value shown below. At cranking (125 rpm)
75 cc or more
At cranking (150 rpm)
90 cc or more
Restoration 1. Stop the engine. 2.
Remove the hose H.
3.
Install the tube (1) on the discharge side of the supply pump.
4.
Tighten the clamp, and make the machine to be the original state. Clamp mounting bolt :20 to 28 Nm {2.1 to 2.9 kgm} Tube sleeve nut: 31 to 39 Nm {3.2 to 4.0 kgm}
TEST SUPPLY PUMP RETURN RATE Install the tools to test 1. Open the engine hood. 2.
Remove the joint bolt (1) of the supply pump (4).
3.
Disconnect the return hoses (2) and (3).
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test fuel discharged volume, return rate, and leakage
4.
Install the tester kit A, joint bolt [1], cap nut [2], and seal washer [3], and put the fuel in the injector and common rail back to the fuel tank.
5.
Install the joint B to the supply pump (4) with joint bolt (1). REMARK Put the sea washer C to the installing part. Joint bolt C: 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
6.
Install the testing hose H to the joint B. REMARK • Adjust the route for the testing hose not to slack, and insert the tip of the hose into tray. • Make sure to connect the return hose (2) and (3) to put the fuel back to the fuel tank, since the fuel flows into the return hose (2) while the engine is running.
Check procedure 7. Start the engine. 8.
Turn the fuel control dial to the MIN (low idle) position. Receive the fuel that flows out with the measuring cylinder F for 1 minute. Under the condition, measure the volume of the fuel. REMARK For judgment, do testing for 20 seconds, and you can multiply the leakage quantity of it by 3. The return volume of the supply pump is normal if it is in the standard value shown below. When engine is in low idle
1000 cc or less
At cranking
140 cc or less
Restoration 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the hose H, the joint B, the joint bolt [1] and the seal washer C from the supply pump.
3.
Remove the cap nut [2], and the seal washer [3] from the return hose (2), (3).
4.
Connect the return hose (2) and (3) to the supply pump with the joint bolt (1), and make the machine back to the original state. Joint bolt (1): 19.6 to 29.4 Nm {2.0 to 3.0 kgm} REMARK • If you do testing of the leakage from the pressure limiter next, and make the machine to be the original state. • If you do testing of the return volume from the injector next, let the machine be as it is, and put the testing hose end into the container.
TEST LEAKAGE FROM PRESSURE LIMITER Install the tools to test 1. Open the engine hood.
PC210-10M0, PC210LC-10M0
30-47
Test fuel discharged volume, return rate, and leakage
2.
Disconnect the return hose (1) of the pressure limiter.
3.
Disconnect the hose clamp (2) from the quick coupler part (a).
4.
Put the connector D on the drain side of the hose.
5.
Put the cap nut [2] of the tester kit A for the fuel not to flow out.
6.
Connect the testing hose L to the pressure side.
30 TESTING AND ADJUSTING
REMARK Adjust the route for the testing hose not to slack, and insert the tip of the hose into tray.
Check procedure 7. Start the engine. 8.
Turn the fuel control dial to the MIN (low idle) position. Receive the fuel that flows out with the measuring cylinder F for 1 minute. Under the condition, measure the volume of the fuel. The leakage volume from the pressure limiter is normal if it is in the standard value shown below. When engine is in low idle
0 cc/min (no leakage)
Restoration 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the testing hose J from the pressure limiter side.
3.
Remove the cap nut [2] from the return hose (1).
4.
Connect the return hose (1) at the quick coupler part (a).
5.
Connect the return hose (1) to the pressure limiter side with the joint bolt. Joint bolt: 20 to 28 Nm {2.0 to 2.8 kgm}
6.
Install the hose clamp (2), and make the machine to be the original state.
TEST RETURN RATE FROM INJECTOR Install the tools to test 1. Open the engine hood.
30-48
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test fuel discharged volume, return rate, and leakage
2.
Disconnect the spill tube (1).
3.
Install the cap nut [2] of the tester kit A to the spill tube (1) to prevent the fuel from flowing out. Put the seal washer E into the installation part.
4.
Install the joint B to the cylinder head side with the joint bolt [1] to prevent the fuel from flowing out. Put the seal washer E into the installation part. Joint bolt [1]: 20 to 28 Nm {2.04 to 2.86 kgm}
5.
Install the hose H to the joint B, and tighten the hose H so that it is not removed.
6.
Adjust the route of the hose H so that it does not slack, and put its end in the measuring cylinder F. REMARK Catch fuel with the oil container not to flow out.
Check procedure 7. Start the engine. 8.
Turn the fuel control dial to the MIN (Low idle) position. Receive the return volume of the injector that flows out with the measuring cylinder F for 30 minute. Measure the volume. NOTICE If the engine is not started, you can do the test while you crank the starting motor. Do not crank the engine continuously for 20 seconds or more to protect the starting motor. Do cranking 15 seconds at first, atop 15 seconds, and do cranking 15 seconds again. The return volume of the injector is normal if it is in the standard value shown below. When engine is in low idle
180 cc or less
At cranking
90 cc or less
Restoration 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the hose H, the joint B, the joint bolt [1], and the seal washer E from the cylinder head side.
3.
Remove the cap nut[2] and the seal washer E from the spill tube (1).
4.
Connect the spill tube (1) to the cylinder head side, and make the machine to the original state..
PC210-10M0, PC210LC-10M0
30-49
BLEED AIR FROM FUEL SYSTEM
30 TESTING AND ADJUSTING
BLEED AIR FROM FUEL SYSTEM Obey the contents that follow to bleed air from the fuel system. If air is mixed in the fuel circuit, the engine cannot be started easily. Bleed air in the cases that follow. •
When the machine run out of fuel
•
When a device in the fuel circuit is removed, installed, or replaced.
Air in the fuel circuit is bled through the path shown in the figure. Path: Fuel tank → pre-filter → feed pump → main filter → metering unit → fuel cooler→ fuel tank Check that the pointer of the fuel gauge is in the green range. If the pointer of the fuel gauge is in the red range, add fuel.
k k
Place the machine on a level ground, lower the work equipment completely to the ground in a stable posture, set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
Bleed air from fuel system 1.
Turn the starting switch to the OFF position.
2.
Open the cover on the right side of the machine.
30-50
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
3.
Loosen the hand primer (1), and pull it out.
4.
Move the hand primer (1) in the forward and reverse directions until its movement becomes heavy, and bleed air.
BLEED AIR FROM FUEL SYSTEM
REMARK You do not need to remove the plug on the upper part of the fuel main filter. 5.
After bleeding air, push the hand primer (1) in, and tighten it.
PC210-10M0, PC210LC-10M0
30-51
Test fuel system for leakage
30 TESTING AND ADJUSTING
Test fuel system for leakage Test a fuel system for leakage according to the procedure below. TOOLS TO TEST FUEL CIRCUIT FOR LEAKAGE Symbol
Part number
A
Commercially available
k
k k
Part name Developer for dye penetrant (color checker)
Q'ty
Remarks
1
The pressure on the high pressure side in the fuel circuit is very high. If the fuel leaks while engine is running, it leads to fire and it is dangerous. If the fuel circuit is tested or the equipment is removed or installed, test the fuel leak. Place the machine on a level ground, lower the work equipment completely to the ground in a stable posture, set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
Clean the engine and the parts around it, and degrease them in advance so that you can easily find the leakage if any.
Test fuel circuit for leakage When engine is stopped 1.
Start the engine.
2.
Turn the fuel control dial to MIN (low idle) position. Stop the engine after the engine automatic warm-up function is automatically canceled and the engine speed is stabilized. REMARK Turn the fuel control dial to MAX (high idle) position, and the engine automatic warm-up function is canceled. For conditions for canceling the engine automatic warm-up function, see "ENGINE AUTOMATIC WARM-UP SYSTEM" in STRUCTURE AND FUNCTION.
3.
Spray the color checker A to the connections to the supply pump, common rail, injector, and high-pressure piping.
4.
Check the fuel piping and the components for fuel leakage. Check the high-pressure circuit, mainly the area where you apply the color checker A, for fuel leakage. If there is fuel leakage, restore the defective part. Then, perform the check procedure again from Step 1.
When engine is in low idle 1.
Start the engine.
2.
Turn the fuel control dial to MIN (low idle) position. Stop the engine after the engine automatic warm-up function is automatically canceled and the engine speed is stabilized. REMARK Turn the fuel control dial to MAX (high idle) position, and the engine automatic warm-up function is canceled. For conditions for canceling the engine automatic warm-up function, see "ENGINE AUTOMATIC WARM-UP SYSTEM" in STRUCTURE AND FUNCTION.
3.
Spray the color checker A to the connections to the supply pump, common rail, injector, and high-pressure piping.
4.
Start the engine.
5.
Turn the fuel control dial to MIN (low idle) position.
6.
Stop the engine.
7.
Check the fuel piping and the components for fuel leakage. Check the high-pressure circuit, mainly the area where you apply the color checker A, for fuel leakage.
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test fuel system for leakage
If there is fuel leakage, restore the defective part. Then, perform the check procedure again from Step 1.
When engine is in high idle 1.
Start the engine.
2.
Turn the fuel control dial to MIN (low idle) position. Stop the engine after the engine automatic warm-up function is automatically canceled and the engine speed is stabilized. REMARK Turn the fuel control dial to MAX (high idle) position, and the engine automatic warm-up function is canceled. For conditions for canceling the engine automatic warm-up function, see "ENGINE AUTOMATIC WARM-UP SYSTEM" in STRUCTURE AND FUNCTION.
3.
Spray the color checker A to the connections to the supply pump, common rail, injector, and high-pressure piping.
4.
Start the engine.
5.
Turn the fuel control dial to MIN (high idle) position.
6.
Stop the engine.
7.
Check the fuel piping and the components for fuel leakage. Check the high-pressure circuit, mainly the area where you apply the color checker A, for fuel leakage. If there is fuel leakage, restore the defective part. Then, perform the check procedure again from Step 1.
2 pumps relief and one-touch power maximizing 1.
Start the engine.
2.
Turn the fuel control dial to MIN (low idle) position. Stop the engine after the engine automatic warm-up function is automatically canceled and the engine speed is stabilized. REMARK Turn the fuel control dial to MAX (high idle) position, and the engine automatic warm-up function is canceled. For conditions for canceling the engine automatic warm-up function, see "ENGINE AUTOMATIC WARM-UP SYSTEM" in STRUCTURE AND FUNCTION.
3.
Spray the color checker A to the connections to the supply pump, common rail, injector, and high-pressure piping.
4.
Start the engine.
5.
Set the engine speed to the speed during operation of 2 pump relief + one-touch power maximizing function. See "TEST ENGINE SPEED".
6.
Stop the engine.
7.
Check the fuel piping and the components for fuel leakage. Check the high-pressure circuit, mainly the area where you apply the color checker A, for fuel leakage. If there is fuel leakage, restore the defective part. Then, perform the check procedure again from Step 1.
PC210-10M0, PC210LC-10M0
30-53
CYLINDER CUT-OUT MODE OPERATION
30 TESTING AND ADJUSTING
CYLINDER CUT-OUT MODE OPERATION Cylinder cutout mode operation uses the reduced number of operating cylinders by de-energizing the injector solenoid of the single/multiple cylinders into no fuel injection state. You can use "Cylinder Cutout Mode Operation" in the "Testing menu" to do cylinder cutout mode operation. Cylinder cutout mode operation has the objectives and effects below. •
Cylinder cutout mode operation is used to find out why one of cylinders in the engine does not output power normally.
•
If the engine speed and output in cylinder cutout mode operation do not change from those in normal operation, it indicates that the no-injection cylinder has a failure. The possible failures are as follows. •
Compression gas leakage from cylinder head gasket area
•
Defective injection
•
Defective piston, piston ring or cylinder liner
•
Defective valve mechanism (valve operating system)
•
Defective electrical system
If a normally operating cylinder is cutout, the following phenomena occur: •
Engine speed decreases (*1).
•
"Inject Fueling Command" increases.
You can check these items on the "Cylinder Cutout Mode Operation" screen. *1: If the engine is running at high idle, the engine speed cannot decrease. •
A common rail fuel injection system individually controls the injector of each cylinder electronically, so you can do cylinder cutout mode operation by the simple operations of the switches. Thus, the common rail fuel injection system can easily narrow down problems, compared with a mechanical fuel injection system.
30-54
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
NO-INJECTION CRANKING OPERATION
NO-INJECTION CRANKING OPERATION The no-injection crank operation de-energizes the injector solenoid of all the cylinder to disable the fuel injectors, and cranks the engine with the starting motor. It has the following purpose and effect. No-injection cranking operation is to be done before restarting the engine after long-term storage of a machine or a bare engine unit. Engine parts are lubricated with no-injection cranking operation to prevent engine seizure.
PC210-10M0, PC210LC-10M0
30-55
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
30 TESTING AND ADJUSTING
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION Obey the contents that follow when test and adjust the tension of the air conditioner compressor belt. Check each pulley for breakage, and the V-groove for wear, and the V-belts for wear. Replace the V-belt in the cases that follow. •
If the V-belt contacts to the bottom of th V-groove
•
If it is stretched and there is no allowance for adjustment
•
If you hear the slipping sound and squeaky sound caused by scratches or cracks on the belt.
k
Place the machine on a level ground, lower the work equipment completely to the ground in a stable posture, set the lock lever to LOCK position, and then stop the engine.
For measurement condition and standard values, see STANDAR VALUE TABLE, "STANDARD VALUE TABLE FOR ENGINE".
CHECK AIR CONDITIONER COMPRESSOR BELT 1.
Remove the bolts (2) (2 pieces).
2.
Remove the guard (1).
3.
Push the middle of the drive pulley (A) and compressor pulley (B) with 60N(6.1kg) force with finger. Standard value of the deflection is 6 to 9mm. If the deflection is not QQ the standard range, adjust it.
ADJUST AIR CONDITIONER COMPRESSOR BELT 1.
Remove the bolts (2) (2 pieces).
2.
Remove the guard (1).
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
3.
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
Loosen the bolts (3) (3 pieces). Removal of the bolts (3) is not necessary. Do not loosen them too much.
4.
Loosen the nuts (4) in the direction of (a). REMARK The nut (4) is for the jack bolt (5) not to be loosened.
5.
Tighten the jack bolt (5). The compressor (6) moves in the direction (a), and the compressor belt is taut.
6.
Push the middle of the drive pulley (A) and compressor pulley (B) with 60N(6.1kg) force with finger. Standard value of the deflection is 6 to 9mm. If the deflection is not in the standard value range, do the steps 4 to 6 again to adjust the belt tension.
7.
If the deflection is correct, tighten the bolt (3) (3 pieces). Tightening torque: 59 to 74Nm {6.0 to 7.5kgm}
8.
Tighten the nut (4) in the direction (b) until it contacts to the boss (7). Then, tighten it further in the direction (b) to avoid loose. Tightening torque: 108 to 132 Nm {11.0 to 13.5kgm}
9.
After it is tightened, check that the belt deflection is correct. If the deflection is not in the standard value range, do the steps from 4 again to adjust the belt tension.
PC210-10M0, PC210LC-10M0
30-57
Test swing circle bearing clearance
30 TESTING AND ADJUSTING
POWER TRAIN Test swing circle bearing clearance Test the clearance of swing circle bearing, according to the procedure below. TOOLS TO TEST SWING CIRCLE BEARING CLEARANCE Symbol
Part number
A
Commercially available
k k
Part name
Q'ty
Dial gauge
Remarks
1
Place the machine on a level ground. Do not put your hand or foot under the truck during the test.
Test swing circle bearing clearance 1.
To fix the dial gauge A on the swing circle outer race (1), apply the pointer to the end surface of inner race (2). To fix the dial gauge A on the swing circle inner race (2), apply the pointer to the end surface of outer race (1). Install the dial gauge A to the front or the rear of the machine.
2.
Fully retract the arm cylinder and the bucket cylinder (maximum reach state). Set the bucket tip to the height of the under surface of the revolving frame. The front of the upper structure moves down, and the rear of the upper structure moves up.
3.
Set the dial gauge A to 0 point.
4.
Set the arm almost perpendicular to the ground. Lower the boom until the track shoe on the machine front floats up by 150 to 200 mm. The front of the upper structure moves up, and the rear of the upper structure moves down.
5.
Read the indicated value of the dial gauge A. The indicated value of the dial gauge A shows the bearing clearance.
6.
Put the machine back to the state it was in Step 2. Make sure that the indicated value of the dial gauge A returns to 0 point. If the indicated value does not return to 0 point, perform Steps 3 to 6 again. After the clearance check is completed, remove the dial gauge A.
30-58
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust track shoe tension
UNDERCARRIAGE AND FRAME Test and adjust track shoe tension Test and adjust track shoe tension, according to the procedure below. TOOLS TO TEST TRACK TENSION Symbol
Part number
A
Commercially available
k
Part name Wooden block
Q'ty
Remarks
1
Place the machine on a level ground, lower the work equipment completely to the ground in a stable posture, set the lock lever to LOCK position, and then stop the engine.
Test track shoe tension 1.
Start the engine.
2.
Turn the fuel control dial to MIN (low idle) position. Move the machine forward slowly by the length of track shoe on ground and then stop it.
3.
Put the square block A on the track shoe located between the idler and the carrier roller. Use an L-shaped less flexible steel as material of the square block A.
4.
Check the maximum clearance (a) between the square block A and the track shoe. Standard value of maximum clearance (a): 16 to 34 mm
Adjust track shoe tension Adjust track shoe tension according to the procedure below, if required.
How to increase the tension 1.
Pump in the grease through the grease fitting (1) by using a grease gun.
2.
Turn the fuel control dial to the MIN (low idle) position. Move the machine forward slowly by the length of track on ground and then stop it.
3.
Check that tension is in the range of the standard value. See "Test track shoe tension". NOTICE You can pump in the grease until the dimension (b) between the ends of the idler guide and the track frame becomes 0 mm. If the tension is loose when the dimension (b) is 0 mm, the pin and the bushing are worn away significantly. Turn 180 deg. or replace the pin and the bushing.
PC210-10M0, PC210LC-10M0
30-59
Test and adjust track shoe tension
30 TESTING AND ADJUSTING
How to decrease the tension 1.
Loosen the valve (2), remove the grease, and tighten the valve (2). k
There is a danger of valve jumping out by the high pressurized grease inside it. Do not loosen valves more than 1 turn.
2.
Turn the fuel control dial to the MIN (low idle) position. Move the machine forward slowly by the length of track on ground and then stop it.
3.
Check that tension is in the range of the standard value. See "Test track shoe tension".
30-60
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
HYDRAULIC SYSTEM RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM If necessary, release remaining pressure from the hydraulic system as follows.
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK Obey the procedures that follow when you bleed the remaining pressure from the hydraulic tank.
k
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
Loosen the oil filler cap (1) of the hydraulic tank gradually to release the air in the tank.
When the remaining pressure is released, tighten the oil filler cap (1), and make it to the original state.
Release remaining pressure in hydraulic cylinder circuit Before disconnecting the piping between the hydraulic cylinder and the control valve, release the remaining pressure in the circuit as follows.
Release remaining pressure for machines without anti-drop valve k
1.
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Loosen the oil filler cap of the hydraulic tank gradually, and release the air in the tank. Leave the oil filler cap removed.
2.
Turn the starting switch to the ON position.
3.
Set the lock lever to the FREE position, and operate the right and left control levers to back and forth, left to right. REMARK The work equipment operates with the pressure accumulated in the accumulator (pilot circuit). Operate the control levers a few times, and the accumulated pressure becomes empty in the accumulator (pilot circuit).
4.
Set the lock lever to the LOCK position.
5.
Start the engine and run it with the fuel control dial at the MIN (low idle) position for approximately 10 seconds to increase the pressure in the accumulator (pilot circuit).
6.
Repeat Step 2. to Step 5. 4 or 5 times, and fully release the remaining pressure from the hydraulic cylinder circuit. After releasing the remaining pressure, tighten the oil filler cap of the hydraulic tank, and restore the machine.
Release remaining pressure for machines with boom anti-drop valve k
1.
Place the machine on a level ground. Check the function of the accumulator (pilot circuit).
PC210-10M0, PC210LC-10M0
30-61
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
1)
30 TESTING AND ADJUSTING
Set the arm cylinder and the bucket cylinder to the most retracted state (to set the machine in maximum reach posture). Hold the work equipment at height (a) above the ground. (a): 1.5 m
2)
Keep the state of Step 1), and stop the engine.
3)
Turn the starting switch to the ON position.
4)
Move the lock lever to FREE position.
5)
Move the control lever to the full stroke position in the boom LOWER direction, and check that the work equipment is lowered to the ground. The function of the accumulator (pilot circuit) is normal if the work equipment is lowered by its own weight to the ground.
NOTICE • Do Step 2) to Step 5) in 15 seconds or fewer. The pressure in the accumulator drops gradually after the engine is stopped. • If the work equipment does not lower or stops halfway, the function of the accumulator (pilot circuit) can be deteriorated. You cannot release remaining pressure in this section. 2.
Start the engine.
3.
Set the arm cylinder and the bucket cylinder to the most extended state (to the maximum digging side) or to the most retracted state (to the maximum dumping side). Lower the work equipment to the ground.
4.
Set the lock bar to the LOCK position.
5.
Stop the engine.
6.
Loosen the oil filler cap of the hydraulic tank gradually, and release the air in the tank. Leave the oil filler cap removed.
7.
Release the remaining pressure in the hydraulic cylinder circuit 1) Turn the starting switch to the ON position. 2)
Set the lock lever to the FREE position, and operate the right and left control levers to back and forth, left to right. REMARK The work equipment operates with the pressure accumulated in the accumulator (pilot circuit). Operate the control levers a few times, and the accumulated pressure becomes empty in the accumulator (pilot circuit).
8.
3)
Set the lock bar to the LOCK position.
4)
Start the engine and run it with the fuel control dial at the MIN (low idle) position for approximately 10 seconds to increase the pressure in the accumulator (pilot circuit).
Repeat Step 1) to Step 4) 4 or 5 times, and fully release the remaining pressure from the hydraulic cylinder circuit. After releasing the remaining pressure, install the oil filler cap of the hydraulic tank, and restore the machine.
30-62
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
Release remaining pressure from swing motor circuit When disconnecting the piping between the swing motor and the control valve, release the remaining pressure from the circuit according to the procedure below. k
1.
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Loosen the oil filler cap (1) of the hydraulic tank gradually, release the air in the tank, and release remaining pressure. Leave the oil filler cap removed.
2.
Turn the starting switch to the ON position.
3.
Set the lock lever to the FREE position, and operate the right and left control levers to back and forth, left to right. k
The work equipment operates 2 or 3 times with the pressure accumulated in the accumulator (pilot circuit).
4.
Set the lock bar to the LOCK position.
5.
Start the engine and run it with the fuel control dial at the MIN (low idle) position for approximately 10 seconds to increase the pressure in the accumulator (pilot circuit).
6.
Repeat Step 2. to Step 5. 4 or 5 times, and fully release the remaining pressure from the swing motor circuit.
After releasing the remaining pressure, tighten the oil filler cap (1), and restore the machine.
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT Obey the procedures that follow when you disconnect the piping between the travel motor and control valve, release the pressure that remains in the circuit.
k
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
Loosen the oil filler cap (1) of the hydraulic tank gradually to release the air in the tank to release the pressure that remains. REMARK The spool circuit of the control valve in the travel circuit is an open circuit. When the pressure that remains in the hydraulic tank is released, the pressure that remains in the travel circuit is released.
When the the pressure that remains is released, tighten the oil filler cap (1), and make it to the original state.
PC210-10M0, PC210LC-10M0
30-63
Test and adjust oil pressure in work equipment, swing, and travel circuits
30 TESTING AND ADJUSTING
Test and adjust oil pressure in work equipment, swing, and travel circuits Test and adjust the oil pressure in work equipment, swing, and travel circuits, according to the procedure below. TOOLS TO TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS Symbol
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5110
Gauge
1
Pressure range: 0 to 60 MPa
2
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 70 MPa
C
799-101-5220
Nipple
2
Size: M10 x 1.25 mm
D
07002-11023
O-ring
2
E
Commercially available
Plate
1
Size: 250 x 260 x 32
F
Commercially available
Pin
1
Size: φ 200 x 80
A
k
Part number
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
See STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR MACHINE" for standard values. When the oil flow is divided at pumps, the front and rear pumps act to each actuator as shown in the table below. The valve to be released differs depending on the actuator. When the pressure is released singly from the work equipment and swing circuits, the pressurized oil flows from the pumps are merged. When the pressure in the travel circuit is released singly, the pressurized oil flows from the pumps are divided. The actuators in the table below are arranged in the order that the control valves are viewed from the front of the machine (the service valve of the actuator when 1ATT is installed). Pump
Actuator
Valve to be relieved (R unload valve) (R main relief valve)
Rear
Service
Safety valve (for service)
Bucket
R main relief valve
L.H. travel
R main relief valve
Boom
R main relief valve (Merge-divider valve) (Travel junction valve) (Self-pressure reducing valve)
Front
Swing
Swing motor safety valve
R.H. travel
F main relief valve
Arm
F main relief valve
(F unload valve) (F main relief valve) (Safety valve for hydraulic drift prevention valve) (Back pressure valve)
Test oil pressure in work equipment, swing, and travel circuits Method for testing the unload pressure by using machine monitor 1.
Start the engine.
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
2.
Test and adjust oil pressure in work equipment, swing, and travel circuits
Select and display the monitoring items below on the "Pre-defined Monitoring (04/11)" or from the "Monitoring Selection Menu". See "SETTING AND OPERATION OF MACHINE MONITOR". Monitoring code: 01100 "Front Pump Pressure" Monitoring code: 01101 "Rear Pump Pressure" Monitoring code: 04401 "Hydraulic Oil Temperature"
3.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 °C
4.
Set the working mode to P mode.
5.
Turn off the auto-deceleration.
6.
Turn the fuel control dial to MAX (High idle) position.
7.
Test the front pump pressure and rear pump pressure when the control lever and the control pedal are in the NEUTRAL position.
Test unload pressure by testing tool k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
Installing testing tools 1. Open the cover on the right side of the machine. 2.
Remove the pickup plugs (PFC) and (PRC). PFC: Pressure pickup port (front pump discharged pressure) PRC: Pressure pickup port (rear pump discharged pressure)
3.
Install the nipple C and the O-ring D to the part where the pickup plug (PFC) is removed.
4.
Connect the gauge A2 of the hydraulic tester A to the nipple C. REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A2.
PC210-10M0, PC210LC-10M0
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Test and adjust oil pressure in work equipment, swing, and travel circuits
30 TESTING AND ADJUSTING
Setting measurement conditions 5. Start the engine. 6.
Select "Pre-defined Monitoring (08/11)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
7.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
8.
Set the working mode to P mode.
9.
Turn off the auto-deceleration.
10. Turn the fuel control dial to MAX (High idle) position. Doing diagnostic tests 11. Test the oil pressure when the control lever and the control pedal are in the NEUTRAL position. Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
2.
Remove the nipple C and the O-ring D.
3.
Install the pickup plugs (PFC) and (PRC), and restore the machine.
Test work equipment relief pressure on machine monitor 1.
Start the engine.
2.
Select and display the monitoring items below on the "Predefined Monitoring (04/11)" or from the "Monitoring Selection Menu". See "SETTING AND OPERATION OF MACHINE MONITOR". Monitoring code: 01100 "Front Pump Pressure" Monitoring code: 01101 "Rear Pump Pressure" Monitoring code: 04401 "Hydraulic Oil Temperature"
3.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 °C
4.
Set the working mode to P mode.
5.
Turn the swing lock switch to the OFF position.
6.
Operate the cylinders to be checked to the stroke end.
7.
Turn the fuel control dial to MAX (High idle) position.
8.
Move the lock lever to FREE position.
9.
Test the "Front Pump Pressure" and "Rear Pump Pressure" when the control lever is operated to release the pressure in the work equipment circuit. Release the pressure in the work equipment circuit for each boom, arm, and bucket. Do diagnostic tests in one-touch power maximizing operation and in normal operation.
TEST WORK EQUIPMENT RELIEF PRESSURE BY TESTING TOOL
k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
30-66
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust oil pressure in work equipment, swing, and travel circuits
1.
Open the cover on the right side of the machine.
2.
Remove the testing plugs (PFC) and (PRC). (PFC): Pressure pickup port (Front pump discharge pressure) (PRC): Pressure pickup port (Rear pump discharge pressure)
3.
Install the nipple C and O-ring D to the positions from where testing plugs (PFC) and (PRC) are removed.
4.
Connect the gauge A1 in the hydraulic tester A to the nipple C. REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A1.
Setting of test condition 5. Start the engine. 6.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(08/11)".
7.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55°C
8.
Set the working mode to P mode.
9.
Set the swing lock switch to OFF position.
10. Operate the cylinders to be checked to the stroke end. 11. Turn the fuel control dial to MAX (High idle) position. Test procedure 12. Set the lock lever to FREE position. 13. Operate the work equipment control levers, and test the oil pressure when the work equipment circuit is relieved. •
Relieve the oil pressure in the work equipment circuit for each work equipment of boom, arm, and bucket.
•
Test when one-touch power maximizing is enabled and not enabled.
Restoration 1. Stop the engine. PC210-10M0, PC210LC-10M0
30-67
Test and adjust oil pressure in work equipment, swing, and travel circuits
k k
30 TESTING AND ADJUSTING
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
2.
Remove the nipple C and O-ring D.
3.
Install the testing plugs (PFC) and (PRC), and make the machine to the original state.
TEST SWING RELIEF PRESSURE ON MACHINE MONITOR 1.
Start the engine.
2.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display the monitoring items that follows by "Pre-defined Monitoring(04/11)" or "Monitoring Selection Menu". Monitoring code: 01100 "Front Pump Pressure" Monitoring code: 01101 "Rear Pump Pressure" Monitoring code: 04401"Hydraulic Oil Temperature"
3.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55 °C
4.
Set the working mode to P mode.
5.
Set the swing lock switch to ON position.
6.
Turn the fuel control dial to MAX (High idle) position.
7.
Set the lock lever to FREE position.
8.
Operate the work equipment control levers, and test the oil pressure when the oil pressure in swing circuit is relieved.
Test swing relief pressure by testing tool
k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to Release remaining pressure from hydraulic system.
1.
Open the cover on the right side of the machine.
2.
Remove the pickup plugs (PFC) and (PRC). PFC: Pressure pickup port (front pump discharged pressure) PRC: Pressure pickup port (rear pump discharged pressure)
30-68
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust oil pressure in work equipment, swing, and travel circuits
3.
Install the nipple C and the O-ring D to the part where the pickup plugs (PFC) and (PRC) are removed.
4.
Connect the gauge A1 of hydraulic tester A to the nipple C. REMARK The digital hydraulic tester B can be also used instead of the gauge A1.
Setting measurement conditions 5. Start the engine. 6.
Select and display the monitoring items below on the "Pre-defined Monitoring (08/11)". See "SETTING AND OPERATION OF MACHINE MONITOR".
7.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
8.
Set the working mode to P mode.
9.
Turn the swing lock switch to the ON position. 10. Turn the fuel control dial to MAX (High idle) position. Doing diagnostic tests 11. Move the lock lever to FREE position. 12. Measure the oil pressure during relief in the swing circuit by operating the work equipment control lever. Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
2.
Remove the nipple C, the O-ring D, and the sensor adapter F.
3.
Install the pickup plugs (PFC) and (PRC), and restore the machine.
TEST TRAVEL RELIEF PRESSURE ON MACHINE MONITOR 1.
Start the engine.
2.
Insert the pin E and the plate F between the sprocket and the track frame for the machine not to move.
3.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display the monitoring items that follow by "Pre-defined Monitoring(04/11)", or "Monitoring Selection Menu". Monitoring code: 01100 "Front Pump Pressure" Monitoring code: 01101 "Rear Pump Pressure"
PC210-10M0, PC210LC-10M0
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Test and adjust oil pressure in work equipment, swing, and travel circuits
30 TESTING AND ADJUSTING
Monitoring code: 04401"Hydraulic Oil Temperature" 4.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55 °C
5.
Set the working mode to P mode.
6.
Turn the fuel control dial to MAX (High idle) position.
7.
Set the lock lever to FREE position.
8.
Operate the travel lever and pedal, and test the front pump pressure and rear pump pressure when the oil pressure in the travel circuit is relieved. k k
Be sure to perform correct lever operation by using clear hand signals and checking. Otherwise wrong lever operation can be a cause of an accident. Before operating the travel lever and the pedal, check the sprocket position locked with pin and locked direction of the travel again.
After you complete the test, remove the pin E and plate F, and make the machine to the original state.
Test travel relief pressure by testing tool
k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
1.
Open the cover on the right side of the machine.
2.
Remove the pickup plugs (PFC) and (PRC). (PFC): Pressure pickup port (front pump discharged pressure) (PRC): Pressure pickup port (rear pump discharged pressure)
3.
Install the nipple C and the O-ring D to the part where the pickup plugs (PFC) and (PRC) are removed.
4.
Connect the gauge A1 of the hydraulic tester A to the nipple C. REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A1.
30-70
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust oil pressure in work equipment, swing, and travel circuits
Setting measurement conditions 5. Start the engine. 6.
Insert the pin E and the plate F between the sprocket and the track frame to securely lock the travel of the machine.
7.
Select "Pre-defined Monitoring (08/23)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
8.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 °C
9.
Set the working mode to P mode.
10. Turn the fuel control dial to MAX (High idle) position. Doing diagnostic tests 11. Move the lock lever to FREE position. 12. Test the front pump pressure and rear pump pressure by operating the travel lever and the pedal for relief in the travel circuit. Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
2.
Remove the pin E and the plate F.
3.
Remove the nipple C and the O-ring D.
4.
Install the pickup plugs (PFC) and (PRC), and restore the machine.
Adjust oil pressure in work equipment, swing, and travel circuits Test unload pressure You cannot adjust the unload valve (unload pressure).
Adjust work equipment and travel relief pressure If the relief pressure of the work equipment during travel is not normal, adjust the main relief valves (1) and (2) as follows. (1): F main relief valve (2): R main relief valve •
To adjust the front pump-side main relief valve (1), remove the cover at the lower part of the control valve.
•
To adjust the rear pump-side main relief valve (2), remove the cover at the upper part of the control valve.
•
On each main relief valve, adjust only the low-pressure setting (By adjusting the low-pressure setting, high-pressure setting is automatically adjusted).
1.
Disconnect the pilot hose (3) or (4).
PC210-10M0, PC210LC-10M0
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Test and adjust oil pressure in work equipment, swing, and travel circuits
30 TESTING AND ADJUSTING
(3): Pilot hose for F main relief valve (1) (4): Pilot hose for R main relief valve (2) 2.
While fixing the holder (6), loosen the lock nut (7).
3.
Turn the holder (6) to adjust the pressure. REMARK • Turning the holder (5) clockwise increases the pressure, and turning it counterclockwise decreases the pressure. • Amount of adjusted pressure per rotation of holder (5): Approximately 20.5 MPa {209 kg/cm2}
4.
While fixing the holder (5), tighten the lock nut (6). Lock nut (7): 49 to 58.8 Nm {5 to 6 kgm}
5.
Connect the pilot hose (3) or (4).
After the adjustment is completed, check the oil pressure again using the preceding check method.
ADJUST SWING RELIEF PRESSURE Obey the procedures that follow to adjust the swing 2-stage relief valve (1) when the swing relief pressure is not correct.
1.
Disconnect the pilot hose (2).
2.
While the holder (3) is fixed, loosen the locknut (4).
3.
Turn the holder (3) to adjust the oil pressure. REMARK • Turn the holder clockwise to raise the pressure. Turn it counterclockwise to lower the pressure. • Quantity of pressure adjustment per turn of holder (3): Approximately 7.68 MPa {78.3kg/cm2}
4.
While the holder (3) is fixed, tighten the locknut (4).
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust oil pressure in work equipment, swing, and travel circuits
Lock nut (4): 58.8 to 78.4Nm {6 to 8kgm} 5.
Connect the pilot hose (2).
After the adjustment, recheck the oil pressure according to the testing procedure previously described.
PC210-10M0, PC210LC-10M0
30-73
TEST OIL PRESSURE OF CONTROL CIRCUIT
30 TESTING AND ADJUSTING
TEST OIL PRESSURE OF CONTROL CIRCUIT Obey the contents that follow to test the oil pressure in the control circuit. TOOLS TO TEST ADJUST CONTROL CIRCUIT OIL PRESSURE Symbol
k k
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
2
Size: M10 x 1.25 mm
D
07002-11023
O-ring
2
A
k
Part number
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the remaining pressure.
For the test conditions and standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR MACHINE".
Test oil pressure of control circuit Installing testing tools 1. Remove the control valve top cover, and remove the pickup plug (1).
2.
Install the nipple C and the O-ring D, and connect them to the gauge A1 of the hydraulic tester A. REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A1.
Setting measurement conditions 3. Start the engine.
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
4.
Select "Pre-defined Monitoring (08/23)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
5.
Set the hydraulic oil temperature within the range of test conditions.
TEST OIL PRESSURE OF CONTROL CIRCUIT
Hydraulic oil temperature: 45 to 55 ℃ 6.
Set the working mode to P mode.
7.
Turn off the auto-deceleration.
8.
Turn the fuel control dial to the MAX (high idle) position.
Doing diagnostic tests 9. Test the oil pressure when the control lever and the control pedal are in the NEUTRAL position. Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
2.
Remove the nipple C and the O-ring D.
3.
Install the pickup plug (1), and restore the machine. NOTICE Do not adjust the relief valve for the control circuit oil pressure. REMARK Control circuit oil pressure can be tested with the nipple C attached to the pickup port (PEPB) of the pump. PFPB: Pressure pickup port (EPC source pressure)
PC210-10M0, PC210LC-10M0
30-75
Test and adjust oil pressure in pump PC control circuit
30 TESTING AND ADJUSTING
Test and adjust oil pressure in pump PC control circuit Test and adjust the oil pressure in the pump PC control circuit, according to the procedure below. Check that the oil pressures in the work equipment, swing, travel circuits and control circuits are normal. Then start the test. TOOLS TO TEST ADJUST PUMP PC CONTROL CIRCUIT OIL PRESSURE Symbol
k
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5110
Gauge
1
Pressure range: 0 to 60 MPa
2
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
4
Size: M10 x 1.25 mm
D
07002-11023
O-ring
4
A
k
Part number
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
For measurement conditions and standard values, see "STANDARD VALUE TABLE FOR MACHINE" in STANDARD VALUE TABLE.
Test PC valve outlet pressure (servo piston inlet pressure) NOTICE To measure the PC valve outlet pressure (servo piston inlet pressure), measure the pump discharged pressure simultaneously and compare them. REMARK Front pump discharged pressure and rear pump discharged pressure can also be tested by using the monitoring function of the machine monitor. Installing testing tools 1. Open the cover on the right side of the machine. Remove the pickup plugs (PFC), (PRC), (PENF), and (PENR). PFC: Pressure pickup port (front pump discharged pressure) PRC: Pressure pickup port (rear pump discharged pressure) PENF: Pressure pickup port (front PC valve outlet pressure) PENR: Pressure pickup port (rear PC valve outlet pressure)
30-76
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
2.
Test and adjust oil pressure in pump PC control circuit
Install the nipple C and the O-ring D, and connect them to the gauge A1 of the hydraulic tester A. REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A1.
Setting measurement conditions 3. Start the engine. 4.
Select Pre-defined Monitoring (08/23), and display it by referring to SET AND OPERATE MACHINE MONITOR.
5.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
6.
Set the working mode to P mode.
7.
Turn the swing lock switch to the ON position.
8.
Turn the fuel control dial to the MAX (high idle) position.
Doing diagnostic tests 9. Move the lock lever to FREE position. 10. Operate the work equipment control lever and release the pressure in the arm IN circuit, and measure the pump discharged pressure and PC valve outlet pressure (servo piston inlet pressure) at the same time. REMARK If the PC valve or the servo piston is abnormal, the PC valve outlet pressure (servo piston inlet pressure) has the same pressure as the pump discharged pressure or approximately 0 MPa {0 kg/cm2}. Restoring the machine 1. Stop the engine. k Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. k
Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
2.
Remove the nipple C and the O-ring D.
3.
Install the pickup plug (1), and restore the machine.
TEST PC-EPC VALVE OUTLET PRESSURE Install test tool 1. Open the cover on the right side of the machine, and remove the testing plugs (PMF) and (PMR). PMF: Pressure pickup port (front PC mode selector pressure) PMR: Pressure pickup port (rear PC mode selector pressure)
PC210-10M0, PC210LC-10M0
30-77
Test and adjust oil pressure in pump PC control circuit
2.
30 TESTING AND ADJUSTING
Install the nipple C and O-ring D, connect the gauge A2 in the hydraulic tester A. REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A2.
Setting of test condition 3. Start the engine. 4.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(08/23)".
5.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55°C
6.
Set the working mode to P mode.
Test procedure 7. Check the oil pressure when the fuel control dial is in MAX (High idle) position or in MIN (Low idle) position after setting all control levers and control pedals in NEUTRAL position. Restoration 1. Stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
2.
Remove the nipple C and O-ring D.
3.
Install the testing plugs (PMF) and (PMR), and make the machine to the original state.
30-78
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust oil pressure in pump PC control circuit
Adjust oil pressure in pump PC control circuit When the phenomena shown below occur and PC valves seem to be defective, adjust the PC valves (1) and (2) according to the procedure below. •
As the working load increases, the engine speed drops largely.
•
The engine speed is normal but the work equipment speed is low.
(1): Front pump PC valve (2): Rear pump PC valve NOTICE The width across flats of the PC valve lock nut is 13 mm, and the width across flats (inside width) of the adjustment screw is 4 mm. Do not turn the other lock nuts and adjustment screws since they affect the hydraulic pump performance. 1. Place a matchmark on the end face of the adjustment screw (4) to show the position of the screw before adjustment. REMARK Record whether the adjustment screw (4) was turned to the right or left to return the screw to its original position. 2.
Loosen the lock nut (3) with the adjustment screw (4) fixed.
3.
Rotate the adjustment screw (4) counterclockwise or clockwise to adjust it. The adjustable range of the adjustment screw (4) is described below. Counterclockwise: Within 1 turn Clockwise: Within 1 turn REMARK When the adjustment screw is turned counterclockwise, pump absorption torque decreases. When the adjustment screw is turned clockwise, pump absorption torque increases. When the engine speed decreases, turn the adjustment screw counterclockwise. When the work equipment speed is low, turn the adjustment screw clockwise.
4.
With the adjustment screw (4) fixed, tighten the lock nut (3). Lock nut (3): 27 to 34 Nm {2.8 to 3.5 kgm}
After adjusting the oil pressure, check that the PC valve output pressure (servo piston input pressure) is normal. See "Test PC valve outlet pressure (servo piston inlet pressure)".
PC210-10M0, PC210LC-10M0
30-79
Test and adjust oil pressure in pump LS control circuit
30 TESTING AND ADJUSTING
Test and adjust oil pressure in pump LS control circuit Test and adjust the oil pressure in the pump LS control circuit, according to the procedure below. Check that the oil pressures in the work equipment, swing, travel circuits and control circuits are normal. Then start the test. TOOLS TO TEST ADJUST PUMP LS CONTROL CIRCUIT OIL PRESSURE Symbol
k k k
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5110
Gauge
1
Pressure range: 0 to 60 MPa
2
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
4
Size: M10 x 1.25 mm
D
07002-11023
O-ring
4
E
799-401-2701
Differential pressure gauge
1
Pressure range: 0 to 50 MPa
F
796T-440-1101
Sensor adapter
1
Pressure range: 0 to 50 MPa
A
k
Part number
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system". Provide enough work space to run the raised track idle off the ground for testing.
For measurement conditions and standard values, see "STANDARD VALUE TABLE FOR MACHINE" in STANDARD VALUE TABLE.
Test LS differential pressure with machine monitor Installing testing tools 1. Open the cover on the right side of the machine. Remove the pickup plugs (PLSFC) and (PLSRC). (PLSFC): Pressure pickup port (front load pressure) (PLSRC): Pressure pickup port (rear load pressure)
2.
Install the nipple C and the O-ring D, and connect the sensor adapter F. The figure shows the rear side.
30-80
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
3.
Test and adjust oil pressure in pump LS control circuit
Connect the sensor adapter F to the service oil pressure connector (P49).
Setting measurement conditions 4. Start the engine. 5.
Select and display the monitoring items below on "Monitoring Selection Menu" by referring to the "SET AND OPERATE MACHINE MONITOR". Monitoring code: 01100 "Front Pump Pressure" Monitoring code: 01101 "Rear Pump Pressure" Monitoring code: 01141 "Service Pressure Sensor" Monitoring code: 04401 "Hydraulic Oil Temperature"
6.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
7.
Move the lock lever to FREE position.
8.
Raise the track shoe to be tested in the work equipment off the ground by operating the work equipment control lever. Measuring the front circuit: Track shoe on the right side Measuring the rear circuit: Track shoe on the left side
9.
Set the working mode to P mode. 10. Set the travel speed to Hi. 11. Turn the fuel control dial to the MAX (high idle) position.
Doing diagnostic tests 12. Test pump discharged pressure and LS pressure (actuator load pressure) simultaneously when the control lever and the control pedal are in the NEUTRAL position and the travel control lever is at half stroke. REMARK Obtain the LS differential pressure: LS differential pressure = Pump discharged pressure - LS pressure Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
2.
Remove the nipple C, the O-ring D, and the sensor adapter F.
3.
Install the pickup plugs (PLSFC) and (PLSRC), and restore the machine.
PC210-10M0, PC210LC-10M0
30-81
Test and adjust oil pressure in pump LS control circuit
30 TESTING AND ADJUSTING
Test LS differential pressure by testing tool To figure out the LS differential pressure, measure the pump discharged pressure and LS pressure (actuator load pressure) simultaneously, and calculate the difference. Installing testing tools 1. Open the cover on the right side of the machine. Remove the pickup plugs (PFC), (PRC), (PLSFC), and (PLSRC). (PFC): Pressure pickup port (front pump discharged pressure) (PRC): Pressure pickup port (rear pump discharged pressure) (PLSFC): Pressure pickup port (front load pressure) (PLSRC): Pressure pickup port (rear load pressure)
2.
Install the nipple C and the O-ring D.
30-82
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
3.
Test and adjust oil pressure in pump LS control circuit
Connect the differential pressure gauge E or the gauge A1 of the hydraulic tester A to the nipple C. •
When using the differential pressure gauge E, connect the high-pressure side (rear side) to the pump discharged pressure and the low-pressure side (bottom side) to the LS pressure. REMARK The differential pressure gauge needs 12 V DC power. Connect it to 1 battery.
•
When using the gauge A1, check the pressure while replacing the same gauge since the differential pressure goes up to approximately 2.9 MPa {approximately 30 kg/cm2}. REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A1.
Setting measurement conditions 4. Start the engine. 5.
Select "Pre-defined Monitoring (08/23)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
6.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
7.
Move the lock lever to FREE position.
8.
Raise the track shoe to be tested in the work equipment off the ground by operating the work equipment control lever. Measuring the front circuit: Track shoe on the right side Measuring the rear circuit: Track shoe on the left side
9.
Set the working mode to P mode. 10. Turn the fuel control dial to the MAX (high idle) position.
Doing diagnostic tests 11. Test pump discharged pressure and LS pressure (actuator load pressure) simultaneously when the control lever and the control pedal are in the NEUTRAL position and the travel control lever is at half stroke. REMARK Obtain the LS differential pressure: LS differential pressure = Pump discharged pressure - LS pressure Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
2.
Remove the nipple C and the O-ring D.
3.
Install the pickup plugs (PFC), (PRC), (PENF), (PLSFC), and (PLSRC), and restore the machine.
PC210-10M0, PC210LC-10M0
30-83
Test and adjust oil pressure in pump LS control circuit
30 TESTING AND ADJUSTING
Test LS valve outlet pressure (servo piston inlet pressure) NOTICE To measure the LS valve outlet pressure (servo piston inlet pressure), measure the pump discharged pressure simultaneously and compare them. REMARK Front pump discharged pressure and rear pump discharged pressure can also be tested by using monitoring function of the machine monitor. Installing testing tools 1. Open the cover on the right side of the machine. Remove the pickup plugs (PFC), (PRC), (PENF), and (PENR). (PFC): Pressure pickup port (front pump discharged pressure) (PRC): Pressure pickup port (rear pump discharged pressure) (PENF): Pressure pickup port (front LS valve outlet pressure) (PENR): Pressure pickup port (rear LS valve outlet pressure)
2.
Install the nipple C and the O-ring D, and connect them to the gauge A1 of the hydraulic tester A.
Setting measurement conditions 3. Start the engine.
30-84
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust oil pressure in pump LS control circuit
4.
Select "Pre-defined Monitoring (08/23)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
5.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
6.
Move the lock lever to FREE position.
7.
Raise the track shoe to be tested in the work equipment off the ground by operating the work equipment control lever. Measuring the front circuit: Track shoe on the right side Measuring the rear circuit: Track shoe on the left side
8.
Set the working mode to P mode.
9.
Set the travel speed to Hi.
10. Turn the fuel control dial to the MAX (high idle) position.
Doing diagnostic tests 11. Test pump discharged pressure and LS pressure (actuator load pressure) simultaneously when the control lever and the control pedal are in the NEUTRAL position and the travel control lever is at half stroke. REMARK Obtain the LS differential pressure: LS differential pressure = Pump discharged pressure - LS pressure Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
2.
Remove the nipple C and the O-ring D.
3.
Install the pickup plugs (PFC), (PRC), (PENF), and (PENR), and restore the machine.
Test LS-EPC valve outlet pressure Installing testing tools 1. Remove the pickup plug (PSIG). 2.
Install the nipple C and the O-ring D, and connect them to the gauge A2 of the hydraulic tester A. REMARK Gauge in digital hydraulic tester B can also be used instead of gauge A2.
PC210-10M0, PC210LC-10M0
30-85
Test and adjust oil pressure in pump LS control circuit
30 TESTING AND ADJUSTING
Setting measurement conditions 3. Start the engine. 4.
Select "Pre-defined Monitoring (01/23)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
5.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
6.
Set the working mode to P mode.
7.
Turn the fuel control dial to the MAX (high idle) position.
8.
Set the travel speed to Lo, Mi, or Hi.
9.
Move the lock lever to FREE position.
Doing diagnostic tests 10. Operate the travel lever to test oil pressure. REMARK Pressure can be tested with a little operation of the travel lever which the PPC oil pressure switch turns on (before the machine starts to operate). Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
2.
Remove the nipple C and the O-ring D.
3.
Install the pickup plug (PSIG), and restore the machine.
Adjust LS valve If the LS differential pressure is not normal, adjust the LS valves (1) and (2) according to the following procedure. (1): Rear pump LS valve (2): Front pump LS valve
1.
Place a matchmark on the end face of the adjustment screw (3) to show the position of the screw before adjustment.
2.
Record whether the adjustment screw (3) was turned to the right or left to return the screw to its original position.
3.
Turn the adjustment screw (3) to adjust the LS differential pressure. One rotation of the adjustment screw (3) adjusts a pressure of approximately 1.1 MPa {10.8 kg/cm2}.
30-86
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test and adjust oil pressure in pump LS control circuit
REMARK Turning the adjustment screw (3) clockwise increases the LS differential pressure, and turning the adjustment screw (3) counterclockwise decreases the LS differential pressure. 4.
While fixing the adjustment screw (3), tighten the lock nut (4). Lock nut (11): :49 to 68.6 Nm {5 to 7 kgm}
After the adjustment is completed, make sure that the LS valve output pressure (servo piston input pressure) is normal. See "TEST LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)".
PC210-10M0, PC210LC-10M0
30-87
Test outlet pressure of solenoid valve
30 TESTING AND ADJUSTING
Test outlet pressure of solenoid valve Test the outlet pressure of the solenoid valve, according to the procedure below. Check the control circuit oil pressure is normal. Then start the test. TOOLS TO TEST SOLENOID VALVE OUTLET PRESSURE Symbol
k k
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-401-3100
Adapter
1
Size: 02
D
799-401-3200
Adapter
1
Size: 03
A
k
Part number
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine. Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
For the test conditions and standard values, see STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR MACHINE".
Test outlet pressure of solenoid valve Installing testing tools 1. Remove the cover (rear side) on the lower part of the operator’s cab and the cover on the lower part of the control valve. Disconnect the outlet hoses (1) to (7) of the solenoid valves to be tested. (1): PPC lock solenoid valve (2): 2-stage relief solenoid valve (3): Swing parking brake solenoid valve (4): Travel speed increase solenoid valve (5): Travel junction solenoid valve (6): 2-stage swing relief solenoid valve (7): Swing stroke control solenoid valve (8): Attachment selector solenoid valve (machine with the attachment)
30-88
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
2.
Install the adapter C or the adapter D, and connect the disconnected hoses.
3.
Install the nipple A2 to the adapter C or the adapter D, and connect it to the gauge A1.
Test outlet pressure of solenoid valve
REMARK Gauge in the digital hydraulic tester B can also be used instead of the gauge A1.
Setting measurement conditions 4. Start the engine. 5.
Select and display the monitoring items below on "Monitoring Selection Menu" by referring to the "SET AND OPERATE MACHINE MONITOR". Monitoring code: 04401 "Hydraulic Oil Temperature" Monitoring code: 02300 "Solenoid Valve 1" Monitoring code: 02301 "Solenoid Valve 2"
6.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
7.
Turn the fuel control dial to the MAX (high idle) position.
Doing diagnostic tests 8. Move the lock lever to FREE position. 9.
Operate each control lever and switches, and measure the outlet pressure when the solenoid valve is energized and de-energized. REMARK • When each control lever and switches are operated, the display of the machine monitor also changes. • For the conditions for turning the solenoid valve ON or OFF, see "OPERATING CONDITION OF SOLENOID VALVE".
Restoring the machine 1. Stop the engine. k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
2.
Remove the adapter C or the adapter D.
3.
Install the oil pressure hose, and restore the machine.
PC210-10M0, PC210LC-10M0
30-89
Test outlet pressure of solenoid valve
30 TESTING AND ADJUSTING
OPERATING CONDITION OF SOLENOID VALVE (1) PPC lock solenoid valve operation table Operating state of solenoid valve
Operating condition of solenoid valve
Lock lever
LOCK position
OFF (de-energized)
RELEASE position
ON (energized)
(2) 2-stage relief solenoid valve operation table Operating state of solenoid valve
Operating condition of solenoid valve When overheat 1st setting is applied
OFF (de-energized)
When overheat 2nd setting is applied All signals of work equipment, swing, and travel Swing lock switch
ON
When travel signal is conducted L mode
ON (energized)
When boom lower signal is conducted
P-mode, E-mode
When one-touch power maximizing switch is turned on
When signals other than swing single signal are conducted When swing single signal is conducted
Other than the above conditions
OFF (de-energized)
(3) Swing parking brake solenoid valve operation table Operating state of solenoid valve
Operating condition of solenoid valve Work equipment signal and swing signal (work equipment including services)
All OFF
OFF (de-energized)
When any of these is turned ON
ON (energized)
(4) Travel speed increase solenoid valve operation table Operating state of solenoid valve
Operating condition of solenoid valve When overheat 2nd setting is applied Engine speed
When 1500 rpm or below
When the travel speed selector switch is set in Lo
OFF (de-energized)
When travel signal is not conducted When the travel speed selector switch is set in Mi, Hi
When travel signal is conducted
When F or R pump pressure is 33.3MPa{340kg/cm2} or higher When F or R pump pressure is 19.6MPa{200kg/cm2} or below
ON (energized)
Other than the above conditions
30-90
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test outlet pressure of solenoid valve
(5) Travel junction solenoid valve operation table Operating state of solenoid valve
Operating condition of solenoid valve When travel steering signal is conducted
When travel steering signal is not conducted
When travel single signal is conducted
When F or R pump pressure is 24.5MPa{250kg/cm2} or higher
ON (energized)
OFF (de-energized)
Other than the above conditions
(6) Swing 2-stage relief solenoid valve operation table Operating state of solenoid valve
Operating condition of solenoid valve When boom When boom raise RAISE PPC pressignal is conduc- sure is When swing sig- ted 2.2MPa{22kg/ nal is conducted cm2} or below When arm signal except the operais not conducted tion of changing swing direction When the pump flow is divided
When F pump pressure is raising or 20.6MPa{210kg/c m2} or higher When F pump pressure is lowering or 25.5MPa{260kg/c m2} or higher
ON (energized)
OFF (de-energized)
Other than the above conditions
(7) Swing stroke regulator solenoid valve operation table Operating condition of solenoid valve
Working mode
Operating state of solenoid valve
E and ATT/E (but, only when E adjustment mode is 1 to E4)
ON (energized)
Other than the above
OFF (de-energized)
(8) Attachment selector solenoid valve operation table Operating condition of solenoid valve
Working mode
PC210-10M0, PC210LC-10M0
Operating state of solenoid valve
Other than B
OFF (de-energized)
B
ON (energized)
30-91
Test PPC valve outlet pressure
30 TESTING AND ADJUSTING
Test PPC valve outlet pressure Test the outlet pressure in the PPC valve according to the procedure below. Test that no abnormality occurs in the PPC valve. TOOLS TO TEST PPC VALVE OUTLET PRESSURE Symbol
Part name
Q'ty
Remarks
-
799-101-5002
Hydraulic tester
1
1
799-101-5130
Gauge
1
Pressure range: 0 to 6 MPa
2
799-101-5160
Nipple
1
Size: R1/8
B
790-261-1205
Digital hydraulic tester
1
Pressure range: 0 to 70 MPa
C
799-101-5220
Nipple
1
Size: 02
D
07002-11023
O-ring
1
Size: 03
A
k
Part number
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
See STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR MACHINE" for standard values.
Test outlet pressure of PPC valve with machine monitor 1.
Start the engine.
2.
Display the following items on the "Pre-defined Monitoring" or from the "Monitoring Selection Menu".See "SETTING AND OPERATION OF MACHINE MONITOR". On the"Pre-defined Monitoring", select (8/11), (9/11), or (10/11) according to the circuit to be tested.
30-92
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test PPC valve outlet pressure
Monitoring code: 04401 "Hydraulic Oil Temperature" Monitoring code: 07400 "Boom Raise PPC Pressure" Monitoring code: 07500 "Boom Lower PPC Pressure" Monitoring code: 07200 "Arm IN PPC Pressure" Monitoring code: 07600 "Arm OUT PPC Pressure" Monitoring code: 07300 "Bucket CURL PPC Pressure" Monitoring code: 07301 "Bucket DUMP PPC Pressure" Monitoring code: 09001 "Swing Left PPC Pressure" Monitoring code: 09002 "Swing Right PPC Pressure" Monitoring code: 07102 "Travel Forward Left PPC Press" Monitoring code: 07103 "Travel Forward Right PPC Press" Monitoring code: 07104 "Travel Reverse Left PPC Press" Monitoring code: 07105 "Travel Reverse Right PPC Press" 3.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 °C
4.
Set the working mode to P mode.
5.
Turn the fuel control dial to MAX (High idle) position.
6.
Move the lock lever to FREE position.
7.
Check the oil pressure in the following two cases: (1) When you move the control lever and the control pedal to NEUTRAL position, (2) When you move the control lever and the control pedal of the circuit to be tested to the their stroke ends.
TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL
k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
Install test tool 1. Remove the upper cover of control valve. 2.
Disconnect the hydraulic hose of the PPC circuit to be tested, and install adapter C or D. (1): Bucket CURL (White) (2): Bucket DUMP (Black) (3): Left travel FORWARD (Red) (4): Left travel REVERSE (-) (5): Boom LOWER (Brown) (6): Boom RAISE (Green) (7): Swing Right (-) (8): Swing Left (Red) (9): Left travel FORWARD (Green) (10): Right travel REVERSE (Blue) (11): Arm IN (Blue)
PC210-10M0, PC210LC-10M0
30-93
Test PPC valve outlet pressure
30 TESTING AND ADJUSTING
(12): Arm OUT (Yellow) ( ) are the colors of the bands installed for piping identification. 3.
Install the disconnected hose to the adapter C or D.
4.
Install the nipple A2 of hydraulic tester A to adapter C or D, and connect the gauge A1. REMARK Gauge in digital hydraulic tester B can also be used instead of gauge A1.
Setting of test condition 5. Start the engine. 6.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(12/11)".
7.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55°C
8.
Set the working mode to P mode.
9.
Turn the fuel control dial to MAX (High idle) position.
Test procedure 10. Set the lock lever to FREE position. 11. Check the oil pressure when the control levers and pedals are in NEUTRAL and when the control lever and pedal of the circuit to be checked are operated to stroke end. Restoration 1. Stop the engine. k k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
2.
Remove the nipple C and O-ring D.
3.
Install the testing plugs (PFC) and (PRC), and make the machine to the original state.
30-94
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Adjust play of work equipment and swing PPC valve
Adjust play of work equipment and swing PPC valve If there is much play in the control lever, adjust the play as follows. Adjust the backlash of the lever end to 0.5 to 3 mm at a position 200 mm away from the center of rotation.
Adjust play of work equipment and swing PPC valve 1.
Remove the boot (1).
2.
Loosen the lock nut (2) and tighten the disc (3) to a position where the disc contacts the heads of the four pistons (4). Do not move the pistons while tightening the disc.
3.
Fix the disc (3) in place by tightening the lock nut (2) to the specified torque. Lock nut (2): 68 to 88 Nm {7 to 9 kgm}
4.
Apply gear oil and grease to the joint sliding parts. Joint sliding part: Grease (G2-Ll)
5.
•
Apply grease of 7 to 10 ml to the entire circumference of the pin (a).
•
Apply gear oil of 0.2 to 0.4 ml to the joint and pin sliding parts (b) (4 places).
Install the boot (1).
PC210-10M0, PC210LC-10M0
30-95
TesTest pump swash plate sensor
30 TESTING AND ADJUSTING
TesTest pump swash plate sensor Test the pump swash plate sensor according to the procedure below. Check that the items below are in the normal state. Then start the test. •
Oil pressure in work equipment, swing, and travel circuits
•
Control circuit oil pressure
•
Running track idle off ground speed
k
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
See STANDARD VALUE TABLE, "STANDARD VALUE TABLE FOR MACHINE" for standard values.
Test pump swash plate sensor 1.
Start the engine.
2.
Select and display the monitoring items below on "Monitoring Selection Menu" by referring to the "SET AND OPERATE MACHINE MONITOR". Monitoring code: 01138 "F Pump Swash Plate Sensor volt" Monitoring code: 01140 "R Pump Swash Plate Sensor volt" Monitoring code: 04401 "Hydraulic Oil Temperature"
3.
Set the hydraulic oil temperature in the range of test conditions. Hydraulic oil temperature: 45 to 55 °C
4.
Move the lock lever to FREE position.
5.
Raise the track shoe to be tested off the ground by operating the work equipment. When testing the front pump swash plate sensor: Left track shoe When testing the rear pump swash plate sensor: Right track shoe k
When idling the track shoe raised by the work equipment, secure the safety of surroundings.
6.
Set the working mode to P mode.
7.
Set the travel speed to Hi.
8.
Turn the swing lock switch to the ON position.
9.
Turn the fuel control dial to MAX (High idle) position.
10. Set the control lever and the control pedal to the NEUTRAL position, and then set the travel lever and the travel pedal to the full stroke position. Test the voltage value in running track idle off ground operation. k
30-96
When idling the track shoe raised by the work equipment, secure the safety of surroundings.
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test parts causing hydraulic drift in work equipment
Test parts causing hydraulic drift in work equipment Test parts causing hydraulic drift in work equipment, according to the procedure below. TOOLS TO TEST PPC VALVE OUTLET PRESSURE Symbol
Part number
A
07376-70315
k k
Part name Plug
Q'ty 1
Remarks Size: 03
Place the machine on a level ground. Do not enter the space under the work equipment during the test.
If the cause of hydraulic drift is defective cylinder packing, lowering speed can increase for the reasons below. When the machine is in a hydraulic drift measuring posture (where holding pressure is applied to the bottom side), pressurized oil leaks from the bottom side to the head side. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the pressurized oil flowing in from the bottom side. As the pressure in the head side (it varies depending on the leakage amount) increases, the pressure in the bottom side also increases. The pressures are balanced on both side, and then lowering speed decreases. Operate the lever to the direction that the oil in the tested cylinder is drained on the head side, and the oil on the head side flows to the drain circuit (the bottom side is blocked by the check valve). The pressure balance between the head side and the bottom side is lost, and then the lowering speed increases.
Test parts causing hydraulic drift of boom cylinder and bucket cylinder 1.
Move work equipment in the hydraulic drift measuring posture, and stop the engine. Apply rated load on the bucket or fill the bucket with soil.
2.
Turn the starting switch to ON position.
3.
To inspect the boom cylinder, move the boom to the boom RAISE side with the control lever. To inspect the bucket cylinder, move the bucket to the bucket CURL side with the control lever. If the pressure in the accumulator decreases, start the engine for approximately 10 seconds for pressure accumulation. Causes of hydraulic drift •
When the lowering speed is increased: The cylinder packing is defective.
•
When the speed does not change: The control valve is defective.
Test parts causing hydraulic drift of arm cylinder 1.
Stop the arm cylinder at a point approximately 100 mm from the digging stroke end. Stop the engine.
2.
Turn the starting switch to ON position.
3.
When inspecting the arm, move it to the Arm IN side with the control lever. If the pressure in the accumulator decreases, start the engine for approximately 10 seconds for pressure accumulation. Causes of hydraulic drift •
When the lowering speed is increased: The cylinder packing is defective.
•
When the speed does not change: The control valve is defective.
PC210-10M0, PC210LC-10M0
30-97
Test parts causing hydraulic drift in work equipment
30 TESTING AND ADJUSTING
Test parts causing hydraulic drift of boom hydraulic drift prevention valve 1.
Set the arm cylinder and the bucket cylinder to the most retracted state (to set the machine in maximum reach) with the boom top being horizontal. Then, stop the engine.
2.
Set the lock lever to the LOCK position.
k
Release the remaining pressure by referring to "Release remaining pressure from hydraulic system".
3.
Disconnect the drain hose (1) of the control valve.
4.
Set the plug A to the disconnected drain hose (1) so that the oil does not flow out. Leave the control valve side open for the testing.
5.
If the hydraulic drift of the work equipment is found, test the control valve in the position where the drain hose was disconnected. Cause of hydraulic drift If the oil flows out from the control valve because of hydraulic drift, the adhesion of the boom hydraulic drift prevention valve is insufficient.
Test parts causing hydraulic drift of PPC valve 1.
In the hydraulic drift measuring posture, stop the engine.
2.
Turn the starting switch to ON position.
3.
Check the amount of descent of the work equipment at the lock and free positions of the lock lever. If the pressure in the accumulator decreases, start the engine for approximately 10 seconds for pressure accumulation. Cause of hydraulic drift If there is a difference in the amount of descent between lock and free positions of the lock lever, the PPC valve is defective (internal fault).
30-98
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test oil leakage
Test oil leakage Check the amount of oil leakage as follows. TOOLS TO TEST OIL LEAKAGE Symbol
Part number
Part name
Q'ty
Remarks
A
Commercially available
Measuring cylinder
1
B
07379-00640
Flange
2
Size: 06
C
07376-70522
Plug
2
Size: 05
D
07376-70422
Plug
1
Size: 04
E
Commercially available
Plate
1
Size: 250 x 260 x 32
F
Commercially available
Pin
1
Size: φ 200 x 80
For measurement conditions and standard values, see "STANDARD VALUE TABLE FOR MACHINE" in STANDARD VALUE TABLE.
TEST OIL LEAKAGE FROM BOOM CYLINDER
k
Place the machine on a level ground.
Install test tool 1. Set the boom cylinder to the RAISE stroke end, and stop the engine. k k k
Operate the lock lever to LOCK position. Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure on the boom cylinder head side by referring to "Release remaining pressure from hydraulic system".
REMARK Release the remaining pressure only by boom RAISE operation. 2.
Disconnect the hose (1) on the cylinder head side, close the hose side with the flange B. k
Be careful not to disconnect the hose on the cylinder bottom side.
Setting of test condition 3. Start the engine. 4.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(08/11)".
5.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55 °C
6.
Turn the fuel control dial to MAX (High idle) position.
PC210-10M0, PC210LC-10M0
30-99
Test oil leakage
30 TESTING AND ADJUSTING
Test procedure 7. Set the lock lever to FREE position. 8.
Operate the work equipment control lever to relieve the oil pressure in boom RAISE circuit.
9.
Measure the leakage volume for 1 minute 30 seconds after the relief has started. k
Be careful not to operate the lever to the Boom LOWER side.
Restoration 1. Stop the engine. k
2.
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
Remove the flange B to install the hose, and make the machine to the original state.
TEST OIL LEAKAGE FROM ARM CYLINDER
k
Place the machine on a flat ground, lower the work equipment completely to the ground in a stable posture, and set the lock lever to LOCK position.
Install test tool 1. Set the arm cylinder to the arm IN stroke end, and stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains.
REMARK Release the pressure that remains in the circuit only by arm IN operation. 2.
Disconnect the hose (1) on the cylinder head side, close the hose side with the flange B. k
Be careful not to disconnect the hose on the cylinder bottom side.
Setting of test condition 3. Start the engine. 4.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(08/11)".
5.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55 °C
6.
Turn the fuel control dial to MAX (High idle) position.
Test procedure 7. Set the lock lever to FREE position. 8.
Operate the work equipment control lever, and relieve the oil pressure in the arm IN circuit.
9.
Measure the leakage volume for 1 minute 30 seconds after the relief has started.
k
Be careful not to operate the lever to arm OUT side.
Restoration 1. Stop the engine. 30-100
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
k
2.
Test oil leakage
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
Remove the flange B to install the hose, and make the machine to the original state.
TEST OIL LEAKAGE FROM BUCKET CYLINDER
k
Place the machine on a flat ground, lower the work equipment completely to the ground in a stable posture, and set the lock lever to LOCK position.
Install test tool 1. Set the bucket cylinder to the bucket CURL end, and stop the engine. k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work. See RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM, and release the pressure that remains on the bucket cylinder head side.
REMARK Release the pressure that remains only with the bucket CURL operation. 2.
Disconnect the hose (1) on the cylinder head side, close the hose side with the flange B. k
Be careful not to disconnect the hose on the cylinder bottom side.
Setting of test condition 3. Start the engine. 4.
See "SETTING AND OPERATION OF MACHINE MONITOR", select and display "Pre-defined Monitoring(08/11)".
5.
Make sure the hydraulic oil temperature is in the specified range. Hydraulic oil temperature: 45 to 55°C
6.
Turn the fuel control dial to MAX (High idle) position.
Test procedure 7. Set the lock lever to FREE position. 8.
Operate the work equipment control lever to relieve the oil pressure in the bucket CURL circuit.
9.
After 30 seconds from when the relief starts, measure the leakage in 1 minute by using measuring cylinder A.
k
Be careful not to operate the lever to bucket DUMP side.
Restoration 1. Stop the engine. k
2.
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
Install the flange B, and make the machine to the original state.
Test oil leakage from swing motor k
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
PC210-10M0, PC210LC-10M0
30-101
Test oil leakage
k k
30 TESTING AND ADJUSTING
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work. Release the remaining pressure by referring to Release remaining pressure from hydraulic system.
1.
Remove the swing machinery upper cover. See DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL SWING MACHINERY ASSEMBLY".
2.
Disconnect the drain hoses (4) (2 pieces), and block the hose side with the plug C.
Setting measurement conditions 3. Turn the swing lock switch to the ON position. 4.
Start the engine.
5.
Select "Pre-defined Monitoring (08/11)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
6.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
7.
Turn the fuel control dial to the MAX (high idle) position.
Doing diagnostic tests 8. Move the lock lever to FREE position. 9.
Release the oil pressure in the swing circuit by operating the work equipment control lever.
10. After 30 seconds passed since the start of the relief, measure the leakage for 1 minute by using the measuring cylinder A. 11. After the test is finished, swing the upper structure 180 °, and then start the test again. Restoring the machine 1. Stop the engine. k
Immediately after the engine is stopped, the parts and oil are very hot and they can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the plug C, and install the hoses.
3.
Install the swing machinery upper cover, and restore the machine.
Test oil leakage from travel motor Installing testing tools Place the machine on a flat ground, lower the work equipment completely to the ground in a stable posture, and set the lock lever to LOCK position.
k k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
1.
Remove the travel motor cover.
2.
Start the engine, insert the plate E and the pin F between the sprocket and the track frame to securely lock the travel of the machine, and stop the engine.
3.
Disconnect the drain hose (5) on the travel motor. Block the hose side with the plug D.
Setting measurement conditions 4. Turn the swing lock switch to the ON position. 5.
Start the engine.
6.
Select "Pre-defined Monitoring (08/11)", and display it by referring to "SET AND OPERATE MACHINE MONITOR".
7.
Set the hydraulic oil temperature within the range of test conditions. Hydraulic oil temperature: 45 to 55 ℃
8.
Turn the fuel control dial to the MAX (high idle) position.
30-102
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test oil leakage
Doing diagnostic tests 9. Move the lock lever to FREE position. 10. Release the oil pressure from the travel circuit by operating the travel lever and the pedal. 11. After 30 seconds passed since the start of the relief, measure the leakage for 1 minute by using the measuring cylinder A. k k
Be sure to perform correct lever operation by using clear hand signals and checking. Otherwise wrong lever operation can be a cause of an accident. Before operating the travel lever, check the position and direction of locked sprocket again.
. 12. Rotate the motor a little and test the oil leakage several times (changing the relative position between the valve plate and the cylinder block in the motor). Restoring the machine 1. Stop the engine. k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
2.
Remove the plug D, and install the hoses.
3.
Install the travel motor cover, and restore the machine.
PC210-10M0, PC210LC-10M0
30-103
Bleed air from hydraulic system
30 TESTING AND ADJUSTING
Bleed air from hydraulic system Bleed air from a hydraulic system according to the procedure below. k Place the machine on a flat ground, lower the work equipment completely to the ground in a stable posture, and set the lock lever to LOCK position. k
Immediately after the engine is stopped, its parts and oil are still very hot, and it can cause burn injury. Wait for the temperature to go down, and then start the work.
Do the items marked with "●" in turn, depending on work. You do not need to do the items marked with "x". Air bleeding procedure and items 1 Details of work
•
Change hydraulic oil
•
Clean the strainer
•
Replacement of the return filter element
•
Replacement and repair of the main pump
•
Removal of the suction piping
•
Replacement and repair of the control valve
•
Removal of the control valve piping
•
Cylinder has been replaced or repaired.
•
Removal of the cylinder piping
•
Replacement and repair of the swing motor
•
Bleed air from main pump
●
2 Start the engine
●
3
4
Bleeding air Bleed air from from swing cylinder motor
●
5
6
Bleed air from Test oil level travel motor
● ↓
● ↓
(*1)
(*1)
●
x
●
x
x
x
●
●
●
●
x
x
●
x
●
●
x
x
●
x
●
●
x
x
●
x
●
x
●
x
●
Removal of the swing motor piping
30-104
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Bleed air from hydraulic system
Air bleeding procedure and items 1 Details of work
•
Replacement and repair of the travel motor
•
Removal of the travel motor piping
•
Replacement and repair of the swivel joint
•
Removal of the swivel joint piping
Bleed air from main pump
2 Start the engine
3
4
Bleeding air Bleed air from from swing cylinder motor
5
6
Bleed air from Test oil level travel motor
x
●
x
x
●
●
x
●
x
x
x
●
*1: Bleed air from the swing motor and the travel motor only when the oil in the motor case is drained.
Bleed air from main pump Keep the oil filler cap of the hydraulic tank loosened during air bleeding work of the main pump. 1. Loosen the air bleeder (1) of the main pump, and check that oil oozes out from the air bleeder. 2.
When the oil without air starts to flow out, tighten the air bleeder (1). Air bleeder (1): 7.8 to 9.8 Nm {0.8 to 1.0 kgm} When starting the engine after doing "Bleed air from main pump", run the engine for 10 minutes with the fuel control dial at the MIN (low idle) position. REMARK Stop the engine once and cancel the automatic warm-up operation by turning the fuel control dial to the MAX position if it is in operation due to the low engine coolant temperature. Keep the fuel control dial at the MAX (high idle) position for 3 seconds or more with the starting switch in the ON position, and automatic warm-up function will be canceled.
Testing the oil level
PC210-10M0, PC210LC-10M0
30-105
Bleed air from hydraulic system
1.
Retract the arm cylinder and the bucket cylinder to the end, lower the work equipment to the ground, and stop the engine.
2.
Check the oil level with the sight gauge (3) of the hydraulic tank. When the oil level is between the lines H and L, it is correct. When the oil level is below the line L, it is insufficient. Add more oil.
30 TESTING AND ADJUSTING
BLEED AIR FROM CYLINDER When the cylinder is replaced, bleed air before the work equipment is connected. Especially, LOWER side of the boom cylinder cannot be operated to the stroke end with the work equipment installed. 1. Start the engine, and run it with the fuel control dial at MIN (Low idle) position for approximately 5 minutes. 2.
Raise the boom and lower it 4 to 5 times while the engine runs with the fuel control dial at MIN (Low idle) position. Be careful to stop the piston rod at approximately 100 mm before each stroke end. This is for the oil pressure in the circuit not to be relieved.
3.
Raise the boom and lower it 4 to 5 times while the engine runs with the fuel control dial at MAX (High idle) position. Be careful to stop the piston rod at approximately 100 mm before each stroke end. This is for the oil pressure in the circuit not to be relieved.
4.
Operate the piston rod to the stroke end. This is for the oil pressure in the circuit to be relieved.
5.
Obey the steps 2 to 4, and bleed air from the arm cylinder and bucket cylinder.
Check hydraulic oil level
30-106
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
1.
Set the arm cylinder and bucket cylinder to the most retracted state, lower the work equipment to the ground, stop the engine.
2.
Test the oil level by sight gauge (3) of the hydraulic tank. When the oil level is between H line and L line, it is correct. When the oil level is below L line, it is insufficient. Add more oil.
Bleed air from hydraulic system
BLEED AIR FROM SWING MOTOR 1.
Start the engine, and set the fuel control dial at MIN (Low idle).
2.
Swing slowly to the right and left to bleed air.
Check hydraulic oil level 1. Retract the arm cylinder and bucket cylinder to the end, lower the work equipment to the ground, and stop the engine. 2. Check the oil level by sight gauge (3) of the hydraulic tank. When the oil level is between the lines H and L, it is correct. When the oil level is below line L, it is insufficient. Add more oil.
BLEED AIR FROM TRAVEL MOTOR 1.
Start the engine, and set the fuel control dial at MIN (Low idle).
PC210-10M0, PC210LC-10M0
30-107
Bleed air from hydraulic system
2.
Loosen the air bleeder (2), and check that oil comes out from the air bleeder.
3.
When the oil without air starts to come out, tighten the air bleeder (2).
30 TESTING AND ADJUSTING
Air bleeder (2): 27.5 to 35.3Nm {2.8 to 3.6kgm}
4.
Raise one track off the ground by pushing the ground with the work equipment.
5.
Slowly run the raised track off the ground for 2 minutes. Run the raised track off the ground evenly in FORWARD and REVERSE.
6.
Run the track off the ground on the opposite side for 2 minutes in the same manner.
Check hydraulic oil level 1. Set the arm cylinder and bucket cylinder to the most retracted state, lower the work equipment to the ground, stop the engine. 2. Test the oil level by sight gauge (3) of the hydraulic tank. When the oil level is between H line and L line, it is correct. When the oil level is below L line, it is insufficient. Add more oil.
30-108
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Test cab tipping stopper
CAB RELATED PARTS Test cab tipping stopper Test the cap tipping stopper according to the procedure below.
k
Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
Test cab tipping stopper 1.
Check the tightening torque of the mounting bolt (2) for the lock plate (1). Bolt (2): 98 to 123 Nm {10 to 12.5 kgm}
2.
Check the tightening torque of the mounting bolt (4) for the stopper plate (3). Be careful that the tightening torque of this bolt differs from that of the standard bolt with a thread diameter of 30 mm. Bolt (4): 245 to 309 Nm {25 to 31.5 kgm}
PC210-10M0, PC210LC-10M0
30-109
ADJUST MIRRORS
30 TESTING AND ADJUSTING
ADJUST MIRRORS
k k
Adjust the mirror always before starting work. If the mirror is not adjusted correctly, you cannot secure the visibility and it can cause a serious personal injury or death. Place the machine on a level ground, and then lower the work equipment completely to the ground in a stable posture. Set the lock lever to LOCK position, and then stop the engine.
Mirror (A): Front left mirror Mirror (B): Front right mirror Mirror (C): Right side mirror Mirror (D): Counterweight mirror
ADJUST MACHINE LEFT FRONT MIRROR (A) 1.
Set the mirror for the machine side to be reflected in the mirror as shown in the figure. Check that the person at the rear left end of the machine can be seen.
2.
If the person cannot be seen, loosen the mounting bolts (1) and (2) and adjust the angle of mirror and stay. NOTICE When you loosened the mounting bolts and adjusted the angle, move them back to the initial position, and stow the mirror. When you loosened the mounting bolts and adjusted the angle, mirror and stay can contact to the machine body when the mirror is stowed. See "ADJUST MACHINE LEFT FRONT MIRROR" when you do adjustment.
30-110
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
ADJUST MIRRORS
Adjust regular position of machine left front mirror (A) 1.
Adjust the stay (1). Mounting position (2): 116 mm Mounting angle (3): 21° Mounting angle (4): 35° Mounting bolt (5): 15.0 to 19.6 Nm {1.52 to 2 kgm}
2.
Adjust the mirror (6). Mounting bolt (7): 6.0 to 7.0 Nm {0.61 to 0.71 kgm} Mounting position (8): 47 mm
NOTICE • Tighten the bolts on the right and left sides of the brackets alternately so that the clearance (L) and the clearance (R) are equal. • Tighten the mounting bolts with specified torque. If tightening the mounting bolts of mirror and stay, the bracket may be broken. • When the side of the machine is reflected in the mirror as shown in the figure, it indicates that the mirror has been adjusted.
PC210-10M0, PC210LC-10M0
30-111
ADJUST MIRRORS
30 TESTING AND ADJUSTING
ADJUST MACHINE RIGHT FRONT MIRROR (B) 1.
Set the mirror for the machine side to be reflected in the mirror as shown in the figure. Check that the person at the rear right end of the machine can be seen.
2.
If the person cannot be seen, loosen the mounting bolts (1) and (2) and adjust the angle of mirror and stay. NOTICE When you loosened the mounting bolts and adjusted the angle, move them back to the initial position, and stow the mirror. When you loosened the mounting bolts and adjusted the angle, mirror and stay can contact to the machine body when the mirror is stowed. See ADJUST MACHINE RIGHT FRONT MIRROR when you do adjustment.
ADJUST REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 1.
Adjust the stay (1). Installation position (2): 98mm Installation position (3): 220mm Installation angle (4):90° Installation angle (5):35°
2.
Adjust the mirror (6). Tightening torque of mounting bolt (7): 6.0 to 7.0Nm {0.61 to 0.71kgm} Installation position (8): 10mm
30-112
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
ADJUST MIRRORS
NOTICE • Tighten the bolts on the right and left sides of the brackets alternately for the clearance on the left (L) and the clearance on the right (R) to be equal. • Be sure to tighten the mounting bolt to the specified torque If tightening the mounting bolts of mirror and stay, the bracket may be broken.
ADJUST MACHINE RIGHT SIDE MIRROR (C) 1.
Adjust the mirror (1) by hands, and make sure you can visually identify persons in 1 meter around the machine. W: 1 m
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2.
30 TESTING AND ADJUSTING
If you cannot visually identify persons, loosen the mounting bolt (2) to adjust the angle. The specified position of the mirror (1) is described below. Tightening torque of the mounting bolt (2): 6.0 to 7.0 Nm {0.61 to 0.71 kgm} Mounting position (3): 55 mm Mounting angle (4): 5° Mounting angle (5): 27°
NOTICE • Tighten the bolts on the right and left sides of the brackets alternately, and make sure the clearance (L) and the clearance (R) are equal. • Tighten the mounting bolt with the specified torque. If it is tightened too much, the bracket can break.
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SETTING AND OPERATION OF MACHINE MONITOR
ELECTRICAL SYSTEM SETTING AND OPERATION OF MACHINE MONITOR
Upper part of machine monitor (a): Multi-information display
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When the engine is started, there can be sudden drop in battery voltage depending on ambient temperature or battery condition. In this case, the display can go off temporarily. But it is not a defect.
Upper part of machine monitor (switches) F1: F1 function switch F2: F2 function switch F3: F3 function switch F4: F4 function switch F5: F5 function switch F6: F6 function switch The multi display (a) shows icons that show the functions assigned to the above function switches. If there is no corresponding icon in the display (a), the function switch is not working.
Lower part of machine monitor (switches) 1: "1" numeral input switch/Auto-deceleration switch 2: "2" numeral input switch/Working mode selector switch 3: "3" numeral input switch/Travel speed selector switch 4: "4" numeral input switch/Buzzer cancel switch 5: "5" numeral input switch/Wiper switch 6: "6" numeral input switch/Window washer switch 7: "7" numeral input switch/Air-conditioning switch 8: "8" numeral input switch/Air-conditioning switch 9: "9" numeral input switch/Air-conditioning switch 0: "0" numeral input switch/Air-conditioning switch Switch with no number: Air-conditioning switch Each of these switches serves two functions. One is a function shown by the icon on the switch, and the other is a function of entering the number. The machine monitor automatically judges which function is activated based on the display of the multi display (a).
Operator mode and service mode of machine monitor The machine monitor has operator mode and service mode. Various information is shown on the multi-information display (a). Some information is shown automatically by the setting of the machine monitor. The others are shown by the operation with switches.
Operator mode The information items in this mode are normally shown. The operator can show and set them by the operation with switches. For details, see the Operation and Maintenance Manual. Operator Mode BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NORMAL SITUATION BASIC OPERATION OF MACHINE MONITOR WHEN STARTING ENGINE IN NORMAL SITUATION ACTION LEVEL DISPLAY MAINTENANCE TIME CAUTION LAMP TRAVEL SPEED DISPLAY SERVIVE METER/CLOCK AUTO-DECELERATION SWITCH
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Operator Mode WINDSHIELD WIPER SWITCH WINDOW WASHER SWITCH BUZZER CANCEL SWITCH CAMERA IMAGE SELECTOR SWITCH USER MENU CHANGE DISPLAY SETTING MAINTENANCE SCREEN SETTING AIR CONDITIONER
The functions that follow become active by the special operations. DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) CHECK FUNCTION OF SERVICE METER USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD
Service mode The information items in this mode are not normally shown. Technicians can operate the specific switches to change the display and settings. These functions are used for testing, adjusting, or troubleshooting. Service Mode CHECK PRE-DEFINED MONITORING INFORMATION CHECK MONITORING INFORMATION CHECK ABNORMALITY RECORD (MECHANICAL SYSTEMS) CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS) CHECK MAINTENANCE RECORD MAINTENANCE MODE SETTING PHONE NUMBER ENTRY SETTING DEFAULT SETTING MENU (KEY-ON MODE) DEFAULT SETTING MENU (UNIT SELECTION) DEFAULT SETTING MENU (WITH/WITHOUT ATTACHMENT) DEFAULT SETTING MENU (CAMERA) Default setting menu (option selection) Default setting menu (With/without quick coupler) TESTING MENU (CYLINDER CUT-OUT OPERATION) ADJUSTMENT MENU (Pump Absorption Torque (F)) ADJUSTMENT MENU (Pump Absorption Torque (R)) ADJUSTMENT MENU (LS differential pressure adjustment) ADJUSTMENT MENU (Low Speed) ADJUSTMENT MENU (Att Flow Adjust in Combined Ope) ADJUSTMENT MENU (CAL F pump swash plate sensor)
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Service Mode ADJUSTMENT MENU (CAL R pump swash plate sensor) ADJUSTMENT MENU (Fan Speed Mode Select) ADJUSTMENT MENU (Pump calibration: Matching speed check) ADJUSTMENT MENU (Pump calibration: Matching speed calibration) ADJUSTMENT MENU (Pump calibration: Restore to default setting) ADJUSTMENT MENU (Pump calibration: return to factory shipment value) NO-INJECTION CRANKING OPERATION KOMTRAX SETTINGS MENU (TERMINAL STATUS) KOMTRAX SETTINGS MENU (GPS AND COMMUNICATION STATUS) KOMTRAX SETTINGS MENU (MODEM STATUS) DISPLAY SERVICE MESSAGE
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SETTING AND OPERATION OF MACHINE MONITOR
OPERATOR MODE The following are the descriptions of items that require operations specific to operator mode. For details on each function and display and operation procedure, see "MACHINE MONITOR" in STRUCTURE AND FUNCTION or "Operation and Maintenance Manual".
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN When the operator identification function is available, while pushing the numeral input switch "4", turn the starting switch to ON position. Then, the Technician ID State screen is shown for two seconds. You can use the function of technician identification state display to distinguish between technician operating state (inspection and maintenance work, etc.) and operator operating state. When you manage operating state, fuel consumption, and machine errors for each operator using the operator identification function, you can distinguish between technician operating state and operator operating state.
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN After the Technician ID State screen is shown, the Operator ID Input screen is shown. •
The screen in the figure is shown when you activate the setting of Operator ID Input.
•
Before an inspection or adjustment by technician, check whether the customer activates the setting of Operator ID Input.
•
When ID input function with SKIP is available, push F1 switch on the Technician ID State screen. The screen changes to the Check Before Starting screen, on which you can start the engine.
•
When ID input function without SKIP is available, check which ID number the technician can use with the person in charge of the machine. Enter the ID, and the screen changes to the Check Before Starting screen, on which you can start the engine.
•
If you do not need to identify technician ID, turn the starting switch to ON position without pushing F4 switch. If you push F6 or F1 after entering an ID, the screen changes to the Check Before Starting screen. On the screen, you can start the engine.
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CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) When you perform the following operation with numeral input switches and function switches on the standard screen, the entire LCD (Liquid Crystal Display) is shown in white. Any part of LCD that has a display error is shown in black. Switch operation: 4 + F2 (Push them at the same time.) Release your finger from F2 first to finish the switch operation. Push any function switch to return to the previous screen.
CHECK FUNCTION OF SERVICE METER When you want to check the service meter with the starting switch turned OFF, operate the numeral input switches as follows. Then, the service meter is shown. Switch operation: 4 + 1 (Push them at the same time.) There is a time lag before startup of the LCD (Liquid Crystal Display). Continue to push the switches until the screen shows service meter. Upon release of either switch, the LCD lights off.
SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD To set the user limitation setting, you can set the password. After the password is set, a password input screen is shown to reset the maintenance time. Set a password for usage limitation or change it as follows.
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1.
SETTING AND OPERATION OF MACHINE MONITOR
On the standard screen, do the following operation with numerical input switches. Switch operation: 4 + 5 → 5 → 5 (While holding down 4, push 5 three times). This switch operation can be accepted only after 10 minutes or more from turning of the starting switch to ON position.
2.
When the "Usage Limitation Password" screen is shown, enter the current password with numeral input switches and accept it with function switches. F5: Deletes the numeric input/Returns the screen to standard screen F6: Accepts the password entry When the password entry is correct, the next screen is shown. When the password entry is not correct, a dialog prompting you to re-enter is shown. REMARK • Default password: 000000 • The password for usage limitation differs from the password for engine start lock.
3.
When the "Usage Limitation Setting" screen is shown, select a setting with function switches. F3: Moves the selected item down F4: Moves the selected item up F5: Cancels the selected item and returns the screen to the previous screen F6: Accepts the selected item
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•
30 TESTING AND ADJUSTING
When the "Usage Limitation Setting" screen is shown, select a setting with function switches. "ON": The password entry window is shown when you reset the Breaker Setting, Attachment Setting, or Maintenance Remain. "OFF": The password entry window is not shown. F3: Moves the selected item down F4: Moves the selected item up F5: Cancels the selected item and returns the screen to the previous screen
•
F6: Accepts the selected item 1) When the "Usage Limitation New Password Input" screen is shown again, re-enter the new password with numeral input switches and accept it with function switches. F5: Deletes the numeric input/Returns the screen to the previous screen F6: Accepts the password entry When the password entry is correct, the next screen is shown. When the password entry is not correct, a dialog prompting you to re-enter is shown. 2)
When the "Usage Limitation New Password Input" screen is shown again, re-enter the new password with numeral input switches and accept it with function switches. F5: Deletes the numeric input/Returns the screen to the previous screen F6: Accepts the password entry If you enter a different password from the previous one, a dialog prompting you to re-enter is shown. When the password change is completed, the screen notifying the end of setting is shown. Then, the screen returns to the standard screen.
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SERVICE MODE Operation of service mode Use the service mode according to the procedure below. 1.
On the standard screen, do the following operation with numerical input switches. Switch operation: 4 + 1 → 2 → 3 (While holding down 4, push 1, 2, and 3 in turn). REMARK This switching operation is available only when the standard screen is displayed.
2.
When the "Service Menu" screen is shown, select the item(s) to be used with function switches or numeral input switches. F3: Moves the selected item down F4: Moves the selected item up F5: Returns to the standard screen (operator mode) F6: Accepts the selected item REMARK By entering a 2-digit code number with the numeral input switches, you can directly select the menus.
The following shows the items selectable with "Service Menu" (including some items which need special switching operations). Items with 2-digit code are the menus displayed on the "Service Menu" screen. The items on the right are the menus on the next hierarchy. Code
Item
Reference
01
Pre-defined Monitoring
Check pre-defined monitoring information
02
Self-define Monitoring
Check monitoring information
03
Mechanical Sys AbnormaliCheck abnormality record (mechanical systems) Abnormality ty Record Record Electrical Sys Abnormality Check abnormality record (electrical systems) Record
04
Maintenance Record
CHECK MAINTENANCE RECORD
05
Maintenance Mode Setting
Maintenance mode setting
06
Phone Number Entry
Phone number entry setting
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Code
07
08
Item
Default
Diagnostic Tests
30 TESTING AND ADJUSTING
Reference
Key-on Mode
Default setting menu (key-on mode)
Unit Selection
Default setting menu (unit selection)
With/Without Attachment
Default setting menu (with/without attachment)
Camera
Default setting menu (camera)
Option
Default setting menu (option)
Cylinder Cutout Mode Operation
Testing menu (cylinder cut-out operation)
Pump Absorption Torque (F)
Adjustment menu (pump absorption torque (F))
Pump Absorption Torque (R)
Adjustment menu (pump absorption torque (R))
LS Differential Pressure AdAdjustment menu (LS differential pressure adjustment) justment
09
Adjust
Travel Low Speed
Adjustment menu (travel low speed)
Att Flow Adjust in Combined Ope
Adjustment menu (Att flow adjust in combined operations)
Calibrate F Pump Swash Plate Sensor
Adjustment menu (calibrate F pump swash plate sensor)
Calibrate R Pump Swash Plate Sensor
Adjustment menu (calibrate R pump swash plate sensor)
Fan Speed Mode Select
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (Fan Speed Mode Select)
Pump Calibration: Matching Adjustment menu (Pump calibration: Matching speed check) Speed Check Pump Calibration: Matching Adjustment menu (Pump calibration: Matching speed calibraSpeed Calibration tion)
11
12
13
Pump Calibration: Restore to Default Setting
Adjustment menu (Pump calibration: Restore to default setting)
Pump Calibration: Restore to Factory Setting
Adjustment menu (Pump calibration: Restore to default setting)
No-Injection Cranking
KOMTRAX Settings
No-injection cranking operation
Terminal Status
KOMTRAX settings menu (terminal status)
GPS & Communication State
KOMTRAX settings menu (GPS and communication status)
Modem Information
KOMTRAX settings menu (modem status)
Service Message
Display service message
Check pre-defined monitoring information You can check the real-time machine status using signals from various switches, sensors, and actuators and information on communications with the controllers that control these devices. In "Pre-defined Monitoring", frequently used monitoring items are selected as group.
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1.
SETTING AND OPERATION OF MACHINE MONITOR
On the "Service Menu" screen, select the "Pre-defined Monitoring". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
On the "Pre-defined Monitoring" screen, you can check the group items with function switches. F1: Goes to the next page (screen) F2: The screen returns to the previous page (screen) F4: Changes between on and off of HOLD (When the HOLD is on, a slash is shown over the "HOLD" area.) F5: The screen returns to "Service Menu" screen. REMARK • The contents changes in accordance with the monitoring item. The contents are as follows. •
Numeric data
•
ON/OFF status
•
Special display
• On the "Unit" screen from "Default" menu in service mode, you can select a display unit from the three types of "SI", "Metric", and "Imperial". • For the items not shown in "Pre-defined Monitoring", you can select and check from "Self-define Monitoring" items. 3.
To set working mode, travel speed, or auto-deceleration on the "Pre-defined Monitoring" screen, push the appropriate switch without changing the data. REMARK • When you change the settings on the "Pre-defined Monitoring" screen, the changes are maintained even after the screen returns to the standard screen. • When you change the working mode to B mode, the dialog to confirm that you want to change the setting is shown.
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TABLE OF PRE-DEFINED MONITORING ITEMS Pre-defined Monitoring (01/11) machine basics No.
Monitoring code
1
01002
Engine speed
2
04107
Coolant temperature
3
37212
4 5
Unit SI
Metric
Imperial
Applicable component
r/min
rpm
rpm
ENG
°C
°C
°F
ENG
Engine oil pressure switch
-
-
-
ENG
04401
Hydraulic oil temperature
°C
°C
°F
Pump
03203
Battery power supply
mV
mV
mV
ENG
Monitoring item
Pre-defined Monitoring (02/11) fuel injection No.
Monitoring code
1
01002
Engine speed
2
04107
Coolant temperature
3
36400
4
Unit SI
Metric
Imperial
Applicable component
r/min
rpm
rpm
ENG
°C
°C
°F
ENG
Common rail pressure
MPa
kg/cm2
psi
ENG
36200
Rail pressure command
MPa
kg/cm2
psi
ENG
5
18500
Charge temperature
°C
°C
°F
ENG
6
37400
Ambient pressure
kPa
kg/cm2
psi
ENG
Monitoring item
Pre-defined Monitoring (03/11) Engine No.
Monitoring code
1
01002
Engine speed
2
37212
Engine oil pressure switch
Monitoring item
Unit SI
Metric
Imperial
Applicable component
r/min
rpm
rpm
ENG
-
-
-
ENG
psi
Pump
psi
ENG
3
42803
Blowby pressure
MPa
kg/cm2
4
36500
Charge pressure
MPa
kg/cm2
Pre-defined Monitoring (04/11) F&R pump basics No.
Monitoring code
1
01002
2
Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
01100
Front pump pressure
MPa
kg/cm2
psi
Pump
3
01101
Rear pump pressure
MPa
kg/cm2
psi
Pump
4
01300
PC-EPC front solenoid current
mA
mA
mA
Pump
5
01302
PC-EPC rear solenoid current
mA
mA
mA
Pump
6
04401
Hydraulic oil temperature
°C
°C
°F
Pump
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Monitoring item
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SETTING AND OPERATION OF MACHINE MONITOR
Pre-defined Monitoring (05/11) F&R pump application No.
Monitoring code
1
01002
2
Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
01100
Front pump pressure
MPa
kg/cm2
psi
Pump
3
01101
Rear pump pressure
MPa
kg/cm2
psi
Pump
4
01137
Front pump displacement
cc/rev
cc/rev
cc/rev
Pump
5
01139
Rear pump displacement
cc/rev
cc/rev
cc/rev
Pump
6
04401
Hydraulic oil temperature
°C
°C
°F
Pump
Monitoring item
Pre-defined Monitoring (06/11) F pump application No.
Monitoring code
1
01002
2
Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
01100
Front pump pressure
MPa
kg/cm2
psi
Pump
3
01141
Service pressure sensor
MPa
kg/cm2
psi
Pump
4
01300
PC-EPC front solenoid current
mA
mA
mA
Pump
5
01137
Front pump displacement
cc/rev
cc/rev
cc/rev
Pump
6
01500
LS-EPC solenoid current
mA
mA
mA
Pump
Monitoring item
Pre-defined Monitoring (07/11) R pump application Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
01101
Rear pump pressure
MPa
kg/cm2
psi
Pump
3
01141
Service pressure sensor
MPa
kg/cm2
psi
Pump
4
01302
PC-EPC rear solenoid current
mA
mA
mA
Pump
5
01139
Rear pump displacement
cc/rev
cc/rev
cc/rev
Pump
6
01500
LS-EPC solenoid current
mA
mA
mA
Pump
No.
Monitoring code
1
01002
2
Monitoring item
Pre-defined Monitoring (08/11) PPC pressure No.
Monitoring code
1
01002
2
Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
07400
Boom RAISE PPC pressure
MPa
kg/cm2
psi
Pump
3
07500
Boom LOWER PPC pressure
MPa
kg/cm2
psi
Pump
4
07200
Arm IN PPC pressure
MPa
kg/cm2
psi
Pump
5
07600
Arm OUT PPC pressure
MPa
kg/cm2
psi
Pump
6
04401
Hydraulic oil temperature
°C
°C
°F
Pump
Monitoring item
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Pre-defined Monitoring (09/11) PPC pressure 2 No.
Monitoring code
1
01002
2
Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
09002
Swing RIGHT PPC pressure
MPa
kg/cm2
psi
Pump
3
09001
Swing LEFT PPC pressure
MPa
kg/cm2
psi
Pump
4
07300
Bucket CURL PPC pressure
MPa
kg/cm2
psi
Pump
5
07301
Bucket DUMP PPC pressure
MPa
kg/cm2
psi
Pump
6
04401
Hydraulic oil temperature
°C
°C
°F
Pump
Monitoring item
Pre-defined Monitoring (10/11) PPC pressure 3 No.
Monitoring code
1
01002
2
Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
07102
Travel forward LEFT PPC pressure
MPa
kg/cm2
psi
Pump
3
07103
Travel forward Right PPC pressure
MPa
kg/cm2
psi
Pump
4
07104
Travel reverse Left PPC pressure
MPa
kg/cm2
psi
Pump
5
07105
Travel reverse Right PPC pressure
MPa
kg/cm2
psi
Pump
6
04401
Hydraulic oil temperature
°C
°C
°F
Pump
Monitoring item
Pre-defined Monitoring (11/11) fan clutch Unit SI
Metric
Imperial
Applicable component
Engine speed
r/min
rpm
rpm
ENG
10010
Fan speed command
r/min
rpm
rpm
Pump
3
10007
Fan speed
r/min
rpm
rpm
Pump
4
10019
Fan speed deviation
r/min
rpm
rpm
Pump
5
04107
Coolant temperature
°C
°C
°F
ENG
6
04401
Hydraulic oil temperature
°C
°C
°F
Pump
No.
Monitoring code
1
01002
2
Monitoring item
CHECK MONITORING INFORMATION You can check the real-time machine status using signals from various switches, sensors, and actuators and information on communications with the controllers that control these devices. "Self-define Monitoring" is used to select a desired monitoring item.
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1.
SETTING AND OPERATION OF MACHINE MONITOR
On the "Service Menu" screen, select the "Self-define Monitoring". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
On the "Monitoring Selection Menu" screen, select the monitoring item (s) with function switches or numeral input switches. F1: Moves the selected item to left F2: Moves the selected item to right F3: Moves the selected item down F4: Moves the selected item up F5: Deletes the numeric input/The screen returns to "Service Menu" screen. F6: Enters the selected item
3.
•
Monitoring items fall into categories based on the devices in charge, and it changes in order that follow. "ENG"→"PUMP"→"MON"→"ENG" (when you push F1, it changes in reverse order).
•
By entering a five-digit code number with the numeral input switches, you can directly select the corresponding item.
•
When the selected item is accepted, the background of the item turns red from yellow.
•
A maximum of 6 monitoring items are selectable at a time. But, the items cannot be set up to 6 by the display of the selected item.
After selecting monitoring items, change the screen to the "Monitoring" screen with function switches or numeral input switches. •
When you use function switches, double-click or hold down (for two seconds) F6.
•
When you use numeral input switches, enter "99999" and then push F6.
•
After the 6th monitoring items is selected, it changes automatically.
REMARK If you select two monitoring items and change the screen to the "Monitoring" screen, push F6 to accept the second item and then push F6 again.
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4.
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The screen changes to the "Monitoring" screen and shows the selected monitoring items. F4: Changes between on and off of HOLD (When the HOLD is on, a slash is shown over the "HOLD" area.) F5: The screen returns to " Monitoring Selection Menu" screen. REMARK The contents changes in accordance with the monitoring item. The contents are as follows. • Shown by value • Shown by ON/OFF • Special display On the "Unit" screen from "Default" menu in service mode, you can select a display unit from the three types of "SI", "Metric", and "Imperial".
5.
To set working mode, travel speed, or auto-deceleration on the "Monitoring" screen, push the appropriate switch without changing the data. REMARK • When you change the settings on the "Monitoring" screen, the changes are maintained even after the screen returns to the standard screen. • When you change the working mode to B mode, the dialog to confirm that you want to change the setting is shown.
6.
You can save or delete the selected monitoring items. F1: Saves the monitoring item F2: Deletes the monitoring item •
If the monitoring item is saved when you select the "Self-define Monitoring" again, the confirmation screen is shown. When you select "Yes" on the confirmation screen, the saved items is shown.
•
When there is the saved item, the confirmation screen will be shown until it is deleted.
•
If other item is saved, the previously saved item is overwritten by the latest one.
TABLE OF MONITORING ITEMS •
The list is in the shown order of the "Monitoring Selection Menu" screen.
•
You can select a unit from 3 types shown on the display "SI" or "Metric" or "Imperial" of "Unit", "Default" in the service mode.
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•
SETTING AND OPERATION OF MACHINE MONITOR
Relevant component ENG: Information from engine controller PUMP: Information from pump controller. MON: Other information inputted into the machine monitor.
SI
Metric
Imperial
Relevant component
r/min
rpm
rpm
ENG
Coolant Temperature
°C
°C
°F
ENG
03203
Battery power supply
mV
mV
mV
ENG
37212
Engine Oil Pressure SW
36400
Common rail pressure
MPa
kg/cm2
psi
ENG
37400
Ambient pressure
kPa
kg/cm2
psi
ENG
18500
Charge temperature
°C
°C
°F
ENG
36500
Charge pressure
MPa
kg/cm2
psi
ENG
36700
Engine Torque Ratio
%
%
%
ENG
18700
Engine Output Torque
Nm
kgm
lbft
ENG
03000
Throttle Position Sensor Voltage
mV
mV
mV
ENG
04105
Coolant Temperature Sensor Volt
mV
mV
mV
ENG
37401
Ambient Pressure Sensor Voltage
mV
mV
mV
ENG
18501
Charge Temperature Sensor Volt
mV
mV
mV
ENG
36501
Charge Pressure Sensor Voltage
mV
mV
mV
ENG
36401
Common Rail Pressure Sensor Volt
mV
mV
mV
ENG
17500
Engine Power Mode Selection
-
-
-
ENG
31701
Throttle Position
%
%
%
ENG
31706
Final Throttle Position
%
%
%
ENG
18600
Inject Fueling Command
mg/st
mg/st
mg/st
ENG
36200
Rail pressure command
MPa
kg/cm2
psi
ENG
37300
Instantaneous Fuel Consumption
ℓ/h
ℓ/h
gal/h
ENG
18800
Water in Fuel Sensor State
-
-
-
ENG
20216
Engine Controller Build Version
-
-
-
ENG
20217
Engine Con Calibration Data Ver
-
-
-
ENG
18900
Engine Con Internal Temperature
°C
°C
°F
ENG
20400
Engine Controller S/N
-
-
-
ENG
01601
2nd Engine Speed Command
r/min
rpm
rpm
Pump
01100
Front pump pressure
MPa
kg/cm2
psi
Pump
01101
Rear pump pressure
MPa
kg/cm2
psi
Pump
07400
Boom RAISE PPC pressure
MPa
kg/cm2
psi
Pump
07500
Boom LOWER PPC pressure
MPa
kg/cm2
psi
Pump
07200
Arm IN PPC pressure
MPa
kg/cm2
psi
Pump
Code No.
Table of Pre-defined Monitoring (Shown on screen)
01002
Engine Speed
04107
PC210-10M0, PC210LC-10M0
Unit (Default: SI)
ON/OFF
Remarks
ENG
30-131
SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
SI
Metric
Imperial
Relevant component
Arm OUT PPC pressure
MPa
kg/cm2
psi
Pump
07300
Bucket CURL PPC pressure
MPa
kg/cm2
psi
Pump
07301
Bucket DUMP PPC pressure
MPa
kg/cm2
psi
Pump
09001
Swing LEFT PPC pressure
MPa
kg/cm2
psi
Pump
09002
Swing RIGHT PPC pressure
MPa
kg/cm2
psi
Pump
07102
Travel forward LEFT PPC pressure
MPa
kg/cm2
psi
Pump
07103
Travel forward Right PPC pressure
MPa
kg/cm2
psi
Pump
07104
Travel reverse Left PPC pressure
MPa
kg/cm2
psi
Pump
07105
Travel reverse Right PPC pressure
MPa
kg/cm2
psi
Pump
01137
Front pump displacement
cc/rev
cc/rev
cc/rev
Pump
01138
F Pump Swash Plate Sensor volt
mV
mV
mV
Pump
01139
Rear pump displacement
cc/rev
cc/rev
cc/rev
Pump
01140
R Pump Swash Plate Sensor volt
mV
mV
mV
Pump
04401
Hydraulic Oil Temperature
°C
°C
°F
Pump
10007
Fan speed
r/min
rpm
rpm
Pump
10010
Fan speed command
r/min
rpm
rpm
Pump
10019
Fan speed deviation
r/min
rpm
rpm
Pump
01300
PC-EPC front solenoid current
mA
mA
mA
Pump
01302
PC-EPC rear solenoid current
mA
mA
mA
Pump
01500
LS-EPC solenoid current
mA
mA
mA
Pump
10018
Fan Clutch Solenoid PWM Command
%
%
%
Pump
08000
Merge-divider Main Sol Current
mA
mA
mA
Pump
08001
Merge-divider LS Sol Current
mA
mA
mA
Pump
01700
Attachment Sol Current
mA
mA
mA
Pump
01369
Att Variable Press EPC 1 Current
mA
mA
mA
Pump
01370
Att Variable Press EPC 2 Current
mA
mA
mA
Pump
03200
Battery Voltage
mV
mV
mV
Pump
04402
Hydraulic Oil Temp Sensor Volt
mV
mV
mV
Pump
01602
2nd Engine Speed Command
%
%
%
Pump
13113
Main Pump Absorb Torque
Nm
kgm
lbft
Pump
15900
Boom Bottom Pressure
MPa
kg/cm2
psi
Pump
01141
Service pressure sensor
MPa
kg/cm2
psi
Pump
01337
PC-EPC Cal Torque 1(Factory)
Nm
kgm
lbft
Pump
01341
PC-EPC Cal Current 1 (Factory)
mA
mA
mA
Pump
01345
PC-EPC Calibration Torque 1
Nm
kgm
lbft
Pump
01349
PC-EPC Calibration Current 1
mA
mA
mA
Pump
Code No.
Table of Pre-defined Monitoring (Shown on screen)
07600
30-132
Unit (Default: SI)
Remarks
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Code No.
Table of Pre-defined Monitoring (Shown on screen)
SETTING AND OPERATION OF MACHINE MONITOR
Unit (Default: SI) SI
Metric
Imperial
Relevant component
Remarks By setting, Display/No display is switched over
42803
Blowby pressure
MPa
kg/cm2
psi
Pump
42804
Blowby Pressure Sensor Volt
mV
mV
mV
Pump
46806
Bypass Valve1 Stroke
mm
mm
mm
Pump
46807
Bypass Valve1 Stroke Sensor Volt
mV
mV
mV
Pump
Swing Travel 01900
Pressure SW 1
Boom LOWER Boom RAISE
ON/OFF
Pump
ON/OFF
Pump
ON/OFF
Pump
ON/OFF
Pump
ON/OFF
Pump
ON/OFF
Pump
ON/OFF
Pump
Arm IN Arm OUT Bucket CURL Bucket DUMP 01901
Pressure SW 2
Service Travel difference pressure Travel junction Swing parking brake
02300
Solenoid Valve 1
Merge-divider 2-step relief Travel speed selection Swing Pressure Cut Off
02301
Solenoid Valve 2
Service Return Variable Back Pressure
02302
03701
Solenoid Valve 3 Controller Output 2
Swing Stroke Control Sol Priming Pump Relay Travel Alarm Knob switch
02200
SW Input 1
Swing parking brake cancel switch Swing lock switch
PC210-10M0, PC210LC-10M0
30-133
SETTING AND OPERATION OF MACHINE MONITOR
Code No.
Table of Pre-defined Monitoring (Shown on screen)
30 TESTING AND ADJUSTING
Unit (Default: SI) SI
Metric
Imperial
Relevant component
Remarks
Machine model selection 1 Machine model selection 2 02201
SW Input 2
Machine model selection 3
ON/OFF
Pump
ON/OFF
Pump
ON/OFF
Pump
ON/OFF
Pump
Machine model selection 4 Machine model selection 5 02202
SW Input 3
02203
SW Input 4
Key switch (ACC) Quick coupler Breaker return filter clogging switch Window limit switch
02204
SW Input 5
P contact W contact
20229
Pump Controller Assembly P/N
-
-
-
Pump
20403
Pump Controller S/N
-
-
-
Pump
20230
Pump Controller Program P/N
-
-
-
Pump
20212
Pump Controller Program Version
-
-
-
Pump
04300
Battery Charge Voltage
mV
mV
mV
MON
04200
Fuel Level Sensor Voltage
mV
mV
mV
MON
05600
Water in fuel Sensor Voltage
mV
mV
mV
MON
05601
WIF Caution Detecting Base Volt
mV
mV
mV
MON
05602
WIF Caution Detect Count (Water)
-
-
-
MON
05603
WIF Caution Detect Count (Fuel)
-
-
-
MON
05604
WIF Caution Detecting State
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
Key switch Start 04500
Monitor Input 1
Preheating Light Radiator coolant level Air cleaner Engine oil level
04501
Monitor Input 2
Battery Charge Voltage Quick coupler
04502
30-134
Monitor Input 3
Swing parking brake switch
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Code No.
Table of Pre-defined Monitoring (Shown on screen)
SETTING AND OPERATION OF MACHINE MONITOR
Unit (Default: SI) SI
Metric
Imperial
Relevant component
Remarks
F1 F2 04503
Monitor Function SW
F3 F4
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
ON/OFF
MON
F5 F6 SW1 SW2 04504
Monitor 1st & 2nd Row SW
SW3 SW4 SW5 SW6 SW7 SW8
04505
Monitor 3rd & 4th Row SW
SW9 SW10 SW11 SW12
04506
SW13 Monitor 5th Row SW14 SW SW15
20227
Monitor Assembly P/N
-
-
-
MON
20402
Monitor S/N
-
-
-
MON
20228
Monitor Program P/N
-
-
-
MON
20200
Monitor Program Version
-
-
-
MON
55300
A/C Compressor State
-
-
-
MON
55000
A/C Fresh Air Temp Code
-
-
-
MON
55100
A/C Recirc Air Temp Code
-
-
-
MON
55200
A/C Mode Data (Monitor)
-
-
-
MON
55201
A/C Mode Data (A/C ECU)
-
-
-
MON
20260
KOMTRAX Assembly P/N
-
-
-
MON
20418
KOMTRAX S/N
-
-
-
MON
20261
KOMTRAX Program P/N
-
-
-
MON
20273
KOMTRAX Program Version
-
-
-
MON
PC210-10M0, PC210LC-10M0
30-135
SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
ABNORMALITY RECORD MENU Check abnormality record (mechanical systems) The machine monitor classifies the past and current abnormality records into mechanical system and electrical system and stores them. Check "Mechanical Sys Abnormality Record" as follows. 1. On the "Service Menu" screen, select "Abnormality Record". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Abnormality Record" screen is shown, select "Mechanical Sys Abnormality Record" with the function switches or the numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
3.
The screen changes to the "Mechanical Sys Abnormality Record" screen and shows the following information. a: Occurrence number in reverse chronological order/Total number of records b: Failure code c: Failure phenomena d: Number of past occurrences e: Time shown on the service meter at the first occurrence f: Time shown on the service meter at the last occurrence F1: Moves to the next page F2: Returns to the previous page F3: Moves down the selected item F4: Moves up the selected item F5: Returns the screen to Abnormality Record screen F6: Scrolls the failure phenomena display to the left (when the number of characters is large).
30-136
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
REMARK • If there is no abnormality record, the screen shows "No Abnormality Record." • The machine monitor records up to 50 mechanical system abnormality records (50 codes) and shows them on the screen. • The time shown on the service meter at the last occurrence is the time when the mechanical system recovers from the failure. • A failure code that has "E" on its left side shows either of the following states. •
A state where an abnormality occurs.
•
A state where a normal recovery from an abnormality cannot be confirmed.
• The contents of the mechanical system abnormality records cannot be deleted. • For failure codes, see "FAILURE CODES TABLE" in TROUBLESHOOTING.
Check abnormality record (electrical systems) The machine monitor classifies the past and current abnormality records into mechanical system and electrical system and stores them. Check "Electrical Sys Abnormality Record" as follows. 1. On the "Service Menu" screen, select "Abnormality Record". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Abnormality Record" screen is shown, select "Electrical Sys Abnormality Record" with the function switches or the numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
3.
The screen changes to the "Electrical Sys Abnormality Record" screen and shows the following information. a: Occurrence number in reverse chronological order/Total number of records b: Failure code c: Failure phenomena d: Number of past occurrences e: Time shown on the service meter at the first occurrence f: Time shown on the service meter at the last occurrence F1: Moves to the next page F2: Returns to the previous page F3: Moves the selected item down F4: Moves the selected item up
PC210-10M0, PC210LC-10M0
30-137
SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
F5: Returns the screen to Abnormality Record screen F6: Scrolls the failure phenomena display to the left (when the number of characters is large). REMARK • If there is no abnormality record, the screen shows "No Abnormality Record". • The machine monitor records up to 20 electrical system abnormality records (20 codes) and shows them on the screen. If the number of records reaches 21 (21 codes), the machine monitor records and shows the latest failure code and deletes the oldest one. • The time shown on the service meter at the last occurrence is the time when the electrical system recovers from the failure. • A failure code that has "E" on its left side shows either of the following states. •
A state where an abnormality occurs.
•
A state where a normal recovery from an abnormality cannot be confirmed.
• For failure codes, see "FAILURE CODES TABLE" in TROUBLESHOOTING.
Delete abnormality record of electrical systems Delete the information about abnormality record by doing the operations below while the "Electrical Sys Abnormality Record" screen is displayed. 1. Switch operation: 4 + 1 -> 2 -> 3 (While holding down 4, push 1, 2, and 3 in turn).
2.
The screen is shown in the deletion mode. When "CLEAR" is displayed in the upper part of F2, select an abnormality record to be deleted with function switches. F2: Selects all the abnormality records F3: Moves the selected item down F4: Moves the selected item up F5: Returns the screen to the "Abnormality Record" screen F6: Selects individual abnormality records REMARK If "E" is displayed on the left of failure code, you can select the item with E but the abnormality record is not deleted.
30-138
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
3.
SETTING AND OPERATION OF MACHINE MONITOR
When the "Electrical Sys Abnormality Rec Reset" screen is shown, operate the function switches to delete the record. F5: Returns the screen to the "Electrical Sys Abnormality Record" screen (deletion mode) F6: Deletes abnormality records REMARK • This is the screen when individual abnormality records are going to be deleted.
• This is the screen when all the abnormality records are going to be deleted. 4.
After the abnormality records were deleted, the screen notifying the end of the deletion is shown. Then, the screen returns to the "Electrical Sys Abnormality Record" (deletion mode) screen.
REMARK • This is the screen displayed after the individual abnormality records were deleted.
• This is the screen displayed when all abnormality records have been deleted.
CHECK MAINTENANCE RECORD The machine monitor records the maintenance information of the filters and oils. Do the operations that follow to display and check.
PC210-10M0, PC210LC-10M0
30-139
SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
If the "Maintenance Due Time Reset" is done in the operator mode when you do maintenance, the number of the times of maintenance is recorded here. 1. Select "Maintenance Record" on the "Service Menu" screen. REMARK For details about how to select, see SERVICE MODE in SERVICE MODE.
2.
The screen changes to the "Electrical Sys Abnormality Record", and the information that follow are shown. a: Maintenance item b: Number of replacements up to now c: Service meter time at the previous replacement F1: The screen proceeds to the next page (screen) F2: The screen returns to the previous page (screen) F3: Moves the selection downward F4: Moves the selection upward F5: The screen returns to "Service Menu" screen. REMARK • Input 2-digit numbers with the numeral input switches to directly select the item. • The back ground color of the selected item changes. Maintenance record items Code
Item
01
Engine Oil Change
02
Engine Oil Filter Change
03
Fuel Main Filter Change
04
Hydraulic Oil Filter Change
05
Hydraulic Oil Tank Breather Change
07
Damper Case Oil Check/Refilling
08
Final Drive Case Oil Change
09
Swing Machinery Case Oil Change
10
Hydraulic Oil Change
30
Hyd Oil Pilot Filter Change
41
Fuel Prefilter Change
44
Fuel Tank Breather Change
49
Air Cleaner Cleaning or Change
60
Coolant Change
68
Additional Hyd Oil Filter Change
76
Additional Fuel Filter Change
30-140
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Code
SETTING AND OPERATION OF MACHINE MONITOR
Item
81
Coolant Filter Change
82
Radiator Cap Change
85
Hydraulic Oil Filter Change
86
Hydraulic Oil Change
MAINTENANCE MODE SETTING Set and change the operating conditions of the maintenance items in the operator mode. •
Set the maintenance items to ENABLED or DISABLED. REMARK • If the maintenance due time (interval) is over, the maintenance time caution lamp lights up in red for the items set to ENABLE when you turn the starting switch to the ON position. • If the maintenance due time (interval) is over the maintenance time caution lamp does not light up for the items set to DISABLED when you turn the starting switch to the ON position. Also, it is not shown on the maintenance screen in the user menu.
• • 1.
Change the replacement interval setting by item. Initialize the replacement interval setting. Select "Maintenance Mode Change" on the "Service Menu" screen. REMARK For the selecting method, see "Operation of service mode" in "SERVICE MODE".
2.
Select an item to be changed on the "Maintenance Mode Change" screen with the function switches or numeral input switches. F1: Moves to the next page F2: Returns to the previous page F3: Moves the selected item down F4: Moves the selected item up F5: The screen returns to "Service Menu" screen F6: Accepts the selected item REMARK Input 2-digit numbers with the numeral input switches to directly select the item.
PC210-10M0, PC210LC-10M0
30-141
SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
Available items on the Maintenance Mode Setting screen Code
Item
00
Maintenance Mode Change
01
Engine Oil Change Interval
02
Engine Oil Filter Change Interval
03
Fuel Main Filter Change Interval
04
Hydraulic Oil Filter Change Interval
05
Hydraulic Oil Tank Breather Change Interval
07
Damper Case Oil Check or Refilling Interval
08
Final Drive Case Oil Change Interval
09
Swing Machinery Case Oil Change Interval
10
Hydraulic Oil Change Interval
30
Hydraulic Oil Pilot Filter Change Interval
41
Fuel Prefilter Change Interval
44
Fuel Tank Breather Change Interval
49
Air Cleaner Cleaning or Change Interval
60
Coolant Change Interval
68
Additional Hydraulic Oil Filter Change Interval
76
Additional Fuel Filter Change Interval
81
Coolant Filter Change Interval
82
Radiator Cap Change Interval
99
All Default Value
00 Maintenance Mode Change 1.
Select "Maintenance Mode On or Off" on the "Maintenance Mode Change" screen. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Maintenance Mode On or Off" screen is shown, select "ON" or "OFF" with the function switches.
Maintenance Mode On or Off
"ON": All available maintenance items are ON in operator mode. "OFF": All available maintenance items are OFF in operator mode. F3: Moves the selected item down F4: Moves the selected item up *
F5: Selection is canceled. The screen returns to the "Maintenance Mode Change" screen. F6: Selection is entered. The screen returns to the "Maintenance Mode Change" screen. 30-142
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
REMARK • Even when ON/OFF for each item is set, this setting has priority. Set the each item again. • When the setting is "ON", the maintenance due time for that item is reset. 3.
On the "Maintenance Mode Change" screen, select "Maintenance Notice Time Setting". REMARK For the selecting method, see "Operation of service mode" in "SERVICE MODE".
4.
When the "Maintenance Notice Time Setting" screen is shown, set the maintenance notice time with the function switches. Default: Maintenance notice time set on the machine monitor (recommended by the manufacturer) Set: Sets the maintenance notice time in the range of 10 to 200 hours F3: Decreases the set value by 10 hours F4: Increases the set value by 10 hours F5: Set value is canceled. The screen returns to the "Maintenance Mode Change" screen. F6: Set value is entered. The screen returns to the "Maintenance Mode Change" screen. REMARK If the machine is operated for 1 hour or more after you set the setting to "ON" and change the maintenance notice time, the maintenance due time will be reset.
Each maintenance item 1.
Select one of the individual maintenance items. When the screen is displayed, select "On or Off Setting". REMARK • For the selecting method, see "Operation of service mode" in "SERVICE MODE". • This is an example of the displayed screen of "Engine Oil Change Interval".
2.
On the screen where ON or OFF is selected, select "ON", "ON (Breaker Synchronization)", or "OFF" with the function switches. "ON": The individual maintenance item is ON in operator mode. "ON (Breaker Synchronization)": The individual maintenance item is ON in operator mode. The maintenance remaining time is reduced at an accelerated rate according to the breaker use time.
PC210-10M0, PC210LC-10M0
30-143
SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
"OFF": The individual maintenance item is OFF in operator mode. F3: Moves the selected item down F4: Moves the selected item up F5: Selection is canceled. The screen returns to the selected maintenance item screen. F6: Selection is entered. The screen returns to the selected maintenance item screen. REMARK You can select "ON (Breaker Synchronization)" for only items where the interval varies with the breaker use remaining time. • "HYDRAULIC OIL" • "HYDRAULIC OIL FILTER" • "ADDITIONAL HYDRAULIC OIL FILTER" • "PILOT FILTER" The default setting is "ON (Breaker Synchronization)". When "ON (Breaker Synchronization)" is selected, "B ON" is displayed in the "On or Off Setting" item. 3.
Select "Set" on the individual maintenance item screen. REMARK For the selecting method, see "Operation of service mode" in "SERVICE MODE".
30-144
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
4.
SETTING AND OPERATION OF MACHINE MONITOR
When the interval screen is shown, set the maintenance time (interval) with function switches. Default: Maintenance time set on the machine monitor (recommended by the manufacturer) Set: Sets the maintenance time F3: Decreases the set value by 25 hours F4: Increases the set value by 25 hours F5: Set value is canceled. The screen returns to the "Maintenance Mode Change" screen. F6: Enters the setting. The screen returns to the "Maintenance Mode Change" screen. REMARK If the machine is operated for 1 hour or more after you set the setting to "ON" and change the maintenance notice time, the maintenance due time will be reset.
99 All Default Value The screen is shifted by selecting "All Default Value", validate the setting with the function switches. F5: The screen returns to "Maintenance Mode Setting" screen. F6: Executes the initialization. All the setting values of the maintenance item returns to the initial values. REMARK When F6 is pushed, the "Initialization completed." screen is shown after a while. Then the screen returns to the "Rearview Monitor Setting" screen.
Phone number entry setting You can register and change the phone number shown on the "Current Abnormality" screen in operator mode as follows. To show the phone number in operator mode, you need to register the phone number in this setting.
PC210-10M0, PC210LC-10M0
30-145
SETTING AND OPERATION OF MACHINE MONITOR
1.
30 TESTING AND ADJUSTING
On the "Service Menu" screen, select "Phone Number Entry". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Phone Number Entry" screen is shown, register or change the phone number with the function switches or the numeral input switches. F2: Deletes all input numbers F3: Moves the cursor to left (other than blanks) F4: Moves the cursor to right (other than blanks) F5: Returns the screen to "Service Menu" screen F6: Accepts the input value REMARK • You can enter a number of up to 14 digits. Justify the number to the left. Leave the remaining digits blank. • Move the cursor (orange background) to the digit you want to change and enter a number. The number overwrites the existing one. • If you accept the input without entering a single digit, the phone number is not shown in operator mode.
DEFAULT SETTING MENU DEFAULT SETTING MENU (KEY-ON MODE) Default setting menu is used to check or change default values of the machine monitor and the machine. On the "Key-on Mode" screen, you can set the working mode when you turn the starting switch to ON position. 1. On the "Service Menu" screen, select the "Default". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
30-146
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
2.
SETTING AND OPERATION OF MACHINE MONITOR
On the "Default" screen, select the "Key-on Mode" with the function switches or the numeral input switches.
㻜㻝
Default
REMARK
Key-on Mode Unit
For selecting method, see "SERVICE MODE" in "SERVICE MODE".
SI
With/Without Attachment Camera With/Without Quick Coupler Option
*
3.
When the "Key-on Mode" screen is shown, select a mode to be set with the function switches. F3: Moves the selected item down F4: Moves the selected item up F5: Cancels the selected item. The screen returns to the "Default" screen F6: Enters the selected item. The screen returns to the Default screen "Power Mode", "Economy Mode", "Lifting Mode", "Breaker Mode", "Attachment/P Mode", "Attachment/E Mode": When the starting switch is turned to ON position, the machine enters each appropriate working mode. "Mode at Previous Key-off": The machine enters the last mode in the previous operation when the starting switch is turned to ON position. REMARK • The factory default setting is "Mode at Previous Key-off". • When you do not select "With Attachment", you cannot select both "Attachment/P Mode" and "Attachment/E Mode". • In the "Attachment/P Mode" or "Attachment/E Mode", if you change the setting to "Without Attachment", the machine enters "Power Mode" when the starting switch is turned to ON position. • If you turn off the starting switch in "Breaker Mode" of operator mode, the machine enters "Breaker Mode" in any setting when you turn the starting switch to ON position.
DEFAULT SETTING MENU (UNIT SELECTION) You can check and change the default values of the machine monitor and machine on the Default setting menu screen. Select the unit for data on the monitoring screen from the "Unit Selection". 1. On the "Service Menu" screen, select the "Default". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
PC210-10M0, PC210LC-10M0
30-147
SETTING AND OPERATION OF MACHINE MONITOR
2.
30 TESTING AND ADJUSTING
When the "Default" screen is shown, select the "Camera" with function switches or numeral input switches.
㻜㻞
Default
REMARK
Key-on Mode
SI
Unit
For selecting method, see "SERVICE MODE" in "SERVICE MODE".
With/Without Attachment Camera With/Without Quick Coupler Option
*
3.
When the "Unit Selection" screen is shown, select the unit to set. F3: Moves the selected item down F4: Moves the selected item up F5: Cancels the selected item. The screen returns to the "Default" screen. F6: Enters the selected item. The screen returns to the "Default" screen. REMARK Factory default setting uses SI unit system.
DEFAULT SETTING MENU (WITH/WITHOUT ATTACHMENT) You can check and change the default values of the machine monitor and machine on the Default setting menu screen. On the "With/Without Attachment" screen, you can do the setting for installation or removal of attachment. 1. On the "Service Menu" screen, select the "Default". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
On the "Default" screen, select the "With/Without Attachment" with function switches or numeral input switches.
㻜㻟
Default
REMARK
Key-on Mode
SI
Unit
For selecting method, see "SERVICE MODE" in "SERVICE MODE".
With/Without Attachment Camera With/Without Quick Coupler Option
*
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30 TESTING AND ADJUSTING
3.
SETTING AND OPERATION OF MACHINE MONITOR
On the "With/Without Attachment" screen, select a setting with function switches. F3: Moves the selected item down F4: Moves the selected item up F5: Cancels the selected item. The screen returns to the "Default" screen. F6: Enters the selected item. The screen returns to the "Default" screen. "Without": When no attachment is attached "With": When attachment is attached NOTICE When an attachment is installed, set "With" by this setting function. If "Without" is selected, you cannot select the attachment in "Working Mode". As a result, the attachment cannot show its optimal performance or a failure can occur in the hydraulic equipments.
DEFAULT SETTING MENU (CAMERA) You can check and change the default values of the machine monitor and machine on the Default menu screen. On the "Camera" screen, you can do the setting for installation or removal of cameras. 1. On the "Service Menu" screen, select the "Default". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Default" screen is shown, select "Camera" with function switches or numeral input switches.
㻜㻠
Default
REMARK
Key-on Mode Unit
For selecting method, see "SERVICE MODE" in "SERVICE MODE".
SI
With/Without Attachment Camera With/Without Quick Coupler Option
*
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3.
30 TESTING AND ADJUSTING
When the "Camera" screen is shown, select a setting with function switches. F3: Moves the selected item down F4: Moves the selected item up F5: Cancels the setting that is not yet accepted and returns the screen to "Default" screen F6: Accepts the selected item of each setting After accepting each setting with F6, push F5 to return the screen to the "Default" screen. At this time, the settings take effect. "Not Use": Uses no cameras "Use": Shows images of the connected cameras in reverse (mirrored image, used as a rear view monitor)
Я: Shows reversed image (mirrored image, used as a rear view monitor) R: Shows normal image (visual image, used as a front monitor or side monitor)
REMARK • When you connect cameras, make correct setting using this function. Otherwise, you cannot use camera images even if you push F3 to change to camera image in operator mode. • If the camera is installed, start doing this setting from the camera1. Make sure that the right and left of the shown image is correctly shown. • The"2 Cameras Display Setting" function is activated when you set Camera 1 and Camera 2 to "Use".
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SETTING AND OPERATION OF MACHINE MONITOR
• When you set the camera 2 to be "Я" as shown in the figure, people and objects on the right side of the machine will be reflected such as they are reflected on the rearview mirror. If you set the camera 2 to "R", the image of the right side of the machine is reflected same as you see visually. • For Camera 1, you cannot switch between "Я" and "R".
DEFAULT SETTING MENU (WITH/WITHOUT QUICK COUPLER) Default setting menu is used to check or change default values of the machine monitor and the machine. For setting With/Without of multi-coupler, refer to this section. 1. Select Default on the Service Menu screen. REMARK For details about how to select, see SERVICE MODE in SERVICE MODE.
2.
On the Default screen, select With/Without Quick Coupler with function switches or numeral input switches.
㻜㻡
Default
REMARK
Key-on Mode Unit
For details about how to select, see SERVICE MODE in SERVICE MODE.
SI
With/Without Attachment Camera With/Without Quick Coupler Option
*
3.
On the With/Without Quick Coupler screen, select the set value with the function switches. "Without": When multi-coupler is not installed "With": When multi-coupler is installed F3: Moves the selected item down F4: Moves the selected item up F5: The screen returns to the Default screen. F6: Enters the selected item. The screen returns to the Default screen
*
Default setting menu (option selection) Default menu is used to check or change default values of the machine monitor and machine. The "Option Selection" function is used to do Machine Model Selection on the default menu and enable the function when all the option selection settings are reset or additional options are installed.
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1.
30 TESTING AND ADJUSTING
Select Default on the Service Menu screen. REMARK For details about how to select, see SERVICE MODE in SERVICE MODE.
2.
When the "Default" screen is shown, select "Option" with function switches or numeral input switches.
㻜㻢
Default
REMARK
Key-on Mode
SI
Unit
For details about how to select, see SERVICE MODE in SERVICE MODE.
With/Without Attachment Camera With/Without Quick Coupler Option
*
3.
When the "Option Selection" screen is displayed, check the option installation status of the machine and set the items.
㻜㻝
Option With/Without Eco mode Easy Setting
REMARK
With/Without Elec. Fuel Primer Pump
When the current settings are acceptable, select either one of the items and push F6 without making any modification, and the settings will be reflected on the machine.
Battery Disconnect Setting
With/Without Blow By Pressure Sensor
F3: Moves the selected item down F4: Moves the selected item up
*
F5: Cancels the selected item and returns the screen to "Default" screen F6: Enters the selected item and goes to the "Option" setting screen Items available for Option Selection function Item name
Initial configuration
Remarks With/Without Eco mode Easy Setting
With/Without Eco mode Easy Setting
With
With/Without Elec. Fuel Primer Pump
With
When an optional component is installed, select "With".
With/Without Blow By Pressure Sensor
With
When an optional component is installed, select "With".
Battery Disconnect Setting
With
When an optional component is installed, select "With".
4.
㻜㻝
Option
When an optional component is installed, select "With".
With/Without Elec. Fuel Primer Pump With/Without Blow By Pressure Sensor Battery Disconnect Setting
*
After the settings of the items are completed, push F5 to return to the "Default" screen from the "Option" screen.
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REMARK If F6 has never been pushed (no change is made) for setting of any item, this screen will not be displayed if the display changes from the "Option" screen to "Default" screen.
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30 TESTING AND ADJUSTING
TESTING MENU TESTING MENU (CYLINDER CUT-OUT OPERATION) You can perform various inspections and reset operations of the machine monitor and the machine on the Testing menu screen. Cylinder cut-out operation operates the operation with less cylinders in number by making the fuel not to be injected under the status that injector solenoids are not energized. This is a method to identify the failed cylinder when any cylinder of the engine is not outputting normally. For judgment criteria of the cylinder cutout mode operation, see "CYLINDER CUT-OUT MODE OPERATION". 1. On the "Service Menu" screen, select the "Diagnostic Tests". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
On the "Diagnostic Tests" screen, select the "Cylinder Cutout Mode Operation" with function switches or numeral input switches.
Diagnostic Tests
㻜㻝
Cylinder Cutout Mode Operation
REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
3.
On the "Cylinder Cutout Mode Operation" screen, select the cylinder to cut off with function switches. F1: Moves the selected item to left F2: Moves the selected item to right F4: Changes between on and off of HOLD (When the HOLD is on, a slash is shown over the "HOLD" area.) F5: The screen returns to "Diagnostic Tests" screen F6: Accepts the selected item
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SETTING AND OPERATION OF MACHINE MONITOR
REMARK • You can perform this operation even when the engine is in operation. • If the background (a) of the cylinder number turns white from pale blue by pushing F6, this means that the cylinder changes to cutoff state. • If you push F6, but the engine controller cannot cut off the cylinder, the background (a) of the cylinder number turns yellow. • You can select and accept multiple cylinder numbers to cut off. • During the cylinder cutout operation, you can select ON/OFF of the automatic decelerator. When you turn on the automatic decelerator, the automatic decelerator pilot lamp (b) lights up. 4.
To change the selected cylinder or when the cylinder cutout mode operation is completed, select the cylinder whose cutout state is to be canceled with function switches . F1: Moves the selected item to left F2: Moves the selected item to right F4: Changes between on and off of HOLD (When the HOLD is on, a slash is shown over the "HOLD" area.) F5: The screen returns to "Diagnostic Tests" screen F6: Accepts the selected item NOTICE The cutoff state is not automatically canceled even after the machine enters operator mode. Be sure to perform the cancel operation when the cylinder cutout mode operation is completed. REMARK • You can perform this operation even when the engine is in operation. • If the background (a) of the cylinder number turns pale blue by pushing F6, this means that the cylinder returns to normal state. • If you push F6, but the engine controller cannot cancel the cutoff state, the background (a) of the cylinder number turns red.
5.
When you push F4, the displayed information is hold in display (c) by pushing F4 in the cylinder cutout mode. The left side keeps display the real-time information. REMARK • Push F4 in the hold state, then the hold function is canceled. • The holding function is available for a cylinder, regardless of whether it is cutout or not.
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30 TESTING AND ADJUSTING
ADJUSTMENT MENU ADJUSTMENT MENU (Pump Absorption Torque (F)) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. On the "Pump Absorption Torque (F)" screen, you can finely adjust the front pump absorption torque. 1. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Adjustment" screen is shown, select "Pump Absorption Torque (F)" with function switches or numeral input switches. REMARK
㻜㻝 LS Differential Pressure Adjustment
For selecting method, see "SERVICE MODE" in "SERVICE MODE".
Travel Low Speed
*
3.
On the "Pump Absorption Torque (F)" screen, select a set value with function switches. Code (left side): A three-digit number that shows this adjustment item (fixed value) Set value (right side): For actual adjustment values, see "Relational table of set values and absorption torque adjustment values". F3: Decreases the set value F4: Increases the set value F6: Enters the selected item. The screen returns to "Adjustment"screen Relational table of set values and absorption torque adjustment values Code
021
30-156
Set value
Absorption torque adjustment values
000
+39.2 Nm {+4 kgm}
001
+29.4 Nm {+3 kgm}
002
+19.6 Nm {+2 kgm}
003
+9.8 Nm {+1 kgm}
004
0 Nm {0 kgm}
005
-9.8 Nm {-1 kgm}
006
-19.6 Nm {-2 kgm}
007
-29.4 Nm {-3 kgm}
008
-39.2 Nm {-4 kgm}
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
ADJUSTMENT MENU (Pump Absorption Torque (R)) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. On the "Pump Absorption Torque (R)" screen, you can finely adjust the rear pump absorption torque. 1. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Adjustment" screen is shown, select "Pump Absorption Torque (R)" with function switches or numeral input switches. REMARK
㻜㻞 LS Differential Pressure Adjustment
For selecting method, see "SERVICE MODE" in "SERVICE MODE".
Travel Low Speed
*
3.
When the "Pump Absorption Torque (R)" screen is shown, select a set value with function switches. Code (left side): A three-digit number that shows this adjustment item (fixed value) Set value (right side): For actual adjustment values, see "Relational table of set values and absorption torque adjustment values". F3: Decreases the set value F4: Increases the set value F6: Accepts the selected item and returns the screen to the "Adjustment"screen Relational table of set values and absorption torque adjustment values Code
022
PC210-10M0, PC210LC-10M0
Set value
Absorption torque adjustment values
000
+39.2 Nm {+4 kgm}
001
+29.4 Nm {+3 kgm}
002
+19.6 Nm {+2 kgm}
003
+9.8 Nm {+1 kgm}
004
0 Nm {0 kgm}
005
-9.8 Nm {-1 kgm}
006
-19.6 Nm {-2 kgm}
007
-29.4 Nm {-3 kgm}
008
-39.2 Nm {-4 kgm}
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30 TESTING AND ADJUSTING
ADJUSTMENT MENU (LS differential pressure adjustment) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. In "LS Differential Pressure Adjustment", LS differential pressure is finely adjusted. 1. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Adjustment" screen is shown, select "LS Differential Pressure Adjustment" with function switches or numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
㻜㻟 LS Differential Pressure Adjustment Travel Low Speed
*
3.
When the "LS Differential Pressure Adjustment" screen is shown, select a set value with function switches. Code (left side): A three-digit number that shows this adjustment item (fixed value) Set value (right side): For actual adjustment values, see "Relational table of set values and LS differential pressure adjustment values".
㻸㻿㻌㻰㼕㼒㼒㼑㼞㼑㼚㼠㼕㼍㼘㻌㻼㼞㼑㼟㼟㼡㼞㼑㻌㻭㼐㼖㼡㼟㼠㼙㼑㼚㼠
㻝㻥㻥 㻜㻜㻡 㻯㼔㼍㼞㼓㼑㻌㼂㼍㼘㼡㼑
F3: Decreases the set value F4: Increases the set value
*
F6: Accepts the selected item and returns the screen to the "Adjustment"screen
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30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
Relational table of set values and LS differential pressure adjustment values Code
199
Set value
LS differential pressure adjustment value
000
0.20 MPa {+2.0 kg/cm2}
001
0.16 MPa {+1.6 kg/cm2}
002
0.12 MPa {+1.2 kg/cm2}
003
0.08 MPa {+0.8 kg/cm2}
004
0.04 MPa {+0.4 kg/cm2}
005
0.0 MPa {+0.0 kg/cm2}
006
-0.04 MPa {-0.4 kg/cm2}
007
-0.08 MPa {-0.8 kg/cm2}
008
-0.12 MPa {-1.2 kg/cm2}
009
-0.16 MPa {-1.6 kg/cm2}
010
-0.20 MPa {-2.0 kg/cm2}
ADJUSTMENT MENU (Low Speed) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. Finely adjust the travel speed at the low speed (Lo) in "Travel Low Speed". 1. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Adjustment" screen is shown, select "Travel Low Speed" with function switches or numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
㻜㻠 LS Differential Pressure Adjustment Travel Low Speed
*
PC210-10M0, PC210LC-10M0
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SETTING AND OPERATION OF MACHINE MONITOR
3.
30 TESTING AND ADJUSTING
When the "Travel Low Speed" screen is shown, select a set value with function switches. Code (left side): A three-digit number that shows this adjustment item (fixed value) Set value (right side): For the actual speed, see "Table of relationship between set value and travel low speed (Lo) value". F3: Decreases the set value F4: Increases the set value F6: Accepts the selected item and returns the screen to the "Adjustment"screen Table of relationship between set value and travel low speed (Lo) value (P mode) Code
020
Set value
Speed value at travel low speed (Lo) (P mode)
000
3.0 km/h
001
2.8 km/h
002
3.2 km/h
003
3.4 km/h
ADJUSTMENT MENU (Att Flow Adjust in Combined Ope) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. On the "Att Flow Adjust in Combined Ope" screen, you can finely adjust the distribution of supply flow rate to attachment in combined operations. 1. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
On the "Adjustment" screen, select "Att Flow Adjust in Combined Ope" with function switches or numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
㻜㻡 LS Differential Pressure Adjustment Travel Low Speed
*
30-160
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30 TESTING AND ADJUSTING
3.
SETTING AND OPERATION OF MACHINE MONITOR
On the "Att Flow Adjust in Combined Ope" screen, select a set value with function switches. Code (left side): A three-digit number that shows this adjustment item (fixed value) Set value (right side): For actual flow rate distribution, see "Relational table of set values and distribution of flow rate to attachment". F3: Decreases the set value F4: Increases the set value F6: Accepts the selected item and returns the screen to the "Adjustment"screen Relational table of set values and distribution of flow rate to attachment Code
037
Set value
Distribution of flow rate to attachment
000
50 %
001
70 %
002
100 %
003
40 %
ADJUSTMENT MENU (CAL F pump swash plate sensor) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. In "Calibrate F Pump Swash Plate Sensor", calibrate a sensor signal deviation that occurs under the conditions below. When the pump swash plate sensor needs to be calibrated Calibrating front pump swash plate sensor
Calibrating rear pump swash plate sensor
Removal and replacement of the front pump swash plate sensor
Required
-
Removal and replacement of the rear pump swash plate sensor
-
Required
Main pump assembly is replaced.
Required
Required
Replacing a pump controller
Required
Required
Adjustment and disassembly of the PC valve (front pump)
Required
-
Adjustment and disassembly of the PC valve (rear pump)
-
Required
Test the pump swash plate sensor and check that it is normal. Then, calibrate the sensor signal deviation. For testing, see "TEST PUMP SWASH PLATE SENSOR". k
Provide enough work space to raise the track shoe for idling during adjustment.
Before you start the calibration, set the machine under the condition that follows. Hydraulic oil temperature: 40 to 90°C Working mode: P Mode Travel speed: Hi
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1.
30 TESTING AND ADJUSTING
On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
Select "Calibrate F Pump Swash Plate Sensor" on the "Adjustment" screen by using function switches or numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
LS Differential Pressure Adjustment Travel Low Speed
*
3.
On the "Calibrate F Pump Swash Plate Sens Max" screen, use the work equipment to push up the track shoe on the left side, and idle the machine under the condition below. k
When idling the track shoe, sufficiently secure the safety of surroundings.
Fuel control dial: MAX (High idle) position Left travel lever: Full stroke (both FORWARD and REVERSE travel can be set). 4.
When the idling speed is stabilized, hold down F1 to start the Max calibration. Rotate the track off the ground until the calibration ends. F1: Starts the calibration F2: Initializes the calibration value F5: The screen returns to the "Adjustment" screen F6: Accepts the selected setting and returns the screen to the "Adjustment" screen Under calibration, its state is displayed in the bar on the screen.
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5.
SETTING AND OPERATION OF MACHINE MONITOR
When the Max calibration was successful, "OK" is displayed in "State of Adjustment". Push F6 to go to Min calibration.
If the Max calibration was failed, "NG" and failure code are shown on the "State of Adjustment". See the failure code table, and find out the cause of failure. Push F5. The screen returns to the "Adjustment" screen. Do the calibration again.
6.
On the "Calibrate F Pump Swash Plate Sens Min" screen, set the control lever and control pedal to the NEUTRAL position. Push and hold F1, and start the Min calibration. Do not move the control lever and control pedal from the NEUTRAL position until the calibration ends. The fuel control dial can be at any position. F1: Starts the calibration F2: Initializes the calibration value F5: The screen returns to the "Adjustment" screen F6: Accepts the selected setting and returns the screen to the "Adjustment" screen REMARK When the calibration value was initialized, "READY" is displayed in "State of Adjustment" on the screen. Under calibration, its state is displayed in the bar on the screen.
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7.
30 TESTING AND ADJUSTING
When the Min calibration was successful, "OK" is displayed in "State of Adjustment". Push F6. The screen returns to the "Adjustment" screen.
If the Min calibration was failed, "NG" and failure code are shown on the "State of Adjustment". See the failure code table, and find out the cause of failure. Push F5. The screen returns to the "Adjustment" screen. Do the calibration again.
Failure code table Object Failure code Min cali- Max calbration ibration
Pump calibration
Content
Action
A-1
●
●
●
The engine speed signal is 0 rpm. Check that the engine is started.
A-2
●
●
●
Hydraulic oil temperature is low.
Check hydraulic oil temperature (40 °C or below). Calibration of the swash plate sensor: Check hydraulic oil temperature (90 °C or above).
A-3
●
●
●
Hydraulic oil temperature is high.
A-4
●
●
●
Overheating
Check engine coolant temperature and hydraulic oil temperature.
A-6
●
●
●
Abnormal pump pressure sensor (F, R)
Test the pump pressure sensor.
A-7
●
●
-
Abnormal pump swash plate sensor (F, R)
Test pump swash plate sensor
A-8
-
-
●
Abnormal pressure sensor (arm IN)
Test the pressure sensor (arm IN).
A-9
-
-
●
Abnormal PC-EPC valve
Test the PC-EPC valve.
A-A
-
-
●
Abnormal CAN communication (engine, monitor, pump)
Test CAN communication.
A-B
-
-
●
Abnormal pressure sensor (bucket Test the pressure sensor (bucket CURL) CURL).
B-1
●
-
-
Pump pressure on the calibration side over a specified value
30-164
Calibration of the pump: Check hydraulic oil temperature (60 °C or above).
Test the relief valve and the pump.
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30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
Object Failure code Min cali- Max calbration ibration
Pump calibration
Content
Action
B-3
●
-
-
Lever is not set to NEUTRAL posi- Set the lever to the NEUTRAL potion. sition.
C-1
-
●
-
Pump pressure on the calibration side below a specified value
Test the relief valve and the pump.
C-2
-
●
-
Travel speed is not Hi.
Set the travel speed to Hi on the monitor.
C-4
-
●
-
Travel operation not recognized as a single operation (work equipment is in operation)
Turn the travel lever to the full stroke position, and set the control lever to the NEUTRAL position.
C-5
-
●
-
Pressurized oil discharged from the front and rear pumps is merged.
Check service adjustment (Normally separated while travel operation is performed singly)
C-6
-
●
-
Abnormal pressure sensor (travel PPC)
Test the travel PPC.
C-7
-
●
-
Travel PPC pressure is specified value or less.
Turn the travel lever to the full stroke position.
●
During arm IN relief, arm IN PPC pressure is below a specified value or the pressure sensor (arm IN PPC) is out of the normal range.
E-1
-
-
Set the control lever to the full stroke position in the arm IN direction. Do troubleshooting. See TROUBLESHOOTING, "FAILURE CODE [DHS3MA]". Test the relief valve and the pump. Do troubleshooting. See TROUBLESHOOTING, "FAILURE CODE [DHPAMA]" and "FAILURE CODE [DHPBMA]".
E-2
-
-
●
Pump pressure (F, R) is out of specified range (*1).
E-3
-
-
●
Engine speed is out of specified range.
Run the engine at high idle.
E-4
-
-
●
Engine torque is out of specified range.
Test the engine and the pump.
E-5
-
-
●
PC-EPC current is out of specified Test PC-EPC current. range. Set the control lever to the full stroke position in the bucket CURL direction.
E-6
-
-
●
During bucket CURL relief, bucket CURL PPC pressure is below a specified value or the pressure sensor (bucket CURL PPC) is out of the normal range.
E-7
-
-
●
The working mode is neither P nor Set the working mode to P. ATT/P.
E-A
-
-
●
Turn on the air conditioner.
FF
●
●
-
The output voltage of the pump swash plate sensor is out of speci- Test pump swash plate sensor fied range.
PC210-10M0, PC210LC-10M0
Do troubleshooting. See TROUBLESHOOTING, "FAILURE CODE [DHS4MA]".
Turn off the air conditioner.
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30 TESTING AND ADJUSTING
*1: When sensor voltage is out of specified range (0.5 to 4.5 V), the pump controller considers relief pressure as 0 MPa {0 kg/cm2}.
ADJUSTMENT MENU (CAL R pump swash plate sensor) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. In the "Calibrate R Pump Swash Plate Sensor", calibrate a sensor signal deviation that occurs under the conditions that follow. When the pump swash plate sensor needs to be calibrated Calibrating front pump swash plate sensor
Calibrating rear pump swash plate sensor
Removal and replacement of the front pump swash plate sensor
Required
-
Removal and replacement of the rear pump swash plate sensor
-
Required
Main pump assembly is replaced.
Required
Required
Replacing a pump controller
Required
Required
Adjustment and disassembly of the PC valve (front pump)
Required
-
Adjustment and disassembly of the PC valve (rear pump)
-
Required
Test the pump swash plate sensor and check that it is normal. Then, calibrate the sensor signal deviation. For testing, see "TEST PUMP SWASH PLATE SENSOR". Before starting calibration, set the machine under the following condition. Hydraulic oil temperature: 40 to 90°C Working mode: P Mode Travel speed: Hi k
1.
Provide enough work space to run the raised track shoe idle off the ground for adjusting. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
Select the "Calibrate R Pump Swash Plate Sensor" on the "Adjustment" screen by using function switches or numeral input switches.
㻜㻣 LS Differential Pressure Adjustment
REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE". 3.
07
For the subsequent calibration procedure, see "ADJUSTMENT MENU (CAL F pump swash plate sensor)". *
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30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
ADJUSTMENT MENU (Fan Speed Mode Select) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. The "Fan Speed Mode Select" is used to select the maximum speed of the cooling fan from the normal control mode, 100 % mode or 70 % mode. 1. Select Adjustment on the Service Menu screen. REMARK For details about how to select, see SERVICE MODE in SERVICE MODE.
2.
On the "Adjustment" screen, select "Fan Speed Mode Select" with function switches or numeral input switches.
㻜㻤 LS Differential Pressure Adjustmeny
REMARK For details about how to select, see SERVICE MODE in SERVICE MODE.
07 08 Fan Speed Mode Select
*
3.
On the Fan Speed Mode Select screen, select the desired value at the right side by using the function switches. Set value: For the actual fan speed, see the table. F3: Decreases the set value. F4: Increases the set value. F6: Setting is confirmed or entered. The screen returns to the "Adjustment" screen. REMARK
*
The 3-digit number in the left column does not change. This is the code for this function. Relationship between set value and mode (speed) Code
055
Set value
Mode (speed)
000
Normal control
001
100 % (1466 rpm)
002
70 % (1026 rpm)
REMARK • Either "001" or "002" is selected as set value, selected fan speed mode is sustained as it is until Fan Speed Mode Select screen is changed and starting switch is turned to OFF position. • Set the control mode to the normal control mode. To set it, select "000" as the set value or turn the starting switch to OFF position and then restart the engine.
ADJUSTMENT MENU (Pump calibration: Matching speed check) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen.
PC210-10M0, PC210LC-10M0
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SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
In "Matching Speed Check", check the engine and the matching speed of the main pump during arm IN or bucket CURL relief operation.
k
Be sure that there is sufficient work space for the matching speed check since you operate the work equipment.
Before checking the matching speed, set the machine under the condition below. Perform warm-up operation for at least 30 minutes. Hydraulic oil temperature: 40 to 60 °C Working mode: P Mode Fuel control dial: MAX (high idle) position Air conditioner: Disabled 1. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
After the Adjustment screen is displayed, enter 40 with numeral input switches, and push F6. REMARK The "Adjustment" screen does not show the items of "Pump Calibration".
3.
When the "Pump Calibration" screen is shown, select "Matching Speed Check" with the function switches or the numeral input switches.
30-168
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
REMARK • For selecting method, see "SERVICE MODE" in "SERVICE MODE". • Alphabets at the top right on the screen shows the below status. D: Default F: Adjustment value at factory shipment U: Calibration value done by user 4.
The "Matching Speed Check" screen for arm IN relief is shown. When engine speed is stabilized during arm IN relief operation, hold down F1 to start matching speed check. Hold the arm IN relief operation until the check ends. k
When the work equipment is operated, ensure the safety around the machine.
F1: Starts the matching speed check F5: The screen returns to the "Pump Calibration" screen During the check, the progress bar is displayed the screen.
5.
When the matching speed check was successful, the confirmation screen is displayed. Push F6, and move on to the check for bucket CURL relief.
*
When the matching speed check is failed, a failure code is shown. See the failure code table for "Calibrate F Pump Swash Plate Sensor", and find out the cause of failure. Push F5. The screen returns to the "Pump Calibration" screen. Do the check again.
*
PC210-10M0, PC210LC-10M0
30-169
SETTING AND OPERATION OF MACHINE MONITOR
6.
30 TESTING AND ADJUSTING
"Matching Speed Check" for the bucket CURL relief is shown. When engine speed is stabilized during bucket CURL relief operation, hold down F1 to start the matching speed check. Hold the bucket CURL relief operation until the check ends. k
When the work equipment is operated, ensure the safety around the machine.
F1: Starts the matching speed check F5: The screen returns to the "Arm IN Relief" screen
*
During the check, the progress bar is displayed the screen.
*
7.
When the matching speed check was successful, the confirmation screen is displayed. Push F6. The screen returns to the " Pump Calibration " screen.
*
When the matching speed check is failed, a failure code is shown. See the failure code table for "Calibrate F Pump Swash Plate Sensor", and find out the cause of failure. Push F5. The screen returns to the "Pump Calibration"screen. Do the check again.
*
ADJUSTMENT MENU (Pump calibration: Matching speed calibration) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. "Matching Speed Calibration" is used to calibrate the matching speed in response to the main pump in the cases that follow. Cases that requires the matching speed calibration Pump matching speed calibration Engine is replaced
-
Main pump assembly is replaced.
Required
Replacing a pump controller
Required
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
Pump matching speed calibration PC valve (front pump) is disassembled.
Required
PC valve (rear pump) is disassembled.
Required
Main valve is replaced.
-
Main relief valve is adjusted or replaced.
-
Set the conditions as follows before you start the matching speed calibration. Perform warm-up operation for at least 30 minutes. Hydraulic oil temperature: 40 to 60 °C Working mode: P Mode Fuel control dial: MAX (High idle) position Air conditioner: Disabled k
1.
Be sure that there is sufficient work space for the matching speed calibration since you operate the work equipment. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
After the Adjustment screen is displayed, enter 40 with numeral input switches, and push F6. Items of "Pump Calibration" are not displayed on the "Adjustment" screen.
PC210-10M0, PC210LC-10M0
30-171
SETTING AND OPERATION OF MACHINE MONITOR
3.
30 TESTING AND ADJUSTING
After the Pump Calibration screen is displayed, select Matching Speed Calibration with numeral input switches. REMARK • For selecting method, see "SERVICE MODE" in "SERVICE MODE". • Alphabets at the top right on the screen shows the below status. D: Default F: Adjustment value at factory shipment
*
U: Calibration value done by user 4.
Fr the steps that follow, see "ADJUSTMENT MENU (Pump calibration: Matching speed check)".
ADJUSTMENT MENU (Pump calibration: Restore to default setting) You can check the various settings of the machine or to adjust the set values on the Adjustment menu screen. On the "Restore to Default Setting", you can restore the matching (rotation) speed between the main pump and the engine to the default setting. 1. On the "Service Menu" screen, select "Adjustment". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
2.
When the "Adjustment" screen is shown, input "40" by using the numeral input switches, and press F6. REMARK Items of "Pump Calibration" are not displayed on the "Adjustment" screen.
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PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
3.
SETTING AND OPERATION OF MACHINE MONITOR
When the "Pump Calibration"screen is shown, select "Restore to Default Setting" with the function switches or the numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
4.
The confirmation screen is shown. Push F6 to restore the value to the default setting. When the operation completes, the upper right part of the "Pump Calibration" screen shows "D".
*
NO-INJECTION CRANKING OPERATION For details about No-Injection cranking, see "NO-INJECTION CRANKING OPERATION". The operation of No-Injection cranking must be done while the engine stops. No-Injection cranking cannot be done while the engine is in operation. 1. Select "No-Injection Cranking" on the "Service Menu" screen. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
2.
On the "No-Injection Cranking" screen, select the operation with function switches. F5: The screen returns to "Service Menu" screen. F6: Executes no-injection cranking
*
PC210-10M0, PC210LC-10M0
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SETTING AND OPERATION OF MACHINE MONITOR
30 TESTING AND ADJUSTING
REMARK If you push F6 while the engine is in operation, "Engine is operating. Please turn the key off once." is shown on the screen.
*
3.
Push F6, and the "Under preparation" screen is shown. Then "No-injection cranking is possible. Please turn the key off after no-injection ends." is shown on the screen. "No-injection cranking is possible." Turn the starting switch to START position, and crank the engine. NOTICE Do not crank the engine continuously for 20 seconds or more to protect the starting motor. *
REMARK For the case below, "Please turn the key off to stop." is shown on the screen, and the No-Injection cranking cannot be done. Turn the starting switch to the OFF position, and start the procedure from the step 1 again. • When the communication between the machine monitor and engine controller is not normal • When the starting switch is turned to the START position before "No-injection cranking is possible. Please turn the key off after no-injection ends." is shown on the screen 4.
After the cranking is completed, turn the starting switch to the OFF position. The screen cannot be changed while the starting switch is in the ON position.
30-174
*
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
SETTING AND OPERATION OF MACHINE MONITOR
KOMTRAX SETTINGS MENU KOMTRAX SETTINGS MENU (TERMINAL STATUS) You can check the setting and operation states of KOMTRAX on the KOMTRAX Settings menu screen. You can check the setting condition of the KOMTRAX terminal with "Terminal Setting State". 1. Select "KOMTRAX Settings" on the "Service Menu" screen. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
2.
On the "KOMTRAX Settings" screen, select "Terminal Status" with function switches or numerical input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
3.
The screen changes to the "Terminal Status" screen and shows the following information. Terminal: Model of KOMTRAX terminal KOMTRAX Communication: Execution status of radio station establishment GMT Time: Greenwich standard time (+9 hours for Japan time) F5: The screen returns to "KOMTRAX Settings" screen. *
KOMTRAX SETTINGS MENU (GPS AND COMMUNICATION STATUS) You can check the setting and operation states of KOMTRAX on the KOMTRAX Settings menu screen. You can check the positioning and communication condition of KOMTRAX terminal with "GPS and Communication State". 1. Select "KOMTRAX Settings" on the "Service Menu" screen. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
PC210-10M0, PC210LC-10M0
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SETTING AND OPERATION OF MACHINE MONITOR
2.
30 TESTING AND ADJUSTING
On the "KOMTRAX Settings" screen, select "GPS & Communication State" with function switches or numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
3.
The screen changes to the "GPS & Communication State" screen and shows the information that follows. Positioning: GPS positioning state Communication: Communication state of the KOMTRAX terminal Number of Message(s) Not Yet Sent: Number of message that not sent yet (For technician) F5: The screen returns to "KOMTRAX Settings" screen. *
KOMTRAX settings menu (modem status) You can check the setting and operation states of KOMTRAX on the KOMTRAX Settings menu screen. On the "Modem Information" screen, you can check the phone number and IMSI of KOMTRAX terminal. IMSI: Acronym for International Mobile Subscription Identity IMSI is an electric communication code for terminal identification. 1. Select "KOMTRAX Settings" on the "Service Menu" screen. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
2.
On the "KOMTRAX Settings" screen, select the "Modem Information" with function switches or numeral input switches. REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
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30 TESTING AND ADJUSTING
3.
SETTING AND OPERATION OF MACHINE MONITOR
The screen changes to the "Modem Information" screen and shows the information that follows. •
Phone number
•
IMSI
F5: The screen returns to "KOMTRAX Settings" screen.
*
Display service message You can check the setting and operation states of KOMTRAX on the KOMTRAX Settings menu screen. You can check the message from the KOMTRAX base station to the technician with "Service Message". You can send a reply to some messages. 1. On the "Service Menu" screen, select "Service Message". REMARK For selecting method, see "SERVICE MODE" in "SERVICE MODE".
*
2.
When the "Service Message" screen is shown, check the message. •
When no message is received "No message." is shown. F5: The screen returns to "Service Menu" screen
•
When a message is received The message is shown. If the lower part of the message shows "Numeric Input", you can send a reply with the numeral input switches and the function switches.
*
F5: The screen returns to "Service Menu" screen F6: Accepts the input value and sends a reply REMARK The message pilot lamp does not light up when this message is received.
*
PC210-10M0, PC210LC-10M0
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START UP KOMTRAX TERMINAL
30 TESTING AND ADJUSTING
START UP KOMTRAX TERMINAL Start up KOMTRAX terminal To start the use of KOMTRAX, perform the following procedure. 1. The person in charge of KOMTRAX operation performs "machine registration" on a KOMTRAX client computer. REMARK For the operating procedure, see "Global KOMTRAX Web Reference Manual (For Key Person)". 2.
Our technician starts the communication inspection.
When KOMTRAX terminal is replaced Replace the KOMTRAX terminal as follows. 1. Our technician provides a new terminal, and records the part number and serial number. 2.
Technician(s) replaces the terminal and then performs KOMTRAX Communication Inspection.
3.
Technician(s) tells the completion of inspection and the part number and serial No. of the new terminal to the person in charge of KOMTRAX operation.
4.
The person in charge of KOMTRAX operation performs "terminal replacement" on a KOMTRAX client computer. REMARK For the operating procedure, see "Global KOMTRAX Web Reference Manual (For Key Person)".
5.
The person in charge of KOMTRAX operation fills out "Application for Discontinuance" for disposal of the old terminal and sends it to the KOMTRAX support center.
Communication inspection When the KOMTRAX Communication Inspection is completed, the KOMTRAX terminal starts communications. Park the machine outside during KOMTRAX Communication Inspection to prevent the radio waves for GPS and data communication from being blocked. Communication Inspection cannot be completed indoor in some cases.
KOMTRAX communication Check the KOMTRAX Communication before Communication Inspection as follows. 1. On the "Service Menu" screen, select "KOMTRAX Settings" with function switches or numeral input switches. REMARK For details about how to operate, see "SERVICE MODE" in "SERVICE MODE".
*
2.
On the "KOMTRAX Settings" screen, select "Terminal Status" with function switches or numerical input switches. REMARK For details about how to operate, see "SERVICE MODE" in "SERVICE MODE".
*
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30 TESTING AND ADJUSTING
3.
START UP KOMTRAX TERMINAL
When the "Terminal Setting State" screen is shown, check "KOMTRAX Communication". If "KOMTRAX Communication Not Open" is shown in "KOMTRAX Communication", do the Communication Inspection. When "Already Open" is shown, Communication Inspection is not required.
*
Do communication inspection Do the Communication Inspection as follows. 1. On the "Service Menu" screen, select "KOMTRAX Settings" with function switches or numeral input switches. REMARK For details about how to operate, see "SERVICE MODE" in "SERVICE MODE".
*
2.
When the "KOMTRAX Settings" screen is shown, select "GPS & Communication State" with function switches or numeral input switches. REMARK For details about how to operate, see "SERVICE MODE" in "SERVICE MODE".
*
3.
When the "GPS & Communication State" screen is shown, do the following operation with numeral input switches. Switch operation: 4 + 1 -> 2 -> 3 (While holding down 4, push 1, 2, and 3 in turn).
*
PC210-10M0, PC210LC-10M0
30-179
START UP KOMTRAX TERMINAL
4.
30 TESTING AND ADJUSTING
If the screen shows "Are you sure you want to inspect?", perform the inspection with function switches. F5: Returns the screen to "GPS & Communication State" screen F6: Performs KOMTRAX Communication Inspection REMARK When the Communication Inspection is completed, this screen will not be shown. *
5.
When the "Communication Inspection in Progress" is shown, make sure that all items show "OK". "Modem": "OK" is shown when the machine is in the communication area "GPS": "OK" is shown when the GPS data is received. "Transmission": "OK" is shown when the message is transmitted normally. "Inspection State": When "OK" is shown on "Modem", "GPS", and "Transmission", "OK" is shown.
*
REMARK • It takes approximately 90 seconds to 15 minutes until all the items becomes "OK". • During Communication Inspection, it is no problem to do as follows. KOMTRAX Communication Inspection continues. Check the "KOMTRAX Communication" to make sure that the terminal is "Already Open". •
Change the screen.
•
Turn the starting switch to OFF position.
•
Start the engine.
6.
When all items become "OK", the "Inspection finished normally." is shown and Communication Inspection completes. Push F6 to return the screen to "GPS & Communication State" screen.
7.
If the "Communication Inspection in Progress" screen does not show "OK", possible causes are listed below. Solve the problem and perform KOMTRAX Communication Inspection again. Phenomenon GPS does not become OK
Cause There are obstacles around the GPS antenna, and the GPS satellite is not in view.
Required action Remove obstacles.
The GPS antenna cable does not connect to Check for the connection. If the connection is the KOMTRAX terminal, or the cable is loose. loose, connect it securely. The cell phone is out of service area.
Check the service area using your cell phone. If the cell phone is out of service area, move the machine within service area.
The communication antenna cable is not conModem does not beCheck for the connection. If the connection is nected to the KOMTRAX terminal or the concome OK loose, connect it securely. nection is loose. The machine-side harness does not connect to the KOMTRAX terminal, or the harness is loose.
30-180
Check for the connection. If the connection is loose, connect it securely.
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
START UP KOMTRAX TERMINAL
When the problems are not solved, consult KOMTRAX support center.
PC210-10M0, PC210LC-10M0
30-181
Adjust rearview camera angle
30 TESTING AND ADJUSTING
Adjust rearview camera angle ADJUST REARVIEW CAMERA ANGLE k
k
Make sure to adjust the camera (1) before you start the work. If it is not adjusted properly, you cannot secure the visibility and a serious personal injury or death may result. Provide a stand, and the work place when you do the angle adjustment of the camera (1). If you try to work on the counterweight, there is a danger of personal injury or death when you fall off from the machine.
Adjust the camera, and make sure that a person who is in the area (W) of approximately 1 m behind the machine, is recognized on the machine monitor at the operator's seat.
*
If the image shown on the monitor is not correct, use the procedure that follow to adjust the installation angle of the rearview camera (A).
1.
Put the flat head screw driver into the hole (4) of the cover (3), and remove it while you push the claw (B) inside.
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30 TESTING AND ADJUSTING
Adjust rearview camera angle
REMARK The claw of the cover (2) is made of plastic, and it is easily broken when you remove it. Be careful to do this work. 2.
Remove the cover (5) (2 places).
3.
Remove the cover (2).
4.
Loosen the camera mounting bolts (7) (3 places), and adjust the camera mounting angle (A) for the corner (D) of the mounting bracket (C) to be aligned to the horizontal line (E).
Angle (A): 45 to 47 °
5.
After the adjustment, tighten the bolt (7). Tightening torque: 11.8 to 14.7 Nm {1.2 to 1.5 kgm} REMARK • A part of the machine is shown on the monitor screen. • Adjust the camera position, and make sure you can see the counterweight on approximately 10% to 15% of the monitor screen.
*
PC210-10M0, PC210LC-10M0
30-183
ENGINE CONTROLLER VOLTAGE CIRCUIT
30 TESTING AND ADJUSTING
ENGINE CONTROLLER VOLTAGE CIRCUIT NOTICE • Remove sand, dust, and moisture completely from the inside of the harness connector on the controller side. Then, connect the harness connector. • Before disconnecting or connecting the connector, be sure to turn the battery disconnect switch to OFF position. • Do not start the engine when the T-adapter is inserted into (or connected to) the engine controller-toengine connector (even during troubleshooting). REMARK You can turn the starting switch to OFF or ON position, but do not turn it to START position.
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30 TESTING AND ADJUSTING
TEST DIODES
TEST DIODES Test the diode array (8-pin) and diode (2-pin) as follows. The drawing shows the continuity direction of the diode array. You can check the continuity direction of the diode (2-pin) with the mark on the surface.
TEST DIODES BY DIGITAL TESTER 1.
Change to the diode range. Check the display value. REMARK The tester normally shows the pressure of the internal battery.
2.
Apply the Red (+) of the tester lead to the anode (P) side of the diode and the Black (-) to the cathode (N) side. Check the display value.
3.
Judge whether the diode is normal or abnormal based on the display value. When the display value does not change: No continuity (Abnormal) When the display value changes: Continuity (Normal) (*) *: For silicon-based diodes, the display value is 460 to 600 mV.
TEST DIODES BY ANALOG TESTER 1.
Change to the resistance range.
2.
Apply the Red (+) of the tester lead to the anode (P) side of the diode and the Black (-) to the cathode (N) side. Check the swing of the pointer.
3.
Apply the Red (+) of the tester lead to the cathode (N) side of the diode and the Black (-) to the anode (P) side. Check the swing of the pointer.
4.
Judge whether the diode is normal or abnormal based on the swing of the pointer. Swing of tester pointer
Normal/abnormal judgment
Step 2.
Step 3.
Swing
Not swing
Swing
Swing
Abnormal (Internal short circuit)
Not swing
Not swing
Abnormal (Internal open circuit)
PC210-10M0, PC210LC-10M0
Normal (The amount of swing (resistance) depends on tester type or selected measurement range.)
30-185
PM CLINIC SERVICE
30 TESTING AND ADJUSTING
Pm-CLINIC PM CLINIC SERVICE Machine model
Serial No.
Service meter
□ PC210-10
h User name
Date of inspection
Inspector
// Specifications Main parts
Attachment
Shoe width
□ Boom Standard □ ( )
□ Breaker
□ 600 mm
□ Arm Standard □ ( )
□ ( )
□ 700 mm
□ Bucket Standard □ ( )
□ ( )
□ ( ) mm
Check of oil and coolant levels □ Radiator coolant
When necessary
□ Engine oil
□ Damper case oil
□ Machinery case oil
□ Hydraulic oil
□ Final drive case oil
□ ( )
Ambient temperature
Altitude °C
m
Operator's comment
Result of visual inspection
Mechanical Sys Abnormality Record
Electrical Sys Abnormality Record
A900NR
Times/First time
h/Latest
h
Times/First time
h/Latest
h
A900N6
Times/First time
h/Latest
h
Times/First time
h/Latest
h
A900NY
Times/First time
h/Latest
h
Times/First time
h/Latest
h
AA10NX
Times/First time
h/Latest
h
Times/First time
h/Latest
h
AB00KE
Times/First time
h/Latest
h
Times/First time
h/Latest
h
B@BAZG
Times/First time
h/Latest
h
Times/First time
h/Latest
h
B@BAZK
Times/First time
h/Latest
h
Times/First time
h/Latest
h
B@BCNS
Times/First time
h/Latest
h
Times/First time
h/Latest
h
B@BCZK
Times/First time
h/Latest
h
Times/First time
h/Latest
h
B@HANS
Times/First time
h/Latest
h
Times/First time
h/Latest
h
CA234
Times/First time
h/Latest
h
Times/First time
h/Latest
h
30-186
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
PM CLINIC SERVICE
Max. range of engine coolant temperature gauge Coolant temperature gauge level
Coolant Temperature
6
105°C
5
102°C
4
100°C
3
85°C
2
60°C
1
30°C
PC210-10M0, PC210LC-10M0
Lighting color of the monitor (a) Red
Blue
White
30-187
PM CLINIC SERVICE
30 TESTING AND ADJUSTING
Max. range of hydraulic oil temperature gauge Oil temperature level
Hydraulic Oil Temperature
6
105°C
5
102°C
4
100°C
3
85°C
2
40°C
1
20°C
30-188
Lighting color of the monitor (a) Red
Blue
White
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
PM CLINIC SERVICE
PM CLINIC CHECK SHEET: PC210-10M0 Engine: SAA6D107E-1 Machine model
Serial number
Service meter
User name
Date of inspection
Inspector
PC210-10M0
Engine Item
Engine speed at high idle (*1)
Engine speed at low idle (*1)
Engine speed when the oil pressure at 2-pump relief (*1)
Testing conditions •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (High idle) position
•
Each control lever and control pedal: NEUTRAL
•
Auto-deceleration: OFF
•
Swing lock switch: ON
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MIN (Low idle) position
•
Each control lever and control pedal: NEUTRAL
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Swing lock switch: ON
•
Fuel control dial: MAX (High idle) position
•
Oil pressure in arm IN circuit is relieved
PC210-10M0, PC210LC-10M0
Unit
Standard value for new machine
Repair limit
rpm
(1780 to 1920)
(1780 to 1920)
rpm
(1000 to 1100)
(1000 to 1100)
rpm
(1600 to 1800)
(1600 to 1800)
No MeasGo go ured od od value
30-189
PM CLINIC SERVICE
Item
Engine speed when oil pressure at 2-pump relief + Onetouch power maximizing is actuated (*1)
Speed when auto deceleration is activated (*1)
Engine oil pressure
Blowby pressure
30-190
30 TESTING AND ADJUSTING
Testing conditions •
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (High idle) position
•
When the oil pressure in arm IN circuit is relieved + One-touch power maximizing function is actuated
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Auto-deceleration: ON
•
Fuel control dial: MAX (High idle) position
•
Each control lever and control pedal: NEUTRAL
•
Engine coolant tem- Fuel control dial: MAX perature: 60 to (High idle) 100 °C
•
Working mode: P Mode
•
Auto-deceleration: OFF
Unit
Standard value for new machine
Repair limit
rpm
(1850 to 2050)
(1850 to 2050)
rpm
position
No MeasGo go ured od od value
(950 to 1150) (950 to 1150)
Min. 0.29
Min. 0.25
{3.0 or more}
{2.5 or more}
Min. 0.10
Min. 0.07
{1.0 or more}
{0.7 or more}
MPa Fuel control dial: MIN (Low idle) position
{kg/cm 2}
•
Engine oil (*2) EO10W30-DH EO15W40-DH EOS0W30-DH EOS5W40-DH
•
Engine coolant temperature: 60 to 100 °C
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Auto-deceleration: OFF
kPa
Max. 0.98
Max. 1.96
•
Swing lock switch: ON
mmH2O
{Max. 100}
{Max. 200}
•
Fuel control dial: MAX (High idle) position
•
When the oil pressure in arm IN circuit is relieved + One-touch power maximizing function is actuated
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
PM CLINIC SERVICE
*1: Item that can be checked in monitoring of the machine monitor *2: KES diesel engine oil Work equipment speed Item
Boom RAISE (time required)
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (High idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 2".
•
Time required to operate the boom from the time when bucket is lowered on the ground to the time when it reaches to the stroke end
•
Hydraulic oil temperature: 45 to 55 °C
•
Fuel control dial: MAX (High idle) position
•
Working mode: P Mode
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 3".
Arm IN (time required)
•
Unit
Standard value for new machine
Repair limit
Second
(2.9 to 3.7)
4.7 or less
Second
(3.1 to 3.9)
4.5 or less
MeasNo Go ured go od value od
Time required to operate the arm from the time when the arm is at arm OUT stroke end to the time when it reaches to the arm IN stroke end
PC210-10M0, PC210LC-10M0
30-191
PM CLINIC SERVICE
Item
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (High idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 3".
Arm OUT (time required)
•
Time required to operate the arm from the time when the arm is at arm IN stroke end to the time when it reaches to the arm OUT stroke end
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (High idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 4".
Bucket CURL (time required)
•
30-192
30 TESTING AND ADJUSTING
Unit
Standard value for new machine
Repair limit
Second
(2.4 to 3.0)
3.5 or less
Second
(2.1 to 2.7)
3.3 or less
No MeasGo go ured od od value
Time required to operate the arm from the time when the bucket is at bucket DUMP stroke end to the time when it reaches to the bucket CURL stroke end
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
PM CLINIC SERVICE
Swing speed Item
Time required for swing
Testing conditions
Unit
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (High idle) position
•
See the measuring posture, STANDARD VALUE TASwing LEFT BLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
•
Swing RIGHT
Standard value for new machine
Repair limit
(21.7 to 26.7)
30 or less
(21.7 to 26.7)
30 or less
Standard value for new machine
Repair limit
No MeasGo go ured od od value
Second
Time required for 5 rotations after 1 swing
Travel speed Item
Testing conditions •
Travel speed (required time, idling)
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (High idle) position
•
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 1".
Lo
Mi
Unit Forward
(44.6 to 54.9) (44.6 to 58.8)
Reverse
(44.6 to 54.9) (44.6 to 58.8)
Forward
(33.7 to 41.3) (33.7 to 45.3)
Reverse Forward Reverse
No MeasGo go ured od od value
(33.7 to 41.3) (33.7 to 45.3)
Second
(25.2 to 27.8) (25.2 to 29.8) (25.2 to 27.8) (25.2 to 29.8)
Hi
Time required for 5 rotations after 1 idling of track shoe
PC210-10M0, PC210LC-10M0
30-193
PM CLINIC SERVICE
30 TESTING AND ADJUSTING
Hydraulic drift of work equipment Item
Hydraulic drift measured at tooth tip (whole work equipment)
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Level ground
•
Bucket filled up with dirt and sand, or at the rated load (0.8 m3: 1440 kg)
•
Stop engine
•
Control lever: NEUTRAL
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 1".
•
Quantity of movement of the machine for 15 minutes after the measuring posture
Unit
Standard value for new machine
Repair limit
mm
600 or less
900 or less
Unit
Standard value for new machine
Repair limit
No MeasGo go ured od od value
Hydraulic circuit Item
Control circuit oil pressure
Unload pressure (*1)
30-194
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Auto-deceleration: OFF
•
Fuel control dial: MAX (High idle) position
•
Each control lever and control pedal: NEUTRAL
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Auto-deceleration: OFF
•
Fuel control dial: MAX (High idle) position
•
Each control lever and control pedal: NEUTRAL
MPa {kg/cm
(2.93 to 3.43) (2.75 to 3.43) 2}
MPa {kg/cm
No MeasGo go ured od od value
2}
{30 to 35}
{28 to 35}
(2.7 to 4.7)
(2.7 to 4.7)
{28 to 48}
{28 to 48}
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Item
Testing conditions •
Arm relief pressure (*1)
Swing relief pressure (*1)
Travel relief pressure (*1)
LS differential pressure (*1)
PM CLINIC SERVICE
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Swing lock switch: OFF
When onetouch power maximizing function is actuated
Fuel control dial: MAX (High idle) position
•
Oil pressure in arm IN circuit is relieved
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Swing lock switch: OFF
•
Fuel control dial: MAX (High idle) position
•
Swing hydraulic relief
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode Fuel control dial: MAX (High idle) position
Lock right travel and travel relief (forward or reverse) Lock left travel and travel relief (forward or reverse)
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Travel speed: Hi
•
Fuel control dial: MAX (High idle) position
•
Travel control lever: Half stroke
•
Rotate the track on one side off the ground
PC210-10M0, PC210LC-10M0
Repair limit
No MeasGo go ured od od value
(33.8 to 35.8) (33.3 to 36.3)
At normal relief
•
•
Standard value for new machine
Unit
{345 to 365}
{340 to 370}
MPa {kg/cm 2}
(36.3 to 38.3) (35.8 to 38.8) {370 to 390}
MPa
{365 to 396}
(27.9 to 30.9) (27.4 to 31.4)
{kg/cm 2}
{285 to 315}
{280 to 320}
(36.7 to 39.7) (36.2 to 40.2) {375 to 405}
{370 to 410}
MPa {kg/cm 2} (36.7 to 39.7) (36.2 to 40.2) {375 to 405}
MPa {kg/cm
{370 to 410}
(1.66 to 1.81) (1.66 to 1.81) 2}
{17 to 18.5}
{17 to 18.5}
30-195
PM CLINIC SERVICE
Item
Testing conditions
Hydraulic oil temperature: 45 to 55 °C
Front pump discharged pressure
•
Working mode: P Mode
•
Swing lock switch: ON
Servo piston inlet pressure
•
PC valve outlet pressure
PC-EPC valve outlet pressure
LS-EPC valve outlet pressure
30 TESTING AND ADJUSTING
•
Fuel control dial: MAX (High idle) position
•
Oil pressure in arm IN circuit is relieved
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Each control lever and control pedal: NEUTRAL
Rear pump discharged pressure
Unit
Standard value for new machine
Repair limit
(36.1 to 38.8) (36.1 to 39.7)
MPa {kg/cm 2}
Servo piston inlet pressure
{368 to 395}
{368 to 405}
Above value x approx. 0.6
Above value x approx. 0.6
(36.1 to 38.8) (36.1 to 39.7) {368 to 395}
{368 to 405}
Above value x approx. 0.6
Above value x approx. 0.6
Fuel control dial: MIN (Low idle) position
Approximate- Approximately 2.6 ly 2.6
Fuel control dial: MAX (High idle) position
Approximate- Approximately 1.0 ly 1.0
{Approx. 26}
{Approx. 10} MPa
{Approx. 26}
{Approx. 10}
Approximate- Approximately 1.2 ly 1.2
Hydraulic oil temperature: 45 to 55 °C
Working mode: E mode
•
Fuel control dial: MAX (High idle) position
Working mode: L mode
Approximate- Approximately 1.7 ly 1.7
•
Each control lever and control pedal: NEUTRAL
Working mode: B mode
Approximate- Approximately 1.4 ly 1.4
•
Hydraulic oil temperature: 45 to 55 °C
Travel speed: Lo
•
Working mode: P Mode
•
• •
•
Auto-deceleration: OFF Fuel control dial: MAX (High idle) position
Travel speed: Mi
No MeasGo go ured od od value
{kg/cm 2}
{Approx. 12}
{Approx. 17}
{Approx. 14}
{Approx. 12}
{Approx. 17}
{Approx. 14}
Approximate- Approximately 2.45 ly 2.45 {Approx. 25}
MPa {kg/cm 2}
Travel speed: Hi
Travel control lever: Fine control
{Approx. 25}
Approximate- Approximately 0.7 ly 0.7 {Approx. 7}
{Approx. 7}
0
0
0
0
*1: Item that can be checked in monitoring of the machine monitor
30-196
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
PM CLINIC SERVICE
PM CLINIC CHECK SHEET: PC210LC-10M0 Engine: SAA6D107E-1 Machine model
Serial number
Service meter
User name
Date of inspection
Inspector
PC210LC-10M0
Engine Item
Engine speed at high idle (*1)
Engine speed at low idle (*1)
Engine speed when the oil pressure of 2 pumps are relieved (*1)
Testing conditions •
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
Each control lever and control pedal: NEUTRAL
•
Auto-deceleration: OFF
•
Swing lock switch: ON
•
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MIN (low idle) position
•
Each control lever and control pedal: NEUTRAL
•
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Swing lock switch: ON
•
Fuel control dial: MAX (high idle) position
•
Oil pressure in arm IN circuit is relieved
PC210-10M0, PC210LC-10M0
Unit
Standard value for new machine
Repair limit
rpm
(1780 to 1920)
(1780 to 1920)
rpm
(1000 to 1100)
(1000 to 1100)
rpm
(1600 to 1800)
(1600 to 1800)
No MeasGo go ured od od value
30-197
PM CLINIC SERVICE
Item
Engine speed when oil pressure of 2 pumps are relieved + Onetouch power maximizing is actuated (*1)
Speed when auto deceleration is activated (*1)
Engine oil pressure
Testing conditions •
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
When the oil pressure in arm IN circuit is relieved + One-touch power maximizing function is actuated
•
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Auto-deceleration: ON
•
Fuel control dial: MAX (high idle) position
•
Each control lever and control pedal: NEUTRAL
•
Engine coolant tem- Fuel control dial: MAX perature: 60 to (high idle) 100 ℃
•
Working mode: P Mode
•
Auto-deceleration: OFF
•
30-198
30 TESTING AND ADJUSTING
Engine oil (*2) EO10W30–LA EO15W40–LA EOS5W30–LA EOS5W40–LA
Unit
Standard value for new machine
Repair limit
rpm
(1850 to 2050)
(1850 to 2050)
rpm
position
No MeasGo go ured od od value
(950 to 1150) (950 to 1150)
Min. 0.29
Min. 0.25
{3.0 or more}
{2.5 or more}
Min. 0.10
Min. 0.07
{1.0 or more}
{0.7 or more}
MPa Fuel control dial: MIN (low idle) position
{kg/cm 2}
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Item
Blowby pressure
Testing conditions •
Engine coolant temperature: 60 to 100 ℃
•
Hydraulic oil temperature: 45 to 55 °C
•
Aftertreatment devices: Regeneration disable
•
Working mode: P Mode
•
Auto-deceleration: OFF
•
Swing lock switch: ON
•
Fuel control dial: MAX (high idle) position
•
When the oil pressure in arm IN circuit is relieved + One-touch power maximizing function is actuated
PM CLINIC SERVICE
Unit
Standard value for new machine
Repair limit
kPa
Max. 0.98
Max. 1.96
mmH2O
{Max. 100}
{Max. 200}
Unit
Standard value for new machine
Repair limit
Second
(2.9 to 3.7)
Max. 4.7
No MeasGo go ured od od value
*1: Item that can be checked in monitoring of the machine monitor *2: KES diesel engine oil Work equipment speed Item
Boom RAISE (time required)
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 2".
•
Time required to move from bucket ground to stroke end
PC210-10M0, PC210LC-10M0
MeasNo Go ured go od value od
30-199
PM CLINIC SERVICE
Item
Arm IN (time required)
Arm OUT (time required)
Bucket CURL (time required)
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 3".
•
Time required to operate the bucket from the DUMP stroke end to the CURL stroke end
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 3".
•
Time required to operate from dozing stroke end to dump stroke end
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 4".
•
30-200
30 TESTING AND ADJUSTING
Unit
Standard value for new machine
Repair limit
Second
(3.1 to 3.9)
Max. 4.5
Second
(2.4 to 3.0)
3.5 or less
Second
(2.1 to 2.7)
3.3 or less
No MeasGo go ured od od value
Time required to operate the bucket from the DUMP stroke end to the CURL stroke end
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
PM CLINIC SERVICE
Swing speed Item
Time required for swing
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "SWING 1".
•
Unit Swing RIGHT
Standard value for new machine
Repair limit
(21.7 to 26.7)
Max. 30
(21.7 to 26.7)
Max. 30
Standard value for new machine
Repair limit
No MeasGo go ured od od value
Second Swing LEFT
Time required for 5 rotations after 1 swing
Travel speed Item
Testing conditions •
Travel speed (required time, idling)
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Fuel control dial: MAX (high idle) position
•
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "TRAVEL 1".
Lo
Mi
Unit Forward
(48.6 to 59.8) (48.6 to 63.8)
Reverse
(48.6 to 59.8) (48.6 to 63.8)
Forward
(36.7 to 44.9) (36.7 to 48.9)
Reverse Forward Reverse
No MeasGo go ured od od value
(36.7 to 44.9) (36.7 to 48.9)
Second
(28.9 to 32.1) (28.9 to 34.1) (28.9 to 32.1) (28.9 to 34.1)
Hi
Time required for 5 rotations after 1 idling of track shoe
PC210-10M0, PC210LC-10M0
30-201
PM CLINIC SERVICE
30 TESTING AND ADJUSTING
Hydraulic drift of work equipment Item
Hydraulic drift measured at tooth tip (whole work equipment)
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Level ground
•
Bucket filled up with dirt and sand, or at the rated load (0.8 m3: 1440 kg)
•
Stop engine
•
Control lever: NEUTRAL
•
See the measuring posture, STANDARD VALUE TABLE, "MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE", "Work equipment 1".
•
Quantity of movement of the machine for 15 minutes after the measuring posture
Unit
Standard value for new machine
Repair limit
mm
600 or less
900 or less
Unit
Standard value for new machine
Repair limit
No MeasGo go ured od od value
Hydraulic circuit Item
Control circuit oil pressure
Unload pressure (*1)
30-202
Testing conditions •
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Auto-deceleration: OFF
•
Fuel control dial: MAX (high idle) position
•
Each control lever and control pedal: NEUTRAL
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Auto-deceleration: OFF
•
Fuel control dial: MAX (high idle) position
•
Each control lever and control pedal: NEUTRAL
MPa {kg/cm
(2.93 to 3.43) (2.75 to 3.43) 2}
MPa {kg/cm
No MeasGo go ured od od value
2}
{30 to 35}
{28 to 35}
(2.5 to 4.5)
(2.5 to 4.5)
{26 to 46}
{26 to 46}
PC210-10M0, PC210LC-10M0
30 TESTING AND ADJUSTING
Item
Testing conditions •
Arm relief pressure (*1)
Swing relief pressure (*1)
Travel relief pressure (*1)
LS differential pressure (*1)
PM CLINIC SERVICE
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Swing lock switch: OFF
When onetouch power maximizing function is actuated
Fuel control dial: MAX (high idle) position
•
Oil pressure in arm IN circuit is relieved
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Swing lock switch: OFF
•
Fuel control dial: MAX (high idle) position
•
Swing hydraulic relief
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode Fuel control dial: MAX (high idle) position
Lock right travel and travel relief (forward or reverse) Lock left travel and travel relief (forward or reverse)
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Travel speed: Hi
•
Fuel control dial: MAX (high idle) position
•
Travel control lever: Half stroke
•
Idling of track shoe on one side
PC210-10M0, PC210LC-10M0
Standard value for new machine
Repair limit
No MeasGo go ured od od value
(33.8 to 35.8) (33.3 to 36.3)
Normal relief
•
•
Unit
{345 to 365}
{340 to 370}
MPa {kg/cm 2}
(36.3 to 38.3) (35.8 to 38.8) {370 to 390}
MPa {kg/cm 2}
{365 to 396}
(27.9 to 30.9) (27.4 to 31.4) {285 to 315}
{280 to 320}
(36.7 to 39.7) (36.2 to 40.2) {375 to 405}
{370 to 410}
MPa {kg/cm 2} (36.7 to 39.7) (36.2 to 40.2) {375 to 405}
MPa {kg/cm 2}
{370 to 410}
(1.66 to 1.81) (1.66 to 1.81) {17 to 18.5}
{17 to 18.5}
30-203
PM CLINIC SERVICE
Item
Testing conditions
Hydraulic oil temperature: 45 to 55 °C
Front pump discharged pressure
•
Working mode: P Mode
•
Swing lock switch: ON
Servo piston inlet pressure
•
PC valve outlet pressure
PC-EPC valve outlet pressure
LS-EPC valve outlet pressure
•
Fuel control dial: MAX (high idle) position
•
Oil pressure in arm IN circuit is relieved
•
Hydraulic oil temperature: 45 to 55 °C
•
Working mode: P Mode
•
Each control lever and control pedal: NEUTRAL
Rear pump discharged pressure
Unit
Standard value for new machine
Repair limit
MPa {kg/cm 2}
Servo piston inlet pressure
{368 to 395}
{368 to 405}
Above value x approx. 0.6
Above value x approx. 0.6
(36.1 to 38.8) (36.1 to 39.7) {368 to 395}
{368 to 405}
Above value x approx. 0.6
Above value x approx. 0.6
Fuel control dial: MIN (low idle) position
Approximate- Approximately 2.6 ly 2.6
Fuel control dial: MAX (high idle) position
Approximate- Approximately 1.0 ly 1.0
{Approx. 26}
{Approx. 10} MPa
{Approx. 26}
{Approx. 10}
Approximate- Approximately 1.2 ly 1.2
Working mode: E mode
•
Fuel control dial: MAX (high idle) position
Working mode: L mode
Approximate- Approximately 1.7 ly 1.7
•
Each control lever and control pedal: NEUTRAL
Working mode: B mode
Approximate- Approximately 1.4 ly 1.4
•
Hydraulic oil temperature: 45 to 55 °C
Travel speed: Lo
•
Working mode: P Mode
• •
Auto-deceleration: OFF Fuel control dial: MAX (high idle) position Travel control lever: Fine control
Travel speed: Mi
{kg/cm 2}
{Approx. 12}
{Approx. 17}
{Approx. 14}
{Approx. 12}
{Approx. 17}
{Approx. 14}
Approximate- Approximately 2.45 ly 2.45 {Approx. 25}
MPa {kg/cm 2}
Travel speed: Hi
No MeasGo go ured od od value
(36.1 to 38.8) (36.1 to 39.7)
Hydraulic oil temperature: 45 to 55 °C
•
•
30-204
30 TESTING AND ADJUSTING
{Approx. 25}
Approximate- Approximately 0.7 ly 0.7 {Approximately 7}
{Approximately 7}
0
0
0
0
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40-1
ABBREVIATION LIST
40 TROUBLESHOOTING
ABBREVIATION LIST •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
•
Abbreviations that are used in general society may not be included.
•
Special abbreviations that appear infrequently are noted in the text.
•
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
Steering
ARAC
Automatic Retarder Accelerator Control
Travel and brake
ARSC
Automatic Retarder Speed Control
Travel and brake (HD, HM)
(WA)
(HD, HM)
Travel and brake (HD, HM)
Explanation A function that releases the brakes when the tires skid (wheels stop rotating), and applies the brakes again when the wheels start to rotate. A function that automatically sets the idle speed. A function that uses a lever to perform the steering operations instead of a steering wheel. Moreover, the lever is used to shifts gear and changes direction (FORWARD, REVERSE). A function that automatically applies the retarder with a constant braking force when the accelerator pedal is released while the machine is traveling downhill. A function that automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when the accelerator pedal is released while the machine is traveling downhill.
ASR
Automatic Spin Regula- Travel and brake tor (HD, HM)
A function that automatically uses the optimum braking force to drive both wheels when the tires spin on soft ground.
ATT
Attachment
A device that can be fixed onto the standard machine in order to enable it to do different jobs.
BCV
Brake cooling oil control Brake valve (HD)
CAN
Controller Area Network
Communication and electronic control
One of communication standards that are used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve that is installed to KCCV ventilator. It is written as CDR valve and it is not used singly.
CLSS
Closed-center Load Sensing System
Hydraulic system
A system that simultaneously actuates multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
A function that maintains optimum fuel injection amount and fuel injection timing by engine controller electronically controlling supply pump, common rail, and injector.
CRI
40-2
Common Rail Injection
WORK EQUIPMENT
A valve that divides part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Travel Suspension System (WA)
A system that ensures smooth high-speed travel by absorbing vibration of machine during travel with spring effect of accumulator.
ECU
Electronic Control Unit
An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
A function that recirculates part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of NOx.
Equipment ManageMACHINE MONITOR ment Monitoring System
A system which enables data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor to be checked on the monitor.
EPC
Electromagnetic ProporHydraulic system tional Control
This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Cab and canopy Structure
EMMS
F-N-R
GPS
GNSS
Forward-Neutral-Reverse Global Positioning System
Electronic control system
Transmission (D, HD, WA, etc)
Electronic control system
Operation Communication (KOMTRAX, KOMTRAX Plus)
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
Explanation An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECU) A proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.
A structure that protects the operator's head from falling objects. ISO 3449 compliant Forward - Neutral - Reverse A system that uses satellites to determine the current location on the earth 1. A system that uses satellites such as GPS, GALILEO, etc. to determine location on the earth. A function which uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly, machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
Steering
HST
Hydrostatic Transmission
Transmission
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
IMA
Inlet Metering Actuator
PC210-10M0, PC210LC-10M0
(D Series)
(D, WA)
A hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears.
40-3
ABBREVIATION LIST
Abbreviation
IMU
Actual word spelled out
Inertial Measurement Unit
40 TROUBLESHOOTING
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
A device that detects the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV (+)
Inlet Metering Valve
Engine
A valve which is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
A mechanism that separates oil in blowby gas and send it back to the intake side for it to be burned again. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
Engine
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
A filter that captures soot in exhaust gas. It is built in to KDPF A catalyst that is used for purifying exhaust gas.
Engine
Komatsu Diesel ParticuEngine late Filter
It is built in to KDPF or used in combination with the muffler in some cases. A component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler. A function that recovers the driving force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle machine travels on the soft ground road.
Komatsu Traction Control System
Travel and brake
LCD
Liquid Crystal Display
MACHINE MONITOR
A display equipment such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic parts
It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
One of communication standards that are used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
One of communication standards that are used in the network on the machine
MAF
Mass Air Flow
Engine
This indicates engine intake air flow. Mass air flow sensor is described as MAF sensor in some cases.
MMS
Multimedia Messaging Service
Communication
A service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
NC
Normally Closed
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally closed if it is not actuated (it opens when it is actuated).
NO
Normally Open
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally open if it is not actuated (it closes when it is actuated).
KTCS
40-4
(HM)
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
Abbreviation OLSS PC
PCCS
Actual word spelled out Open-center Load Sensing System
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system) Hydraulic system
Pressure Compensation Hydraulic system Palm command control system
Steering (D Series)
Explanation A hydraulic system that can operate multiple actuators at the same time regardless of the load. A function used to correct oil pressure. A function that electronically controls the engine and transmission. It is done by a controller that instantly analyses data from each lever, pedal, and dial.
PCV
Pre-stroke Control Valve Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This system is used for controlling proportional pressure. It moves actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power train system
PTP
Power Tilt and power Pitch dozer
WORK EQUIPMENT
ROPS
Roll-Over Protective Structure
Hydraulic system Hydraulic system (D, PC, etc)
(D Series)
Cab and canopy
A piston type hydraulic pump and motor A mechanism that takes out the force for the work equipment separately from the travel. A function that hydraulically performs tilt operation and pitch operation of the bulldozer blade. A protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. ISO 3471 compliant
SCR
Selective Catalytic Reduction
Urea SCR system
An exhaust gas purifier using urea water to convert nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It Done also be mentioned as exhaust gas purification catalyst , or part of the of related devices.
Le Système internationUnit al d'unités
A universal unit system and "a single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
An actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
A solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
The turbocharger on which the cross-section area of the exhaust passage is made variable.
SI
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
PC210-10M0, PC210LC-10M0
40-5
ABBREVIATION LIST
40 TROUBLESHOOTING
List of abbreviations used in the circuit diagrams Abbreviation A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
40-6
Actual word spelled out
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONTENTS
CONTENTS ABBREVIATION LIST .................................................................................................................................... 40-2 RELATED INFORMATION TO TROUBLESHOOT ....................................................................................... 40-13 PRECAUTIONS FOR TROUBLESHOOTING ....................................................................................... 40-13 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................ 40-14 CHECKS BEFORE TROUBLESHOOTING ........................................................................................... 40-16 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ............................................................ 40-18 WALK-AROUND CHECK............................................................................................................... 40-18 TEST ENGINE RELATED PARTS.................................................................................................. 40-19 TEST WORK EQUIPMENT AND UNDERCARRIAGE ................................................................... 40-21 CHECK ELECTRIC EQUIPMENT.................................................................................................. 40-22 CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER ............................................................. 40-27 CONNECT ADAPTER TO TROUBLESHOOT MONITOR.............................................................. 40-27 CONNECT ADAPTER TO TROUBLESHOOT PUMP CONTROLLER ........................................... 40-29 CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL .......................................... 40-33 CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER........................................ 40-35 CONNECT ADAPTER TO TROUBLESHOOT ENGINE INTERMEDIATE CONNECTOR .............. 40-36 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH .............................................. 40-38 DISCONNECT AND CONNECT DEUTSCH CONNECTOR........................................................... 40-38 DISCONNECT AND CONNECT BOSCH CONNECTOR ............................................................... 40-38 DISCONNECT AND CONNECT AMP CONNECTOR .................................................................... 40-39 DISCONNECT AND CONNECT SUMITOMO CONNECTOR ........................................................ 40-40 DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL ............................................... 40-41 DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR ............. 40-41 DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR .............................................................. 40-42 DISCONNECT AND CONNECT FRAMATOME CONNECTOR ..................................................... 40-42 DISCONNECT AND CONNECT TYCO CONNECTOR .................................................................. 40-43 DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE.................................... 40-44 PROCEDURE FOR TROUBLESHOOTING .......................................................................................... 40-45 INFORMATION DESCRIBED IN TROUBLESHOOTING....................................................................... 40-46 DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS . 40-49 CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE...................................................... 40-52 CONNECTOR LAYOUT .......................................................................................................................40-126 CONNECTOR CONTACT IDENTIFICATION .......................................................................................40-132 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .........................................................................40-174 FUSE LOCATION AND CONNECTION TABLE ...................................................................................40-180 DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING ..............40-183 FAILURE CODES TABLE ....................................................................................................................40-185 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ............................................................40-193 FAILURE CODE [602KNX]...................................................................................................................40-193 FAILURE CODE [6AZ0ZG] ..................................................................................................................40-196 FAILURE CODE [879AKA]...................................................................................................................40-200 FAILURE CODE [879AKB]...................................................................................................................40-202 FAILURE CODE [879BKA]...................................................................................................................40-204 FAILURE CODE [879BKB]...................................................................................................................40-207 FAILURE CODE [879CKA]...................................................................................................................40-210 FAILURE CODE [879CKB]...................................................................................................................40-212 FAILURE CODE [879DKZ]...................................................................................................................40-214 FAILURE CODE [879EMC] ..................................................................................................................40-218 FAILURE CODE [879FMC] ..................................................................................................................40-220 FAILURE CODE [879GKX] ..................................................................................................................40-222 FAILURE CODE [989L00] ....................................................................................................................40-225 FAILURE CODE [989M00] ...................................................................................................................40-227 FAILURE CODE [989N00] ...................................................................................................................40-229 FAILURE CODE [AA10NX] ..................................................................................................................40-230 FAILURE CODE [AB00KE] ..................................................................................................................40-233 FAILURE CODE [B@BAZG] ................................................................................................................40-237 PC210-10M0, PC210LC-10M0
40-7
CONTENTS
40 TROUBLESHOOTING
FAILURE CODE [B@BAZK].................................................................................................................40-241 FAILURE CODE [B@BCZK] ................................................................................................................40-244 FAILURE CODE [B@BCNS] ................................................................................................................40-246 FAILURE CODE [B@BCQA]................................................................................................................40-250 FAILURE CODE [B@HANS] ................................................................................................................40-252 FAILURE CODE [CA111] .....................................................................................................................40-254 FAILURE CODE [CA115] .....................................................................................................................40-259 ENGINE Ne (CRANKSHAFT) SPEED SENSOR ..........................................................................40-265 FAILURE CODE [CA122] .....................................................................................................................40-267 FAILURE CODE [CA123] .....................................................................................................................40-270 FAILURE CODE [CA131] .....................................................................................................................40-274 FAILURE CODE [CA132] .....................................................................................................................40-277 FAILURE CODE [CA144] .....................................................................................................................40-281 FAILURE CODE [CA145] .....................................................................................................................40-285 FAILURE CODE [CA153] .....................................................................................................................40-289 FAILURE CODE [CA154] .....................................................................................................................40-293 FAILURE CODE [CA155] .....................................................................................................................40-297 FAILURE CODE [CA187] .....................................................................................................................40-299 FAILURE CODE [CA221] .....................................................................................................................40-302 FAILURE CODE [CA222] .....................................................................................................................40-305 FAILURE CODE [CA227] .....................................................................................................................40-308 FAILURE CODE [CA234] .....................................................................................................................40-311 FAILURE CODE [CA238] .....................................................................................................................40-313 FAILURE CODE [CA271] .....................................................................................................................40-316 FAILURE CODE [CA272] .....................................................................................................................40-319 FAILURE CODE [CA322] .....................................................................................................................40-321 FAILURE CODE [CA323] .....................................................................................................................40-325 FAILURE CODE [CA324] .....................................................................................................................40-329 FAILURE CODE [CA325] .....................................................................................................................40-333 FAILURE CODE [CA331] .....................................................................................................................40-337 FAILURE CODE [CA332] .....................................................................................................................40-341 FAILURE CODE [CA342] .....................................................................................................................40-345 FAILURE CODE [CA351] .....................................................................................................................40-350 FAILURE CODE [CA352] .....................................................................................................................40-355 FAILURE CODE [CA386] .....................................................................................................................40-358 FAILURE CODE [CA435] .....................................................................................................................40-360 FAILURE CODE [CA441] .....................................................................................................................40-363 FAILURE CODE [CA442] .....................................................................................................................40-368 FAILURE CODE [CA449] .....................................................................................................................40-372 FAILURE CODE [CA451] .....................................................................................................................40-378 FAILURE CODE [CA452] .....................................................................................................................40-381 FAILURE CODE [CA488] .....................................................................................................................40-384 FAILURE CODE [CA553] .....................................................................................................................40-387 FAILURE CODE [CA559] .....................................................................................................................40-392 TEST LOW PRESSURE FUEL CIRCUIT DEVICES .....................................................................40-398 FAILURE CODE [CA689] .....................................................................................................................40-400 FAILURE CODE [CA731] .....................................................................................................................40-405 INSTALLATION POINTS OF CRANKSHAFT AND CAMSHAFT SPEED SENSORS ....................40-408 FAILURE CODE [CA757] .....................................................................................................................40-410 FAILURE CODE [CA778] .....................................................................................................................40-415 ENGINE Ne (CRANKSHAFT) SPEED SENSOR ..........................................................................40-420 FAILURE CODE [CA2185] ...................................................................................................................40-422 FAILURE CODE [CA2186] ...................................................................................................................40-424 FAILURE CODE [CA2249] ...................................................................................................................40-427 TEST LOW PRESSURE FUEL CIRCUIT DEVICES .....................................................................40-433 FAILURE CODE [CA2311] ...................................................................................................................40-435 FAILURE CODE [CA2555] ...................................................................................................................40-442 FAILURE CODE [CA2556] ...................................................................................................................40-446 40-8
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONTENTS
FAILURE CODE [D110KB]...................................................................................................................40-450 FAILURE CODE [D19JKZ] ...................................................................................................................40-453 FAILURE CODE [D1N0KA] ..................................................................................................................40-458 FAILURE CODE [D1N0KB] ..................................................................................................................40-460 FAILURE CODE [D1N0KY] ..................................................................................................................40-462 FAILURE CODE [D811MC] ..................................................................................................................40-463 FAILURE CODE [D862KA]...................................................................................................................40-464 FAILURE CODE [D8AQKR] .................................................................................................................40-466 FAILURE CODE [D8ALKA] ..................................................................................................................40-474 FAILURE CODE [D8ALKB] ..................................................................................................................40-478 FAILURE CODE [DA20MC] .................................................................................................................40-481 FAILURE CODE [DA22KK] ..................................................................................................................40-482 FAILURE CODE [DA25KP] ..................................................................................................................40-487 FAILURE CODE [DA26KP] ..................................................................................................................40-491 FAILURE CODE [DA29KQ]..................................................................................................................40-497 FAILURE CODE [DA2LKA] ..................................................................................................................40-502 FAILURE CODE [DA2LKB] ..................................................................................................................40-506 FAILURE CODE [DA2QKR] .................................................................................................................40-509 FAILURE CODE [DA2RKR] .................................................................................................................40-518 FAILURE CODE [DAF0MB] .................................................................................................................40-526 FAILURE CODE [DAF0MC] .................................................................................................................40-527 FAILURE CODE [DAF9KQ]..................................................................................................................40-528 FAILURE CODE [DAFGMC] ................................................................................................................40-530 FAILURE CODE [DAFLKA] ..................................................................................................................40-531 FAILURE CODE [DAFLKB] ..................................................................................................................40-535 FAILURE CODE [DAFQKR] .................................................................................................................40-538 FAILURE CODE [DAZ9KQ]..................................................................................................................40-547 FAILURE CODE [DAZQKR] .................................................................................................................40-549 FAILURE CODE [DB2QKR] .................................................................................................................40-557 FAILURE CODE [DDPAKA] .................................................................................................................40-566 FAILURE CODE [DGH2KA] .................................................................................................................40-569 FAILURE CODE [DGH2KB] .................................................................................................................40-572 FAILURE CODE [DHA4KA]..................................................................................................................40-575 FAILURE CODE [DHE5MA] .................................................................................................................40-578 FAILURE CODE [DHPAMA].................................................................................................................40-582 FAILURE CODE [DHPBMA].................................................................................................................40-586 FAILURE CODE [DHS3MA] .................................................................................................................40-590 FAILURE CODE [DHS4MA] .................................................................................................................40-594 FAILURE CODE [DHS8MA] .................................................................................................................40-598 FAILURE CODE [DHS9MA] .................................................................................................................40-602 FAILURE CODE [DHSAMA].................................................................................................................40-606 FAILURE CODE [DHSBMA].................................................................................................................40-610 FAILURE CODE [DHSCMA] ................................................................................................................40-614 FAILURE CODE [DHSDMA] ................................................................................................................40-618 FAILURE CODE [DHSFMA].................................................................................................................40-622 FAILURE CODE [DHSGMA] ................................................................................................................40-626 FAILURE CODE [DHSHMA] ................................................................................................................40-630 FAILURE CODE [DHSJMA] .................................................................................................................40-634 FAILURE CODE [DJG1KX] ..................................................................................................................40-638 FAILURE CODE [DKR0MA] .................................................................................................................40-642 FAILURE CODE [DKR1MA] .................................................................................................................40-646 FAILURE CODE [DKR2MA] .................................................................................................................40-650 FAILURE CODE [DKR2NX] .................................................................................................................40-654 FAILURE CODE [DLM5KA]..................................................................................................................40-656 FAILURE CODE [DLM5MB] .................................................................................................................40-660 FAILURE CODE [DR21KX] ..................................................................................................................40-664 FAILURE CODE [DR31KX] ..................................................................................................................40-667 FAILURE CODE [DV20KB] ..................................................................................................................40-668 PC210-10M0, PC210LC-10M0
40-9
CONTENTS
40 TROUBLESHOOTING
FAILURE CODE [DW43KA] .................................................................................................................40-671 FAILURE CODE [DW43KB] .................................................................................................................40-674 FAILURE CODE [DW43KY] .................................................................................................................40-677 FAILURE CODE [DW45KA] .................................................................................................................40-679 FAILURE CODE [DW45KB] .................................................................................................................40-683 FAILURE CODE [DW45KY] .................................................................................................................40-687 FAILURE CODE [DW91KA] .................................................................................................................40-690 FAILURE CODE [DW91KB] .................................................................................................................40-692 FAILURE CODE [DW91KY] .................................................................................................................40-695 FAILURE CODE [DW97KA] .................................................................................................................40-697 FAILURE CODE [DW97KB] .................................................................................................................40-699 FAILURE CODE [DW97KY] .................................................................................................................40-702 FAILURE CODE [DWA2KA] .................................................................................................................40-704 FAILURE CODE [DWA2KB] .................................................................................................................40-706 FAILURE CODE [DWA2KY] .................................................................................................................40-709 FAILURE CODE [DWK0KA].................................................................................................................40-711 FAILURE CODE [DWK0KB].................................................................................................................40-713 FAILURE CODE [DWK0KY].................................................................................................................40-716 FAILURE CODE [DWK2KA].................................................................................................................40-718 FAILURE CODE [DWK2KB].................................................................................................................40-720 FAILURE CODE [DWK2KY].................................................................................................................40-723 FAILURE CODE [DWK8KA].................................................................................................................40-725 FAILURE CODE [DWK8KB].................................................................................................................40-727 FAILURE CODE [DWK8KY].................................................................................................................40-730 FAILURE CODE [DWN5KA].................................................................................................................40-732 FAILURE CODE [DWN5KB].................................................................................................................40-735 FAILURE CODE [DWN5KY].................................................................................................................40-738 FAILURE CODE [DXA8KA]..................................................................................................................40-740 FAILURE CODE [DXA8KB]..................................................................................................................40-743 FAILURE CODE [DXA9KA]..................................................................................................................40-747 FAILURE CODE [DXA9KB]..................................................................................................................40-750 FAILURE CODE [DXE0KA]..................................................................................................................40-754 FAILURE CODE [DXE0KB]..................................................................................................................40-756 FAILURE CODE [DXE4KA]..................................................................................................................40-759 FAILURE CODE [DXE4KB]..................................................................................................................40-761 FAILURE CODE [DXE4KY]..................................................................................................................40-764 FAILURE CODE [DXE5KA]..................................................................................................................40-766 FAILURE CODE [DXE5KB]..................................................................................................................40-768 FAILURE CODE [DXE6KA]..................................................................................................................40-771 FAILURE CODE [DXE6KB]..................................................................................................................40-773 FAILURE CODE [DY20KA] ..................................................................................................................40-776 FAILURE CODE [DY20MA]..................................................................................................................40-780 FAILURE CODE [DY2CKB]..................................................................................................................40-784 FAILURE CODE [DY2DKB]..................................................................................................................40-789 FAILURE CODE [DY2EKB]..................................................................................................................40-792 FAILURE CODE [F@BBZL] .................................................................................................................40-795 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ..................................................................40-798 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .......................................................40-798 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK.................................................................40-808 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ...........................................................40-812 E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP ......40-816 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING...................................................................................................................................................40-821 E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW...........................................................................40-826 E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW.........................................................40-828
40-10
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONTENTS
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION ........ .........................................................................................................................................................40-830 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION .40-832 E-10 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION.... .........................................................................................................................................................40-834 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION ..............40-836 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION ....................40-840 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION ......40-841 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.................................................................................................................................................40-842 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 40-844 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION.................................................................................................................................................40-845 E-17 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM ..........................................40-847 E-18 FUEL GAUGE INDICATES INCORRECT LEVEL ........................................................................40-850 E-19 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM.......40-852 E-20 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE .....................40-853 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM........ .........................................................................................................................................................40-855 E-22 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE ...........40-858 E-23 MACHINE MONITOR SHOWS INCORRECT MODEL ................................................................40-860 E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ...............................40-861 E-25 FUNCTION SWITCH DOES NOT OPERATE ..............................................................................40-862 E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) .....................40-863 E-27 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED .........................................................................................................40-865 E-28 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION ..............................................................................................................................................40-866 E-29 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED ...........................................................................................................................................40-869 E-30 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED .......................................................................................................................................40-870 E-31 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED. .........................................................................................................................................................40-871 E-32 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED........................40-872 E-33 ALARM BUZZER DOES NOT STOP ...........................................................................................40-874 E-34 SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION......40-875 E-35 MACHINE DOES NOT CHANGE TO SERVICE MODE...............................................................40-876 E-36 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE.....................................40-877 E-37 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK............................................40-881 E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED .........................................................................................................................................................40-883 E-39 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON ...................40-887 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY .......................................................................................................................40-890 E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED.......................................40-894 E-42 TRAVEL ALARM DOES NOT SOUND ........................................................................................40-896 E-43 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS..................................................40-899 E-44 HORN DOES NOT SOUND.........................................................................................................40-901 E-45 HORN DOES NOT STOP............................................................................................................40-905 E-46 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED ........ .........................................................................................................................................................40-907 E-47 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED ....................................40-908 E-48 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED ...... .........................................................................................................................................................40-911 E-49 BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION .........................40-914 E-50 BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION .......................40-915 E-51 ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION .......................40-916 PC210-10M0, PC210LC-10M0
40-11
CONTENTS
40 TROUBLESHOOTING
E-52 ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION ...................................40-917 E-53 BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION..............40-918 E-54 BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION ..............40-919 E-55 SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION....................................40-920 E-56 TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION ..................................40-921 E-57 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION ...................40-922 E-58 ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................................................40-925 E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ..........................................................40-927 E-60 QUICK COUPLER DOES NOT WORK........................................................................................40-929 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) ..............................40-934 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE) ........................................40-934 H-1 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK............................................40-935 H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER ............................40-937 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR.....................................................40-950 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ...........................................40-955 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ...........................................................40-957 H-6 BOOM SPEED OR POWER IS LOW ............................................................................................40-966 H-7 Arm speed or power is low. ...........................................................................................................40-978 H-8 BUCKET SPEED OR POWER IS LOW.........................................................................................40-989 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION ..............................................40-999 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE ...............................................................................40-1003 H-11 HYDRAULIC DRIFT OF ARM IS LARGE ..................................................................................40-1005 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE............................................................................40-1009 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES ..........................................................................................................................................40-1012 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE ........................................................................40-1014 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE ................................40-1021 H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED...................................................................40-1024 H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED ............................................40-1026 H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER........................................................................................................................................40-1028 H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 40-1030 H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW ..40-1031 H-21 MACHINE DOES NOT TRAVEL STRAIGHT .............................................................................40-1032 H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW....................................40-1043 H-23 TRAVEL SPEED IS SLOW........................................................................................................40-1058 H-24 ONE OF TRACKS DOES NOT RUN .........................................................................................40-1069 H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST .........40-1078 H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT................................................................40-1081 H-27 SWINGS ONLY IN ONE DIRECTION........................................................................................40-1086 H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) ... .......................................................................................................................................................40-1089 H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION ................40-1096 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT).....................................................................................................................................40-1100 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) ............................................................................................40-1102 H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS........................................................40-1106 H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS ..........................40-1108 H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)...... 40-1111 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED).. 40-1113 H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE) ........................... 40-1117 H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN ................................................................ 40-1119
40-12
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PRECAUTIONS FOR TROUBLESHOOTING
RELATED INFORMATION TO TROUBLESHOOT PRECAUTIONS FOR TROUBLESHOOTING •
Before starting the troubleshooting, repair and maintenance, read and understand the precautions for safety described in the materials that follow. •
"SAFETY" in the Operation and Maintenance Manual
•
"FOREWORD, SAFETY, BASIC INFORMATION" in the shop manual
•
Safety signs attached to the machine and engine
•
The troubleshooting procedures describe the most effective method and judgment for finding the cause of abnormality and failure, and deciding the remedy. If you followed the description but could not find the cause, examine the phenomenon to find the correct method to troubleshoot and resolve the problem.
•
If the abnormality or failure is resolved temporarily, it can occur again unless its root cause is resolved. Always find the root cause and take the remedy for it.
PC210-10M0, PC210LC-10M0
40-13
SEQUENCE OF EVENTS IN TROUBLESHOOTING
40 TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING 1.
Hear from the customer to collect information of the failure. 1) When you accept a repair order, hear from the customer to collect the information that follows.
2)
3)
2.
•
Customer's name and company's name
•
Machine model and serial number
•
Machine working hours
•
Machine working place and address of worksite
If possible, hear from the customer to collect the information that follows. Estimate the contents of the failure and repair. •
Contents of abnormality and failure, or failure code shown on machine monitor
•
Operation conditions of machine when the abnormality or failure occurs
•
Are there problems other than the abnormality or failure which is informed?
•
Were unusual symptoms noticed on the machine before the abnormality or failure occurred?
•
Did the abnormality or failure occur suddenly? Was the machine in a bad condition for some time?
•
If the machine was in a bad condition for some time, what was it like actually?
•
Were repairs or replacements made before the abnormality or failure occurred?
•
Did a similar abnormality or failure occur in the past?
If possible, check the information that follows with KOMTRAX. •
Machine working hours
•
Machine working place
•
Failure code and content
•
Abnormality record
•
Replacement record of consumable parts
•
Record of working conditions until the abnormality or failure occurred
Estimate the cause of the failure. Before going to the worksite, read the shop manual. Estimate the cause of the abnormality or failure from the information collected in step 1.
3.
Prepare the tools to troubleshoot the estimated cause and replacement parts. Prepare tools and replacement parts to troubleshoot the estimated cause in the field. Also, prepare items for the place. For details, see "T-BRANCH BOX AND T-BRANCH ADAPTER TABLE". If multiple causes are estimated, prepare items for all cases.
4.
5.
6.
Carry the tools and replacement parts with you. Visit the worksite of machine. Check the machine. •
Check the serial number of the machine on which you are informed to have an abnormality or failure.
•
Check the machine working hours with the service meter.
Hear from the customer the detailed situation when the abnormality or failure occurred. •
Were unusual symptoms noticed on the machine before the abnormality or failure occurred?
•
Did the abnormality or failure occur suddenly? Was the machine in a bad condition for a while? Were symptoms noticed?
•
Were repairs or replacements made before the abnormality or failure occurred?
If possible, drive and operate the machine. Reproduce the abnormality or failure. Judge the items that follow. •
Is it caused by abnormality or failure?
•
Is it caused by the handling method or operating method?
In the cases below, go to step 7 even if you cannot reproduce the problem. • Cases you cannot reproduce 40-14
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
7.
8.
•
It is judged that the failure possibly increases by reproducing
•
It cannot be possible to reproduce safely
Before starting the troubleshooting, check the machine for the points that follow. Check even if you judged that the problem is caused by the handling method or operating method in step 6. •
Are there abnormal symptoms other than informed?
•
Items of "Check before starting"
•
Items which can be checked by appearance
Troubleshoot to find the cause of the failure. •
9.
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Check the points that follow for the failure code recorded in the abnormality record. •
Is it associated with the estimated cause of the abnormality or failure?
•
Is it recorded at the same time of the occurrence of abnormality or failure?
•
Is it recorded repeatedly?
•
Follow the description and flow in the troubleshooting chapter to use the correct method for the contents of failure and failure code to troubleshoot.
•
Check in the order that follows. 1) At first, check the items which can be accessed and judged easily. 2)
Next, check the items which have a high possibility of being the cause of the failure.
3)
Then, check the associated contents.
Based on the troubleshooting results, do one of the tasks that follows. •
Repair or replacement of parts
•
Repair with the machine brought to the plant
PC210-10M0, PC210LC-10M0
40-15
CHECKS BEFORE TROUBLESHOOTING
40 TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING WALK-AROUND CHECK No.
Item
Standard
Remedy
1
Check unusual noise and smell
-
Repair
2
Check around engine and remove dirt
-
Remove
3
Check around engine for water leakage
-
Repair
4
Check around engine for oil leakage
-
Repair
5
Check fuel line for leakage
-
Repair
6
Check radiator and remove dirt
-
Remove.
7
Check around muffler and remove dirt
-
Remove.
8
Check around muffler for exhaust gas leakage
-
Repair
9
Check hydraulic equipment, hydraulic tank, hoses, joints for oil leakage
-
Repair
10
Check work equipment, cylinders, linkages and hoses
-
Repair
11
Check undercarriage
-
Repair
12
Check handrails and steps
-
Repair
13
Check and clean machine monitor display
-
Clean or repair
14
Check and clean rearview camera
-
Clean or repair
15
Check and clean rearview mirrors
-
Cleaning or repair
16
Check seat belt and mounting hardware
-
Replace
TEST ENGINE RELATED PARTS No.
Item
Standard
Remedy
1
Check fuel level
Fuel gauge in the green range
Add fuel
2
Drain foreign material in fuel
-
Drain foreign material
3
Check water separator
Water or sediment not accumulated in transparent cup
Drain water and sediment
4
Check fuel prefilter
Replacement interval not passed
Replace
5
Check fuel main filter
Replacement interval not passed
Replace
6
Check engine oil level
Between H and L
Add or drain engine oil
7
Check coolant level
Between FULL and LOW
Add or drain coolant
8
Check if air cleaner is clogged
Air cleaner clogging caution lamp is not Clean or replace lit
9
Bleed air from fuel system
-
Bleed air
No. Item
Standard
Remedy
1
Between H and L
Add or drain hydraulic oil
TEST WORK EQUIPMENT AND UNDERCARRIAGE
Check hydraulic oil level
40-16
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
No. Item
Standard
Remedy
2
Clean hydraulic tank strainer
-
Clean
3
Check hydraulic filter
Replacement interval not passed
Replace.
4
Check swing machinery case oil level
Between H and L
Add or drain power train oil
5
Check damper case oil level
Oil level is close to the lower edge of the plug hole
Add or drain power train oil
6
Check final drive case oil level
Down to 10 mm from the lower edge of Add or drain powthe plug hole er train oil
7
Bleed air from hydraulic system
-
Bleed air
No. Item
Standard
Remedy
1
Check battery terminals for looseness and corrosion
-
Retighten or replace
2
Check battery electrolyte level
Between UPPER LEVEL (highest elec- Add or remove putrolyte level) and LOWER LEVEL (low- rified water est electrolyte level)
3
Check battery voltage
Min. 24V
Charge or replace
4
Check battery electrolyte specific gravity
Min. 1.26
Charge or replace
5
Check alternator terminal for looseness and corrosion
-
Retighten or replace
6
Check alternator voltage
27.5 to 29.5V
Repair or replace
7
Check starting motor terminals for looseness and corrosion
Retighten or replace
8
Check wiring harness for discoloration, burn and cover peeling
-
Repair or replace
9
Check wiring harness installation
-
Repair
10
Check ground terminal for looseness and connection
-
Retighten or repair
11
Check connector for looseness and connection
-
Repair or replace
12
Check connector mounting bolt for looseness and connection
Retighten
13
Check connector pins for corrosion, bends and deformation
-
Repair or replace
14
Check connector for entry of water and foreign material
-
Dry, clean or replace
15
Check of wiring harness for open or short circuit
-
Repair or replace
16
Check fuse
-
Replace
17
Check battery relay operation sound
-
Replace
18
Check and clean camera (machines with camera) -
CHECK ELECTRIC EQUIPMENT
PC210-10M0, PC210LC-10M0
Repair or replace
40-17
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
40 TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING WALK-AROUND CHECK Before you start the engine, look around and under the machine. Check the points that follow. k
Combustible materials accumulated around the exhaust pipe, muffler, turbocharger, or other high temperature engine parts or the battery, and leakage of fuel or oil will cause the machine to catch fire. Check carefully. If an abnormality is found, always repair it.
CHECK UNUSUAL NOISE AND SMELL Check for unusual noise and odor. For some causes, if the machine is operated under such condition, the machine can suffer damage. So, if there is an unusual noise or smell, immediately make a repair.
CHECK AROUND ENGINE AND REMOVE DIRT Check for dirt accumulated around the engine. Check for combustible materials (dry leaves, twigs, etc.) around the battery, exhaust pipe, muffler, turbocharger, or other high temperature parts. If dirt or combustible materials are found, remove them.
CHECK AROUND ENGINE FOR WATER LEAKAGE Check the coolant system for leakage. If an abnormality is found, repair it.
CHECK AROUND ENGINE FOR OIL LEAKAGE Check the engine for oil leakage. If an abnormality is found, repair it.
CHECK FUEL LINE FOR LEAKAGE Check for fuel leakage. Check the hoses and tubes for damage. If an abnormality is found, repair it.
CHECK RADIATOR AND REMOVE DIRT Check for accumulated dirt and combustibles (dry leaves, twigs, etc.) around the radiator. If dirt or combustible materials are found, remove them.
CHECK AdBlue/DEF LINE FOR LEAKAGE Check for oil leakage from AdBlue/DEF tank, pump, injector, hose or connections. If an abnormality is found, repair it.
CHECK AROUND MUFFLER AND REMOVE DIRT Check for accumulated dirt and combustibles (dry leaves, twigs, etc.) around the muffler. If dirt or combustible materials are found, remove them.
Check around muffler for exhaust gas leakage Check the piping between the turbocharger and KDPF, and the connecting parts of the muffler for leakage of exhaust gas (sticking of soot, etc.). If an abnormality is found, repair it.
CHECK HYDRAULIC EQUIPMENT, HYDRAULIC TANK, HOSES, JOINTS FOR OIL LEAKAGE Check the hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage. If an abnormality is found, repair it.
CHECK WORK EQUIPMENT, CYLINDERS, LINKAGES AND HOSES Check the work equipment, cylinders, linkage, and hoses for breakage and excessive wear. Check that the clearances are in their normal range. If an abnormality is found, repair it.
CHECK UNDERCARRIAGE Check the tracks, sprockets, idlers and guards for breakage and excessive wear. Also check the rollers for oil leakage. If an abnormality is found, repair it. If the bolts are loose, retighten them.
40-18
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
CHECK HANDRAILS AND STEPS Check the handrails and steps for breakage and deformation. If an abnormality is found, repair it. If the bolts are loose, retighten them.
CHECK AND CLEAN MACHINE MONITOR DISPLAY Check the display of the machine monitor for breakage. If an abnormality is found, repair it. If the surface of the display is dusty or dirty, wipe with a dry soft cloth.
CHECK AND CLEAN REARVIEW CAMERA Check the rearview camera and the camera mount for breakage and deformation. Check that the camera position is correct. If an abnormality is found, repair it. If the camera lens is dirty, wipe it with a dry soft cloth.
CHECK AND CLEAN REARVIEW MIRRORS Check the rearview mirror for breakage and deformation. If an abnormality is found, repair it. Clean the mirror surface. Adjust the mirror angle so that the rear of the machine can be seen from the operator's seat.
CHECK SEAT BELT AND MOUNTING HARDWARE Check the seat belt and mounting hardware (hook, lock, and hook mounting parts) for damage. If an abnormality is found, replace it.
TEST ENGINE RELATED PARTS Check fuel level Check that the fuel gauge (1) of the machine monitor is in the green range. If the level is in the red range, add fuel.
Drain foreign material in fuel Remote drain 1. Open the door on the right side of machine. 2.
Place a container under the drain hose (1) to catch the drained fuel.
3.
Turn the drain valve (2) to position (O). Discharge the sediment and water accumulated at the bottom together with fuel.
4.
When only clean fuel flows out, turn the drain valve (2) to the closed position (S).
5.
Close the door.
PC210-10M0, PC210LC-10M0
40-19
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
40 TROUBLESHOOTING
Direct drain 1. The drain port (3) is at the opening in the undercover under the fuel tank. 2. Place a container under the drain port (3) to catch the drained fuel. 3. Turn the drain valve (4) to position (O). Discharge the sediment and water accumulated at the bottom together with fuel. 4. When only clean fuel flows out, turn the drain valve (4) to the closed position (S).
Check water separator Check that water and sediment are not accumulated in the transparent cup (1) of the water separator. If water and sediment are accumulated, open the drain valve (3) to drain.
Check fuel prefilter Check that the replacement interval of the fuel prefilter cartridge (initial setting is 500 hours) is not passed. If the replacement interval is passed, replace.
Check fuel main filter Check that the replacement interval of the fuel main filter cartridge (initial setting is 1000 hours) is not passed. If the replacement interval is passed, replace.
Check engine oil level Check that the engine oil level is between H and L on the dipstick for the oil pan. If the level is out of the range, add or drain engine oil.
Check coolant level Check that the coolant level is between FULL and LOW of the reservoir tank. If the level is out of the range, add or drain coolant.
40-20
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
Check if air cleaner is clogged Check that the air cleaner clogging caution lamp (1) of the machine monitor is not lit. If it is lit, clean or replace the air cleaner element.
*
Bleed air from fuel system Bleed air from the fuel system. For the method of air bleeding, see TESTING AND ADJUSTING, "BLEED AIR FROM FUEL SYSTEM".
TEST WORK EQUIPMENT AND UNDERCARRIAGE CHECK HYDRAULIC OIL LEVEL Check that the hydraulic oil level is between H and L of the site gauge of the hydraulic oil tank. If the oil level is out of the range, add or drain hydraulic oil.
CLEAN HYDRAULIC TANK STRAINER After every 2000 hours of operation, remove any dirt stuck to the hydraulic tank strainer. Wash the strainer in flushing oil.
CHECK HYDRAULIC FILTER Check that the replacement interval of the hydraulic oil filter element (initial setting is 1000 hours) has not passed. If the replacement interval is passed, replace.
CHECK SWING MACHINERY CASE OIL LEVEL Check that the oil level in the swing machinery case is between H and L on the dipstick. If the oil level is out of the range, add or drain power train oil.
PC210-10M0, PC210LC-10M0
40-21
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
40 TROUBLESHOOTING
CHECK DAMPER CASE OIL LEVEL Check that the oil level in the damper case is close to the lower edge of the plug (G) hole. If the oil level is low, add power train oil. If the oil level is too high, drain.
CHECK FINAL DRIVE CASE OIL LEVEL Check that the oil level in the final drive case is between the lower edge of the plug (F) hole and 10 mm below. If the oil level is low, add power train oil. If the oil level is too high, drain.
BLEED AIR FROM HYDRAULIC SYSTEM Bleed air from the hydraulic system. For bleeding air from the hydraulic system, see TESTING AND ADJUSTING, "BLEED AIR FROM HYDRAULIC CIRCUIT".
CHECK ELECTRIC EQUIPMENT k
For inspection items other than those tested on a live wire, always turn the starting switch to the OFF position. Also, turn the battery disconnect switch to the OFF position and remove the switch key.
Check battery terminals for looseness and corrosion Check the battery terminals (A) for looseness and corrosion. If the terminal is corroded, replace it.
40-22
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
Check battery electrolyte level Check the battery electrolyte level by one of the methods below. If the battery electrolyte level is high, remove battery electrolyte. •
When electrolyte level can be checked through the side face of the battery •
•
Check that the battery electrolyte level is between UPPER LEVEL (highest electrolyte level) and LOWER LEVEL (lowest electrolyte level).
When electrolyte level cannot be checked through the side face of the battery •
Remove the cap on the upper face of battery. Look down on the battery. Check that the electrode plates look distorted like (A). REMARK • (A) Correct level: Since the electrolyte level reaches the bottom of the sleeve (6), the electrode plate looks distorted by the surface tension. • (B) Low level: Since the electrolyte level does not reach the bottom of the sleeve (6), the electrode plates look straight.
Check battery voltage Check the battery voltage with the engine stopped. When the voltage is 24 V or above, it is normal. If the battery voltage is low, charge or replace the battery.
Check battery electrolyte specific gravity Check the specific gravity of the battery electrolyte. When the specific gravity is 1.26 or above, it is normal. If the specific gravity is low, charge or replace the battery.
Check alternator terminal for looseness and corrosion Check the terminals B (1), E (2), and R (3) of the alternator for looseness and corrosion. If the terminals are loose, retighten them. If the terminal is corroded, replace it.
PC210-10M0, PC210LC-10M0
40-23
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
40 TROUBLESHOOTING
Check alternator voltage •
Connect the red (+) lead wire of the multimeter to terminal B (1) of the alternator.
•
Connect the black (-) lead wire of the multimeter to the ground terminal (T11).
•
Start the engine.
•
After warm-up operation, check the alternator voltage with the engine running at a medium speed or above. When the voltage is between 27.5 and 29.5 V, it is normal. If the voltage is out of range, make a repair or replacement.
Check starting motor terminals for looseness and corrosion Check terminals B (1) and C (2) of the starting motor for looseness and corrosion. If the terminals are loose, retighten them. If the terminal is corroded, replace it.
Check wiring harness for discoloration, burn and cover peeling •
Check the wiring harnesses and cables for discoloration, burns, and damage or peeled material of the insulation. If an abnormality is found, make repair or replacement.
•
If there is a discoloration or if the material is burned, there can be a short circuit or ground fault. Check the applicable circuit.
40-24
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
Check wiring harness installation Check that the installation condition of the wiring harness is as follows. •
The wiring harness is not released from the clamp.
•
The wiring harness is not sagged.
•
The wiring harness is not tensioned.
NOTICE Especially, carefully check around hot parts and movable parts. If the installation condition is defective, fix the wiring harness again. When fixing the wiring harness again, provide a sufficient play so that the wiring harness does not receive excessive force while the machine moves. Also, set the wiring harness not to contact other parts at where the harness is not protected by a tube.
Check ground terminal for looseness and connection •
Check the mounting bolts and nuts of ground terminals for looseness. If they are loose, retighten them.
•
Check the contact faces between the ground terminal and the mounting place on the chassis are free of rust and other non-conductive foreign materials. If there are rust or foreign materials, remove them.
•
For the position of each ground terminal, see "CONNECTOR LAYOUT".
Check connector for looseness and connection •
Pull the male and female of connector by hand. Check that they are not loose. If loose, securely connect the connector. If the connector is unlocked, lock it. NOTICE Do not pull the electric cable by hand. It can cause a defective contact or open circuit.
•
Check that the lock part of connector and the housing are free of cracks. If an abnormality is found, replace it.
Check connector mounting bolt for looseness and connection •
Check the mounting bolts (2) (2 pieces) of the engine controller connector for looseness. If they are loose, retighten them.
•
Tool: Hexagonal socket (or hexagonal wrench)
•
Bolt (2): Width across flats 5 mm, M6
Check connector pins for corrosion, bends and deformation •
Disconnect the connector. Check the items below. If there are abnormal pins, make a repair or replacement. •
The pins must be free of corrosion and bends.
•
There must be no pins retracted than other pins.
PC210-10M0, PC210LC-10M0
40-25
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
• •
40 TROUBLESHOOTING
Female pins must not be widened.
If the pin is not shiny, there can be a defective contact caused by corrosion and oxidation of the contact surface. Apply contact restorer. Connect and disconnect the connector for 10 times or so until the pins become shiny.
Check connector for entry of water and foreign material •
Disconnect the connector. Check for entry of water or foreign material (soil or dust) in the connector.
•
If water or foreign material is found inside the connector, the seals can be defective. Check the seals for damage. If you find any abnormalities, make a repair or replacement.
•
Wipe off the water entered inside the connector with a dry cloth. Dry it with a drier. Wipe off the foreign material with a dry cloth or blow off with air.
Check wiring harness for open or short circuit •
Check the connection between the connector and the wiring harness. If there are disconnections like (A), make a repair or replacement of the wiring harness or connector.
•
Check that the wiring harness does not contact with adjacent pins by defective crimping of pins. If they are contacted to each other, make a repair or replacement of the wiring harness or connector.
Check fuse Check the fuses, fusible links and slow-blow fuses for the items that follow. If an abnormality is found, replace it. For the installation position and capacity, see "FUSE LOCATION AND CONNECTION TABLE". •
They must have the specified capacity.
•
They must have no open circuits.
•
They must be free of corrosion.
•
The installation must not be loose.
NOTICE When replacing a fuse, fusible link, or slow-blow fuse, always replace with the one of the specified capacity.
Check battery relay operation sound Turn the starting switch ON and OFF. Check if an operation sound is heard from the battery relay. If the operation sound is not heard, replace the battery relay. REMARK Open the side cover on the left side of the machine. You can hear the sound easier.
40-26
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER To troubleshoot the electrical system of each controller, connect the adapter for troubleshooting to the connector by the procedure that follows. k k k k
Place the machine on a level ground. Lower the work equipment to the ground in a stable position. Set the work equipment lock lever to the LOCK position. Turn the starting switch to the OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, BATTERY DISCONNECT SWITCH.)
CONNECT ADAPTER TO TROUBLESHOOT MONITOR Front window assembly 1. Install the front (lower) window (2).
2.
Release the lock. Close the front window assembly.
Panel 3. Install the panel (4) with the bolts (3) (2 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (3): Width across flats 10 mm, M6 Bolt (3): 11.8 to 14.7 Nm {1.2 to 1.5 kgm}
PC210-10M0, PC210LC-10M0
40-27
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
40 TROUBLESHOOTING
Cover 4. Remove the cover (5).
5.
Remove the bolts (6) (3 pieces). Remove the cover (7). Tool: Hexagonal wrench Hexagonal socket head bolt (6): Width across flats 4 mm, M6
6.
Disconnect connector P31 (8). Remove the cover (7).
7.
Remove the bolt (9). Remove the duct (10). Tool: Impact wrench, socket Bolt (9): Width across flats 10 mm, M6
40-28
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
8.
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
Insert a flat-head screwdriver in the slit (a) and pull it upward. Remove the cover (11) while avoiding the lug (b). REMARK The cover (11) has a tab (c) on the back side to hold the cover (11). Tool: Flat-head screwdriver
INSTALL MACHINE MONITOR ASSEMBLY Machine monitor assembly 1. Connect connectors CM02 (16), CM03 (17) and CM04 (18). Then connect connector CM01 (15).
CONNECT ADAPTER TO TROUBLESHOOT PUMP CONTROLLER REMOVE OPERATOR SEAT Operator's seat 1. Pull the lever (1). Move the operator's seat (2) forward.
PC210-10M0, PC210LC-10M0
40-29
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
40 TROUBLESHOOTING
Cover 2. Open the cover (1).
3.
Remove the bolts (2) (5 pieces). Tool: Impact wrench, socket Bolt (2): Width across flats 10 mm, M6
4.
Disconnect the hose (3). Remove the box (4).
5.
Remove the bolts (5) (2 pieces). Remove the screw (6). Tool: Impact wrench, socket, extension bar (300 mm), Phillips screwdriver Bolt (5): Width across flats 10 mm, M6
6.
Disconnect connector M13 (8) behind the box (7). Remove the box (7).
40-30
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
7.
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
Remove the bolts (9) (3 pieces). Remove the cover (10). NOTICE Be careful not to let it interfere with the connectors and harnesses behind the cover (10). Tool: Impact wrench, socket Bolt (9): Width across flats 10 mm, M6
8.
Remove the bolts (11) (7 pieces). Tool: Impact wrench, socket Bolt (11): Width across flats 12 mm, M8
9.
Disconnect connector M04 (13) behind the cover (12). Remove the cover (12).
10. Remove the bolts (7) (4 pieces). Remove the pump controller assembly (8). Tool: Impact wrench, socket Bolt (7): Width across flats 12 mm, M8
11. Disconnect connectors CP01 (5) and CP02 (6) with the procedure below.
PC210-10M0, PC210LC-10M0
40-31
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
1)
While you push the lock (L1), turn the lock (L2) to the opposite side.
2)
The slider (B) comes out. The lock is released.
3)
Disconnect connectors CP01 (5) and CP02 (6).
40 TROUBLESHOOTING
Reference: Procedure for removing the connector cover (1) 1. Cut the band (2). 2.
Move the lever (3) upward.
3.
Lightly push part (A) of the connector cover (1) from 2 sides to release the claw (B).
4.
Since there is a claw (C), move the connector cover (1) in an arc to remove it.
REMARK The figure on the right shows the connector with the connector cover (1) removed.
40-32
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
CONNECT ADAPTER TO TROUBLESHOOT KOMTRAX TERMINAL REMOVE OPERATOR SEAT Operator's seat 1. Pull the lever (1). Move the operator's seat (2) forward.
Cover 2. Open the cover (1).
3.
Remove the bolts (2) (5 pieces). Tool: Impact wrench, socket Bolt (2): Width across flats 10 mm, M6
4.
Disconnect the hose (3). Remove the box (4).
PC210-10M0, PC210LC-10M0
40-33
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
5.
40 TROUBLESHOOTING
Remove the bolts (5) (2 pieces). Remove the screw (6). Tool: Impact wrench, socket, extension bar (300 mm), Phillips screwdriver Bolt (5): Width across flats 10 mm, M6
6.
Disconnect connector M13 (8) behind the box (7). Remove the box (7).
7.
Remove the bolts (9) (3 pieces). Remove the cover (10). NOTICE Be careful not to let it interfere with the connectors and harnesses behind the cover (10). Tool: Impact wrench, socket Bolt (9): Width across flats 10 mm, M6
8.
Remove the bolts (11) (7 pieces). Tool: Impact wrench, socket Bolt (11): Width across flats 12 mm, M8
9.
Disconnect connector M04 (13) behind the cover (12). Remove the cover (12).
40-34
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
KOMTRAX terminal 10. Disconnect the communication antenna GPS (14). 11. Disconnect connectors CK01 (15) and CK02 (16). 12. Disconnect the communication antenna (17).
CONNECT ADAPTER TO TROUBLESHOOT ENGINE CONTROLLER Undercover 1. Install the cover (4) with the bolts (3) (6 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (3): Width across flats 19 mm, M12 Bolt (3): 98 to 123 Nm {10.0 to 12.5 kgm}
Bracket 2. Remove the nuts (9) (2 pieces) and bolts (9a). Remove the bracket (10). Tool: Ratchet handle, socket Nut (9): Width across flats 10 mm, M6
Connector 3. Connect connectors CE02 (77) and CE03 (78).
PC210-10M0, PC210LC-10M0
40-35
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
4.
1)
While part (a) of the connector pushed, slide lock lever (b) in direction (c) to unlock.
2)
Disconnect the connector in direction (d).
40 TROUBLESHOOTING
Connect the adapters for troubleshooting to connectors ECM J1 (4) and ECM J2 (3).
CONNECT ADAPTER TO TROUBLESHOOT ENGINE INTERMEDIATE CONNECTOR Undercover 1. Install the cover (4) with the bolts (3) (6 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (3): Width across flats 19 mm, M12 98 to 123 Nm {10.0 to 12.5 kgm}
Bracket 2. Remove the nuts (2 pieces). Remove the bracket (10). Tool: Ratchet handle, socket Nut (9): Width across flats 10 mm, M6
Connector 3. Disconnect connector N08 (2) according to the procedure that follows.
40-36
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECT ADAPTER TO TROUBLESHOOT CONTROLLER
1)
Push lock (a) to release the lock.
2)
While part (a) of the connector is pushed, disconnect the connector in direction (b).
3)
Connect the adapter for troubleshooting to connector N08 (2).
PC210-10M0, PC210LC-10M0
40-37
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH
40 TROUBLESHOOTING
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH DISCONNECT AND CONNECT DEUTSCH CONNECTOR DISCONNECT DEUTSCH CONNECTOR Push the locks (a) and (b) from the both sides. Pull the female connector (2) straight to disconnect.
CONNECT DEUTSCH CONNECTOR 1.
Insert the female connector (2) straight in the direction of the arrow (x) until a click is heard when the lock engages.
2.
Check that the locks (a) and (b) are fully locked (not retracted). REMARK In the figure, lock (a) is retracted and not fully locked. Lock (b) is not retracted and fully locked. If not fully locked, insert the female connector (2) by moving in the direction of arrows (y) and (z) (downward and upward) in an arc.
DISCONNECT AND CONNECT BOSCH CONNECTOR DISCONNECT BOSCH CONNECTOR While the lock pushed, pull the connector straight to disconnect (a and b in the figure).
40-38
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH
CONNECT BOSCH CONNECTOR Insert straight until a click is heard when the lock engages (c and d in the figure).
REMARK The lock (e) on the harness side connector engages with the triangle notch (f) on the other side connector. There is the square guide (g) on the opposite side of the triangle notch (f). Be careful not to connect the connector in the 180° inverted position.
DISCONNECT AND CONNECT AMP CONNECTOR DISCONNECT AMP CONNECTOR Push to unlock. Pull the connector straight to disconnect (a and b in the figure).
CONNECT AMP CONNECTOR Insert the connector straight until a click is heard when the connector is locked (c and d in the figure). REMARK Be careful not to connect the connector in the 180° inverted position.
PC210-10M0, PC210LC-10M0
40-39
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH
40 TROUBLESHOOTING
DISCONNECT AND CONNECT SUMITOMO CONNECTOR DISCONNECT SUMITOMO CONNECTOR Push to unlock. Pull the connector straight to disconnect (a and b in the figure).
CONNECT SUMITOMO CONNECTOR Insert the connector straight until a click is heard when the connector is locked (c and d in the figure).
40-40
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR DISCONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR Pull to unlock. Pull the connector straight to disconnect (a and b in the figure).
CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR Insert the connector straight until a click is heard when the connector is locked (c and d in the figure).
PC210-10M0, PC210LC-10M0
40-41
DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR
40 TROUBLESHOOTING
DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR DISCONNECT AND CONNECT FRAMATOME CONNECTOR DISCONNECT FRAMATOME CONNECTOR 1.
Slide the lever in the direction of the arrow to unlock.
2.
Push the knob on the top. Pull the connector straight in the direction of the arrow to disconnect.
CONNECT FRAMATOME CONNECTOR 1.
While unlocked, insert the connector straight.
2.
Slide the lever in the direction of the arrow to lock.
40-42
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR
DISCONNECT AND CONNECT TYCO CONNECTOR DISCONNECT TYCO CONNECTOR 1.
Insert a flat-head screwdriver into the tab (b) of the lever (yellow) (a). Twist the screwdriver clockwise and counterclockwise to slowly release the lock.
2.
When the lock is halfway released, lightly hold the lever (yellow) (a) by hand, and twist the flat-head screwdriver clockwise and counterclockwise to release the lock fully. REMARK Be careful not to apply too much force as the lever (yellow) (a) can come off.
3.
Slide the lever (yellow) (a) in the direction of the arrow. REMARK Do not remove the lever (yellow) (a).
4.
Pull the connector straight to disconnect it.
CONNECT TYCO CONNECTOR 1.
While you pull up the lever (yellow) (a), insert the connector straight.
2.
Push in the lever (yellow) (a) until a sound is heard when locked.
PC210-10M0, PC210LC-10M0
40-43
DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE
40 TROUBLESHOOTING
DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE DISCONNECT CONNECTOR WITH HOUSING TO ROTATE 1.
Turn the housing (H1) counterclockwise.
2.
Pull the connector (6) straight in the direction of the arrow to disconnect. REMARK The housing (H1) stays on the wiring harness side.
CONNECT CONNECTOR WITH HOUSING TO ROTATE 1.
Align the grooves of the connector. Insert to the end.
2.
Turn the housing clockwise until a click is heard when the connector is locked.
40-44
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PROCEDURE FOR TROUBLESHOOTING
PROCEDURE FOR TROUBLESHOOTING Troubleshooting is classified as follows. Category
Content
Display of code
Troubleshooting by failure code
E mode H mode
Troubleshooting of electrical system Troubleshooting by phenomenon on the machine
S mode
Troubleshooting of hydraulic and mechanical systems Troubleshooting of engine
Operate the machine monitor. Open the "Mechanical System Abnormality Record" and the "Electrical system abnormality record" screen of the service menu. The occurred failure code is shown with an "E" in the left side of the Abnormality Record screen. •
If there is a failure code shown with an "E"
For all failure codes shown with an "E", do the applicable troubleshooting for the [code shown]. •
When there is no failure code shown with an "E"
There can be an abnormality which the machine cannot find by self-diagnosis. Troubleshoot the applicable [E mode], [H mode], or [S mode]. For details, see "SYMPTOM AND TROUBLESHOOTING NUMBERS". REMARK • For the operating method of machine monitor, see TESTING AND ADJUSTING, "CHECK ABNORMALITY RECORD (MECHANICAL SYSTEMS)" and "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)". • You can also check occurred failure codes on the "Current Abnormality" screen in the operator mode. However, these are limited to failure codes of action level "L01" to "L04".
CONFIRMATION OF REPAIR After the repair, check below. •
There is no failure code shown with an "E" in "Mechanical Sys Abnormality Record" and "Electrical Sys Abnormality Record"
•
There must be no "Symptom assumed to be a failure" shown in the "SYMPTOM AND TROUBLESHOOTING NUMBERS" table.
DELETE ABNORMALITY RECORD OF ELECTRICAL SYSTEMS After confirmation of repair, clear all the failure codes in the electrical system abnormality record. For the operating method, see TESTING AND ADJUSTING, "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)". REMARK The mechanical system abnormality record cannot be cleared.
PC210-10M0, PC210LC-10M0
40-45
INFORMATION DESCRIBED IN TROUBLESHOOTING
40 TROUBLESHOOTING
INFORMATION DESCRIBED IN TROUBLESHOOTING Troubleshooting describes information such as follows. Understand the contents fully before you start the troubleshooting.
INFORMATION SECTION ASSOCIATED WITH FAILURE Details of failure Action level
•
Contents of failure sensed by machine monitor or controller
•
Reason for machine monitor or controller to judge it as failure
Level of emergency for the abnormality that occurs on the machine •
Shown on the machine monitor as "-" or "L01" through "L04"
•
As the number is larger, the influence to the machine is larger.
Action of controller
Remedies to protect the system and equipment when the machine monitor or controller senses a failure
Phenomenon on machine
Failure phenomenon which occurs on the machine as a reaction to the response of the machine monitor or controller (see previous section).
Associated information
Information associated with the occurred failure and its troubleshooting
TROUBLESHOOTING PROCEDURE SECTION •
Example)
No.
1
Inspection item
Procedure of troubleshooting 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector XXX and connector YYY.
4.
Connect the T-adapter to the female side of each connector.
Open circuit 5. in wiring 6. harness
Judgment and remedy
Does the measurement result agree with the standard value?
Resistance
Measuring point and measurement condition
Standard value
Between XXX (female) (1) and YYY (female) (6)
Max. 1 Ω
Between XXX (female) (2) and YYY (female) (7)
Max. 1 Ω
NO
YES
2
40-46
Reconfirmation of inspection item
NO
1.
Do the inspection above again.
2.
Can you identify the cause by doing again?
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the resistance.
Item
•
The repair is completed. •
The XXX can be defective.
•
Replace the XXX.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
Inspection item
No.
Confirmation of repair
3
INFORMATION DESCRIBED IN TROUBLESHOOTING
Procedure of troubleshooting 1.
Turn the starting switch to the OFF position.
2.
Install and connect all the component parts.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
Judgment and remedy YES NO
Return to the first inspection item. The repair is completed.
(1) At first, check the equipment or wiring harness which could be the cause of the failure. After finding the cause of failure by YES/NO judgment on the inspection result, take necessary remedies. Go to "Confirmation of repair". (2) If the cause of failure cannot be identified after inspection of the equipment and wiring harness, do "Reconfirmation of inspection item". If the cause of failure cannot be identified after "Reconfirmation of inspection item", replace the equipment and controller on which inspection and diagnosis are difficult. (3) Check that the cause of failure is cleared by "Confirmation of repair". If the failure code is cleared, repair is completed. If not cleared, return to the first inspection item to do over again. REMARK •
Descriptions like "Between XXX (female) (1) and YYY (female) (6)" specifies a path as follows. Between pin No.1 on the female side of connector XXX and pin No.6 on the female side of connector YYY
•
Ground in descriptions like "Between ground and ..." means a place which has continuity to the frame (unpainted bolt, rust free bolt hole, etc.).
•
For some failure codes, the inspection order of the equipment and wiring harness can be different.
•
For the inspection and troubleshooting for the wiring harness, the order is basically as follows. 1) Open circuit in wiring harness •
"Open circuit" means an abnormal state that an electric cable (signal line, power source line, ground line) in the wiring harness has no continuity.
•
Measure the resistance of the electric cable between both ends of the target wiring harness.
2) Ground fault in wiring harness •
"Ground fault" means an abnormal state that an electric cable that must be disconnected from ground circuits contacts the ground circuit or chassis.
•
After disconnecting all the connectors of the target wiring harness, measure the resistance between the electric cable and ground.
3) Short circuit in wiring harness •
"Short circuit" means an abnormal state that electric cables that must be disconnected contact each other.
•
After disconnecting all the connectors of target wiring harness, measure the resistance between the electric cables.
4) Hot short circuit in wiring harness •
"Hot short circuit" means an abnormal state that an electric cable that must be disconnected from the power supply circuit contacts the power supply circuit.
•
Remove the equipment side of the target wiring harness with the controller side connected to measure the voltage.
PRECAUTIONS FOR TROUBLESHOOTING •
Unless specified differently, the T-adapter is connected or inserted as follows. 1) Insertion of T-adapter Disconnect the connected connector. Insert the T-adapter between the male side and female side (connect the T-adapter to the male side and female side at the same time). 2) Connection of T-adapter
PC210-10M0, PC210LC-10M0
40-47
INFORMATION DESCRIBED IN TROUBLESHOOTING
40 TROUBLESHOOTING
Disconnect the connected connector. Connect the T-adapter to the male side or the female side. In a troubleshooting procedure which requires connection of the T-adapter, which of the male and female sides the T-adapter must be connected to is specified. REMARK • Male and female refer to those of connector pins. They do not mean the male and female sides of the connector housing. • For connectors of such as the DT series, be careful because male and female are opposite for the pins and housing of the same connector half. •
Unless specified differently, the (+) lead and (-) lead of a multimeter is connected as follows. •
Connect the (+) lead to the pin number or wiring harness which is specified first. Connect the (-) lead to the pin number or wiring harness which is specified last.
•
Example) When specified as "Between XXX (female) (1) and YYY (female) (6)" Connect the positive (+) lead wire to pin No. 1 on the female side of connector XXX. Connect the negative (-) lead wire to pin No. 6 on the female side of connector YYY.
ASSOCIATED CIRCUIT DIAGRAM This is an excerpted circuit diagram associated to troubleshooting. •
Example)
•
A circuit diagram contains the information that follows. •
Connections, branches and merges of electric cables (signal lines, power supply lines, ground lines) in wiring harnesses
•
Connector numbers, connector types, connector colors, and pin numbers
•
Name of signals, etc. (GND, 24V, P47, E25, MB02, etc.)
•
Signal wires shown in different circuit diagrams are connected when they have the same name.
•
Thick white arrows ("ENGINE" and "REVOLVING FRAME" arrows in the example figure) roughly show the installation position of equipment and connectors.
•
If the connector No. is different for the male side and female side, it could be described with a "/". Example) "OEM CONNECTION (E24)" is described as "OEM CONNECTION/E24" in the circuit diagram.
40-48
PC210-10M0, PC210LC-10M0
DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS
40 TROUBLESHOOTING
DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS For the open circuit in the wiring harness of the pressure sensor system, troubleshoot it as follows. •
Target failure code and pressure sensor •
CA123: Charge Air Pressure Sensor Low Error REMARK The charge air pressure sensor is common for the 107 series engines and the 114 series engines.
• •
CA451: Common Rail Pressure Sensor High Error
Precautions for troubleshooting •
The pressure sensor is consists of not only a resistor but also an electronic circuits such as an amplifier. It has a polarity.
•
Since electricity is charged in the pressure sensor, the measurement value can have variation.
PROCEDURE
1.
Measure and record resistances R1 and R2 of the pressure sensor unit. 1) Disconnect the connector (1) of the pressure sensor. Connect the socket (2). 2)
Measure and record resistances R1 and R2. Follow the table below.
Pressure sensor
Resistance
Measuring place of socket (2)
Internal resistance of pressure sensor (reference value)
R1
Between pin No.1 and pin No.4 (between SIG and GND)
Approximately 100 Ω
R2
Between pin No.2 and pin No.4 (between 5V and GND)
Approximately 200 Ω
R1
Between pin No.2 and pin No.1 (between SIG and GND)
Approximately 23 kΩ
R2
Between pin No.3 and pin No.1 (between 5V and GND)
Approximately 10 MΩ
Charge air pressure sensor
Common rail pressure sensor
PC210-10M0, PC210LC-10M0
40-49
DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS
40 TROUBLESHOOTING
REMARK • If the measurement value of resistance is infinite, reverse the polarity of the multimeter probes. Measure the resistance again. • To measure resistance R1 of the common rail pressure sensor, connect the positive multimeter probe to pin No.1 and the negative probe to pin No.2. If the polarity is reversed, the resistance becomes infinite. • If the polarity of the multimeter probes are reversed, the measurement value can change. For that reason, measure the resistance with the same polarity as in step 1 and step 2. • Variation can occur on the measurement value. Take measurement several times. 2.
Measure and record resistances R1' and R2' while the wiring harness between pressure sensor and engine controller is connected.
1)
For the charge air pressure sensor, disconnect the connector of the sensors that follow. Ambient pressure sensor, engine Bkup speed sensor, crankcase pressure sensor REMARK Disconnect the 5 V power supply circuit. Otherwise, it can give an incorrect reading.
2)
Disconnect the connector (3) of the engine controller. Insert the T-adapter (4).
3)
Connect the T-adapter box (5) to the T-adapter (4).
4)
Measure and record resistances R1' and R2'. Follow the table below. Pressure sensor
Resistance R1'
Charge air pressure sensor
40-50
R2'
Measuring place of T-adapter box (5) Between pin No.45 and pin No.54 (between SIG and GND) Between pin No.78 and pin No.54 (between 5V and GND)
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
Pressure sensor
DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS
Resistance R1'
Common rail pressure sensor
R2'
Measuring place of T-adapter box (5) Between pin No.42 and pin No.58 (between SIG and GND) Between pin No.82 and pin No.58 (between 5V and GND)
REMARK
3.
•
If the measurement value of resistance is infinite, reverse the polarity of the multimeter probes. Measure the resistance again.
•
To measure resistance R1' of the common rail pressure sensor, connect the positive multimeter probe to pin No. 58 and the negative probe to pin No. 42. If the polarity is reversed, the resistance becomes infinite.
•
If the polarity of the multimeter probes are reversed, the measurement value can change. For that reason, measure the resistance with the same polarity as in step 1 and step 2.
•
Variation can occur on the measurement value. Take measurement several times.
Compare the resistance R1 measured in step 1 with the resistance R1' measured in step 2. Also, compare the resistance R2 measured in step 1 with the resistance R2' measured in step 2. If these resistances are different by 10 times or more, it is judged that the wiring harness has an open circuit.
PC210-10M0, PC210LC-10M0
40-51
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE Connector (from) Address ConnecWiring CONtor (terminal) No. NECTOR harness LAYOUT diagram
A
A
A
A
40-52
-
-
-
-
H412
M411
E372
H427
Equipment name
Joint (service PPC oil pressure switch)
Joint (2ATT service PPC oil pressure switch)
Joint (R.H. console upper wiring harness)
Joint (camera 1)
Connector (to)
Type
-
-
-
-
Number of pins
-
-
-
-
Pin number
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
P13 (male)
1
0.85L
P14 (service PPC oil pressure switch)
1
0.85L
P15 (service PPC oil pressure switch)
1
0.85L
C (2ATT service PPC oil pressure switch)
-
0.85L
P13 (male)
1
0.85L
P14 (2ATT service PPC oil pressure switch)
1
0.85L
P15 (2ATT service PPC oil pressure switch)
1
0.85L
H15 (male)
7
0.5GL
S02
1
0.5GL
S02
6
0.5GL
A40 (female)
3
BRAID
A40 (female)
4
0.5B
A45
4
0.5B
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
A
A13 (female)
A13 (male)
A15 (female)
A15 (male)
A17 (female)
A17 (male)
-
I4
I4
I1
I1
I10
I10
-
Equipment name
Joint (R.H. console upper wiring harness) (quick coupler specifications)
E414
Intermediate connector (floor harness)
H273
Intermediate connector (work equipment wiring harness)
D319
Intermediate connector (rear working lamp)
D437
Intermediate connector (floor harness)
K346
Intermediate connector (for quick coupler specification)
-
PC210-10M0, PC210LC-10M0
Intermediate connector (floor harness)
Connector (to)
Type
-
DT
DT
DT
DT
DT
DT
Number of pins
-
2
2
2
2
4
4
Connector (terminal) No.
Pin number
Diameter and color of wire
H15 (male)
7
0.5GL
S02 (quick coupler specifications)
1
0.5GL
S02 (quick coupler specifications)
6
0.5GL
1
L01
1
2R
2
L01
2
2B
1
FX
-
1.25R
2
BT
-
1.25B
1
R10
5
1.25RL
2
GY
-
1.25B
1
L09
1
2R
2
L09
2
2B
1
R40
5
0.85R
2
H28 (female)
3
0.85RL
3
AF
-
0.85B
4
CP01
54
0.85R
1
V40
1
-
2
V40
2
-
3
P50
1
-
4
P50
2
-
Pin number
-
40-53
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
A19 (female)
A19 (male)
A21 (female)
A21 (male)
A40 (female)
A40 (male)
A45
AA
40-54
I2
I2
B3
B3
A7
A7
B11
-
Equipment name
Connector (to)
Type
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
R43
5
2R
2
BH
-
2B
1
AY
-
2R
2
AZ
-
2B
G323
Intermediate connector (electric priming pump)
D443
Intermediate connector (floor harness)
DT
2
O294
Intermediate connector (fuel refill pump (power supply))
DT
2
1
M24
1
1.25RY
I437
Intermediate connector (floor harness)
DT
2
1
M96
-
1.25RY
1
A45
1
0.5R
2
A45
2
0.5W
I421
Intermediate connector (floor harness) (camera 1)
3
A (camera 1)
-
BRAID
4
A (camera 1)
-
0.5B
1
CM04
1
0.5R
2
CM04
2
0.5W
3
XD
-
BRAID
4
CM04
5
0.5B
5
CM04
3
0.5W
6
CM04
6
0.5B
1
A40 (female)
1
0.5R
2
A40 (female)
2
0.5W
4
A (camera 1)
-
0.5B
CP01
46
0.5B
K05
2
0.85G
P22
1
0.5B
P322
I428
E230
Intermediate connector (camera 1)
Camera 1
Joint
DT
DT
DT
DT
-
2
6
6
4
-
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
AB
AB
AB
AC
AC01
AC02
AC03
-
A33
A33
-
F24
H23
B11
H260
Equipment name
Joint
Connector (to)
Type
-
Number of pins
-
Pin number
-
Connector (terminal) No.
Pin number
Diameter and color of wire
H28 (female)
2
0.85GL
R40
1
0.85GL
R40
3
0.85GY
D427
Alternator terminal B (alternator G)
Terminal
1
-
E12 (female)
2
1.25G
-
Alternator terminal B (starting motor)
Terminal
1
-
SB (starting motor)
-
-
J05
16
1.25RL
L19
2
1.25RL
R24
1
0.85RL
1
YB
-
0.5L
2
ZB
-
0.5W
4
R21
2
0.5Lg
6
P17
1
0.5GB
7
P18
1
0.85BrR
8
P18
2
0.85RW
9
P31
2
0.5YW
10
P31
1
0.5RB
1
KA
-
2B
2
GD
-
2RY
3
F01
18
0.5RL
4
GC
-
0.5R
1
R21
3
2W
K277
N231
G232
C335
PC210-10M0, PC210LC-10M0
Joint
Air conditioner unit
A/C unit
A/C compressor
-
YAZAKI
SUMITOMO
X
-
10
4
1
-
40-55
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
AC95 (female)
40-56
C24
P208
Equipment name
Intermediate connector (GW controller connected) (when KOMTRAX controller is connected)
Connector (to)
Type
S090
Number of pins
22
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
J06
5
1.25R
2
J06
6
1.25R
3
XJ
-
1.25B
4
XJ
-
1.25B
5
J03
4
0.5LR
6
J06
13
0.5GW
7
J05
19
1.25RL
8
XF
-
0.5L
9
XE
-
0.5RW
10
ZB
-
0.5W
11
YB
-
0.5L
12
ZZ
-
0.5WB
13
YZ
-
0.5LB
14
N08
7
0.5L
15
N08
5
0.5WB
16
N08
8
0.5LB
20
MM
-
2GR
21
MN
-
2B
22
ML
-
1.25G
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
AC95 (male)
-
N446
PC210-10M0, PC210LC-10M0
Equipment name
Intermediate connector (floor harness) (when KOMTRAX controller is connected)
Connector (to)
Type
S090
Number of pins
22
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CK02
6
1.25R
2
CK02
7
1.25R
3
CK02
1
1.25B
4
CK02
2
1.25B
5
CK02
3
0.5LR
6
CK01
14
0.5GW
7
CK01
15
1.25RL
8
CK02
4
0.5L
9
CK02
11
0.5RW
10
CK01
10
0.5W
11
CK01
11
0.5L
12
AC95 (male)
15
0.5WB
13
AC95 (male)
16
0.5LB
15
AC95 (male)
12
0.5WB
16
AC95 (male)
13
0.5LB
40-57
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
AC95 (male)
AF
C24
-
-
M278
Equipment name
Intermediate connector (floor harness) (when GW controller is connected)
Joint
Connector (to)
Type
S090
-
Number of pins
22
-
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CK05
1
1.25R
2
CK05
3
1.25R
3
CK05
2
1.25B
4
CK05
4
1.25B
5
CK05
24
0.5LR
6
CK05
62
0.5GW
7
CK05
63
0.85RL
8
CK05
41
0.5L
9
CK05
22
0.5RW
10
CK05
45
0.5W
11
CK05
64
0.5L
12
CK05
7
0.5WB
13
CK05
26
0.5LB
14
CK05
20
0.5L
15
CK05
66
0.5WB
16
CK05
9
0.5LB
17
CK05
58
0.5GW
20
G (when GW controller is connected)
-
2RL
21
F (when GW controller is connected)
-
2B
22
CK08
2
1.25G
A17 (female)
3
0.85B
LC
-
1.25B
T06
-
1.25B
-
AG
-
-
Alternator terminal G
Terminal
1
-
E12 (male)
2
-
AL
-
-
Alternator terminal L
Terminal
1
-
E12 (male)
1
-
40-58
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram AMB.AIR PRESSURE
AR
AS
AT
AY
AZ
B
G31
-
-
-
-
-
-
-
K325
F324
K319
D448
D448
H412
PC210-10M0, PC210LC-10M0
Connector (to)
Equipment name
Type
Ambient pressure sensor
FRAMATOME
Joint
Joint
Joint
Joint
Joint
Joint (service PPC oil pressure switch)
-
-
-
-
-
-
Number of pins
3
-
-
-
-
-
-
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CE01
33
0.85W
2
CE01
38
0.85B
3
CE01
3
0.85G
AS
-
0.85WB
P27
A
0.85WB
P28
A
0.85WB
AR
-
0.85WB
AT
-
0.85WB
P57
1
0.85R
PD
-
0.85WB
AS
-
0.85WB
P47
1
0.85G
P49
3
0.85WB
P67
A
0.85WB
A19 (male)
1
2R
D20
1
2R
M37
1
2R
A19 (male)
2
2B
D20
2
2B
M37
2
2B
P13 (male)
2
0.85B
P14 (service PPC oil pressure switch)
2
0.85B
P15 (service PPC oil pressure switch)
2
0.85B
-
-
-
-
-
-
40-59
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
B
B
B
BA
BB
40-60
-
-
-
-
-
M412
E372
-
M242
O236
Equipment name
Joint (2ATT service PPC oil pressure switch)
Joint (R.H. console upper wiring harness)
Joint (R.H. console upper wiring harness) (quick coupler specifications)
Joint
Joint
Connector (to)
Type
-
-
-
-
-
Number of pins
-
-
-
-
-
Pin number
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
D (2ATT service PPC oil pressure switch)
-
0.85B
P13 (male)
2
0.85B
P14 (2ATT service PPC oil pressure switch)
2
0.85B
P15 (2ATT service PPC oil pressure switch)
2
0.85B
H15 (male)
21
0.5GR
S02
3
0.5GR
S02
4
0.5GR
H15 (male)
21
0.5GR
S02 (quick coupler specifications)
3
0.5GR
S02 (quick coupler specifications)
4
0.5GR
H16 (female)
2
0.85GY
H16 (female)
4
0.85GY
RF
-
0.85GY
H09 (female)
1
1.25R
H09 (female)
3
1.25RL
R12
5
1.25R
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
BC
BD
BE
BF
BG
BH
BJ
BK
BL
BOOST PRESS. & IMT
-
-
-
-
-
-
-
-
-
H36
N349
N349
O349
B228
K276
K275
M241
H305
N349
-
PC210-10M0, PC210LC-10M0
Equipment name
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Boost pressure and temperature sensor
Connector (to)
Type
-
-
-
-
-
-
-
-
-
SUMITOMO
Number of pins
-
-
-
-
-
-
-
-
-
4
Connector (terminal) No.
Pin number
Diameter and color of wire
BD
-
0.85B
BL
-
0.85B
V04
2
0.85B
BC
-
0.85B
BE
-
0.85B
V03
2
0.85B
BD
-
0.85B
BK
-
0.85B
V02
2
0.85B
V07
2
0.85B
FC
-
0.85B
V23
2
0.85B
XQ
-
0.85B
BH
-
3B
BT
-
2B
T09
-
5B
A19 (female)
2
2B
BG
-
3B
BR (floor harness)
-
0.85B
FQ
-
0.85GR
H16 (female)
1
0.85GR
MM
-
1.25GR
BE
-
0.85B
V25
2
0.85B
XQ
-
0.85B
BC
-
0.85B
V05
2
0.85B
V06
2
0.85B
V08
2
0.85B
1
CE01
44
0.85G
2
CE01
37
0.85W
3
CE01
23
0.85G
4
CE01
47
0.85B
Pin number
-
-
-
-
-
-
-
-
-
40-61
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
BP
BQ
BR
BR
BS
BT
BW
BY
40-62
-
-
-
-
-
-
-
-
O237
E395
E399
J349
G282
K273
K230
G285
Equipment name
Joint
Joint
Joint (cab harness)
Joint (floor wiring harness)
Joint
Joint
Joint
Joint
Connector (to)
Type
-
-
-
-
-
-
-
-
Number of pins
-
-
-
-
-
-
-
-
Pin number
-
-
-
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
H09 (female)
2
3B
H16 (female)
3
0.85B
HY
-
0.85B
T01
-
3B
BR (cab harness)
-
3B
L05 (female)
2
0.85B
M40
1
1.25B
M41
1
1.25B
BQ
-
3B
H09 (male)
2
3B
T02
-
3B
BH
-
0.85B
P23
2
0.85B
P68
2
0.85B
V01
2
0.85B
H15 (female)
20
0.85GW
K04
2
0.85GW
R08
1
0.85GB
A13 (male)
2
1.25B
BG
-
2B
M07
1
1.25B
M08
1
1.25B
F01
17
2RY
H15 (female)
1
0.85RB
J06
9
2RY
K04
1
0.85B
KA
-
5B
MN
-
5B
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
BZ
C
CAM SENSOR
-
-
H31
K272
M413
-
PC210-10M0, PC210LC-10M0
Equipment name
Joint
Joint (2ATT service PPC oil pressure switch) Cam (Bkup) speed sensor
Connector (to)
Type
-
-
FRAMATOME
Number of pins
-
-
3
Connector (terminal) No.
Pin number
Diameter and color of wire
M07
2
1.25GW
M08
2
1.25GW
R08
5
0.85GW
A (2ATT service PPC oil pressure switch)
-
0.85L
P16
1
0.85L
P30
1
0.85L
1
CE01
37
0.85W
2
CE01
47
0.85B
3
CE01
26
0.85G
Pin number
-
-
40-63
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CE01
40-64
I31
-
Equipment name
Engine controller
Connector (to)
Type
DRC26
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
2
CP3 PUMP REGULATOR
1
0.85W
3
AMB.AIR PRESSURE
3
0.85G
6
TOOL PORT
B
0.85B
8
TOOL PORT
A
0.85W
14
E06
1
0.85W
15
COOLANT TEMP.
B
0.85G
16
CRANK SENSOR
1
0.85W
17
OIL PRESSURE SWITCH
-
0.85G
23
BOOST PRESS. & IMT
3
0.85G
25
FUEL RAIL PRESS.
2
0.85G
26
CAM SENSOR
3
0.85G
27
CRANK SENSOR
3
0.85G
32
CP3 PUMP REGULATOR
2
0.85B
60
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
Equipment name
Connector (to)
Type
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
33
AMB.AIR PRESSURE
1
0.85W
BOOST PRESS. & IMT
2
0.85W
CAM SENSOR
1
0.85W
FUEL RAIL PRESS.
3
0.85W
AMB.AIR PRESSURE
2
0.85B
COOLANT TEMP.
A
0.85B
44
BOOST PRESS. & IMT
1
0.85G
45
INJECTOR CYL 1&2 (female)
3
2W
46
INJECTOR CYL 5&6 (female)
3
2W
BOOST PRESS. & IMT
4
0.85B
CAM SENSOR
2
0.85B
E06
2
0.85B
FUEL RAIL PRESS.
1
0.85B
48
CRANK SENSOR
2
0.85B
51
INJECTOR CYL 1&2 (female)
1
2B
37
38
CE01
I31
-
Engine controller
DRC26
60
47
PC210-10M0, PC210LC-10M0
40-65
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CE01
40-66
I31
-
Equipment name
Engine controller
Connector (to)
Type
DRC26
Number of pins
60
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
52
INJECTOR CYL 3&4 (female)
4
2B
53
INJECTOR CYL 1&2 (female)
4
2B
54
INJECTOR CYL 1&2 (female)
2
2W
55
INJECTOR CYL 3&4 (female)
3
2W
56
INJECTOR CYL 3&4 (female)
2
2W
57
INJECTOR CYL 5&6 (female)
2
2W
58
INJECTOR CYL 3&4 (female)
1
2B
59
INJECTOR CYL 5&6 (female)
1
2B
60
INJECTOR CYL 5&6 (female)
4
2B
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CE02
CE03
CK01
CK02
G31
I33
-
-
O332
J332
N436
L440
PC210-10M0, PC210LC-10M0
Equipment name
Engine controller
Engine controller
KOMTRAX controller
KOMTRAX controller
Connector (to)
Type
DRC26
DTP
070
070
Number of pins
50
4
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
9
H15 (female)
15
0.85L
22
H15 (female)
14
0.85WB
23
H15 (female)
16
0.85B
33
HK
-
0.85B
39
F01
20
0.85LW
40
R18
1
0.85Y
42
R18
2
0.85YB
46
ZA
-
0.5W
47
YA
-
0.5L
49
D11
2
0.85RY
1
T12
-
3B
3
HD
-
3RW
10
AC95 (male)
10
0.5W
11
AC95 (male)
11
0.5L
14
AC95 (male)
6
0.5GW
15
AC95 (male)
7
1.25RL
1
AC95 (male)
3
1.25B
2
AC95 (male)
4
1.25B
3
AC95 (male)
5
0.5LR
4
AC95 (male)
8
0.5L
6
AC95 (male)
1
1.25R
7
AC95 (male)
2
1.25R
11
AC95 (male)
9
0.5RW
18
12
40-67
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CK04
40-68
-
-
Equipment name
Sensor extension connector
Connector (to)
Type
DT-D
Number of pins
12
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CK05
76
0.5R
2
CK05
57
0.5B
3
CK05
37
0.5B
4
CK05
38
0.5RG
5
K
-
0.5LR
6
L
-
0.5YB
7
H
-
0.5LY
8
J
-
0.5YG
11
CK05
19
0.5WB
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CK05
-
-
PC210-10M0, PC210LC-10M0
Equipment name
GW controller
Connector (to)
Type
AMP
Number of pins
81
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
AC95 (male)
1
1.25R
2
AC95 (male)
3
1.25B
3
AC95 (male)
2
1.25R
4
AC95 (male)
4
1.25B
7
AC95 (male)
12
0.5WB
8
H
-
0.5LY
9
AC95 (male)
16
0.5LB
14
CK07
8
0.5BW
15
CK07
7
0.5L
16
CK07
6
0.5G
17
CK07
5
0.5Y
18
CK07
4
0.5R
19
CK04
11
0.5WB
20
AC95 (male)
14
0.5L
22
AC95 (male)
9
0.5RW
24
AC95 (male)
5
0.5LR
26
AC95 (male)
13
0.5LB
27
J
-
0.5YG
37
CK04
3
0.5B
38
CK04
4
0.5RG
39
CK06
2
0.5BrW
41
AC95 (male)
8
0.5L
45
AC95 (male)
10
0.5W
46
K
-
0.5LR
40-69
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CK05
CK06
40-70
-
-
-
-
Equipment name
GW controller
Communication terminal connector
Connector (to)
Type
AMP
AMP
Number of pins
81
8
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
56
CK06
1
0.5R
57
CK04
2
0.5B
58
AC95 (male)
17
0.5GW
62
AC95 (male)
6
0.5GW
63
AC95 (male)
7
0.85RL
64
AC95 (male)
11
0.5L
65
L
-
0.5YB
66
AC95 (male)
15
0.5WB
67
CK08
12
0.5G
68
CK08
11
0.5Y
69
CK08
10
0.5YG
70
CK08
9
0.5LY
71
CK06
8
0.5BW
72
CK06
7
0.5L
73
CK06
6
0.5G
74
CK06
5
0.5Y
75
CK06
3
0.5B
76
CK04
1
0.5R
77
E (when GW controller is connected)
-
0.5RB
81
CK06
4
0.5Br
1
CK05
56
0.5R
2
CK05
39
0.5BrW
3
CK05
75
0.5B
4
CK05
81
0.5Br
5
CK05
74
0.5Y
6
CK05
73
0.5G
7
CK05
72
0.5L
8
CK05
71
0.5BW
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CK07
-
-
PC210-10M0, PC210LC-10M0
Equipment name
ICT service connector/ Extension WiFi
Connector (to)
Type
DT-B
Number of pins
12
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
G (when GW controller is connected)
-
1.25RL
4
CK05
18
0.5R
5
CK05
17
0.5Y
6
CK05
16
0.5G
7
CK05
15
0.5L
8
CK05
14
0.5BW
10
E (when GW controller is connected)
-
0.5RB
12
F (when GW controller is connected)
-
1.25B
40-71
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CK08
CM01
40-72
-
E13
-
D270
Equipment name
3rd party component connector
Machine monitor
Connector (to)
Type
AMP
070
Number of pins
12
18
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
G (when GW controller is connected)
-
1.25RL
2
AC95 (male)
22
1.25G
3
F (when GW controller is connected)
-
1.25B
4
E (when GW controller is connected)
-
0.5RB
5
K
-
0.5LR
6
L
-
0.5YB
7
H
-
0.5L
8
J
-
0.5BW
9
CK05
70
0.5LY
10
CK05
69
0.5YG
11
CK05
68
0.5Y
12
CK05
67
0.5G
1
J06
3
1.25R
2
J06
4
1.25R
3
MB
-
1.25B
4
MB
-
1.25B
5
J06
12
0.5GW
6
R07
2
0.5BR
8
J05
17
1.25RL
9
HA
-
0.5G
10
MA
-
0.5LW
11
J01
14
0.5RW
12
J02
7
0.5RY
13
MA
-
0.5LR
14
J05
2
0.5B
15
P21
1
0.85Y
16
J02
13
0.5L
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CM02
CM04
COOLANT TEMP.
E13
D13
F31
E270
G270
-
PC210-10M0, PC210LC-10M0
Equipment name
Machine monitor
Machine monitor (for camera connection)
Coolant temperature sensor
Connector (to)
Type
070
070
PACKARD
Number of pins
12
8
2
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
2
P44
1
0.85Y
3
P24
1
0.85GL
4
P23
1
0.85LR
5
J02
17
0.5RW
6
D03
8
0.85R
7
HE
-
0.5W
8
HE
-
0.5W
9
YB
-
0.5L
10
HF
-
0.5WB
11
HF
-
0.5WB
12
YZ
-
0.5LB
1
A40 (male)
1
0.5R
2
A40 (male)
2
0.5W
3
A40 (male)
5
0.5W
5
A40 (male)
4
0.5B
6
A40 (male)
6
0.5B
8
XD
-
1.25B
A
CE01
38
0.85B
B
CE01
15
0.85G
40-73
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CP01
40-74
C14
B264
Equipment name
Pump controller
Connector (to)
Type
AMP
Number of pins
81
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
J06
1
1.25R
2
J05
7
1.25B
3
J04
13
0.85GY
4
J06
2
1.25R
5
J04
10
1.25B
6
XT
-
0.85WB
7
ZZ
-
0.5WB
8
P49
2
0.85GW
9
PB
-
0.85B
11
P25
2
0.85GR
12
P07
2
0.85YL
13
P02
2
0.85BrR
14
P04
2
0.85LgR
15
P10
2
0.85Lg
17
P68
1
0.85G
18
XN
-
0.85B
20
J02
16
0.5RW
21
S30
3
0.5YB
24
LG
-
0.5LR
26
YZ
-
0.5LB
28
P22
2
0.85YR
30
P26
2
0.85YB
31
P03
2
0.85GL
32
P06
2
0.85BrY
34
P09
2
0.85LgY
35
P13 (female)
1
0.85P
38
DY
-
0.5Br
39
S25 (female)
16
0.5LB
40
S30
2
0.5YG
42
H16 (female)
5
0.85GW
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CP01
C14
B264
PC210-10M0, PC210LC-10M0
Equipment name
Pump controller
Connector (to)
Type
AMP
Number of pins
81
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
43
LG
-
0.5LR
44
EY
-
0.5Y
45
ZB
-
0.5W
46
AA
-
0.5B
49
P27
C
0.85LB
50
P05
2
0.85LgW
51
P08
2
0.85BrW
53
P12
2
0.85WL
54
A17 (female)
4
0.85R
55
P57
3
0.85GY
56
M05
6
0.5LR
58
S30
7
0.5RY
59
S30
1
0.5R
61
XE
-
0.5RW
62
J06
11
0.5GW
63
PD
-
0.85WB
64
YB
-
0.5L
68
P28
C
0.85LW
69
P01
2
0.85LgB
72
P11
2
0.85WR
74
P67
C
0.85LB
75
M05
4
0.5LW
76
H09 (female)
5
0.5YR
77
S30
4
0.5GW
80
FM
-
0.5LR
40-75
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
CP02
CP3 PUMP REGULATOR CRANK SENSOR
40-76
B13
G36
I32
F203
Equipment name
Pump controller
Connector (to)
Type
AMP
-
Pump regulator valve (IMA)
BOSCH
-
Crankshaft (Ne) speed sensor
FRAMATOME
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
85
V05
1
0.85BrR
86
V07
1
0.85BrG
88
V19
1
0.85GY
89
V24
1
0.85RL
93
V04
1
0.85GR
94
V06
1
0.85BrW
96
S25 (female)
3
0.85GW
97
V30
1
0.85G
98
R43
1
0.5G
99
EJ
-
0.5Br
100
FR
-
0.85RL
101
D01
7
0.85LW
104
S25 (female)
9
0.85GB
106
V08
1
0.85BrW
107
M14
1
0.85RL
108
J01
1
0.85R
109
V02
1
0.85GL
112
V23
1
0.85LR
113
V25
1
0.85RW
114
M05
1
0.85L
115
GR
-
1.25B
116
FN
-
1.25RY
117
FH
-
1.25B
118
FN
-
1.25RY
119
M05
3
0.85YL
120
FL
-
1.25B
121
LF
-
1.25RY
1
CE01
2
0.85W
2
CE01
32
0.85B
1
CE01
16
0.85W
2
CE01
48
0.85B
3
CE01
27
0.85G
40
2
3
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
D
D01
D02
D03
-
A23
A22
A22
M413
N211
N213
N214
Equipment name
Joint (2ATT service PPC oil pressure switch)
Diode
Diode
Diode
Connector (to)
Type
-
SWP
SWP
SWP
Number of pins
-
8
8
8
D10
E24
N203
Diode
M
2
D11
E24
N204
Diode
M
2
D20
-
D451
Diode
DT
2
PC210-10M0, PC210LC-10M0
Connector (terminal) No.
Pin number
Diameter and color of wire
B (2ATT service PPC oil pressure switch)
-
0.85B
P16
2
0.85B
P30
2
0.85B
1
HG
-
0.85RB
2
J01
4
0.85RB
3
J02
3
0.85WR
4
J02
18
0.85LgR
5
H15 (female)
2
0.85RB
6
J02
11
0.85L
7
CP02
101
0.85LW
8
J05
15
0.85BW
1
J02
8
0.85RY
3
J03
16
0.85WL
5
J05
14
0.85BW
7
J04
15
0.85GY
1
HB
-
0.5G
2
HB
-
0.5G
3
GS
-
0.85YL
4
H28 (female)
5
0.85B
5
HA
-
0.5GL
6
H15 (female)
21
0.5GR
7
GR
-
0.85B
8
CM02
6
0.85R
1
HC
-
0.85Br
2
HG
-
0.85RB
1
HC
-
0.85Br
2
CE02
49
0.85RY
1
AY
-
2R
2
AZ
-
2B
Pin number
-
40-77
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
DA
DB
DD
DE
DF
DG
DK
DL
DM
DR
40-78
-
-
-
-
-
-
-
-
-
-
K218
K213
D347
D347
K276
K273
K230
E282
B228
K276
Equipment name
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Connector (to)
Type
-
-
-
-
-
-
-
-
-
-
Number of pins
-
-
-
-
-
-
-
-
-
-
Pin number
-
-
-
-
-
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
DB
-
5RY
F01
11D
3R
F01
1A
3R
DA
-
5RY
F01
6B
3R
F04
2
8RW
NA
-
0.85WB
NB
-
0.85WB
P25
3
0.85WB
P26
3
0.85WB
NF
-
0.85B
NG
-
0.85B
P25
1
0.85B
P26
1
0.85B
DR
-
0.85B
P67
B
0.85B
XN
-
0.85B
E08 (male)
-
1.25L
R17 (female)
2
1.25L
XF
-
1.25L
J05
1
1.25B
J05
13
1.25B
KA
-
2B
KB
-
3B
MC
-
2B
T05
-
5B
J04
3
1.25BW
J04
5
1.25B
T04
-
3B
DF
-
0.85B
P27
B
0.85B
P28
B
0.85B
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
DY
E
E
-
-
-
H308
-
-
Equipment name
Joint
Joint (when GW controller is connected)
Connector (to)
Type
-
-
Number of pins
-
-
Joint (quick coupler specifications)
-
Terminal
1
-
Connector (terminal) No.
Pin number
Diameter and color of wire
CP01
38
0.5Br
K12
1
0.85Br
M16
1
0.5L
CK05
77
0.5RB
CK07
10
0.5RB
CK08
4
0.5RB
H28 (male)
4
0.85GY
S42
1
0.85GW
S42
7
0.85GY
-
R16A
-
15R
1
CE01
14
0.85W
2
CE01
47
0.85B
Pin number
-
-
-
E01
F36
H334
Electric intake air heater (ribbon heater)
E06
I34
-
W.I.F
DT
2
E421
Intermediate connector (floor harness)
X
1
1
E12 (female)
1
1.25L
I444
Intermediate connector (floor harness) (brushless alternator)
X
1
1
E13
-
1.25L
A316
Intermediate connector (engine wiring harness)
X
1
-
DG
-
1.25L
B316
Intermediate connector (starting motor)
DT
1
-
R28-C
-
8R
E08 (female)
E08 (female)
E08 (male)
E10 (female)
D32
D32
D32
D32
PC210-10M0, PC210LC-10M0
40-79
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
E10 (male)
E12 (female)
D32
B34
-
F427
Connector (to)
Equipment name
Type
Number of pins
Intermediate connector (floor harness)
DT
1
Intermediate con- SUMITOnector (alMO ternator)
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
SC
-
8R
1
E08 (female)
1
1.25L
2
AB (alternator terminal B)
-
1.25G
1
AL
-
-
2
AG
-
-
3
Intermediate connector SUMITO(engine MO wiring harness)
3
E12 (male)
B34
-
E13
-
I450
Alternator terminal R
Terminal
1
-
E08 (female)
1
1.25L
E15
-
G450
Alternator terminal E
Terminal
1
-
E16
-
5B
E16
-
I445
Engine body ground
Terminal
1
-
E15
-
5B
EJ
-
H307
Joint
-
-
-
CP02
99
0.5Br
M16
4
0.5G
CP01
44
0.5Y
K12
2
0.85Gr
M16
2
0.5G
H16 (male)
5
0.85GW
M23
4
0.85GW
S11
2
0.85GW
AC95 (male)
21
2B
CK07
12
1.25B
CK08
3
1.25B
EY
F
F
40-80
-
-
-
H309
-
-
Joint
Joint (L.H. console wiring harness) Joint (when GW controller is connected)
-
-
-
-
-
-
-
-
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
F
F01
F04
-
A20
A2
-
E210
A297
PC210-10M0, PC210LC-10M0
Equipment name
Joint (quick coupler specifications)
Fuse box
Fusible link (65A)
Connector (to)
Type
-
-
L
Number of pins
-
-
2
Connector (terminal) No.
Pin number
Diameter and color of wire
H15 (male)
22
0.5B
S02 (quick coupler specifications)
2
0.5B
S42
9
0.85B
1
FD
-
0.85W
2
LF
-
3RY
3
LD
-
0.85W
4
J03
13
0.85WL
5
GE
-
1.25GW
6
R18
3
0.85Br
7
J03
20
0.85GL
8
FW
-
2LR
9
RF
-
0.85GY
10
GC
-
0.85R
11
GD
-
2RL
12
R43
3
2R
13
R12
3
1.25LR
14
ML
-
2G
15
J03
11
2LR
16
MM
-
2GR
17
BW
-
2RY
18
AC02
3
0.5RL
19
HJ
-
3RW
20
CE02
39
0.85LW
10C
J03
5
0.85LW
11D
DA
-
3R
16E
F05
2
3RW
1A
DA
-
3R
20F
J03
6
0.85LW
6B
DB
-
3R
1
R03 (battery relay M)
-
8R
2
DB
-
8RW
Pin number
-
40-81
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram F05
FC
FD
FF
FH
FJ
FL
FM
FN
40-82
G1
-
-
-
-
-
-
-
-
E298
B228
K219
K210
K242
K241
C228
G251
H207
Connector (to)
Equipment name
Type
Number of pins
Fusible link (30A)
M
2
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
R04
-
3R
2
F01
16E
3RW
BF
-
0.85B
FL
-
0.85B
JX
-
BRAID
JY
-
0.85B
F01
1
0.85W
H15 (female)
6
0.5LR
K01
1
0.85W
S25 (female)
13
0.85W
FJ
-
1.25B
S25 (female)
6
0.85B
S25 (female)
12
0.85B
CP02
117
1.25B
FJ
-
0.85B
FL
-
1.25B
GR
-
1.25B
FF
-
1.25B
FH
-
0.85B
V19
2
0.85B
V30
2
0.85B
CP02
120
1.25B
FC
-
0.85B
FH
-
1.25B
V24
2
0.85B
CP01
80
0.5LR
J03
8
0.5LW
LG
-
0.5LW
CP02
116
1.25RY
CP02
118
1.25RY
LF
-
1.25RY
-
-
-
-
-
-
-
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
FP
FQ
FR
FS
FT
FUEL RAIL PRESS.
FW
FX
G
G
-
-
-
-
-
E36
-
-
-
-
K204
G228
K215
J212
K216
-
E233
K274
-
-
PC210-10M0, PC210LC-10M0
Equipment name
Joint
Joint
Joint
Joint
Joint
Common rail pressure sensor
Joint
Joint
Joint (L.H. console wiring harness) Joint (when GW controller is connected)
Connector (to)
Type
-
-
-
-
-
BOSCH
-
-
-
-
Number of pins
-
-
-
-
-
3
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
J04
4
0.85B
LE
-
0.85B
S25 (female)
15
0.5B
BJ
-
0.85GR
L03
2
0.85GR
L19
1
1.25GR
CP02
100
0.85RL
J05
20
1.25RL
N08
4
1.25RL
K01
2
0.85WL
S25 (female)
1
0.85GR
S25 (female)
7
0.85GR
J04
8
1.25B
N08
9
1.25B
N08
12
1.25B
1
CE01
47
0.85B
2
CE01
25
0.85G
3
CE01
37
0.85W
F01
8
2LR
R05
3
1.25LR
R10
3
1.25LR
A13 (male)
1
1.25R
L02
1
1.25R
R05
5
1.25R
H16 (male)
4
0.85GY
M23
1
0.85GY
S11
1
0.85GY
AC95 (male)
20
2RL
CK07
1
1.25RL
CK08
1
1.25RL
Pin number
-
-
-
-
-
-
-
-
-
40-83
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
G
GA
GB
GC
GD
GE
GF
GND
GR
GS
GY
H
40-84
-
-
-
-
-
-
-
-
-
-
-
-
-
H307
H303
E231
E231
E229
E234
-
H207
G282
H304
-
Equipment name
Connector (to)
Type
Joint (quick coupler specifications)
-
Joint
-
Joint
Joint
Joint
Joint
Joint
Ground
Joint
Joint
Joint
Joint
-
-
-
-
-
-
-
-
-
-
Number of pins
-
-
-
-
-
-
-
-
-
-
-
-
Pin number
-
-
-
-
-
-
-
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
H28 (male)
1
0.85GR
S42
4
0.85GR
S42
6
0.85GR
JY
-
0.5Y
M16
3
0.5L
GY
-
2B
L02
2
1.25B
T10
-
5B
AC02
4
0.5R
F01
10
0.85R
R21
1
0.5R
AC02
2
2RY
F01
11
2RL
R21
5
2RY
F01
5
1.25GW
H15 (female)
19
0.85GW
R08
3
0.85GW
J05
9
0.85B
R08
2
0.85B
R12
2
0.5B
R28-E
-
0.85B
CP02
115
1.25B
D03
7
0.85B
FH
-
1.25B
D03
3
0.85YL
H15 (female)
12
0.85YL
V03
1
0.85YL
A15 (female)
2
1.25B
GB
-
2B
P24
2
0.85B
CK04
7
0.5LY
CK05
8
0.5LY
CK08
7
0.5L
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
H08 (female)
H08 (male)
H09 (female)
H09 (male)
F30
F30
F30
F30
L403
D403
O224
E403
PC210-10M0, PC210LC-10M0
Equipment name Intermediate connector (cab harness) Intermediate connector (L.H. console wiring harness)
Intermediate connector (cab harness)
Intermediate connector (floor harness)
Connector (to)
Type
M
M
M
M
Number of pins
4
4
8
8
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
M01
4
0.85RB
2
M01
9
0.85RL
3
M01
2
0.85R
4
M01
6
0.85RW
1
M02
1
0.85RB
2
M02
2
0.85RL
3
M03
1
0.85R
4
M03
2
0.85RW
1
BB
-
1.25R
2
BP
-
3B
3
BB
-
1.25RL
4
J01
15
0.85Y
5
CP01
76
0.5YR
6
J04
11
0.5B
1
M40
2
1.25R
2
BR (cab harness)
-
3B
3
M41
2
1.25RL
4
L05 (female)
1
0.85Y
5
W03
1
0.5YR
6
W03
2
0.5B
40-85
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
H15 (female)
40-86
A19
H279
Equipment name
Intermediate connector (R.H. console upper harness)
Connector (to)
Type
S090
Number of pins
22
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
BW
-
0.85RB
2
D01
5
0.85RB
3
J02
5
0.85RY
4
J01
11
0.85RW
5
J03
7
0.85LW
6
FD
-
0.5LR
7
HA
-
0.5GL
9
J02
15
0.5RW
10
J05
4
0.85B
11
J02
1
0.85WR
12
GS
-
0.85YL
14
CE02
22
0.85WB
15
CE02
9
0.85L
16
CE02
23
0.85B
17
J03
19
0.85GL
18
J01
16
0.85Y
19
GE
-
0.85GW
20
BS
-
0.85GW
21
D03
6
0.5GR
22
HY
-
0.5B
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
H15 (male)
A19
E366
PC210-10M0, PC210LC-10M0
Equipment name
Intermediate connector (floor harness)
Connector (to)
Type
S090
Number of pins
22
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
SSW-B
B
0.85RB
2
SSW-BR
BR
0.85R
3
SSW-R1
R1
0.85RY
4
SSW-C
C
0.85RW
5
SSWACC
ACC
0.85LW
6
S02
5
0.5LR
7
A (R.H. console upper wiring harness)
-
0.5GL
9
S04
5
0.5RW
10
S04
6
0.5B
11
S04
3
0.5WR
12
S04
4
0.5YL
14
P20
1
0.5WB
15
P20
2
0.5L
16
P20
3
0.5B
17
S07
5
0.85GL
18
S07
6
0.85Y
19
S10
1
0.85GY
20
S10
2
0.85GW
21
B (R.H. console upper wiring harness)
-
0.5GR
22
S02
2
0.5B
40-87
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
H15 (male)
40-88
A19
-
Equipment name
Intermediate connector (floor harness) (quick coupler specification)
Connector (to)
Type
S090
Number of pins
22
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
SSW-B (quick coupler specifications)
B
0.85RB
2
SSW-BR (quick coupler specifications)
BR
0.85R
3
SSW-R1 (quick coupler specifications)
R1
0.85RY
4
SSW-C (quick coupler specifications)
C
0.85RW
5
SSWACC (quick coupler specifications)
ACC
0.85LW
6
S02 (quick coupler specifications)
5
0.5LR
7
A (quick coupler specifications)
-
0.5GL
9
S04 (quick coupler specifications)
5
0.5RW
10
S04 (quick coupler specifications)
6
0.5B
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
H15 (male)
A19
-
PC210-10M0, PC210LC-10M0
Equipment name
Intermediate connector (floor harness) (quick coupler specification)
Connector (to)
Type
S090
Number of pins
22
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
11
S04 (quick coupler specifications)
3
0.5WR
12
S04 (quick coupler specifications)
4
0.5YL
14
P20 (quick coupler specifications)
1
0.5WB
15
P20 (quick coupler specifications)
2
0.5L
16
P20 (quick coupler specifications)
3
0.5B
17
S07 (quick coupler specifications)
5
0.85GL
18
S07 (quick coupler specifications)
6
0.85Y
19
M22
1
0.85GY
20
M22
4
0.85GW
21
B (quick coupler specifications)
-
0.5GR
22
F (quick coupler specifications)
-
0.5B
40-89
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
H16 (male)
H28 (female)
H28 (male)
HA
HB
40-90
G24
A19
A19
-
-
N403
H283
-
D279
K204
Equipment name
Intermediate connector (floor harness)
Intermediate connector (R.H. console upper harness)
Intermediate connector (floor harness)
Joint
Joint
Connector (to)
Type
S
S090
S090
-
-
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
M01
8
0.85GR
2
M01
3
0.85GY
3
M01
7
0.85B
4
G (L.H. console wiring harness)
-
0.85GY
5
F (L.H. console wiring harness)
-
0.85GW
6
S14
1
0.85W
7
S14
2
0.85LgR
8
S14
3
0.5GL
12
M23
2
0.85GR
1
HY
-
0.85B
2
AB (joint)
-
0.85GL
3
A17 (female)
2
0.85RL
4
RF
-
0.85GY
5
D03
4
0.85B
1
G (quick coupler specifications)
-
0.85GR
2
S42
5
0.85GL
3
S42
2
0.85RL
4
E (quick coupler specifications)
-
0.85GY
5
S42
8
0.85RL
CM01
9
0.5G
D03
5
0.5GL
H15 (female)
7
0.5GL
D03
1
0.5G
D03
2
0.5G
J01
8
0.5GL
12
22
22
-
-
-
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
HC
HD
HE
HF
HG
HJ
HK
HY
INJECTOR #1
-
-
-
-
-
-
-
-
F32
K203
K242
D274
D275
K238
J209
H209
G282
-
PC210-10M0, PC210LC-10M0
Equipment name
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Injector #1
Connector (to)
Type
-
-
-
-
-
-
-
-
Terminal
Number of pins
-
-
-
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
D10
1
0.85Br
D11
1
0.85Br
R23
1
0.85Br
R24
5
0.85Br
CE03
3
3RW
R23
5
2LR
R24
4
2LR
CM02
7
0.5W
CM02
8
0.5W
ZB
-
0.5W
CM02
10
0.5WB
CM02
11
0.5WB
ZZ
-
0.5WB
D01
1
0.85RB
D10
2
0.85RB
J01
2
0.85RB
F01
19
3RW
R23
3
2R
R24
3
2R
CE02
33
0.85B
R23
2
0.85B
R24
6
0.85B
BP
-
0.85B
H15 (female)
22
0.5B
H28 (female)
1
0.85B
1
INJECTOR CYL 1&2 (male)
3
1.25D
2
INJECTOR CYL 1&2 (male)
4
1.25Y
Pin number
-
-
-
-
-
-
-
-
2
40-91
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
INJECTOR #2
INJECTOR #3
INJECTOR #4
INJECTOR #5
INJECTOR #6
INJECTOR CYL 1&2 (female)
40-92
F32
E33
E33
E34
D35
F33
-
-
-
-
-
-
Equipment name
Injector #2
Injector #3
Injector #4
Injector #5
Injector #6
Intermediate connector (injector #1 and #2 harness)
Connector (to)
Type
Terminal
Terminal
Terminal
Terminal
Terminal
GT280
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
INJECTOR CYL 1&2 (male)
2
1.25Br
2
INJECTOR CYL 1&2 (male)
1
1.25R
1
INJECTOR CYL 3&4 (male)
3
1.25D
2
INJECTOR CYL 3&4 (male)
4
1.25Y
1
INJECTOR CYL 3&4 (male)
2
1.25Br
2
INJECTOR CYL 3&4 (male)
1
1.25R
1
INJECTOR CYL 5&6 (male)
3
1.25D
2
INJECTOR CYL 5&6 (male)
4
1.25Y
1
INJECTOR CYL 5&6 (male)
2
1.25Br
2
INJECTOR CYL 5&6 (male)
1
1.25R
1
CE01
51
2B
2
CE01
54
2W
3
CE01
45
2W
4
CE01
53
2B
2
2
2
2
2
4
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
INJECTOR CYL 1&2 (male)
INJECTOR CYL 3&4 (female)
INJECTOR CYL 3&4 (male)
INJECTOR CYL 5&6 (female)
INJECTOR CYL 5&6 (male)
J
F33
E34
E34
D36
D36
-
-
-
-
-
-
-
PC210-10M0, PC210LC-10M0
Equipment name
Intermediate connector (engine wiring harness)
Intermediate connector (injector #3 and #4 harness)
Intermediate connector (engine wiring harness)
Intermediate connector (injector #5 and #6 harness)
Intermediate connector (engine wiring harness)
Joint
Connector (to)
Type
GT280
GT280
GT280
GT280
GT280
-
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
INJECTOR #2
2
1.25R
2
INJECTOR #2
1
1.25Br
3
INJECTOR #1
1
1.25D
4
INJECTOR #1
2
1.25Y
1
CE01
58
2B
2
CE01
56
2W
3
CE01
55
2W
4
CE01
52
2B
1
INJECTOR #4
2
1.25R
2
INJECTOR #4
1
1.25Br
3
INJECTOR #3
1
1.25D
4
INJECTOR #3
2
1.25Y
1
CE01
59
2B
2
CE01
57
2W
3
CE01
46
2W
4
CE01
60
2B
1
INJECTOR #6
2
1.25R
2
INJECTOR #6
1
1.25Br
3
INJECTOR #5
1
1.25D
4
INJECTOR #5
2
1.25Y
CK04
8
0.5YG
CK05
27
0.5YG
CK08
8
0.5BW
4
4
4
4
4
-
-
40-93
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
J01
40-94
H23
I231
Equipment name
Junction connector (black)
Connector (to)
Type
J
Number of pins
20
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CP02
108
0.85R
2
HG
-
0.85RB
3
R02
-
1.25R
4
D01
2
0.85RB
5
R12
1
0.5GL
6
R10
1
0.5GL
7
R05
1
0.5GL
8
HB
-
0.5GL
11
H15 (female)
4
0.85RW
12
XE
-
0.5RW
13
R06
5
0.85BW
14
CM01
11
0.5RW
15
H09 (female)
4
0.85Y
16
H15 (female)
18
0.85Y
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
J02
A19
B231
PC210-10M0, PC210LC-10M0
Equipment name
Junction connector (black)
Connector (to)
Type
J
Number of pins
20
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
H15 (female)
11
0.85WR
2
S25 (female)
14
0.85WR
3
D01
3
0.85WR
5
H15 (female)
3
0.85RY
6
R15
-
0.85RY
7
CM01
12
0.5RY
8
D02
1
0.85RY
9
R18
5
0.85RY
11
D01
6
0.85L
12
XF
-
1.25L
13
CM01
16
0.5L
15
H15 (female)
9
0.5RW
16
CP01
20
0.5RW
17
CM02
5
0.5RW
18
D01
4
0.85LgR
19
V01
1
0.85LgR
20
H16 (female)
7
0.85LgR
40-95
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
J03
40-96
A19
B235
Equipment name
Junction connector (green)
Connector (to)
Type
J
Number of pins
20
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
2
M11
1
2LR
4
AC95 (female)
5
0.5LR
5
F01
10C
0.85LW
6
F01
20F
0.85LW
7
H15 (female)
5
0.85LW
8
FM
-
0.5LW
9
N08
2
0.85LB
10
MA
-
0.5LW
11
F01
15
2LR
13
F01
4
0.85WL
14
M04
1
0.85WL
15
M06
2
0.85WL
16
D02
3
0.85WL
19
H15 (female)
17
0.85GL
20
F01
7
0.85GL
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
J04
H24
I235
PC210-10M0, PC210LC-10M0
Equipment name
Junction connector (green)
Connector (to)
Type
J
Number of pins
20
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
LC
-
1.25B
2
KB
-
1.25B
3
DM
-
1.25BW
4
FP
-
0.85B
5
DM
-
1.25B
6
M09
2
2B
7
J05
3
1.25B
8
FT
-
1.25B
9
R06
2
0.5B
10
CP01
5
1.25B
11
H09 (female)
6
0.5B
12
P17
2
0.5B
13
CP01
3
0.85GY
14
M06
1
0.85GY
15
D02
7
0.85GY
17
M11
3
2BR
18
KB
-
2BR
19
M04
2
0.85B
20
XJ
-
1.25B
40-97
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
J05
J06
G24
E24
I239
I242
Equipment name
Junction connector (pink)
Junction connector (pink)
Connector (to)
Type
J
J
Number of pins
20
20
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
DK
-
1.25B
2
CM01
14
0.5B
3
J04
7
1.25B
4
H15 (female)
10
0.85B
5
R05
2
0.5B
6
R10
2
0.5B
7
CP01
2
1.25B
8
S30
8
0.5B
9
GF
-
0.85B
10
R43
2
0.5B
13
DK
-
1.25B
14
D02
5
0.85BW
15
D01
8
0.85BW
16
AC
-
1.25RL
17
CM01
8
1.25RL
19
AC95 (female)
7
1.25RL
20
FR
-
1.25RL
1
CP01
1
1.25R
2
CP01
4
1.25R
3
CM01
1
1.25R
4
CM01
2
1.25R
5
AC95 (female)
1
1.25R
6
AC95 (female)
2
1.25R
8
N08
1
1.25R
9
BW
-
2RY
11
CP01
62
0.5GW
12
CM01
5
0.5GW
13
AC95 (female)
6
0.5GW
14
N08
6
0.5GW
JW
-
H308
Joint
-
-
-
JY
-
BRAID
JX
-
H307
Joint
-
-
-
FC
-
BRAID
40-98
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
JY
K
-
-
B228
-
Equipment name
Joint
Joint
Connector (to)
Type
-
-
Number of pins
-
-
K01
C13
I213
Resister for PCEPC valve
K02
I34
H329
CAN terminating resistor
I202
Horn relay dummy resistance (for wrist control lever)
DT
2
K04
C24
M
2
DT
3
DT
2
K05
D24
O254
Dummy resistance (WIF sensor)
K12
B24
K254
Fan clutch resistance
SWP
2
K13
C24
M254
CAN terminating resistor
DT
3
KA
KB
KD
L
-
-
-
-
F228
K230
F322
-
PC210-10M0, PC210LC-10M0
Joint
Joint
Joint
Joint
-
-
-
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
FC
-
0.85B
GA
-
0.5Y
JW
-
BRAID
CK04
5
0.5LR
CK05
46
0.5LR
CK08
5
0.5LR
1
FD
-
0.85W
2
FS
-
0.85WL
A
ZA
-
0.5W
B
YA
-
0.5L
1
BY
-
0.85B
2
BS
-
0.85GW
1
PB
-
0.85B
2
AA
-
0.85G
1
DY
-
0.85Br
2
EY
-
0.85Gr
A
ZZ
-
0.5WB
B
YZ
-
0.5LB
AC02
1
2B
BY
-
5B
DK
-
2B
DL
-
3B
J04
2
1.25B
J04
18
2BR
P49
1
0.85B
P57
2
0.85B
XW
-
0.85B
CK04
6
0.5YB
CK05
65
0.5YB
CK08
6
0.5YB
Pin number
-
-
-
-
-
-
40-99
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
L01
F1
E410
Equipment name
Connector (to)
Type
Boom working lamp
DT
Number of pins
F1
J294
R.H. working lamp
DT
2
L03
C30
D249
Room lamp
M
2
C392
Intermediate connector (revolving lamp)
L05 (male)
L09
L15
L19
LC
LD
40-100
A29
A29
A9
-
A1
-
-
M421
Intermediate connector (cab harness)
D433
Rear working lamp
O425
D293
B225
K209
SWP
SWP
D
Revolving lamp
DT
System operating lamp
DT
Joint
Joint
-
-
Pin number
Diameter and color of wire
1
A13 (female)
1
2R
2
A13 (female)
2
2B
1
FX
-
1.25R
2
GB
-
1.25B
2
FQ
-
0.85GR
1
H09 (male)
4
0.85Y
2
BQ
-
0.85B
1
L15
1
0.85R
2
L15
2
0.85B
1
A15 (male)
1
2R
2
A15 (male)
2
2B
1
L05 (male)
1
0.85R
2
L05 (male)
2
0.85B
1
FQ
-
1.25GR
2
AC
-
1.25RL
AF
-
1.25B
J04
1
1.25B
P13 (female)
2
0.85B
R24
2
0.85B
F01
3
0.85W
H16 (female)
6
0.85W
R07
1
0.5WR
2
L02
L05 (female)
Pin number
Connector (terminal) No.
2
2
2
2
2
-
-
-
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
LE
LF
LG
M01
M01A
M01B
M02
M03
-
-
-
I22
H22
F30
A30
A28
K210
K211
G254
J392
B410
B415
C394
C391
PC210-10M0, PC210LC-10M0
Equipment name
Joint
Joint
Joint
Radio
Radio (AUX jack)
AUX jack
Speaker (L.H.)
Speaker (R.H.)
Connector (to)
Type
-
-
-
PA
-
M
M
M
Number of pins
-
-
-
9
3
3
Connector (terminal) No.
Pin number
Diameter and color of wire
FP
-
0.85B
S25 (female)
4
0.85BW
S25 (female)
10
0.85BW
CP02
121
1.25RY
F01
2
3RY
FN
-
1.25RY
CP01
24
0.5LR
CP01
43
0.5LR
FM
-
0.5LW
2
H08 (female)
3
0.85R
3
H16 (male)
2
0.85GY
4
H08 (female)
1
0.85RB
6
H08 (female)
4
0.85RW
7
H16 (male)
3
0.85B
8
H16 (male)
1
0.85GR
9
H08 (female)
2
0.85RL
1
M01B
1
0.3B
2
M01B
2
0.3L
3
M01B
3
0.3BW
1
M01A
1
0.3B
2
M01A
2
0.3L
3
M01A
3
0.3BW
1
H08 (male)
1
0.85RB
2
H08 (male)
2
0.85RL
1
H08 (male)
3
0.85R
2
H08 (male)
4
0.85RW
Pin number
-
-
-
2
2
40-101
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram M04
M05
A19
G13
F280
B277
Connector (to)
Equipment name
Type
Number of pins
Cigarette lighter
YAZAKI
2
Front window wiper motor
M
6
M06
H10
I345
Front window washer motor
M07
I4
N272
Horn treble tone
090
2
M08
I3
N271
Horn bass tone
090
2
N236
Optional power supply connector (1)
N233
Optional power supply connector (2)
M09
M10
M11
G24
F24
C24
O205
DC/DC converter
YAZAKI
2
M
M
DT
2
2
6
M13
D24
M224
12V power supply socket
M
2
M14
I6
M347
Travel alarm
DT
2
M16
40-102
C12
E337
Fan clutch
DT
6
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
J03
14
0.85WL
2
J04
19
0.85B
1
CP02
114
0.85L
3
CP02
119
0.85YL
4
CP01
75
0.5LW
5
MC
-
1.25B
6
CP01
56
0.5LR
1
J04
14
0.85GY
2
J03
15
0.85WL
1
BT
-
1.25B
2
BZ
-
1.25GW
1
BT
-
1.25B
2
BZ
-
1.25GW
1
ML
-
2G
2
J04
6
2B
1
X
-
2LR
2
Y
-
2B
1
J03
2
2LR
3
J04
17
2BR
4
X
-
2L
6
Y
-
2BW
1
X
-
2L
2
Y
-
2BW
1
CP02
107
0.85RL
2
XQ
-
0.85B
1
DY
-
0.5L
2
EY
-
0.5G
3
GA
-
0.5L
4
EJ
-
0.5G
5
PD
-
0.75fG
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
M22
M23
M24
M37
-
-
A10
-
-
-
Equipment name Right knob switch (horn)
L.H. knob switch (quick coupler specifications)
Connector (to)
Type
090
090
Number of pins
6
DT
C449
Electric priming pump
DT
X
2
2
2
M40
A26
B396
L.H. headlamp of cab
M41
B25
E385
R.H. headlamp of cab
X
2
M96
C1
I432
Battery (+)
Terminal
1
MA
MB
MC
ML
-
-
-
-
D276
D273
D280
O237
PC210-10M0, PC210LC-10M0
Joint
Joint
Joint
Joint
-
-
-
-
Pin number
Diameter and color of wire
1
H15 (male)
19
0.85GY
4
H15 (male)
20
0.85GW
1
G (L.H. console wiring harness)
-
0.85GY
2
H16 (male)
12
0.85GR
4
F (L.H. console wiring harness)
-
0.85GW
1
A21 (female)
1
1.25RY
2
T11
-
1.25B
1
AY
-
2R
2
AZ
-
2B
1
BQ
-
1.25B
2
H09 (male)
1
1.25R
1
BQ
-
1.25B
2
H09 (male)
3
1.25RL
-
A21 (male)
1
1.25RY
CM01
10
0.5LW
CM01
13
0.5LR
J03
10
0.5LW
CM01
3
1.25B
CM01
4
1.25B
MC
-
2B
DL
-
2B
M05
5
1.25B
MB
-
2B
AC95 (female)
22
1.25G
F01
14
2G
M09
1
2G
6
Fuel refill pump
I322
Pin number
Connector (terminal) No.
-
-
-
-
-
-
-
-
40-103
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
MM
MN
N08
NA
NB
NC
ND
NE
40-104
-
-
A20
-
-
-
-
-
M242
M278
N219
D348
D349
E349
E349
F349
Equipment name
Joint
Joint
Service connector
Joint
Joint
Joint
Joint
Joint
Connector (to)
Type
-
-
DT
-
-
-
-
-
Number of pins
-
-
12
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
AC95 (female)
20
2GR
BJ
-
1.25GR
F01
16
2GR
AC95 (female)
21
2B
BY
-
5B
T07
-
5B
1
J06
8
1.25R
2
J03
9
0.85LB
3
ZB
-
0.5W
4
FR
-
1.25RL
5
AC95 (female)
15
0.5WB
6
J06
14
0.5GW
7
AC95 (female)
14
0.5L
8
AC95 (female)
16
0.5LB
9
FT
-
1.25B
10
YB
-
0.5L
12
FT
-
1.25B
DD
-
0.85WB
P01
3
0.85WB
P07
3
0.85WB
DD
-
0.85WB
NC
-
0.85WB
P04
3
0.85WB
NB
-
0.85WB
ND
-
0.85WB
P05
3
0.85WB
NC
-
0.85WB
NE
-
0.85WB
P06
3
0.85WB
ND
-
0.85WB
P03
3
0.85WB
XM
-
0.85WB
Pin number
-
-
-
-
-
-
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
NF
NG
NH
NI
NJ
OIL PRESSURE SWITCH
P01
P02
P03
P04
P05
-
-
-
-
-
I35
H2
H2
I2
I2
I2
C349
D349
E349
E349
F349
Equipment name
Joint
Joint
Joint
Joint
Joint
-
Engine oil pressure switch
C360
Bucket CURL PPC oil pressure sensor
C358
C352
C356
C355
PC210-10M0, PC210LC-10M0
Boom LOWER PPC oil pressure sensor Swing LEFT PPC oil pressure sensor Arm IN PPC oil pressure sensor Bucket DUMP PPC oil pressure sensor
Connector (to)
Type
-
-
-
-
-
FRAMATOME
AMP
AMP
AMP
AMP
AMP
Number of pins
-
-
-
-
-
2
3
3
3
3
3
Connector (terminal) No.
Pin number
Diameter and color of wire
DE
-
0.85B
P01
1
0.85B
P07
1
0.85B
DE
-
0.85B
NH
-
0.85B
P04
1
0.85B
NG
-
0.85B
NI
-
0.85B
P05
1
0.85B
NH
-
0.85B
NJ
-
0.85B
P06
1
0.85B
NI
-
0.85B
P03
1
0.85B
XL
-
0.85B
-
CE01
17
0.85G
1
NF
-
0.85B
2
CP01
69
0.85LgB
3
NA
-
0.85WB
1
XL
-
0.85B
2
CP01
13
0.85BrR
3
XM
-
0.85WB
1
NJ
-
0.85B
2
CP01
31
0.85GL
3
NE
-
0.85WB
1
NG
-
0.85B
2
CP01
14
0.85LgR
3
NB
-
0.85WB
1
NH
-
0.85B
2
CP01
50
0.85LgW
3
NC
-
0.85WB
Pin number
-
-
-
-
-
40-105
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
P06
P07
P08
P09
P10
P11
P12
P13 (female)
40-106
I2
H2
I2
I16
I17
I15
I15
H13
C353
C357
C351
J290
J289
J287
J286
O286
Equipment name Boom RAISE PPC oil pressure sensor Swing RIGHT PPC oil pressure sensor Arm OUT PPC oil pressure sensor L.H. travel FORWARD PPC oil pressure sensor Travel Reverse Left PPC oil pressure sensor Travel Forward Right PPC oil pressure sensor Travel Reverse Right PPC oil pressure sensor Intermediate connector (service PPC oil pressure switch)
Connector (to)
Type
AMP
AMP
AMP
AMP
AMP
AMP
AMP
X
Number of pins
3
3
3
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
NI
-
0.85B
2
CP01
32
0.85BrY
3
ND
-
0.85WB
1
NF
-
0.85B
2
CP01
12
0.85YL
3
NA
-
0.85WB
1
XL
-
0.85B
2
CP01
51
0.85BrW
3
XM
-
0.85WB
1
XR
-
0.85B
2
CP01
34
0.85LgY
3
XT
-
0.85WB
1
XS
-
0.85B
2
CP01
15
0.85Lg
3
XU
-
0.85WB
1
XS
-
0.85B
2
CP01
72
0.85WR
3
XU
-
0.85WB
1
XS
-
0.85B
2
CP01
53
0.85WL
3
XU
-
0.85WB
1
CP01
35
0.85P
2
LC
-
0.85B
3
3
3
3
2
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
P13 (male)
P13 (male)
P14
P14
H13
H13
-
-
H411
M410
H415
N411
PC210-10M0, PC210LC-10M0
Equipment name Intermediate connector (floor harness) (service PPC oil pressure switch) Intermediate connector (floor harness) (2ATT service PPC oil pressure switch) R.H. attachment control pedal forward tilt PPC oil pressure switch (service PPC oil pressure switch) R.H. attachment control pedal forward tilt PPC oil pressure switch (2ATT service PPC oil pressure switch)
Connector (to)
Type
X
X
X
X
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
A (service PPC oil pressure switch)
-
0.85L
2
B (service PPC oil pressure switch)
-
0.85B
1
A (2ATT service PPC oil pressure switch)
-
0.85L
2
B (2ATT service PPC oil pressure switch)
-
0.85B
1
A (service PPC oil pressure switch)
-
0.85L
2
B (service PPC oil pressure switch)
-
0.85B
1
A (2ATT service PPC oil pressure switch)
-
0.85L
2
B (2ATT service PPC oil pressure switch)
-
0.85B
2
2
2
2
40-107
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
P15
P15
P16
P17
P18
40-108
-
-
-
I22
G12
I415
N413
L415
Equipment name R.H. attachment control pedal reverse tilt PPC oil pressure switch (service PPC oil pressure switch) R.H. attachment control pedal reverse tilt PPC oil pressure switch (2ATT service PPC oil pressure switch) Left attachment control pedal forward tilt PPC oil pressure switch
H287
Air conditioner high-low pressure switch
G339
Air conditioner outside air temperature sensor
Connector (to)
Type
X
X
X
S090
090
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
A (service PPC oil pressure switch)
-
0.85L
2
B (service PPC oil pressure switch)
-
0.85B
1
A (2ATT service PPC oil pressure switch)
-
0.85L
2
B (2ATT service PPC oil pressure switch)
-
0.85B
1
C (2ATT service PPC oil pressure switch)
-
0.85L
2
D (2ATT service PPC oil pressure switch)
-
0.85B
1
AC01
6
0.5GB
2
J04
12
0.5B
1
AC01
7
0.85BrR
2
AC01
8
0.85RW
2
2
2
2
2
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
P20
P20
P21
P22
B16
B16
D2
A8
C374
Equipment name
Fuel control dial
Fuel level sensor
DT
P323
Hydraulic oil temperature sensor
DT
2
X
2
I347
P24
H11
I342
Coolant level sensor
F345
Front pump oil pressure sensor
P27
P28
H1
A6
A6
3
G293
G12
P26
M
Number of pins
M
-
P23
I1
Type
Fuel control dial (quick coupler specifications)
Air cleaner clogging sensor
P25
Connector (to)
F343
K328
L328
PC210-10M0, PC210LC-10M0
Rear pump oil pressure sensor Front pump swash plate sensor Rear pump swash plate sensor
DT
AMP
AMP
DT
DT
3
2
2
3
3
3
3
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
H15 (male)
14
0.5WB
2
H15 (male)
15
0.5L
3
H15 (male)
16
0.5B
1
H15 (male)
14
0.5WB
2
H15 (male)
15
0.5L
3
H15 (male)
16
0.5B
1
CM01
15
0.85Y
1
AA
-
0.5B
2
CP01
28
0.85YR
1
CM02
4
0.85LR
2
BR (floor harness)
-
0.85B
1
CM02
3
0.85GL
2
GY
-
0.85B
1
DE
-
0.85B
2
CP01
11
0.85GR
3
DD
-
0.85WB
1
DE
-
0.85B
2
CP01
30
0.85YB
3
DD
-
0.85WB
A
AR
-
0.85WB
B
DR
-
0.85B
C
CP01
49
0.85LB
A
AR
-
0.85WB
B
DR
-
0.85B
C
CP01
68
0.85LW
40-109
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
P30
-
M415
Equipment name
Connector (to)
Type
Left attachment control pedal backward tilt PPC oil pressure switch
X
Number of pins
D14
B272
Sunlight sensor
050
2
P44
H2
C318
Engine oil level sensor
DT
2
P47
B5
I319
Water-infuel sensor
DT
2
N320
Service oil pressure sensor
P50
P57
P67
P68
PB
40-110
B5
-
E12
B4
H10
-
-
I326
K316
M343
E234
AMP
Quick coupler pressure switch
DT
Crankcase pressure sensor
FRAMATOME
Clogging sensor for hydraulic oil return filter Clogging sensor for attachment return filter
Joint
DT
DT
-
Pin number
Diameter and color of wire
1
C (2ATT service PPC oil pressure switch)
-
0.85L
2
D (2ATT service PPC oil pressure switch)
-
0.85B
1
AC01
10
0.5RB
2
AC01
9
0.5YW
1
CM02
2
0.85Y
1
AT
-
0.85G
2
PB
-
0.85B
1
KD
-
0.85B
2
CP01
8
0.85GW
3
AT
-
0.85WB
1
A17 (male)
3
-
2
A17 (male)
4
-
1
AS
-
0.85R
2
KD
-
0.85B
3
CP01
55
0.85GY
A
AT
-
0.85WB
B
DF
-
0.85B
C
CP01
74
0.85LB
1
CP01
17
0.85G
2
BR (floor harness)
-
0.85B
CP01
9
0.85B
K05
1
0.85B
P47
2
0.85B
2
P31
P49
Pin number
Connector (terminal) No.
3
2
3
3
2
-
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
PD
-
H309
Equipment name
Joint
Connector (to)
Type
-
Number of pins
-
Pin number
-
Connector (terminal) No.
Pin number
Diameter and color of wire
AS
-
0.85WB
CP01
63
0.85WB
M16
5
0.75fG
XM
-
0.85WB
R01
B3
H299
Battery relay terminal E
Terminal
1
-
T08
-
0.85B
R02
A3
G299
Battery relay terminal BR
Terminal
1
-
J01
3
1.25R
D299
Battery relay terminal M (priming pump)
Terminal
1
-
F04
1
8R
B420
Battery relay terminal M (starting motor)
Terminal
1
-
SB (starting motor)
-
60R
Terminal
1
-
R16B
-
15R
Terminal
1
-
F05
1
3R
1
J01
7
0.5GL
2
J05
5
0.5B
3
FW
-
1.25LR
5
FX
-
1.25R
1
H16 (female)
8
0.5GL
2
J04
9
0.5B
3
R07
4
0.85RW
5
J01
13
0.85BW
1
LD
-
0.5WR
2
CM01
6
0.5BR
3
R17 (female)
1
0.85BW
4
R06
3
0.85RW
R03
R03
B3
B3
R03
B3
-
Battery relay terminal M (ribbon heater relay)
R04
A3
C299
Battery relay terminal B
R05
R06
R07
A21
A21
A21
F263
N217
N216
PC210-10M0, PC210LC-10M0
Lamp relay
Starting motor cutoff relay (for PPC lock) Starting motor cutoff relay (for personal code)
Relay
Relay
Relay
5
5
5
40-111
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
R08
R10
R12
R15
R16A
R16B
R17 (female)
40-112
A22
A21
A20
C1
B1
A1
A2
K261
H263
E263
Equipment name
Horn relay
Rear working lamp relay
Cab headlamp relay
Connector (to)
Type
Relay
Relay
Relay
Number of pins
5
5
5
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
BS
-
0.85GB
2
GF
-
0.85B
3
GE
-
0.85GW
5
BZ
-
0.85GW
1
J01
6
0.5GL
2
J05
6
0.5B
3
FW
-
1.25LR
5
A15 (female)
1
1.25RL
1
J01
5
0.5GL
2
GF
-
0.5B
3
F01
13
1.25LR
5
BB
-
1.25R
P296
Electric intake air heater (ribbon heater) (coil circuit)
Terminal
1
-
J02
6
0.85RY
P297
Electric intake air heater (ribbon heater) (contact circuit A)
Terminal
1
-
E01
-
15R
R03 (battery relay M)
-
15R
-
Electric intake air heater (ribbon heater) (contact circuit B)
R28-B
-
15R
1
R07
3
0.85BW
2
DG
-
1.25L
B295
Intermediate connector (starting motor safety relay)
Terminal
X
1
2
-
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
R17 (male)
R18
R21
R23
R24
R28-B
R28-C
R28-E
R28-R
A2
B23
D24
B23
B23
A2
A2
A2
A2
Equipment name
-
Intermediate connector (floor harness)
I211
Auto preheater relay
H231
E209
G211
Air conditioner compressor solenoid clutch relay
CM850 relay (1)
CM850 relay (2)
Connector (to)
Type
X
Relay
Relay
Relay
Relay
Number of pins
2
5
5
5
6
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
R28-S
-
0.85B
2
R28-R
-
0.85W
1
CE02
40
0.85Y
2
CE02
42
0.85YB
3
F01
6
0.85Br
5
J02
9
0.85RY
1
GC
-
0.5R
2
AC01
4
0.5Lg
3
AC03
1
2W
5
GD
-
2RY
1
HC
-
0.85Br
2
HK
-
0.85B
3
HJ
-
2R
5
HD
-
2LR
1
AC
-
0.85RL
2
LC
-
0.85B
3
HJ
-
2R
4
HD
-
2LR
5
HC
-
0.85Br
6
HK
-
0.85B
-
Starting motor safety relay (B)
Terminal
1
-
R16B
-
15R
O298
Starting motor safety relay (C)
Terminal
1
-
E10 (female)
-
8R
-
Starting motor safety relay (E)
Terminal
1
-
GND
-
0.85B
-
Starting motor safety relay (R)
Terminal
1
-
R17 (male)
2
0.85W
PC210-10M0, PC210LC-10M0
40-113
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
R28-S
R40
R43
RF
S02
40-114
A2
A22
B24
-
B17
-
K259
I254
H282
D373
Connector (to)
Equipment name
Type
Number of pins
Starting motor safety relay (S)
Terminal
1
Quick coupler relay
Electric priming pump relay
Joint
Lamp switch
Relay
Relay
-
SWP
5
5
-
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
-
R17 (male)
1
0.85B
1
AB (joint)
-
0.85GL
2
H16 (female)
12
0.85GB
3
AB (joint)
-
0.85GY
5
A17 (female)
1
0.85R
1
CP02
98
0.5G
2
J05
10
0.5B
3
F01
12
2R
5
A19 (female)
1
2R
BA
-
0.85GY
F01
9
0.85GY
H28 (female)
4
0.85GY
1
A (R.H. console upper wiring harness)
-
0.5GL
2
H15 (male)
22
0.5B
3
B (R.H. console upper wiring harness)
-
0.5GR
4
B (R.H. console upper wiring harness)
-
0.5GR
5
H15 (male)
6
0.5LR
6
A (R.H. console upper wiring harness)
-
0.5GL
-
6
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
S02
S04
S04
S07
B17
B17
B17
A17
-
D371
-
D370
PC210-10M0, PC210LC-10M0
Equipment name
Lamp switch (quick coupler specifications)
Swing lock switch
Swing lock switch (quick coupler specifications)
Revolving lamp switch
Connector (to)
Type
SWP
SWP
SWP
SWP
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
A (quick coupler specifications)
-
0.5GL
2
F (quick coupler specifications)
-
0.5B
3
B (quick coupler specifications)
-
0.5GR
4
B (quick coupler specifications)
-
0.5GR
5
H15 (male)
6
0.5LR
6
A (quick coupler specifications)
-
0.5GL
3
H15 (male)
11
0.5WR
4
H15 (male)
12
0.5YL
5
H15 (male)
9
0.5RW
6
H15 (male)
10
0.5B
3
H15 (male)
11
0.5WR
4
H15 (male)
12
0.5YL
5
H15 (male)
9
0.5RW
6
H15 (male)
10
0.5B
5
H15 (male)
17
0.85GL
6
H15 (male)
18
0.85Y
6
6
6
6
40-115
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
S07
S10
S11
S14
40-116
A17
B16
I21
I21
-
E380
I386
N386
Equipment name Revolving lamp switch (quick coupler specifications) R.H. knob switch (horn switch) L.H. knob switch (onetouch power maximizing switch) Junction connector of PPC oil pressure lock switch
Connector (to)
Type
SWP
Y090
Y090
M
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
5
H15 (male)
17
0.85GL
6
H15 (male)
18
0.85Y
1
H15 (male)
19
0.85GY
2
H15 (male)
20
0.85GW
1
G (L.H. console wiring harness)
-
0.85GY
2
F (L.H. console wiring harness)
-
0.85GW
1
H16 (male)
6
0.85W
2
H16 (male)
7
0.85LgR
3
H16 (male)
8
0.5GL
6
2
2
3
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
S21
S22
A14
A14
K370
K374
PC210-10M0, PC210LC-10M0
Equipment name
Emergency pump drive switch
Swing parking brake cancel switch
Connector (to)
Type
-
-
Number of pins
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
S25 (male)
1
0.85GR
2
S25 (male)
2
0.85G
3
S25 (male)
3
0.85GB
4
S25 (male)
4
0.85BW
5
S25 (male)
5
0.85B
6
S25 (male)
6
0.85BR
7
S25 (male)
7
0.85GR
8
S25 (male)
8
0.85Y
9
S25 (male)
9
0.85YB
10
S25 (male)
10
0.85BrW
11
S25 (male)
11
0.85Br
12
S25 (male)
12
0.85BrR
2
S25 (male)
13
0.85WR
3
S25 (male)
14
0.85W
5
S25 (male)
15
0.85LB
6
S25 (male)
16
0.85L
12
6
40-117
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
S25 (female)
S25 (male)
40-118
A15
A15
I221
N372
Equipment name
Intermediate connector (secondary drive switch connector)
Intermediate connector (floor harness)
Connector (to)
Type
S090
090
Number of pins
16
16
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
FS
-
0.85GR
2
V11
1
0.85GW
3
CP02
96
0.85GW
4
LE
-
0.85BW
5
V11
2
0.85B
6
FF
-
0.85B
7
FS
-
0.85GR
8
V12
1
0.85GB
9
CP02
104
0.85GB
10
LE
-
0.85BW
11
V12
2
0.85B
12
FF
-
0.85B
13
FD
-
0.85W
14
J02
2
0.85WR
15
FP
-
0.5B
16
CP01
39
0.5LB
1
S21
1
0.85GR
2
S21
2
0.85G
3
S21
3
0.85GB
4
S21
4
0.85BW
5
S21
5
0.85B
6
S21
6
0.85BR
7
S21
7
0.85GR
8
S21
8
0.85Y
9
S21
9
0.85YB
10
S21
10
0.85BrW
11
S21
11
0.85Br
12
S21
12
0.85BrR
13
S22
2
0.85WR
14
S22
3
0.85W
15
S22
5
0.85LB
16
S22
6
0.85L
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
S30
S42
SB
A20
-
C31
D257
-
Equipment name
Model selection connector
Quick coupler drive switch
Connector (to)
Type
S
BRITAX
Number of pins
8
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CP01
59
0.5R
2
CP01
40
0.5YG
3
CP01
21
0.5YB
4
CP01
77
0.5GW
7
CP01
58
0.5RY
8
J05
8
0.5B
1
E (quick coupler specifications)
-
0.85GW
2
H28 (male)
3
0.85RL
4
G (quick coupler specifications)
-
0.85GR
5
H28 (male)
2
0.85GL
6
G (quick coupler specifications)
-
0.85GR
7
E (quick coupler specifications)
-
0.85GY
8
H28 (male)
5
0.85RL
9
F (quick coupler specifications)
-
0.85B
12
-
Starting motor terminal B (alternator B)
Terminal
1
-
AB (alternator terminal B)
-
-
Terminal
1
-
R03 (battery relay M)
-
60R
Terminal
1
-
E10 (male)
1
8R
SB
C31
B427
Starting motor terminal B (battery relay M)
SC
D31
-
Starting motor C terminal
PC210-10M0, PC210LC-10M0
40-119
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram SSWACC
B16
Connector (to) Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
ACC
H15 (male)
5
0.85LW
Terminal
1
ACC
H15 (male)
5
0.85LW
Equipment name
Type
Number of pins
C378
Starting motor switch ACC
Terminal
SSWACC
B16
-
Starting motor switch ACC (quick coupler specifications)
SSW-B
B16
D378
Starting switch B
Terminal
1
B
H15 (male)
1
0.85RB
Terminal
1
B
H15 (male)
1
0.85RB
SSW-B
B16
-
Starting motor switch B (quick coupler specifications)
SSW-BR
B16
C377
Starting motor switch BR
Terminal
1
BR
H15 (male)
2
0.85R
Terminal
1
BR
H15 (male)
2
0.85R
SSW-BR
B16
-
Starting motor switch BR (quick coupler specifications)
SSW-C
B16
D376
Starting motor switch C
Terminal
1
C
H15 (male)
4
0.85RW
Terminal
1
C
H15 (male)
4
0.85RW
Terminal
1
R1
H15 (male)
3
0.85RY
SSW-C
B16
-
Starting motor switch C (quick coupler specifications)
SSW-R1
B16
C376
Starting motor switch R1
40-120
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
SSW-R1
B16
Connector (to) Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
R1
H15 (male)
3
0.85RY
BP
-
3B
H16 (female)
11
1.25B
Equipment name
Type
Number of pins
-
Starting motor switch R1 (quick coupler specifications)
Terminal
1
Terminal
1
-
T01
H23
K225
Floor frame ground
T02
G30
G400
Cab ground
Terminal
1
-
BR (cab harness)
-
3B
T04
I19
P277
Revolving frame ground
Terminal
1
-
DM
-
3B
T05
I19
P276
Revolving frame ground
Terminal
1
-
DL
-
5B
T06
I19
P275
Revolving frame ground
Terminal
1
-
AF
-
1.25B
T07
I20
P274
Revolving frame ground
Terminal
1
-
MN
-
5B
T08
G1
J298
Revolving frame ground
Terminal
1
-
R01
-
0.85B
T09
I20
P273
Revolving frame ground
Terminal
1
-
BG
-
5B
T10
I20
P272
Revolving frame ground
Terminal
1
-
GB
-
5B
T11
D12
I324
Fuel refill pump ground
Terminal
1
-
M24
2
1.25B
T12
I35
C330
Engine controller ground
Terminal
1
-
CE03
1
3B
TOOL PORT
CE01
8
0.85W
-
Communication connector
A
H31
DT
3
B
CE01
6
0.85B
1
J02
19
0.85LgR
O352
PPC lock solenoid valve
2
BR (floor harness)
-
0.85B
V01
I7
PC210-10M0, PC210LC-10M0
DT
2
40-121
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
V02
V03
V04
I7
I8
I8
Equipment name
N355
Swing parking brake solenoid valve
N356
Travel speed increase solenoid valve
DT
2
DT
2
I9
N357
V06
I9
N359
Swing cut off solenoid valve
F309
Attachment selector solenoid valve
D308
Swing stroke solenoid valve
N328
Front pump PCEPC valve
V08
V11
V12
V19
V23
40-122
I5
A8
A7
A9
H1
Number of pins
N354
V05
C3
Type
2-stage relief solenoid valve
Travel junction solenoid valve
V07
Connector (to)
DT
DT
DT
DT
DT
DT
Rear pump PCEPC valve
DT
O328
LS-EPC valve
DT
C340
Merge-divider EPC valve (for main spool)
P325
DT
2
2
2
2
2
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CP02
109
0.85GL
2
BE
-
0.85B
1
GS
-
0.85YL
2
BD
-
0.85B
1
CP02
93
0.85GR
2
BC
-
0.85B
1
CP02
85
0.85BrR
2
BL
-
0.85B
1
CP02
94
0.85BrW
2
BL
-
0.85B
1
CP02
86
0.85BrG
2
BE
-
0.85B
1
CP02
106
0.85BrW
2
BL
-
0.85B
1
S25 (female)
2
0.85GW
2
S25 (female)
5
0.85B
1
S25 (female)
8
0.85GB
2
S25 (female)
11
0.85B
1
CP02
88
0.85GY
2
FJ
-
0.85B
1
CP02
112
0.85LR
2
BF
-
0.85B
2
2
2
2
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
V24
V25
V30
V40
W03
X
XD
XE
XF
XJ
H1
H11
H14
-
A28
-
-
-
-
-
Equipment name
E340
Merge-divider EPC valve (for LS spool)
E311
Variable back pressure solenoid valve
M286
Attachment flow adjustment EPC valve
-
Quick coupler solenoid valve
D388
O238
E272
J228
I228
K237
PC210-10M0, PC210LC-10M0
Window rear limit switch
Joint
Joint
Joint
Joint
Joint
Connector (to)
Type
DT
DT
DT
DT
X
-
-
-
-
-
Number of pins
2
2
2
Pin number
Connector (terminal) No.
Pin number
Diameter and color of wire
1
CP02
89
0.85RL
2
FL
-
0.85B
1
CP02
113
0.85RW
2
BK
-
0.85B
1
CP02
97
0.85G
2
FJ
-
0.85B
1
A17 (male)
1
-
2
A17 (male)
2
-
1
H09 (male)
5
0.5YR
2
H09 (male)
6
0.5B
M10
1
2LR
M11
4
2L
M13
1
2L
A40 (male)
3
BRAID
CM04
8
1.25B
AC95 (female)
9
0.5RW
CP01
61
0.5RW
J01
12
0.5RW
AC95 (female)
8
0.5L
DG
-
1.25L
J02
12
1.25L
AC95 (female)
3
1.25B
AC95 (female)
4
1.25B
J04
20
1.25B
2
2
-
-
-
-
-
-
-
-
-
-
40-123
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
40 TROUBLESHOOTING
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
XL
XM
XN
XQ
XR
XS
XT
XU
XW
Y
40-124
-
-
-
-
-
-
-
-
-
-
F349
F349
K277
G285
M288
L288
N288
L288
H304
O238
Equipment name
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Joint
Connector (to)
Type
-
-
-
-
-
-
-
-
-
-
Number of pins
-
-
-
-
-
-
-
-
-
-
Pin number
-
-
-
-
-
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
NJ
-
0.85B
P02
1
0.85B
P08
1
0.85B
XW
-
0.85B
NE
-
0.85WB
P02
3
0.85WB
P08
3
0.85WB
PD
-
0.85WB
CP01
18
0.85B
DF
-
0.85B
XR
-
0.85B
XW
-
0.85B
BF
-
0.85B
BK
-
0.85B
M14
2
0.85B
P09
1
0.85B
XN
-
0.85B
XS
-
0.85B
P10
1
0.85B
P11
1
0.85B
P12
1
0.85B
XR
-
0.85B
CP01
6
0.85WB
P09
3
0.85WB
XU
-
0.85WB
P10
3
0.85WB
P11
3
0.85WB
P12
3
0.85WB
XT
-
0.85WB
KD
-
0.85B
XL
-
0.85B
XN
-
0.85B
M10
2
2B
M11
6
2BW
M13
2
2BW
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR AND WIRING HARNESS IDENTIFICATION TABLE
Connector (from) Address ConnecCONWiring tor (terminal) No. NECTOR harness LAYOUT diagram
YA
YB
YZ
ZA
ZB
ZZ
-
-
-
-
-
-
F327
D229
D229
F327
D229
D229
PC210-10M0, PC210LC-10M0
Equipment name
Joint
Joint
Joint
Joint
Joint
Joint
Connector (to)
Type
-
-
-
-
-
-
Number of pins
-
-
-
-
-
-
Pin number
-
-
-
-
-
-
Connector (terminal) No.
Pin number
Diameter and color of wire
CE02
47
0.5L
K02
B
0.5L
YB
-
0.5L
AC01
1
0.5L
AC95 (female)
11
0.5L
CM02
9
0.5L
CP01
64
0.5L
N08
10
0.5L
YA
-
0.5L
AC95 (female)
13
0.5LB
CM02
12
0.5LB
CP01
26
0.5LB
K13
B
0.5LB
CE02
46
0.5W
K02
A
0.5W
ZB
-
0.5W
AC01
2
0.5W
AC95 (female)
10
0.5W
CP01
45
0.5W
HE
-
0.5W
N08
3
0.5W
ZA
-
0.5W
AC95 (female)
12
0.5WB
CP01
7
0.5WB
HF
-
0.5WB
K13
A
0.5WB
40-125
CONNECTOR LAYOUT
40 TROUBLESHOOTING
CONNECTOR LAYOUT 1/6
40-126
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR LAYOUT
2/6
PC210-10M0, PC210LC-10M0
40-127
CONNECTOR LAYOUT
40 TROUBLESHOOTING
3/6
40-128
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR LAYOUT
4/6
PC210-10M0, PC210LC-10M0
40-129
CONNECTOR LAYOUT
40 TROUBLESHOOTING
5/6
40-130
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
CONNECTOR LAYOUT
6/6
PC210-10M0, PC210LC-10M0
40-131
CONNECTOR CONTACT IDENTIFICATION
40 TROUBLESHOOTING
CONNECTOR CONTACT IDENTIFICATION (Rev.2017.3)
The male or female is for pin, and the convex or concave is for engaging portion (housing).
40-132
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-133
CONNECTOR CONTACT IDENTIFICATION
40-134
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-135
CONNECTOR CONTACT IDENTIFICATION
40-136
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-137
CONNECTOR CONTACT IDENTIFICATION
40-138
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-139
CONNECTOR CONTACT IDENTIFICATION
40-140
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-141
CONNECTOR CONTACT IDENTIFICATION
40-142
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-143
CONNECTOR CONTACT IDENTIFICATION
40-144
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-145
CONNECTOR CONTACT IDENTIFICATION
40-146
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-147
CONNECTOR CONTACT IDENTIFICATION
40-148
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-149
CONNECTOR CONTACT IDENTIFICATION
40-150
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-151
CONNECTOR CONTACT IDENTIFICATION
40-152
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-153
CONNECTOR CONTACT IDENTIFICATION
40-154
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-155
CONNECTOR CONTACT IDENTIFICATION
40-156
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-157
CONNECTOR CONTACT IDENTIFICATION
40-158
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-159
CONNECTOR CONTACT IDENTIFICATION
40-160
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-161
CONNECTOR CONTACT IDENTIFICATION
40-162
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-163
CONNECTOR CONTACT IDENTIFICATION
40-164
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-165
CONNECTOR CONTACT IDENTIFICATION
40-166
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-167
CONNECTOR CONTACT IDENTIFICATION
40-168
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-169
CONNECTOR CONTACT IDENTIFICATION
40 TROUBLESHOOTING
*: No.1 and 7 pin in male pin side (12-pin connector) do not exist.
40-170
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-171
CONNECTOR CONTACT IDENTIFICATION
40-172
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
PC210-10M0, PC210LC-10M0
CONNECTOR CONTACT IDENTIFICATION
40-173
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
40 TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE (Rev.2014.11)
The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of harness checker assemblies are listed in the horizontal line. Non-kit part
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
●
799-601-8000
37
● ●
799-601-7500
799-601-3200 T-box (for MS)
799-601-7400
●
799-601-7100
37
●
799-601-7000
799-601-3100 T-box (for MS)
●
799-601-2800
21
ID marking
799-601-2700
799-601-2600 T-box (for ECONO)
Part No.
799-601-2500
Part name
Number of pins
T-adapter kit
●
799-601-3380 Plate for MS (14 pins)
●
799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
●
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
●
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
●
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
●
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
●
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
●
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
●
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
●
799-601-3470 Case
●
799-601-2710 Adapter for MIC
5
MIC-5P
● ●
●
799-601-2720 Adapter for MIC
13
MIC-13P
● ●
●
799-601-2730 Adapter for MIC
17
MIC-17P
● ● ●
● ●
●
799-601-2740 Adapter for MIC
21
MIC-21P
● ● ●
● ●
●
799-601-2950 Adapter for MIC
9
MIC-9P
● ● ●
●
799-601-2750 Adapter for ECONO
2
ECONO 2P
● ●
799-601-2760 Adapter for ECONO
3
ECONO 3P
● ●
799-601-2770 Adapter for ECONO
4
ECONO 4P
● ●
799-601-2780 Adapter for ECONO
8
ECONO 8P
● ●
799-601-2790 Adapter for ECONO
12
ECONO 12P
● ●
799-601-2810 Adapter for DLI
8
DLI-8P
● ●
799-601-2820 Adapter for DLI
12
DLI-12P
● ●
799-601-2830 Adapter for DLI
16
DLI-16P
● ●
40-174
PC210-10M0, PC210LC-10M0
799-601-2840
Extension cable (ECONO type)
799-601-2850 Case 799-601-4350 T-box (for DRC60, ECONO)
● ●
Non-kit part
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
●
● 60
●
799-601-4360 Case
●
799-601-7010 Adapter for X (T-adapter)
1
●
●
799-601-7020 Adapter for X
2
X2P
● ● ●
●
799-601-7030 Adapter for X
3
X3P
● ● ●
●
799-601-7040 Adapter for X
4
X4P
● ● ●
●
799-601-7050 Adapter for SWP
6
SW6P
● ● ●
799-601-7060 Adapter for SWP
8
SW8P
● ● ●
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
799-601-7090 Adapter for M
2
799-601-7110
Adapter for M
● ●
● ●
●
●
M2P
● ● ●
●
3
M3P
● ● ●
●
799-601-7120 Adapter for M
4
M4P
● ● ●
●
799-601-7130 Adapter for M
6
M6P
● ● ●
●
799-601-7340 Adapter for M
8
M8P
799-601-7140 Adapter for S
8
S8P
● ● ●
●
799-601-7150 Adapter for S (white)
10
S10P
● ● ●
●
799-601-7160 Adapter for S (blue)
12
S12P
● ● ●
799-601-7170 Adapter for S (blue)
16
S16P
● ● ●
799-601-7330 Adapter for S (white)
16
S16PW
799-601-7350 Adapter for S (white)
12
S12PW
799-601-7180 Adapter for AMP040
8
A8P
●
799-601-7190 Adapter for AMP040
12
A12P
●
●
799-601-7210 Adapter for AMP040
16
A16P
● ● ●
●
799-601-7220 Adapter for AMP040
20
A20P
● ● ●
●
799-601-7230 Short socket adapter for X
2
● ● ●
●
799-601-7240 Case
●
● ● ●
● ●
799-601-7270 Case
●
799-601-7510 Adapter for 070
10
07-10
●
799-601-7520 Adapter for 070
12
07-12
●
PC210-10M0, PC210LC-10M0
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
ECONO 12P
799-601-7000
12
799-601-2800
ID marking
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
Number of pins
40 TROUBLESHOOTING
40-175
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
40 TROUBLESHOOTING
5
REL-5P
●
799-601-7370 Adapter for relay
6
REL-6P
●
799-601-7380 Adapter for JFC
2
799-601-9010 Adapter for DTM
2
DTM2
●
●
799-601-9020 Adapter for DT
2
DT2
●
●
799-601-9030 Adapter for DT
3
DT3
●
●
799-601-9040 Adapter for DT
4
DT4
●
●
799-601-9050 Adapter for DT
6
DT6
●
●
799-601-9060 Adapter for DT (gray)
8
DT8GR
●
●
799-601-9070 Adapter for DT (black)
8
DT8B
●
●
799-601-9080 Adapter for DT (green)
8
DT8G
●
●
799-601-9090 Adapter for DT (brown)
8
DT8BR
●
●
799-601-9110
12
DT12GR
●
●
799-601-9120 Adapter for DT (black)
12
DT12B
●
●
799-601-9130 Adapter for DT (green)
12
DT12G
●
●
799-601-9140 Adapter for DT (brown)
12
DT12BR
●
●
799-601-9210 Adapter for HD30-18
8
D18-8
● ●
799-601-9220 Adapter for HD30-18
14
D18-14
● ●
799-601-9230 Adapter for HD30-18
20
D18-20
● ●
799-601-9240 Adapter for HD30-18
21
D18-21
● ●
799-601-9250 Adapter for HD30-24
9
D24-9
● ●
799-601-9260 Adapter for HD30-24
16
D24-16
● ●
799-601-9270 Adapter for HD30-24
21
D24-21
● ●
799-601-9280 Adapter for HD30-24
23
D24-23
● ●
799-601-9290 Adapter for HD30-24
31
D24-31
● ●
Adapter for DT (gray)
●
799-601-9310 Plate for HD30 (24 pins) 799-601-9320 T-box (for ECONO)
24
799-601-9330 Case
● ●
● ●
● ●
●
● ●
●
●
799-601-9340 Case
●
799-601-9350 Adapter for DRC
40
DRC-40
●
799-601-9360 Adapter for DRC
24
DRC-24
●
799-601-9410* Socket for engine (CRI-T2)
2
G
40-176
Non-kit part
799-601-7360 Adapter for relay
799-601-4201
●
799-601-4101
07-20
799-601-9300
20
799-601-9200
799-601-7550 Adapter for 070
799-601-9100
●
799-601-9000
07-18
799-601-8000
18
799-601-7500
799-601-7540 Adapter for 070
799-601-7400
●
799-601-7100
07-14
799-601-7000
14
799-601-2800
799-601-7530 Adapter for 070
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
●
PC210-10M0, PC210LC-10M0
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
T-adapter kit
S
●
2
C
● ●
795-799-5540* Socket TIM for engine (CRIT3)
2
A
● ●
795-799-5460 Cable for engine (HPI-T2)
3
●
795-799-5470 Cable for engine (HPI-T2)
3
●
795-799-5480 Cable for engine (HPI-T2)
3
●
Non-kit part
2
799-601-4201
795-799-5520* Socket for engine (HPI-T2)
799-601-4101
●
799-601-9300
1, 2, 3
799-601-9200
3
799-601-9100
799-601-9440* Socket for engine (CRI-T2)
799-601-9000
● ●
799-601-8000
P
799-601-7500
2
799-601-7400
799-601-9430* Socket PCV for engine (CRIT3)
799-601-7100
● ●
799-601-7000
A3
799-601-2800
3
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
40 TROUBLESHOOTING
Adapter for engine (CRI-T2) 799-601-9420
Adapter PFUEL for engine (CRI-T3) Oil pressure sensor Socket for engine (CRI-T2)
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor Socket for engine (HPI-T2)
799-601-4110
Adapter PIM for engine (140T3)
4
ITT3N
● ●
799-601-4130
Adapter NE, CAM for engine (CRI-T3)
3
FCIN
● ●
3
FCIG
● ●
3
FCIB
● ●
2
4160
● ●
3
4180
● ●
3
1, 2, 3L
● ●
4
1, 2, 3, 4C
● ●
799-601-4140 799-601-4150 799-601-4160 799-601-4180 799-601-4190* 799-601-4230*
Adapter for engine (CRI-T3) Ambient pressure Adapter POIL for engine (CRI-T3) Adapter for engine (CRI-T3) Oil pressure switch Adapter PEVA for engine (CRI-T3) Socket for engine (CRI-T3) Common rail pressure Socket for engine (CRI-T3) Intake pressure/temperature
799-601-4240*
Socket PAMB for engine (CRI-T3)
3
1, 2, 3A
● ●
799-601-4250*
Socket PIM for engine (CRIT3)
3
1, 2, 3B
● ●
799-601-4330*
Socket G for engine (CRIT3)
3
1, 2, 3G
● ●
PC210-10M0, PC210LC-10M0
40-177
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
40 TROUBLESHOOTING
799-601-4220 Adapter for controller (ENG)
60
DRC60
●
799-601-4390*
Socket for controller (95ENG)
Non-kit part
●
799-601-4201
DRC50
799-601-4101
50
799-601-9300
Adapter for controller (ENG)
799-601-9200
799-601-4211
799-601-9100
DTP4
799-601-9000
4
799-601-8000
799-601-4260 Adapter for controller (ENG)
799-601-7500
1, 2, 3, 4T
799-601-7400
4
799-601-7100
Socket for engine (CRI-T3) 799-601-4380* (95) Intake pressure/temperature
Pump actuator
799-601-7000
2, PA
Socket for engine (CRI-T3)
799-601-2800
2
799-601-4340*
Part name
799-601-2700
ID marking
Part No.
799-601-2500
Number of pins
T-adapter kit
● ●
● ● ●
60
●
799-601-4280* Box for controller (PUMP)
121
●
799-601-9720 Adapter for controller (HST)
16
HST16A
●
799-601-9710 Adapter for controller (HST)
16
HST16B
●
799-601-9730 Adapter for controller (HST)
26
HST26A
●
2, 3, 4
●
799-902-9600 T-adapter for ICT control box
26
●
799-902-9700 T-box
26
●
7
●
799-601-9890
799-970-1010
Multi-adapter for DT 2 to 4, DTM 2 pins
Adapter for radio control receiver
*: These are not T-adapters but sockets.
40-178
PC210-10M0, PC210LC-10M0
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
4
799-601-4620
●
799-601-4630 Adapter for controller (ENG-T4)
2
799-601-4630
●
799-601-4640 Adapter for controller (ENG-T4)
2
799-601-4640
●
799-601-4651 Adapter for controller (ENG-T4)
24
799-601-4651
●
799-601-4660 Adapter for controller (ENG-T4)
3
799-601-4660
●
799-902-9310 Adapter for control box
19
799-902-9310
●
799-902-9320 Adapter for IMU
10
799-902-9320
●
799-902-9330 Adapter for MS cylinder
6
799-902-9330
●
799T-601-4611
KDPF differential pressure sensor short socket adapter
4
799T-601-4611
●
799T-601-4670
KDPF outlet pressure sensor short socket adapter
4
799T-601-4670
●
799T-601-4680 KDPF dummy temperature sensor
4
799T-601-4680
●
PC210-10M0, PC210LC-10M0
799-902-9300
799-601-4620 Adapter for controller (ENG-T4)
Part name
799-A65-4600
ID marking
Part No.
Non-kit part
T-adapter kit
Number of pins
40 TROUBLESHOOTING
40-179
FUSE LOCATION AND CONNECTION TABLE
40 TROUBLESHOOTING
FUSE LOCATION AND CONNECTION TABLE Locations and connection tables of fuses, fusible links and slow-blow fuses are shown. Before you troubleshoot the electrical system, check the fuses, fusible links and slow-blow fuses. For details of the inspection method, see "INSPECTION PROCEDURE BEFORE TROUBLESHOOTING", "CHECK ELECTRIC EQUIPMENT".
LOCATIONS OF FUSE BOXES AND FUSE NO. •
Remove the rear right cover in the cab. You will find fuse box F01.
*
•
Fuse No. in fuse box F01
LOCATIONS OF FUSIBLE LINKS AND SLOW-BLOW FUSES •
Remove the upper cover of the air cleaner. Remove the battery relay cover inside of it. You will find fusible links F04, F05 and slow-blow fuse F12.
G0042691
40-180
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FUSE LOCATION AND CONNECTION TABLE
CONNECTION TABLE OF FUSE BOX F01 Type of power supply
Power supply to fuse
Fusible link F04 (65A) Switched power supply
Starting switch ACC terminal
Continuous power supply
Fuse capacity
1
5A
2
30A
Solenoid valve
3
5A
PPC hydraulic lock solenoid
4
10A
Window washer, cigarette lighter
5
10A
Horn
6
5A
Auto preheater
7
10A
Revolving lamp (option)
8
20A
Working lamp
9
10A
Radio, speaker, onetouch power maximizing switch
10
20A
Headlamp, rear working lamp
11
20A
Air conditioner unit
12
10A
Optional power supply (1)
13
30A
Optional power supply (2), 12V power supply
14
5A
Air conditioner controller
15
5A
Starting switch ACC signal
16
10A
Working lamp
17
10A
Radio backup, room lamp, system operating lamp
18
20A
Machine monitor, pump controller, starting switch terminal B
19
30A
Engine controller
20
5A
Air conditioner controller backup
21
10A
Optional power supply (continuous power supply)
Fusible link F05 (65A)
PC210-10M0, PC210LC-10M0
Power supply connected to
Fuse No.
40-181
FUSE LOCATION AND CONNECTION TABLE
40 TROUBLESHOOTING
CONNECTION TABLE OF SLOW-BLOW FUSE F12 Type of power supply
Power supply to fuse
Fuse capacity
Switched power supply
Electric intake air heater relay 80A (Ribbon heater relay)
Power supply connected to Electric intake air heater (ribbon heater)
REMARK • A switched power supply supplies power only when the starting switch is in the ON position. A continuous power supply supplies power always regardless of the starting switch position. • A connection table is attached on the back of fuse box cover. There can be different notations for the same destination.
40-182
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING
DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING Short socket adapter for KDPF differential pressure sensor
REMARK • This is used for the troubleshooting for failure code [CA1883]. • The KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated. • This is included in kit part number 799-A65-4600.
PC210-10M0, PC210LC-10M0
40-183
DRAWING OF SHORT CIRCUIT ELECTRICAL CONNECTOR FOR TROUBLESHOOTING
40 TROUBLESHOOTING
Short socket adapter for KDPF outlet pressure sensor
REMARK • This is used for the troubleshooting for failure code [CA3135]. • The KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated. • This is included in kit part number 799-A65-4600.
40-184
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODES TABLE
FAILURE CODES TABLE Failure code
Failure (displayed on screen)
Applicable equipment
Action level
History category
602KNX
Additional Hyd Oil Filter Clogging
PUMP
-
Mechanical system
6AZ0ZG
Quick Coupler System Abnormality
PUMP
Mechanical system
879AKA
A/C Recirculation Air Temperature Sensor Open Circuit
MON
-
Electrical system
879AKB
Air Conditioner Recirculation Air Temperature Sensor Short Circuit
MON
-
Electrical system
879BKA
Air Conditioner Outside Air Temperature Sensor Open Circuit
MON
-
Electrical system
879BKB
Air Conditioner Outside Air Temperature Sensor Short Circuit
MON
-
Electrical system
879CKA
Ventilating Sensor Open Circuit
MON
-
Electrical system
879CKB
Ventilating Sensor Short Circuit
MON
-
Electrical system
879DKZ
Sunlight Sensor Open Circuit or Short Circuit
MON
-
Electrical system
879EMC
Ventilation Damper Malfunction
MON
L01
Electrical system
879FMC
Air Mix Damper Malfunction
MON
L01
Electrical system
879GKX
Refrigerant Pressure Input Signal Out of Range
MON
L01
Electrical system
989L00
Engine Controller Lock Caution 1
MON
-
Electrical system
989M00
Engine Controller Lock Caution 2
MON
-
Electrical system
989N00
Engine Controller Lock Caution 3
MON
-
Electrical system
AA10NX
Air Cleaner Clogging
MON
L01
Mechanical system
AB00KE
Charge Voltage Low
MON
L03
Mechanical system
B@BAZG Engine Oil Pressure Low
ENG
L03
Mechanical system
B@BAZK Eng Oil Level Low
MON
L01
Mechanical system
B@BCNS Eng Water Overheat
ENG
L02
Mechanical system
B@BCQA Eng Water Level Low
MON
L02
Mechanical system
B@BCZK Eng Water Level Low
MON
L01
Mechanical system
PC210-10M0, PC210LC-10M0
Remarks
40-185
FAILURE CODES TABLE
Failure code
Failure (displayed on screen)
B@HANS Hydraulic Oil Overheat
40 TROUBLESHOOTING
Applicable equipment
Action level
History category
PUMP
L02
Mechanical system
CA111
Engine Controller Internal Abnormality
ENG
L04
Electrical system
CA115
Engine NE and Bkup Speed Sensor Error
ENG
L04
Electrical system
CA122
Charge Air Pressure Sensor High Error
ENG
L03
Electrical system
CA123
Charge Air Pressure Sensor Low Error
ENG
L03
Electrical system
CA131
Throttle Sensor High Error
ENG
L03
Electrical system
CA132
Throttle Sensor Low Error
ENG
L03
Electrical system
CA144
Coolant Temperature Sensor High Error
ENG
L01
Electrical system
CA145
Coolant Temperature Sensor Low Error
ENG
L01
Electrical system
CA153
Charge Air Temperature Sensor High Error
ENG
L03
Electrical system
CA154
Charge Air Temperature Sensor Low Error
ENG
L03
Electrical system
CA155
Charge Air Temperature High Speed Derate
ENG
L03
Electrical system
CA187
Sensor 2 Supply Voltage Low Error
ENG
L03
Electrical system
CA221
Ambient Pressure Sensor High Error
ENG
L03
Electrical system
CA222
Ambient Pressure Sensor Low Error
ENG
L03
Electrical system
CA227
Sensor 2 Supply Voltage High Error
ENG
L03
Electrical system
CA234
Engine Overspeed
ENG
L02
Mechanical system
CA238
NE Speed Sensor Supply Voltage Error
ENG
L01
Electrical system
CA271
PCV 1 Short Circuit Error
ENG
L03
Electrical system
CA272
PCV 1 Open Circuit Error
ENG
L03
Electrical system
CA322
Injector #1 (L#1) Open Circuit Error or Short Circuit Error
ENG
L03
Electrical system
CA323
Injector #5 (L#5) Open Circuit Error or Short Circuit Error
ENG
L03
Electrical system
CA324
Injector #3 (L#3) Open Circuit Error or Short Circuit Error
ENG
L03
Electrical system
40-186
Remarks
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODES TABLE
Failure code
Failure (displayed on screen)
Applicable equipment
Action level
History category
CA325
Injector #6 (L#6) Open Circuit Error or Short Circuit Error
ENG
L03
Electrical system
CA331
Injector #2 (L#2) Open Circuit Error or Short Circuit Error
ENG
L03
Electrical system
CA332
Injector #4 (L#4) Open Circuit Error or Short Circuit Error
ENG
L03
Electrical system
CA342
Calibration Code Incompatibility
ENG
L04
Electrical system
CA351
Injectors Drive Circuit Error
ENG
L03
Electrical system
CA352
Sensor 1 Supply Voltage Low Error
ENG
L03
Electrical system
CA386
Sensor 1 Supply Voltage High Error
ENG
L03
Electrical system
CA435
Engine Oil Pressure SW Error
ENG
L01
Electrical system
CA441
Power Voltage Low Error
ENG
L04
Electrical system
CA442
Power Voltage High Error
ENG
L04
Electrical system
CA449
Common Rail Pressure High Error 2
ENG
L03
Electrical system
CA451
Common Rail Pressure Sensor High Error
ENG
L03
Electrical system
CA452
Common Rail Pressure Sensor Low Error
ENG
L03
Electrical system
CA488
Charge Air Temperature High Torque Derate
ENG
L03
Electrical system
CA553
Common Rail Pressure High Error 1
ENG
L01
Electrical system
CA559
Common Rail Pressure Low Error 1
ENG
L01
Electrical system
CA689
Engine NE Speed Sensor Error
ENG
L01
Electrical system
CA731
Engine Bkup Speed Sensor Phase Error
ENG
L01
Electrical system
CA757
All Continuous Data Lost Error
ENG
L04
Electrical system
CA778
Engine Backup Speed Sensor Error
ENG
L01
Electrical system
CA2185
Throttle Sensor Supply Voltage High Error
ENG
L03
Electrical system
CA2186
Throttle Sensor Supply Voltage Low Error
ENG
L03
Electrical system
CA2249
Common Rail Pressure Low Error 2
ENG
L03
Electrical system
PC210-10M0, PC210LC-10M0
Remarks
40-187
FAILURE CODES TABLE
Failure code
Failure (displayed on screen)
40 TROUBLESHOOTING
Applicable equipment
Action level
History category
CA2311
IMV Solenoid Error
ENG
L03
Electrical system
CA2555
Intake Air Heater Relay Open Circuit Error
ENG
L01
Electrical system
CA2556
Intake Air Heater Relay Short Circuit Error
ENG
L01
Electrical system
D110KB
Battery Relay Output Short Circuit
PUMP
L01
Electrical system
D19JKZ
Personal code relay open circuit or short circuit
MON
L03
Electrical system
D1N0KA
Open circuit in electric priming pump relay
PUMP
L01
Electrical system
D1N0KB
Short circuit in electric priming pump relay
PUMP
L01
Electrical system
D1N0KY
Hot short circuit in electric priming pump relay
PUMP
L01
Electrical system
D811MC
KOMTRAX Malfunction
KOMTRAX
-
Electrical system
D862KA
GPS Antenna Open Circuit
KOMTRAX
-
Electrical system
D8ALKA
System Operating Lamp Open Circuit (KOMTRAX)
KOMTRAX
-
Electrical system
D8ALKB
System Operating Lamp Short Circuit (KOMTRAX)
KOMTRAX
-
Electrical system
D8AQKR CAN 2 Defective Communication (KOMTRAX)
MON
-
Electrical system
DA20MC Pump Controller Malfunction
PUMP
-
Electrical system
DA22KK
Pump Controller Solenoid Power Voltage Low Error
PUMP
L03
Electrical system
DA25KP
5 V Sensor Power Supply Output 1 Voltage Low
PUMP
-
Electrical system
DA26KP
5 V Sensor Power Supply Output 2 Voltage Low
PUMP
-
Electrical system
PUMP
L01
Electrical system
DA29KQ Model Selection Signal Mismatch (Pump Controller) DA2LKA
System Operating Lamp Open Circuit (Pump Controller)
PUMP
-
Electrical system
DA2LKB
System Operating Lamp Short Circuit (Pump Controller)
PUMP
-
Electrical system
DA2QKR
Controller Area Network 2 Defective Communication (Pump Controller)
MON
L03
Electrical system
DA2RKR
Controller Area Network 1 Defective Communication (Pump Controller)
MON
L04
Electrical system
MON
-
Electrical system
DAF0MB Monitor ROM Abnormality
40-188
Remarks
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applicable equipment
Action level
History category
DAF0MC Monitor Malfunction
MON
-
Electrical system
DAF9KQ Model Selection Signal Mismatch (Monitor)
MON
L03
Electrical system
KOMTRAX
-
Electrical system
Failure code
Failure (displayed on screen)
DAFGMC GPS Module Malfunction DAFLKA
System Operating Lamp Open Circuit (Monitor)
MON
-
Electrical system
DAFLKB
System Operating Lamp Short Circuit (Monitor)
MON
-
Electrical system
KOMTRAX
-
Electrical system
DAZ9KQ Model Selection Signal Mismatch (Air Conditioner)
MON
-
Electrical system
DAZQKR CAN 2 defective communication (Air conditioner)
MON
L01
Electrical system
DB2QKR CAN 2 defective communication (Engine controller)
MON
L03
Electrical system
DDPAKA Additional Hyd Oil Filter Clog Switch Open Circuit
PUMP
L01
Electrical system
DGH2KA Hydraulic Oil Temperature Sensor Open Circuit
PUMP
L01
Electrical system
DGH2KB Hydraulic Oil Temperature Sensor Ground Fault
PUMP
L01
Electrical system
DHA4KA Air Cleaner Clog Sensor Open Circuit
MON
L01
Electrical system
DHE5MA Blow By Pressure Sensor Defective Function
PUMP
-
Electrical system
DHX1MA Overload Warning Sensor Defective Function
PUMP
L04
Electrical system
DHPAMA Front Pump Pressure Sensor Defective Function
PUMP
L01
Electrical system
DHPBMA Rear Pump Pressure Sensor Defective Function
PUMP
L01
Electrical system
DHS3MA Arm IN PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
DAFQKR CAN 2 Defective Communication (Monitor)
DHS4MA
Bucket CURL PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
DHS8MA
Boom RAISE PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
PUMP
L01
Electrical system
DHS9MA Boom LOWER PPC pressure sensor malfunction DHSAMA
Swing Right PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
DHSBMA
Swing Left PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
PC210-10M0, PC210LC-10M0
Remarks
40-189
FAILURE CODES TABLE
Failure code
Failure (displayed on screen)
DHSCMA Arm OUT PPC Pressure Sensor Defective Function
40 TROUBLESHOOTING
Applicable equipment
Action level
History category
PUMP
L01
Electrical system
DHSDMA
Bucket DUMP PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
DHSFMA
Travel Forward Left PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
DHSGMA
Travel forward RIGHT PPC pressure sensor malfunction
PUMP
L01
Electrical system
DHSHMA
Travel Reverse Left PPC Pressure Sensor Defective Function
PUMP
L01
Electrical system
DHSJMA
Travel reverse RIGHT PPC pressure sensor malfunction
PUMP
L01
Electrical system
DJG1KX
WIF Sensor Input Signal Out of Range
PUMP
-
Mechanical system
DKR0MA Front Pump Swash Plate Sensor Defective Function
PUMP
L01
Electrical system
DKR1MA R pump swash plate sensor malfunction
PUMP
L01
Electrical system
PUMP
L01
Electrical system
DKR2NX Return Filter1 Clogging
KPLUS
-
Mechanical system
DLM5KA Fan speed sensor open circuit
PUMP
L01
Electrical system
DLM5MB Fan control: Mismatch
PUMP
L01
Electrical system
DKR2MA
Return Filter Bypass Stroke Sensor 1 Defective Function
DR21KX
Camera 2 Picture Reverse Drive Input Out of Range
MON
L01
Electrical system
DR31KX
Camera 3 Picture Reverse Drive Input Out of Range
MON
L01
Electrical system
DV20KB
Travel Alarm Short Circuit
PUMP
L01
Electrical system
DW43KA Travel Speed Solenoid Open Circuit
PUMP
L01
Electrical system
DW43KB Travel Speed Solenoid Short Circuit
PUMP
L01
Electrical system
DW43KY Travel Speed Solenoid Hot Short Circuit
PUMP
L01
Electrical system
DW45KA Swing Parking Brake Solenoid Open Circuit
PUMP
L03
Electrical system
DW45KB Swing Parking Brake Solenoid Short Circuit
PUMP
L03
Electrical system
HYB Controller
L03
Electrical system
PUMP
L01
Electrical system
DW45KY
Short circuit in swing parking brake solenoid power supply line
DW91KA Travel Junction Solenoid Open Circuit
40-190
Remarks
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODES TABLE
Applicable equipment
Action level
History category
DW91KB Travel Junction Solenoid Short Circuit
PUMP
L01
Electrical system
DW91KY Travel Junction Solenoid Hot Short Circuit
PUMP
L01
Electrical system
DW97KA Swing Stroke Control Solenoid Open Circuit
PUMP
L01
Electrical system
DW97KB Swing Stroke Control Solenoid Short Circuit
PUMP
L01
Electrical system
DW97KY Swing Stroke Control Solenoid Hot Short Circuit
PUMP
L01
Electrical system
Failure code
Failure (displayed on screen)
DWA2KA
Attachment Single or 2-Way Change Solenoid Open Circuit
PUMP
L03
Electrical system
DWA2KB
Attachment Single or 2-Way Change Solenoid Short Circuit
PUMP
L03
Electrical system
DWA2KY
Attachment Single or 2-Way Change Solenoid Hot Short Circuit
PUMP
L03
Electrical system
DWK0KA 2-Stage Relief Solenoid Open Circuit
PUMP
L01
Electrical system
DWK0KB 2-Stage Relief Solenoid Short Circuit
PUMP
L01
Electrical system
DWK0KY 2-Stage Relief Solenoid Hot Short Circuit
PUMP
L01
Electrical system
DWK2KA Variable Back Pressure Solenoid Open Circuit
PUMP
L01
Electrical system
DWK2KB Variable Back Pressure Solenoid Short Circuit
PUMP
L01
Electrical system
DWK2KY Variable Back Pressure Solenoid Hot Short Circuit
PUMP
L01
Electrical system
DWK8KA Swing Pressure Cutoff Solenoid Open Circuit
PUMP
L01
Electrical system
DWK8KB Swing Pressure Cutoff Solenoid Short Circuit
PUMP
L01
Electrical system
DWK8KY Swing Pressure Cutoff Solenoid Hot Short Circuit
PUMP
L01
Electrical system
DWN5KA Fan Clutch Solenoid Open Circuit
PUMP
L03
Electrical system
DWN5KB Fan Clutch Solenoid short Circuit
PUMP
L03
Electrical system
DWN5KY Fan Clutch Solenoid Hot Short Circuit
PUMP
L03
Electrical system
DXA8KA Front Pump PC-EPC Solenoid Open Circuit
PUMP
L03
Electrical system
DXA8KB Front Pump PC-EPC Solenoid Short Circuit
PUMP
L03
Electrical system
DXA9KA Rear Pump PC-EPC Solenoid Open Circuit
PUMP
L03
Electrical system
PC210-10M0, PC210LC-10M0
Remarks
40-191
FAILURE CODES TABLE
40 TROUBLESHOOTING
Applicable equipment
Action level
History category
DXA9KB Rear Pump PC-EPC Solenoid Short Circuit
PUMP
L03
Electrical system
DXE0KA LS-EPC Solenoid Open Circuit
PUMP
L01
Electrical system
DXE0KB LS-EPC Solenoid Short Circuit
PUMP
L01
Electrical system
Failure code
Failure (displayed on screen)
DXE4KA
Attachment Flow Regulating EPC Solenoid Open Circuit
PUMP
-
Electrical system
DXE4KB
Attachment Flow Regulating EPC Solenoid Short Circuit
PUMP
-
Electrical system
DXE4KY Attachment Flow EPC Hot Short Circuit
PUMP
-
Electrical system
DXE5KA Merge-divider Main Solenoid Open Circuit
PUMP
L01
Electrical system
DXE5KB Merge-divider Main Solenoid Short Circuit
PUMP
L01
Electrical system
DXE6KA Merge-divider LS Solenoid Open Circuit
PUMP
L01
Electrical system
DXE6KB Merge-divider LS Solenoid Short Circuit
PUMP
L01
Electrical system
DY20KA
PUMP
-
Electrical system
DY20MA Wiper Motor Defective Function
PUMP
-
Electrical system
DY2CKB Washer Motor Short Circuit
PUMP
-
Electrical system
DY2DKB Wiper Motor (Normal Rotation) Short Circuit
PUMP
-
Electrical system
DY2EKB Wiper Motor (Reverse Rotation) Short Circuit
PUMP
-
Electrical system
F@BBZL Blow By Pressure High Error
MON
L01
Electrical system
Wiper Motor Open Circuit
•
In this table, failure codes are arranged in alphabetical order.
•
Applicable equipment is the controller which checks the system. MON: Machine monitor
Remarks
ENG: Engine controller PUMP: Pump controller KOMTRAX: KOMTRAX terminal KPLUS: KOMTRAX PLUS controller HYB Con: HYBRID controller •
Failure codes that do not have a number in their action level column are not shown on the standard screen when a failure occurs. They are only recorded in the abnormality record (electrical system and mechanical system) of the service menu.
•
History category shows which category (of electrical system and mechanical system) the failure belongs to. This is recorded in the abnormality record of the service menu. (For details, see "Troubleshooting by failure code (Display of code)".)
40-192
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [602KNX]
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) FAILURE CODE [602KNX] Details of failure
The pump controller senses a clogged hydraulic oil additional filter.
Action level
-
Action of controller
None in particular.
Phenomenon on machine
If the machine continues to be operated, the hydraulic components can suffer a damage.
Associated informa- tion No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The hydraulic oil additional filter is normal.
NO
• YES 1. 2
Hydraulic oil additional filter
2.
Check if the hydraulic oil additional filter is clogged.
• •
Is the hydraulic oil additional filter normal? Abnormal phenomenon The hydraulic oil additional filter is clogged.
PC210-10M0, PC210LC-10M0
NO
Go to the next inspection item. The hydraulic oil additional filter is defective.
•
Clean or replace the hydraulic oil additional filter.
•
Go to "Confirmation of repair".
40-193
FAILURE CODE [602KNX]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P68. Connect the T-adapter to the male side.
3.
Measure the resistance.
Clogging 4. switch for hydraulic oil additional filter
Item
Measuring point and measurement condition
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01 and P68. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Measuring point and measurement condition
Between CP01 (female) (17) and Resist- P68 (female) (1) ance Between P68 (female) (2) and ground
Standard value
The clogging switch for the hydraulic oil additional filter is normal.
•
Go to the next inspection item. The clogging switch for the hydraulic oil additional filter is defective.
•
NO
Max. 1 Ω
1.
• YES
Does the troubleshooting result agree with the standard value?
ResistBetween P68 (male) (1) and (2) ance
4
Diagnosis and treatment
•
Replace the clogging switch for the hydraulic oil additional filter.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
• YES
NO
Max. 1 Ω
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 1 Ω
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair
40-194
Do the troubleshooting above again.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position to troubleshoot.
4.
Check the abnormality record.
5.
Is this failure code shown in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [602KNX]
Circuit diagram associated with clogging switch for hydraulic oil additional filter
PC210-10M0, PC210LC-10M0
40-195
FAILURE CODE [6AZ0ZG]
40 TROUBLESHOOTING
FAILURE CODE [6AZ0ZG] Details of failure
The pump controller senses a low pressure in the quick coupler.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
If the machine continues to be operated, the hydraulic components can suffer a damage.
Pre-troubleshooting If failure code [DHPAMA] or [DHPBMA] is also shown, do the troubleshooting for that Associated informacode first. tion Monitoring code The pump pressure can be monitored. (Code: 01100, 01101) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P50. Connect the T-adapter to the male side.
3.
Start the engine.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The quick coupler pressure switch is normal.
NO
• YES •
Go to the next inspection item.
•
The quick coupler pressure switch is defective.
•
Replace the quick coupler pressure switch.
•
Go to "Confirmation of repair".
REMARK
2
Quick coupler 4. pressure switch 5.
Check that the pressure of the F pump and R pump are 3.43 MPa (35 kg/cm2) or above. Measure the continuity. Does the troubleshooting result agree with the standard value? Item
Continuity
40-196
StandMeasurement position and condition ard value Between P50 (male) (2) and (1)
Continuity
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [6AZ0ZG]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, P50. Connect the Tadapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
StandMeasurement position and condition ard value
Between CP01 (female) (54) and Resist- P50 (female) (2) ance Between P50 (female) (1) and
4
Turn the starting switch to the OFF position.
2.
Disconnect connector P50.
3.
Connect the T-adapter to the female side of connector P50.
4.
Turn the starting switch to the ON position.
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between P50 (female) (2) and (1)
Ground fault in wiring harness
NO
•
Max. 1 Ω
1.
Item
5
YES
Max. 1 Ω
ground
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02, S42.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
PC210-10M0, PC210LC-10M0
YES
StandMeasurement position and condition ard value
Resist- Between CM02 (female) (6) or S42 ance (female) (8) and ground
NO
Min. 1 MΩ
NO
40-197
FAILURE CODE [6AZ0ZG]
No.
6
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02, S42.
3.
Connect the T-adapter to the female side of connector CM02.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
YES
StandMeasurement position and condition ard value
Resist- Between CM02 (female) (6) and ance each pin other than (6)
Diagnosis and treatment
NO
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair
40-198
Do the troubleshooting above again.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position to troubleshoot.
4.
Check the abnormality record.
5.
Is this failure code displayed in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [6AZ0ZG]
Circuit diagram associated with quick coupler pressure switch
Circuit diagram associated with quick coupler alarm buzzer switch
PC210-10M0, PC210LC-10M0
40-199
FAILURE CODE [879AKA]
40 TROUBLESHOOTING
FAILURE CODE [879AKA] Details of failure
The air conditioner controller senses an open circuit in the recirculation air temperature sensor.
Action level
•
The air conditioner controller sends an open circuit information of the recirculation air temperature sensor to the machine monitor by CAN communication.
•
When in the automatic air conditioner mode, stops the air conditioner.
Action of controller
Phenomenon on machine
Since the inside air temperature sensor of the air conditioner has an open circuit, the automatic air conditioner does not operate. (The air conditioner operates in manual mode.)
Associated informa- Reference information tion Replace the air conditioner unit as an assembly. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The removed air conditioner controller is normal.
NO
•
2
Air conditioner controller
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
YES
•
Restore the removed air conditioner controller.
•
Go to the next inspection item. NO The repair is completed. YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
40-200
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
Cause
FAILURE CODE [879AKA]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-201
FAILURE CODE [879AKB]
40 TROUBLESHOOTING
FAILURE CODE [879AKB] Details of failure
The air conditioner controller senses a short circuit in the recirculation air temperature sensor.
Action level
•
The air conditioner controller sends a short circuit information of the recirculation air temperature sensor to the machine monitor by CAN communication.
•
When in the automatic air conditioner mode, stops the air conditioner.
Action of controller
Phenomenon on machine
Since the inside air temperature sensor of the air conditioner has a short circuit, the automatic air conditioner does not operate. (The air conditioner operates in manual mode.)
Associated informa- Reference information tion Replace the air conditioner unit as an assembly. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The removed air conditioner controller is normal.
NO
•
2
Air conditioner controller
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
YES
•
Restore the removed air conditioner controller.
•
Go to the next inspection item. NO The repair is completed. YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
40-202
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
Cause
FAILURE CODE [879AKB]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-203
FAILURE CODE [879BKA]
40 TROUBLESHOOTING
FAILURE CODE [879BKA] Details of failure
The air conditioner controller senses an open circuit in the fresh air temperature sensor.
Action level
-
Action of controller
Phenomenon on machine
•
The air conditioner controller sends an open circuit information of the fresh air temperature sensor to the machine monitor by CAN communication.
•
Ignores data of the outside air temperature sensor and continues control of the air conditioner in automatic air conditioner mode.
Since the outside air temperature sensor of air conditioner has an open circuit, the outside air temperature is not considered in the automatic air conditioner mode. (The air conditioner operates in manual mode.) Pre-troubleshooting •
Check if this failure code is shown on the electrical system abnormality record screen in the service mode of the machine monitor.
Reference information Associated information
No.
•
See "INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS” for each connector location.
•
Since a T-adapter is not provided for the air conditioner controller connector ACECU and the pins are small, use an intermediate connector to troubleshoot. (Although the intermediate connector also has no T-adapter, it has large pins.)
•
If it is necessary to repair the air conditioner wiring harness between the air conditioner controller connector ACECU and the intermediate connector, replace the air conditioner unit.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
40-204
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [879BKA]
Cause
Outside air temperature sensor
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P18.
3.
Connect the T-adapter to the female side of connector P18.
4.
Measure the resistance.
5.
Does the measurement result match with the judgment criteria? Item
Measurement position/condition
Between P18 Resist(male) (2) and ance (1)
3
Diagnosis and treatment
Temperature: 25°C
Standard value
2.
Disconnect connector AC01 and connector P18.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result match with the judgment criteria? Measurement position/condition
NO
Approximately 1.7 kΩ
Turn the starting switch to the OFF position.
Item
Standard value
YES
(female) (1)
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system. REMARK For the operating method, see TESTING AND ADJUSTING, "Setting and operation of machine monitor", "Method for confirming abnormality record (electrical systems)".
5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
PC210-10M0, PC210LC-10M0
Go to the next inspection item.
•
The outside air temperature sensor is defective.
•
Replace the outside air temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed air conditioner controller is normal.
•
Restore the removed air conditioner controller.
•
Go to the next inspection item.
Ω
1.
Air conditioner controller
•
NO
Between AC01 (female) (8) and P18 Max. 1 Ω Resist- (female) (2) ance Between AC01 (female) (7) and P18 Max. 1
4
The outside air temperature sensor is normal.
YES
1.
Open circuit in wiring harness
•
YES
NO The repair is completed.
40-205
FAILURE CODE [879BKA]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
NO The repair is completed.
Circuit diagram associated with air conditioner outside air temperature sensor
40-206
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [879BKB]
FAILURE CODE [879BKB] Details of failure
The air conditioner controller senses a short circuit in the fresh air temperature sensor.
Action level
-
Action of controller
Phenomenon on machine
•
The air conditioner controller sends a short circuit information of the fresh air temperature sensor to the machine monitor by CAN communication.
•
Ignores data of the outside air temperature sensor and continues control of the air conditioner in automatic air conditioner mode.
Since the outside air temperature sensor of air conditioner has an open circuit, the outside air temperature is not considered in the automatic air conditioner mode. (The air conditioner operates in manual mode.)
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
2
Outside air temperature sensor
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P18.
3.
Connect the T-adapter to the female side of connector P18.
4.
Measure the resistance.
5.
Does the measurement result match with the judgment criteria? Item
Measurement position/condition
Between P18 Resist(male) (1) and ance (2)
PC210-10M0, PC210LC-10M0
Temperature: 25°C
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The outside air temperature sensor is normal.
NO
• YES
Standard value Approximately 1.7 kΩ
NO
•
Go to the next inspection item.
•
The outside air temperature sensor is defective.
•
Replace the outside air temperature sensor.
•
Go to "Confirmation of repair".
40-207
FAILURE CODE [879BKB]
No.
3
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector AC01 and connector P18.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result match with the judgment criteria? Item
Measurement position/condition
Resist- Between AC01 (female) (8) or P18 ance (female) (2) and ground
4
Short circuit in wiring harness
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connector AC01 and connector P18.
3.
Connect the T-adapter to the female side of connector AC01.
4.
Measure the resistance.
5.
Does the measurement result match with the judgment criteria? Measurement position/condition
Resist- Between AC01 (female) (8) and ance each pin other than (8)
Standard value
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system. For the operating method, see TESTING AND ADJUSTING, "Setting and operation of machine monitor", "Method for confirming abnormality record (electrical systems)".
Air conditioner controller
40-208
5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed air conditioner controller is normal.
•
Restore the removed air conditioner controller.
•
Go to the next inspection item.
NO
YES
NO
Min. 1 MΩ
REMARK
5
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [879BKB]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
NO The repair is completed.
Circuit diagram associated with air conditioner outside air temperature sensor
PC210-10M0, PC210LC-10M0
40-209
FAILURE CODE [879CKA]
40 TROUBLESHOOTING
FAILURE CODE [879CKA] Details of failure
The air conditioner controller senses an open circuit in the evaporator temperature (frost) sensor.
Action level
•
The air conditioner controller transmits an open circuit information of the evaporator temperature (frost) sensor to the machine monitor by CAN communication.
•
Stops the air conditioner.
Action of controller
Phenomenon on machine
The air conditioner does not operate because there is an open circuit in the evaporator temperature (frost) sensor.
Associated informa- Reference information tion Replace the air conditioner unit as an assembly. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The removed air conditioner controller is normal.
NO
•
2
Air conditioner controller
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
YES
•
Restore the removed air conditioner controller.
•
Go to the next inspection item. NO The repair is completed. YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
40-210
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [879CKA]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Diagnosis and treatment YES
Return to the first inspection item.
REMARK 4
For the operating method, see TESTING AND ADJUSTING, "Setting and operation of machine monitor", "Method for confirming abnormality record (electrical systems)".
Confirmation of repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-211
FAILURE CODE [879CKB]
40 TROUBLESHOOTING
FAILURE CODE [879CKB] Details of failure
The air conditioner controller senses a short circuit in the evaporator temperature (frost) sensor.
Action level
•
The air conditioner controller transmits an open circuit information of the evaporator temperature (frost) sensor to the machine monitor by CAN communication.
•
Stops the air conditioner.
Action of controller
Phenomenon on machine
The air conditioner does not operate because there is a short circuit in the evaporator temperature (frost) sensor.
Associated informa- Reference information tion Replace the air conditioner unit as an assembly. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The removed air conditioner controller is normal.
NO
•
2
Air conditioner controller
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
YES
•
Restore the removed air conditioner controller.
•
Go to the next inspection item. NO The repair is completed. YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
40-212
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
Cause
FAILURE CODE [879CKB]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-213
FAILURE CODE [879DKZ]
40 TROUBLESHOOTING
FAILURE CODE [879DKZ] Details of failure
The air conditioner controller senses an open or short circuit in the sunlight sensor.
Action level
-
Action of controller
Phenomenon on machine
•
The air conditioner controller transmits an open or short circuit information of the sunlight sensor to the machine monitor by CAN communication.
•
When in the automatic air conditioner mode, ignores data of the sunlight sensor and continues control of the air conditioner.
Since the air conditioner sunlight sensor has an open or a short circuit, sunlight intensity is not considered in automatic air conditioner mode. (The air conditioner is not affected in manual mode.) Reference information
Associated information
No.
•
Replace the air conditioner unit as an assembly.
•
If it is necessary to repair the air conditioner wiring harness between the air conditioner controller connector ACECU and the intermediate connector, replace the air conditioner unit.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
40-214
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [879DKZ]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P31.
3.
Connect the T-adapter to the male side of the connector.
4.
Does the measurement result match with the judgment criteria? Item
2
Measurement position/condition
Sunlight sensor
Between P31 Voltage (male) (1) and (2)
3
YES
Standard value
Direct sunlight
Approx. 0.55V
Cloudy
Approximately 0.45V
Inside the cab
Approximately 0.4V
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector AC01 and connector P31.
3.
Connect the T-adapter to the female side of each connector.
4.
Does the measurement result match with the judgment criteria?
Open circuit in wiring harness
Item
Measurement position/condition
Diagnosis and treatment
Standard value
NO
YES
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector AC01 and connector P31.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Does the measurement result match with the judgment criteria? Item
Measurement position/condition
Resist- Between AC01 (female) (10) and ance P31 (female) (1)
PC210-10M0, PC210LC-10M0
Standard value Min. 1 MΩ
The sunlight sensor is normal.
•
Go to the next inspection item.
•
The sunlight sensor is defective.
•
Replace the sunlight sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Between AC01 (female) (10) and Max. 1 P31 (female) (1) Ω Resistance Between AC01 (female) (9) and P31 Max. 1 (female) (2) Ω
1.
•
YES
NO
40-215
FAILURE CODE [879DKZ]
No.
5
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector AC01 and connector P31.
3.
Connect the T-adapter to the female side of connector AC01.
4.
Does the measurement result match with the judgment criteria? Item
Measurement position/condition
Resist- Between AC01 (female) (10) and ance each pin other than (10)
Standard value
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
40-216
Do the inspection above again. NO
YES
•
The air conditioner controller can be defective.
•
Replace the air conditioner controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [879DKZ]
Circuit diagram associated with sunlight sensor
PC210-10M0, PC210LC-10M0
40-217
FAILURE CODE [879EMC]
40 TROUBLESHOOTING
FAILURE CODE [879EMC] Details of failure
The air conditioner controller reads the potentiometer voltage of the servo motor and finds that the servo motor of the vent changeover (mode) damper does not rotate.
Action level
L01
Action of controller
The air conditioner controller transmits an error of the vent changeover (mode) damper to the machine monitor by CAN communication.
Phenomenon on machine
Changeover of the vent (mode) cannot be operated but the air conditioner operates.
Associated informa- Reference information tion Replace the air conditioner unit as an assembly. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
2
Air conditioner controller
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The removed air conditioner controller is normal.
NO
•
YES
•
Restore the removed air conditioner controller.
•
Go to the next inspection item.
NO The repair is completed.
YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
40-218
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
Cause
FAILURE CODE [879EMC]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-219
FAILURE CODE [879FMC]
40 TROUBLESHOOTING
FAILURE CODE [879FMC] Details of failure
The air conditioner controller reads the potentiometer voltage of the servo motor and finds that the servo motor of the air mix (for temperature adjustment) damper does not rotate.
Action level
L01
Action of controller
The air conditioner controller transmits an error of the air mix damper to the machine monitor by CAN communication.
Phenomenon on machine
Since the temperature cannot be adjusted, the air conditioner does not operate.
Associated informa- Reference information tion Replace the air conditioner unit as an assembly. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The removed air conditioner controller is normal.
NO
•
2
Air conditioner controller
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
YES
•
Restore the removed air conditioner controller.
•
Go to the next inspection item. NO The repair is completed. YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
40-220
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
Cause
FAILURE CODE [879FMC]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-221
FAILURE CODE [879GKX]
40 TROUBLESHOOTING
FAILURE CODE [879GKX] Details of failure
The air conditioner controller senses that the dual pressure switch is OFF.
Action level
L01
Action of controller
•
The air conditioner controller transmits an abnormality information of the refrigerant pressure to the machine monitor by CAN communication.
•
Since refrigerant pressure is abnormal, the air conditioner controller turns off the compressor clutch relay.
(The air conditioner compressor stops.) Phenomenon on machine
The air conditioner does not function (in cooling mode). k
Associated information
k
If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it touches your skin, you may suffer from frostbite. When you collect or fill refrigerant, always wear protective eyeglasses, gloves and working clothes with long sleeves.
Notice Before you handle refrigerant, always read the precautions for refrigerant in the chapter OTHERS.
No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "Related information of troubleshooting", "Check before troubleshooting", "Electrical parts".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The refrigerant (dual) pressure switch is normal.
NO
•
2
1.
Check the refrigerant (dual) pressure switch. For details, see chapter 80, OTHERS, TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.
Defective re2. frigerant (dual) pressure switch
Is the refrigerant (dual) pressure switch normal?
• •
NOTICE Before you replace the dual pressure switch, be sure to collect refrigerant. See chapter 80, OTHERS, "PRECAUTIONS FOR REFRIGERANT".
40-222
YES
NO
Go to the next inspection item. The refrigerant (dual) pressure switch is defective.
•
Replace the defective refrigerant (dual) pressure switch.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [879GKX]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector AC01, P17.
3.
Connect the T-adapter to the female side of each connector.
4.
Does the measurement result match with the judgment criteria?
Open circuit in wiring harness
Item
Measurement position/condition
YES
Standard value
4
Air conditioner controller
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed air conditioner controller is normal.
•
Restore the removed air conditioner controller.
NO
Between AC01 (female) (6) and P17 Max. 1 Ω Resist- (female) (1) ance Between P17 (female) (2) and Max. 1 ground
•
Ω
1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
YES
•
Go to the next inspection item. NO The repair is completed. YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The air conditioner unit can be defective.
•
Replace the air conditioner unit.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Check the abnormality record.
5.
Is "E" shown in the record of this failure code?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-223
FAILURE CODE [879GKX]
40 TROUBLESHOOTING
Circuit diagram associated with refrigerant (dual) pressure switch
40-224
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [989L00]
FAILURE CODE [989L00] Details of failure
The machine monitor senses an error of the engine controller lock. (Factor 1)
Action level
-
Action of controller Phenomenon on machine
•
None in particular.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The engine does not start.
Reference information Associated informaIf this failure code is shown after the machine monitor is replaced, the user password tion needs to be changed back to the previous one. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Setting of the user password is proper.
NO
• YES
2
Setting of user password
1.
Check the user password (machine monitor).
2.
Did you set the user password to the previous one after replacing the machine monitor?
• •
NO
Go to the next inspection item. Setting of the user password is improper.
•
Set the user password to the previous one.
•
Go to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
40-225
FAILURE CODE [989L00]
No.
4
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Confirmation of 5. repair 6.
40-226
40 TROUBLESHOOTING
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [989M00]
FAILURE CODE [989M00] Details of failure
The machine monitor senses an error of the engine controller lock. (Factor 2)
Action level
-
Action of controller Phenomenon on machine
•
None in particular.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The engine does not start.
Reference information Associated informaIf this failure code is shown after the machine monitor is replaced, the user password tion needs to be changed back to the previous one. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Setting of the user password is proper.
NO
• YES
2
Setting of user password
1.
Check the user password (machine monitor).
2.
Did you set the user password to the previous one after replacing the machine monitor?
• •
NO
Go to the next inspection item. Setting of the user password is improper.
•
Set the user password to the previous one.
•
Go to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
40-227
FAILURE CODE [989M00]
No.
4
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Confirmation of 5. repair 6.
40-228
40 TROUBLESHOOTING
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [989N00]
FAILURE CODE [989N00] Details of failure
The machine monitor senses an error of the engine controller lock. (Factor 3)
Action level
-
Action of controller Phenomenon on machine
•
Tries automatic recovery.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The engine does not start.
Associated informa- None in particular. tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Confirmation of 5. repair 6.
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-229
FAILURE CODE [AA10NX]
40 TROUBLESHOOTING
FAILURE CODE [AA10NX] Details of failure
When the engine is running, the signal voltage of the air cleaner clogging switch is not 1 V or less. The machine monitor senses that the air cleaner is clogged (sensor contacts are opened).
Action level
L01
Action of controller
Shows the air cleaner clogging monitor in yellow on the machine monitor.
Phenomenon on machine
If machine is used as it is, the engine can be damaged.
Associated informa- Monitoring code tion The input (ON or OFF) from air cleaner clogging switch can be monitored. (Code: 04501) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The air cleaner is normal.
NO
• YES
2
Air cleaner
1.
Check the air cleaner for clogging.
2.
Is the air cleaner normal?
• NO
40-230
•
Go to the next inspection item. The air cleaner is defective.
•
Clean or replace the air cleaner.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [AA10NX]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P23.
3.
Connect the T-adapter to the female side of connector P23.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Air cleaner clogging switch
Item
4
YES
StandMeasurement position and condition ard value
Between P23 Resist(male) (1) and ance (2)
Filter normal
Max. 1 Ω
Filter clogged
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector P23.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Open circuit in wiring harness
Item
StandMeasurement position and condition ard value
Between CM02 (female) (4) and Resist- P23 (female) (1) ance Between P23 (female) (2) and ground
Diagnosis and treatment
NO
YES
•
The air cleaner clogging switch is normal.
•
Go to the next inspection item.
•
The air cleaner clogging switch is defective.
•
Replace the air cleaner clogging switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω Max. 1 Ω
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-231
FAILURE CODE [AA10NX]
40 TROUBLESHOOTING
Circuit diagram associated with air cleaner clogging switch
40-232
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [AB00KE]
FAILURE CODE [AB00KE] Details of failure
While the engine is running, the voltage from alternator drops. The machine monitor senses a low charge voltage.
Action level
L03
Action of controller
Shows the battery charge level monitor in red on the machine monitor.
Phenomenon on machine
If machine is used as it is, the battery will possibly be not charged.
Associated informa- Monitoring code tion The battery voltage can be monitored. (Code: 04300) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Diode
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01.
3.
Connect the T-adapter to the female side of connector D01.
4.
Measure the continuity.
5.
Does the measurement result agree with the standard value? Item
Continuity
PC210-10M0, PC210LC-10M0
StandMeasurement position and condition ard value Between D01 (male) (6) (+) and (2) (-)
Continuity
Between D01 (male) (2) (+) and (6) (-)
No continuity
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The diode is normal.
NO
• YES •
NO
Go to the next inspection item.
•
The diode is defective.
•
Replace the diode.
•
Go to "Confirmation of repair".
40-233
FAILURE CODE [AB00KE]
No.
3
Cause
Open circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM01 and connector E12.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CM01 (female) (16) and ance E12 (female) (1)
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CM01 and connector E12.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CM01 (female) (16) or E12 ance (female) (1) and ground
5
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CM01 and connector E12.
3.
Connect the T-adapter to the female side of connector CM01.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CM01 (female) (16) and ance each pin other than (16)
40-234
Min. 1 MΩ
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
1.
Item
YES
Max. 1 Ω
1.
Item
Diagnosis and treatment
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
FAILURE CODE [AB00KE]
Cause
Alternator
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector E12.
3.
Start the engine.
4.
Run the engine at medium speed or higher.
5.
Measure the voltage.
6.
Does the measurement result agree with the standard value? Item
YES
StandMeasurement position and condition ard value
Voltage Between E12 (1) and ground
Diagnosis and treatment
NO
•
The alternator is normal.
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
27.5 to 29.5V
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-235
FAILURE CODE [AB00KE]
40 TROUBLESHOOTING
Circuit diagram associated with battery charging system
J02 (J-20) (Black)
11 12 13
AC95 (090-22) CK02
8
Pump controller XF DG HG
Battery(GND) Battery(GND)
D10
(X-1)
E12 1 2
G0024197
40-236
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [B@BAZG]
FAILURE CODE [B@BAZG] Details of failure
The signal voltage from the engine oil pressure switch becomes GND while the engine is running. The engine controller senses an abnormally low engine oil pressure.
Action level
L03
Action of controller Phenomenon on machine
•
Shows the engine oil pressure monitor in red on the machine monitor.
•
The engine power is derated.
•
The engine output is reduced.
•
If machine is used as it is, the engine can be seized.
Monitoring code The engine oil pressure can be monitored. (Code: 37200) Associated informaReference information tion The engine controller inputs signals from the engine oil pressure switch, and transmits the information to the machine monitor through CAN communication. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-237
FAILURE CODE [B@BAZG]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Diagnosis and treatment
Check the engine oil pressure to troubleshoot. YES
REMARK
•
The engine oil pressure is normal.
•
Go to the next inspection item.
•
The engine oil pressure is abnormal.
•
Do the troubleshooting for "OIL PRESSURE DROPS" in S mode.
•
If the engine oil consumption is large, do the troubleshooting for ENGINE OIL CONSUMPTION IS EXCESSIVE in S mode.
•
Go to "Confirmation of repair".
•
The engine oil pressure switch is normal.
•
Go to the next inspection item.
•
The engine oil pressure switch is defective.
•
Replace the engine oil pressure switch.
•
Go to "Confirmation of repair".
For the checking method, see TESTING AND ADJUSTING, "TEST ENGINE OIL PRESSURE ". 2.
Does the troubleshooting result agree with the standard value? Item
2
Measuring point and measurement condition
Engine oil pressure High idle Engine Engine oil presoil pressure pickup port sure Low idle
3
Min. 0.29 MPa {min. 3.0kg/ cm2}
NO
Min. 0.10 MPa {min. 1.0kg/ cm2}
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector OIL PRESSURE SWITCH.
3.
Connect the T-adapter to the male side of connector OIL PRESSURE SWITCH.
4.
Measure the resistance to troubleshoot.
Engine oil pres- 5. sure switch
YES
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Standard value
Resist- Between OIL PRESSURE SWITCH ance and ground
Max. 10 Ω
Item
40-238
Standard value
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [B@BAZG]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector OIL PRESSURE SWITCH.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between ECM (female) (17) and ance OIL PRESSURE SWITCH
5
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector OIL PRESSURE SWITCH.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Resist- Between ECM (female) (17) and ance ground
6
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector OIL PRESSURE SWITCH.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Resist- Between ECM (female) (17) and ance each pin other than (17)
PC210-10M0, PC210LC-10M0
NO
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
YES
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Item
YES
•
Max. 10 Ω
1.
Item
Short circuit in wiring harness
Standard value
Diagnosis and treatment
Standard value Min. 100 kΩ
YES
NO
40-239
FAILURE CODE [B@BAZG]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Start the engine to troubleshoot.
5.
Is this failure code shown again?
NO The repair is completed.
Circuit diagram associated with engine oil pressure switch
ECM (DRC26-60)
(Low)
G0024213
40-240
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [B@BAZK]
FAILURE CODE [B@BAZK] Details of failure
When the starting switch is turned to the ON position, the signal voltage from engine oil level switch is not 1 V or less. The machine monitor senses Engine Oil Level Low (oil level switch OPEN).
Action level
L01
Action of controller
Shows the engine oil level in yellow on the machine monitor.
Phenomenon on machine
If machine is used as it is, the engine can be seized.
Associated informa- Monitoring code tion The engine oil level switch can be monitored. (Code: 04501) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The engine oil level is normal.
NO
• 1.
Measure the engine oil pressure.
YES
REMARK 2
•
For the measuring method, see TESTING AND ADJUSTING, "TEST ENGINE OIL PRESSURE".
Engine oil level 2.
Does the measurement result agree with the standard value?
PC210-10M0, PC210LC-10M0
•
NO
Go to the next inspection item. The engine oil level is incorrect.
•
Add engine oil to the correct level.
•
Go to "Confirmation of repair".
40-241
FAILURE CODE [B@BAZK]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P44.
3.
Connect the T-adapter to the female side of connector P44.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Engine oil level sensor
Item
4
Open circuit in wiring harness
YES
StandMeasurement position and condition ard value
Between P44 Resist(male) (1) and ance ground
When the engine oil level is normal
Max. 1 Ω
When the engine oil level is low
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector P44.
3.
Connect the T-adapter to the female side of connector CM02 and the male side of connector P44.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Between CM02 (female) (2) and Resist- P44 (female) (1) ance Between P44 (male) (1) and ground
Diagnosis and treatment
NO
YES
•
The engine oil level sensor is normal.
•
Go to the next inspection item.
•
The engine oil level sensor is defective.
•
Replace the engine oil level sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω Max. 1 Ω
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-242
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [B@BAZK]
Circuit diagram associated with engine oil level Monitor panel
CM01 (070-18) Battery (GND) Battery (GND)
CM02 (070-12) Engine oil level
P44 ( D T- 2 )
Engine oil level sensor AEX
G0024184
PC210-10M0, PC210LC-10M0
40-243
FAILURE CODE [B@BCZK]
40 TROUBLESHOOTING
FAILURE CODE [B@BCZK] Details of failure
When the engine is stopped, the signal circuit of the radiator coolant level switch is opened (disconnected from GND).
Action level
L01
Action of controller Phenomenon on machine
When the coolant level is low, if the machine is used as it is, the engine can overheat.
Associated informa- Monitoring code tion The radiator coolant level switch can be monitored. (Code: 04500) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The radiator coolant level is normal.
NO
• YES
2
Radiator coolant level
1.
Check the radiator for coolant level and leakage.
2.
Is the radiator coolant level between FULL and LOW of the sub-tank?
• NO
3
Radiator coolant level sensor
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P24.
3.
Connect the T-adapter to the female side of connector P24.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
ResistBetween P24 (male) (1) and (2) ance
40-244
Max. 1 Ω
NO
Go to the next inspection item. The radiator coolant level is incorrect.
•
Add radiator coolant to the correct level.
•
Go to "Confirmation of repair". The radiator coolant level sensor is normal.
• YES
StandMeasurement position and condition ard value
•
•
Go to the next inspection item.
•
The radiator coolant level sensor is defective.
•
Replace the radiator coolant level sensor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [B@BCZK]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02, P24.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Open circuit in wiring harness
Item
Diagnosis and treatment YES
StandMeasurement position and condition ard value
Between CM02 (female) (3) and Resist- P24 (female) (1) ance Between P24 (female) (2) and
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω Max. 1 Ω
ground
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with radiator coolant level switch Monitor panel
Battery (GND) Battery (GND) Radiator water level sensor Radiator water level
T10 G0024185
PC210-10M0, PC210LC-10M0
40-245
FAILURE CODE [B@BCNS]
40 TROUBLESHOOTING
FAILURE CODE [B@BCNS] Details of failure
While the engine is running, the voltage from the engine coolant temperature sensor drops. The engine controller senses overheating of the engine coolant.
Action level
L02
Action of controller
Shows the engine coolant temperature monitor in red on the machine monitor.
Phenomenon on machine
•
The engine output is reduced.
•
If machine is used as it is, the engine can be seized.
Monitoring code The engine coolant temperature can be monitored. (Code: 04107) Associated informaReference information tion The engine controller inputs the signal voltage from the engine coolant temperature sensor, and transmits the information to the machine monitor through CAN communication. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The engine coolant temperature is normal.
NO
• YES
• •
1.
2
Engine coolant 2. temperature
Check the engine coolant temperature.
•
Do "COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)" in S mode. Decrease the engine coolant temperature (run the engine at low idle or stop the engine).
•
Go to "Confirmation of repair".
Is the engine coolant temperature 102°C or below? NO
40-246
Go to the next inspection item. The engine coolant temperature is high.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [B@BCNS]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of connector COOLANT TEMP.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
3
Coolant temperature sensor
Between COOLANT TEMP (male) (B) and (A)
Between COOLANT TEMP (male) (B) and ground
4
YES
0°C
0 to 37 kΩ
25℃
9.3 to 10.7 kΩ
700 to 800 Ω
All
Min. 100 kΩ
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
COOLANT TEMP (female) (A)
PC210-10M0, PC210LC-10M0
The coolant temperature sensor is normal.
•
Go to the next inspection item.
•
The coolant temperature sensor is defective.
•
Replace the coolant temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
1.0 to 1.3 kΩ
95℃
Between ECM (female) (15) and Resist- COOLANT TEMP (male) (B) ance Between ECM (female) (38) and
NO
3.2 to 3.8 kΩ
1.
Item
•
StandMeasurement position and condition ard value
50℃ (Coolant temperResist- ature sensor ance thermal charac- 80℃ teristics)
Open circuit in wiring harness
Diagnosis and treatment
Max. 10 Ω
YES
NO
Max. 10 Ω
40-247
FAILURE CODE [B@BCNS]
No.
5
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
6
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of connector COOLANT TEMP.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
40-248
YES
StandMeasurement position and condition ard value
Resist- Between ECM (female) (15) and ance each pin other than (15)
NO
•
Min. 100 kΩ
1.
Item
7
YES
StandMeasurement position and condition ard value
Between ECM (female) (15) or ResistCOOLANT TEMP (female) (B) and ance ground
Diagnosis and treatment
StandMeasurement position and condition ard value Between COOLANT TEMP (female) (B) and (A)
Max. 5.25V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [B@BCNS]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
8
9
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Electrical circuit diagram associated with coolant temperature sensor
water
ECM (DRC26-60) AIR Pressure sensor GND
G0024201
PC210-10M0, PC210LC-10M0
40-249
FAILURE CODE [B@BCQA]
40 TROUBLESHOOTING
FAILURE CODE [B@BCQA] Details of failure
Signal circuit of radiator coolant level switch is in "OPEN" (disconnected from GND) state continuously for 1 hour or more.
Action level
L02
Action of controller
-
Phenomenon on machine
When the coolant level is low, if the machine is used as it is, the engine can suffer a damage.
Associated informa- Monitoring code tion The radiator coolant level switch can be monitored. (Code: 04500) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The radiator coolant level is normal.
NO
• YES 1. 2
3
Radiator coolant level
Radiator coolant level sensor
2.
Check the radiator for the coolant level and leakage. Is the radiator coolant level between FULL and LOW of the sub-tank?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P24. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
ResistBetween P24 (male) (1) and (2) ance
40-250
Standard value Max. 1 Ω
• •
NO
•
Add radiator coolant to the correct level.
•
Go to "Confirmation of repair". The radiator coolant level sensor is normal.
• YES
NO
Go to the next inspection item. The radiator coolant level is incorrect.
•
Go to the next inspection item.
•
The radiator coolant level sensor is defective.
•
Replace the radiator coolant level sensor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [B@BCQA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02, P24. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Measuring point and measurement condition
Between CM02 (female) (3) and Resist- P24 (female) (1) ance Between P24 (female) (2) and
Standard value
Diagnosis and treatment YES
NO
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 1 Ω
ground
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with radiator coolant level switch Monitor panel
Battery (GND) Battery (GND) Radiator water level sensor Radiator water level
T10 G0024185
PC210-10M0, PC210LC-10M0
40-251
FAILURE CODE [B@HANS]
40 TROUBLESHOOTING
FAILURE CODE [B@HANS] No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The hydraulic oil temperature is normal.
NO
• YES
• •
2
Hydraulic oil temperature
1.
Check the hydraulic oil temperature.
2.
Is the hydraulic oil temperature 102°C or below?
•
Operate the engine at low idle or stop the engine. Wait for the hydraulic oil temperature to go down.
•
Go to "Confirmation of repair".
NO
40-252
Go to the next inspection item. The hydraulic oil temperature is high.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [B@HANS]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P22.
3.
Connect the T-adapter to the female side of connector P22.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
3
Hydraulic oil temperature sensor
Diagnosis and treatment •
The hydraulic oil temperature sensor is normal.
•
Go to the next inspection item.
•
The hydraulic oil temperature sensor is defective.
•
Replace the hydraulic oil temperature sensor.
•
Go to "Confirmation of repair".
YES
StandMeasurement position and condition ard value
Between P22 (male) (2) and (1) (Oil temperature Resist- sensor thermal ance characteristics)
Between P22 (male) (2) and ground
25℃
38.1 to 47.8 kΩ
30℃
31.0 to 40.0 kΩ
80℃
6.1 to 7.0 kΩ
90℃
4.6 to 5.2 kΩ
100℃
3.6 to 4.0 kΩ
All
Min. 1 MΩ
NO
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-253
FAILURE CODE [CA111]
40 TROUBLESHOOTING
FAILURE CODE [CA111] Details of failure
There is an internal defect in the engine controller.
Action level
L04
Action of controller
None in particular.
Phenomenon on machine
The engine operates normally but it can stop during operation, or it cannot be started when it is stopped.
Associated informa- Monitoring code tion The power supply voltage of the engine controller can be monitored. (Code: 03203) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
Check the battery voltage.
2.
Does the battery voltage agree with the standard value? Item
Measuring point and measurement condition
Voltage Between battery terminal (+) and (-)
3
Alternator
20 to 30 V
Turn the starting switch to the OFF position.
2.
Start the engine.
3.
Run the engine at a medium speed or above.
4.
Measure the voltage.
5.
Does the troubleshooting result agree with the standard value?
Voltage
40-254
Standard value
1.
Item
Measuring point and measurement condition Between alternator terminal GI and ground
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The battery output voltage is normal.
NO
•
1.
Battery voltage
•
YES
• NO
26 to 30.5 V
NO
Go to the next inspection item. The battery output voltage is low.
•
Charge or replace the battery.
•
Go to "Confirmation of repair". The alternator is normal.
• YES
Standard value
•
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA111]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment • YES •
4
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse No.19 in the fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
•
When it is not blown but it has no resistance, replace the fuse.
•
Go to "Confirmation of repair". The removed engine controller power supply relay is normal.
1.
Turn the starting switch to the OFF position.
2.
ConnectorR23, R24Disconnect the connector, and replace the relay with same type.
•
Turn the starting switch to the ON position to troubleshoot.
•
Engine controller power sup3. ply relay 4.
Is this failure code cleared?
YES •
NO •
6
Open circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect the connectors. Connect the T-adapter to each female side.CE03, R23, R24
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CE03 (female) (3) and R23 Max. 1 (female) (5) Ω Between CE03 (female) (3) and R24 Max. 1 (female) (4) Ω Resist- Between R23 (female) (3) and ance F01-19
Max. 1 Ω
Between R24 (female) (3) and F01-19
Max. 1 Ω
Between CE03 (female) (1) and ground
Max. 1 Ω
PC210-10M0, PC210LC-10M0
• YES
Go to the next inspection item. If blown, go to "Ground fault of wiring harness".
• NO
•
5
The fuse is normal.
Restore the removed relay. Go to the next inspection item. The removed engine controller power supply relay is defective. The repair is completed. The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-255
FAILURE CODE [CA111]
No.
7
40 TROUBLESHOOTING
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect the connectors. Connect the T-adapter to the female side of one of the connectors.CE03, R23, R24
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between CE03 (female) (3), R23 (female) (5), or R24 (female) (4) and Resist- ground ance Between R23 (female) (3), R24 (female) (3), or F01-18 and ground
8
Short circuit in wiring harness
Standard value
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect the connector. Connect the T-adapter to the female side.CE03
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value?
Resist- Between CE03 (female) (3) and ance each pin other than (3)
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
Turn the starting switch to the OFF position.
Measuring point and measurement condition
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Standard value Min. 1 MΩ
YES The repair is completed.
9
Reconfirmation 1. of inspection 2. item
40-256
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
10
Cause
FAILURE CODE [CA111]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
40-257
FAILURE CODE [CA111]
40 TROUBLESHOOTING
Circuit diagram associated with engine controller power supply CEN2
R16B R16A
Monitor panel
A/C unit MA
CP01 LG
Key switch (ACC) Key switch (ACC) Key switch (C) Key switch (ACC)
61
XE
80
AC95 9 LE
CP02
FP
AC95 (090-22) FT
HJ HK
CP01 ECM_J3 L19 2 J 0 5 16
AC
1
2
3
4
5
6
T06 Relay for starter out (PPC lock)
40-258
Relay for starter out (Personal code)
Relay for auto preheat
Relay for CM850 (1)
Relay for CM850 (2)
G0024217
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA115]
FAILURE CODE [CA115] Details of failure
Errors occur at the same time in the signal circuits of the engine NE speed sensor and the engine Bkup speed sensor.
Action level
L04
Action of controller
Stop the engine.
Phenomenon on machine
•
The engine does not start. (When the engine is stopped)
•
The engine stops. (When the engine is running)
Pre-troubleshooting Associated informaIf failure code [CA238], [CA689] or [CA778] is also shown, do the troubleshooting for that tion code first. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
1.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The installation position of the speed sensing wheel on the crankshaft side is correct.
NO
•
Make it possible to see the vibration damper. REMARK For details, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL ENGINE FRONT OIL SEAL".
2
Installation position of speed sensing wheel on crankshaft side
2.
Align the painted mark (M1) on the vibration damper with the damper mounting bolt (M2).
3.
Is the installation position of speed sensing wheel on crankshaft side correct?
YES •
Go to the next inspection item.
•
The installation position of the speed sensing wheel on the crankshaft side is incorrect.
•
Adjust the installation position of the speed sensing wheel on the crankshaft side.
•
Go to "Confirmation of repair".
REMARK • If the center of the slotted hole (WS) in the speed sensing wheel is at the top surface (M3) of the engine NE speed sensor, the installation position of the speed sensing wheel on the crankshaft side is correct. • The specified position is not the compression top dead center of No.1 cylinder. (Approximately 76 to 80° before compression top dead center)
PC210-10M0, PC210LC-10M0
NO
40-259
FAILURE CODE [CA115]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The installation condition of the engine NE speed sensor is normal.
•
Go to the next inspection item. The installation condition of the engine NE speed sensor is defective.
YES
3
1. Installation condition of engine NE speed 2. sensor
•
Check the installation condition of the engine NE speed sensor. Check for damages or looseness. Is the installation condition of the engine NE speed sensor normal?
•
Install the engine NE speed sensor again.
•
If a damage is found, replace the engine NE speed sensor.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
NO
4
Open circuit in wiring harness
40-260
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM J1 and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value Between ECM J1 (female) (79) and CAM SENSOR (female) (1)
Max. 10 Ω
Resist- Between ECM J1 (female) (31) and ance CAM SENSOR (female) (3)
Max. 10 Ω
Between ECM J1 (female) (55) and CAM SENSOR (female) (2)
Max. 10 Ω
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [CA115]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM J1 and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM J1 (female) (31) or ResistCAM SENSOR (female) (3) and ance ground
6
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM J1 and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of connector ECM J1.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between ECM J1 (female) (31) and ance each pin other than (31)
7
NO
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
YES
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CAM SENSOR.
3.
Connect the T-adapter to the female side of connector CAM SENSOR.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
YES
•
Min. 100 kΩ
1.
Item
Diagnosis and treatment
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
PC210-10M0, PC210LC-10M0
StandMeasurement position and condition ard value Between CAM SENSOR (female) (3) and (2)
Max. 1 V
NO
40-261
FAILURE CODE [CA115]
No.
8
Cause
Engine NE speed sensor
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CAM SENSOR.
3.
Turn the starting switch to the ON position to troubleshoot.
4.
Diagnosis and treatment YES
•
The engine NE speed sensor is normal.
•
Go to the next inspection item. The engine NE speed sensor is defective.
•
Is this failure code shown again? REMARK
NO
Since connectors are disconnected, the failure codes for the disconnected devices are shown.
•
Replace the engine NE speed sensor.
•
Go to "Confirmation of repair". The installation condition of the speed sensing ring on the camshaft side is normal.
•
YES •
9
Installation condition of speed sensing ring on camshaft side
1.
Set the No.1 cylinder to the compression top dead center. (Align stamping mark)
2.
Remove the engine Bkup speed sensor.
3.
Can you see the 2 grooves (with 1 rib) (B) on the speed sensing ring through the sensor mounting hole (H)?
•
•
Adjust the installation position of the speed sensing ring on the camshaft side. For details, see "CHECK CAMSHAFT GEAR FOR LOOSENING" that follows.
•
Go to "Confirmation of repair". The installation condition of the engine Bkup speed sensor is normal.
NO
• YES • 1. Installation condition of en10 gine Bkup 2. speed sensor
•
Check the installation condition of the engine Bkup speed sensor. Check for damages and looseness. Is the installation condition of the engine Bkup speed sensor normal?
Go to the next inspection item. The installation condition of the engine Bkup speed sensor is defective.
•
Install the engine Bkup speed sensor again.
•
If a damage is found, replace the engine Bkup speed sensor.
•
Go to "Confirmation of repair".
NO
40-262
Go to the next inspection item. The installation condition of the speed sensing ring on the camshaft side is defective.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
11
12
FAILURE CODE [CA115]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM J1 and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Ground fault in wiring harness
Item
StandMeasurement position and condition ard value Between ECM J1 (female) (78) and CAM SENSOR (female) (1)
Max. 10 Ω
Resist- Between ECM J1 (female) (18) and ance CAM SENSOR (female) (3)
Max. 10 Ω
Between ECM J1 (female) (54) and CAM SENSOR (female) (2)
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM J1 and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM J1 (female) (18) or ResistCAM SENSOR (female) (3) and ance ground
Short circuit in 13 wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM J1 and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of connector ECM J1.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between ECM J1 (female) (18) and ance each pin other than (18)
PC210-10M0, PC210LC-10M0
YES
NO
YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Item
Diagnosis and treatment
Min. 100 kΩ
YES
NO
40-263
FAILURE CODE [CA115]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CAM SENSOR.
3.
Connect the T-adapter to the female side of connector CAM SENSOR.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. 14 in wiring har6. ness
StandMeasurement position and condition ard value Between CAM SENSOR (female) (3) and (2)
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The engine Bkup speed sensor is normal.
•
Go to the next inspection item. The engine Bkup speed sensor is defective.
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector .
3.
Turn the starting switch to the ON position to troubleshoot.
4.
The wiring harness has no hot short circuits.
YES
Does the troubleshooting result agree with the standard value?
Voltage
Engine Bkup speed sensor
•
Measure the voltage to troubleshoot.
Item
15
Diagnosis and treatment
YES
•
Is this failure code shown again? REMARK Since connectors are disconnected, the failure codes for the disconnected devices are shown.
NO
•
Replace the engine Bkup speed sensor.
•
Go to "Confirmation of repair".
YES The repair is completed. Reconfirmation 1. 16 of inspection 2. item
17
Confirmation of repair
40-264
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA115]
Circuit diagram associated with engine Bkup speed sensor
ENGINE Ne (CRANKSHAFT) SPEED SENSOR
Reference: Inspection of camshaft gear for looseness (107 Engine) Remove the pulley, damper, front seal, front cover, and housing. Check the looseness of the camshaft ring. REMARK Prepare the front seal, gasket, liquid gasket LG-7, and front seal tool (795-799-6400).
REMOVAL 1.
Remove the cooling assembly.
2.
Remove the compressor belt. For details, see DISASSEMBLY AND ASSEMBLY, REMOVE AND INSTALL ENGINE FRONT OIL SEAL.
PC210-10M0, PC210LC-10M0
40-265
FAILURE CODE [CA115]
3.
40 TROUBLESHOOTING
Remove the damper assembly (1).
DP: Dowel pin 4.
Remove the front cover (2).
5.
Remove the front seal (3).
RING: Ring 6.
Check that the mounting bolt (4) of the camshaft ring (5) is not loose. Mounting bolt (4): 10 ± 2 Nm {0.98 ± 0.2 kgm}
INSTALLATION REMARK For the figure, see Removal. 1. Install the front cover (2). Housing: Liquid gasket LG-7 2. Install the front seal (3). For details, see DISASSEMBLY AND ASSEMBLY, REMOVE AND INSTALL ENGINE FRONT OIL SEAL. 1) 2) Install the dowel pin (DP). Install the damper assembly (1). 3) Install the compressor belt. 4)
40-266
Install the cooling assembly.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA122]
FAILURE CODE [CA122] Details of failure
A high voltage occurs in the signal circuit of the charge air pressure sensor (boost pressure sensor).
Action level
L03
Action of controller
Sets the charge air pressure (boost pressure) to a fixed value (400 kPa {4.1 kg/cm2}), and runs the engine.
Phenomenon on machine
•
Engine acceleration becomes slow.
•
The engine output is reduced.
Pre-troubleshooting If failure codes [CA352] and [CA386] are also shown, do the the troubleshooting for them first. Associated informa- Monitoring code tion • The signal voltage from the charge air pressure sensor (boost pressure sensor) can be monitored. (Code: 36501) •
No.
The pressure (boost pressure) sensed by the charge air pressure sensor (boost pressure sensor) can be monitored. (Code: 36500)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Open circuit in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (47) and ance BOOST PRESS & IMT (female) (4)
PC210-10M0, PC210LC-10M0
Max. 10 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-267
FAILURE CODE [CA122]
No.
3
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of connector BOOST PRESS & IMT.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The charge air pressure sensor is normal.
•
Go to the next inspection item.
•
The charge air pressure sensor is defective.
•
Replace the charge air pressure sensor.
•
Go to "Confirmation of repair".
YES
Does the troubleshooting result agree with the standard value?
Voltage
4
•
Measure the voltage to troubleshoot.
Item
Charge air pressure sensor
Diagnosis and treatment
StandMeasurement position and condition ard value Between BOOST PRESS & IMT (female) (1) and (4)
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector BOOST PRESS & IMT.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between BOOST PRESS & IMT (1) Voltage and (4)
NO
YES
NO
0.3 to 4.7V
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-268
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA122]
Circuit diagram associated with charge air pressure sensor
ECM (DRC26-60) Sensor power (+5V) ENG position sensor GND
E06
G0024199
PC210-10M0, PC210LC-10M0
40-269
FAILURE CODE [CA123]
40 TROUBLESHOOTING
FAILURE CODE [CA123] Details of failure
A low voltage occurs in the signal circuit of the charge air pressure sensor (boost pressure sensor).
Action level
L03 •
Sets the charge air pressure (boost pressure) to a fixed value (400 kPa {4.1 kg/ cm2}), and runs the engine.
•
Closes the EGR valve and fully opens the VGT.
•
Engine acceleration becomes slow.
•
The engine output is reduced.
Action of controller
Phenomenon on machine
Pre-troubleshooting If failure codes [CA352] and [CA386] are also shown, do the the troubleshooting for them first. Monitoring code Associated information
•
The signal voltage from the charge air pressure sensor (boost pressure sensor) can be monitored. (Code: 36501)
•
The pressure (boost pressure) sensed by the charge air pressure sensor (boost pressure sensor) can be monitored. (Code: 36500)
Reference information If the sensor connector is disconnected, this failure code is shown. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-270
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [CA123]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (37) and Resist- BOOST PRESS & IMT (female) (2) ance Between ECM (female) (44) and BOOST PRESS & IMT (female) (1)
3
Ground fault in wiring harness
4
Short circuit in wiring harness
2.
Disconnect connector ECM and connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between ECM (female) (44) and ance each pin other than (44)
PC210-10M0, PC210LC-10M0
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
YES
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Item
NO
•
Max. 10 Ω
Turn the starting switch to the OFF position.
Between ECM (female) (44) or ResistBOOST PRESS & IMT (female) (1) ance and ground
YES
Max. 10 Ω
1.
Item
Diagnosis and treatment
Min. 100 kΩ
YES
NO
40-271
FAILURE CODE [CA123]
No.
5
40 TROUBLESHOOTING
Cause
Charge air pressure sensor
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector BOOST PRESS & IMT.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between BOOST PRESS & IMT (1) Voltage and (4)
Diagnosis and treatment YES
NO
0.3 to 4.7V
•
The charge air pressure sensor is normal.
•
Go to the next inspection item.
•
The charge air pressure sensor is defective.
•
Replace the charge air pressure sensor.
•
Go to "Confirmation of repair".
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-272
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA123]
Circuit diagram associated with charge air pressure sensor
ECM (DRC26-60) Sensor power (+5V) ENG position sensor GND
E06
G0024199
PC210-10M0, PC210LC-10M0
40-273
FAILURE CODE [CA131]
40 TROUBLESHOOTING
FAILURE CODE [CA131] Details of failure
A high voltage occurs in the signal circuit of the fuel control dial.
Action level
L03 •
If an abnormality occurs while the starting switch is set to the ON position, the controller fixes the setting to the value before detection of the abnormality and runs the engine.
•
If the starting switch is turned to the ON position after the abnormality has occurred, the controller runs the engine at the value of 100%.
Action of controller
Phenomenon on machine
The engine speed cannot be controlled by using the fuel control dial.
Pre-troubleshooting Associated information
•
Monitoring code •
No.
If failure code [CA2185] or [CA2186] is also shown, do the troubleshooting for that code first.
Cause
The signal voltage from the fuel control dial can be monitored. (Code: 03000) Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-274
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
3
FAILURE CODE [CA131]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P20.
3.
Connect the T-adapter to the female side of connector P20.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Fuel control dial
Open circuit in wiring harness
Item
StandMeasurement position and condition ard value 4.0 to 6.0 kΩ
ResistBetween P20 (male) (1) and (2) ance
0.25 to 5.0 kΩ
Between P20 (male) (2) and (3)
0.25 to 5.0 kΩ
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector P20.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value?
YES
NO
•
The fuel control dial is normal.
•
Go to the next inspection item.
•
The fuel control dial is defective.
•
Repair or replace the fuel control dial.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P20.
3.
Connect the T-adapter to the female side of connector P20.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
NO
StandMeasurement position and condition ard value
Resist- Between CE02 (female) (33) and ance P20 (female) (3)
4
YES
Between P20 (male) (1) and (3)
Item
Diagnosis and treatment
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage Between P20 (female) (2) and (3)
PC210-10M0, PC210LC-10M0
Max. 1 V
NO
40-275
FAILURE CODE [CA131]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with throttle sensor
CE02
G0024200
40-276
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA132]
FAILURE CODE [CA132] Details of failure
Low voltage occurs in the signal circuit of the fuel control dial.
Action level
L03 •
If an abnormality occurs while the starting switch is set to the ON position, the controller fixes the setting to the value before detection of the abnormality and runs the engine.
•
If the starting switch is turned to the ON position after the abnormality has occurred, the controller runs the engine at the value of 100%.
Action of controller
Phenomenon on machine
The engine speed cannot be controlled by using the fuel control dial.
Pre-troubleshooting If failure code [CA2185] or [CA2186] is also shown, do the troubleshooting for that code Associated informafirst. tion Monitoring code The signal voltage from the fuel control dial can be monitored. (Code: 03000) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-277
FAILURE CODE [CA132]
No.
2
3
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P20.
3.
Connect the T-adapter to the female side of connector P20.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Fuel control dial
Open circuit in wiring harness
Item
YES
StandMeasurement position and condition ard value Between P20 (male) (1) and (3)
4.0 to 6.0 kΩ
ResistBetween P20 (male) (1) and (2) ance
0.25 to 5.0 kΩ
Between P20 (male) (2) and (3)
0.25 to 5.0 kΩ
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector P20.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between CE02 (female) (9) and P20 Max. 10 Ω Resist- (female) (1) ance Between CE02 (female) (22) and Max. 10 P20 (female) (2) Ω
40-278
Diagnosis and treatment
NO
YES
NO
•
The fuel control dial is normal.
•
Go to the next inspection item.
•
The fuel control dial is defective.
•
Repair or replace the fuel control dial.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [CA132]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector P20.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Item
Short circuit in wiring harness
NO
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector P20.
4.
Connect the T-adapter to the female side of connector CE02.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value?
YES
NO
StandMeasurement position and condition ard value
Resist- Between CE02 (female) (22) and ance each pin other than (22)
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Item
YES
StandMeasurement position and condition ard value
Resist- Between CE02 (female) (22) or P20 ance (female) (2) and ground
5
Diagnosis and treatment
Min. 100 kΩ
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-279
FAILURE CODE [CA132]
40 TROUBLESHOOTING
Circuit diagram associated with throttle sensor
CE02
G0024200
40-280
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA144]
FAILURE CODE [CA144] Details of failure
A high voltage occurs in the signal circuit of the engine coolant temperature sensor.
Action level
L01
Action of controller
Sets the coolant temperature to a fixed value, and runs the engine.
Phenomenon on machine
•
The engine startability will be degraded at low temperatures.
•
The overheat prevention function does not operate.
k
When the coolant temperature is high, do not check or replace the coolant temperature sensor.
Monitoring code
Associated information
•
The signal voltage from the engine coolant temperature sensor can be monitored. (Code: 04105(V))
•
The temperature sensed by the engine coolant temperature sensor can be monitored. (Code: 04107(°C))
Reference information
No.
•
If the sensor connector is disconnected, this failure code is shown.
•
The "socket" for troubleshooting this sensor has only a female connector. Since the socket cannot be connected to the female connector on the wiring harness side of the sensor, open circuits cannot be checked. (T-adapter is not provided.)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-281
FAILURE CODE [CA144]
No.
2
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of connector COOLANT TEMP.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Coolant temperature sensor
0°C
95℃
3
0 to 37 kΩ 9.3 to 10.7 kΩ
The coolant temperature sensor is normal.
•
Go to the next inspection item.
•
The coolant temperature sensor is defective.
•
Replace the coolant temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
700 to 800 Ω
2.
Disconnect connector ECM and connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
COOLANT TEMP (female) (A)
•
1.0 to 1.3 kΩ
Turn the starting switch to the OFF position.
Between ECM (female) (15) and Resist- COOLANT TEMP (male) (B) ance Between ECM (female) (38) and
NO
3.2 to 3.8 kΩ
1.
Item
40-282
YES
StandMeasurement position and condition ard value
Between COOLANT TEMP 25℃ (male) (B) and Resist- (A) 50℃ ance (Coolant temperature sensor thermal charac- 80℃ teristics)
Open circuit in wiring harness
Diagnosis and treatment
Max. 10 Ω
YES
NO
Max. 10 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [CA144]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of connector COOLANT TEMP.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment •
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between COOLANT TEMP (female) (B) and (A)
NO
Max. 5.25V
YES The repair is completed.
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
REMARK 6
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-283
FAILURE CODE [CA144]
40 TROUBLESHOOTING
Electrical circuit diagram associated with coolant temperature sensor
water
ECM (DRC26-60) AIR Pressure sensor GND
G0024201
40-284
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA145]
FAILURE CODE [CA145] Details of failure
A low voltage occurs in the signal circuit of the engine coolant temperature sensor.
Action level
L01
Action of controller
Sets the coolant temperature to a fixed value (100 °C), and runs the engine.
Phenomenon on machine
•
The engine startability will be degraded at low temperatures.
•
The overheat prevention function does not operate.
k
When the coolant temperature is high, do not check or replace the coolant temperature sensor.
Monitoring code
Associated information
•
The signal voltage from the engine coolant temperature sensor can be monitored. (Code: 04105)
•
The temperature sensed by the engine coolant temperature sensor can be monitored. (Code: 04107)
Reference information
No.
•
If the sensor connector is disconnected, failure code [CA144] is shown.
•
The "socket" for troubleshooting this sensor has only a female connector. Since the socket cannot be connected to the female connector on the wiring harness side of the sensor, open circuits cannot be checked. (T-adapter is not provided.)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-285
FAILURE CODE [CA145]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of connector COOLANT TEMP.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
2
Coolant temperature sensor
Between COOLANT TEMP (male) (B) and (A)
Between COOLANT TEMP (male) (B) and ground
Ground fault in wiring harness
0°C
0 to 37 kΩ
25℃
9.3 to 10.7 kΩ
The coolant temperature sensor is normal.
•
Go to the next inspection item.
•
The coolant temperature sensor is defective.
•
Replace the coolant temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
1.0 to 1.3 kΩ
95℃
700 to 800 Ω
All
Min. 100 kΩ
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (15) or ResistCOOLANT TEMP (female) (B) and ance ground
NO
3.2 to 3.8 kΩ
1.
Item
40-286
YES
•
StandMeasurement position and condition ard value
50℃ (Coolant temperResist- ature sensor ance thermal charac- 80℃ teristics)
3
Diagnosis and treatment
Min. 100 kΩ
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [CA145]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector COOLANT TEMP.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (15) and ance each pin other than (15)
Diagnosis and treatment YES
NO
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
YES The repair is completed.
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
REMARK 6
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-287
FAILURE CODE [CA145]
40 TROUBLESHOOTING
Electrical circuit diagram associated with coolant temperature sensor
water
ECM (DRC26-60) AIR Pressure sensor GND
G0024201
40-288
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA153]
FAILURE CODE [CA153] Details of failure
A high voltage occurs in the signal circuit of the charge air (boost) temperature sensor.
Action level
L03 •
Sets the charge air temperature (boost temperature) to a fixed value, and runs the engine.
•
Closes the EGR valve.
•
The engine startability will be degraded at low temperatures.
•
The engine output is reduced.
Action of controller
Phenomenon on machine
Monitoring code •
The signal voltage from the charge air temperature sensor (boost temperature sensor) can be monitored. (Code: 18501)
•
The temperature sensed by the charge air temperature sensor (boost temperature sensor) can be monitored. (Code: 18500)
Associated information Reference information
No.
•
If the sensor connector is disconnected, this failure code is shown.
•
The "socket" for troubleshooting this sensor has only a female connector. Since the socket cannot be connected to the female connector on the wiring harness side of the sensor, open circuits cannot be checked. (T-adapter is not provided.)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-289
FAILURE CODE [CA153]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of connector BOOST PRESS & IMT.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
2
3
Charge air temperature sensor
Open circuit in wiring harness
-40℃
41 to 48 kΩ
-20℃
14 to 16 kΩ 5.4 to 6.1 kΩ 1.6 to 1.8 kΩ
90℃
230 to 250 Ω
130℃
80 to 90 Ω
The charge air temperature sensor is normal.
•
Go to the next inspection item.
•
The charge air temperature sensor is defective.
•
Replace the charge air temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
BOOST PRESS & IMT (female) (4)
NO
500 to 600 Ω
1.
Between ECM (female) (23) and Resist- BOOST PRESS & IMT (female) (3) ance Between ECM (female) (47) and
40-290
•
StandMeasurement position and condition ard value
Between BOOST 0°C PRESS & IMT Resist- (male) (3) and 30℃ ance (4) (Charge thermal 60℃ characteristics)
Item
Diagnosis and treatment
Max. 10 Ω
YES
NO
Max. 10 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [CA153]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of connector BOOST PRESS & IMT.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment •
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between BOOST PRESS & IMT (female) (3) and (4)
NO
Max. 5.25V
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-291
FAILURE CODE [CA153]
40 TROUBLESHOOTING
Circuit diagram associated with charge air pressure sensor
ECM (DRC26-60) Sensor power (+5V) ENG position sensor GND
E06
G0024199
40-292
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA154]
FAILURE CODE [CA154] Details of failure
A low voltage occurs in the signal circuit of the charge air (boost) temperature sensor.
Action level
L03 •
Sets the charge air temperature (boost temperature) to a fixed value (70 °C), and runs the engine.
•
Closes the EGR valve.
•
The engine startability will be degraded at low temperatures.
•
The engine output is reduced.
Action of controller
Phenomenon on machine
Monitoring code •
The signal voltage from the charge air temperature sensor (boost temperature sensor) can be monitored. (Code: 18501)
•
The temperature sensed by the charge air temperature sensor (boost temperature sensor) can be monitored. (Code: 18500)
Associated informaReference information tion • If the sensor connector is disconnected, failure code [CA153] for High Error is shown. •
No.
Cause
The "socket" for troubleshooting this sensor has only a female connector. Since the socket cannot be connected to the female connector on the wiring harness side of the sensor, open circuits cannot be checked. (T-adapter is not provided.) Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-293
FAILURE CODE [CA154]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of connector BOOST PRESS & IMT.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
2
Charge air temperature sensor
-40℃
41 to 48 kΩ
-20℃
14 to 16 kΩ
Between BOOST 0°C PRESS & IMT (male) (3) and 30℃ (4)
1.6 to 1.8 kΩ 500 to 600 Ω
90℃
230 to 250 Ω
130℃
80 to 90 Ω
The charge air temperature sensor is normal.
•
Go to the next inspection item.
•
The charge air temperature sensor is defective.
•
Replace the charge air temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (23) or ResistBOOST PRESS & IMT (female) (3) ance and ground
NO
Min. 100 kΩ
1.
Item
40-294
5.4 to 6.1 kΩ
60℃
Between BOOST PRESS & IMT All (male) (3) and ground
Ground fault in wiring harness
•
StandMeasurement position and condition ard value
Resist- (Charge thermal ance characteristics)
3
Diagnosis and treatment
Min. 100 kΩ
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [CA154]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (23) and ance each pin other than (23)
Diagnosis and treatment YES
NO
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-295
FAILURE CODE [CA154]
40 TROUBLESHOOTING
Circuit diagram associated with charge air pressure sensor
ECM (DRC26-60) Sensor power (+5V) ENG position sensor GND
E06
G0024199
40-296
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA155]
FAILURE CODE [CA155] Details of failure
The temperature signal from the boot pressure and temperature sensor exceeds the upper control limit.
Action level
L03
Action of controller
Operates with the engine power derated.
Phenomenon on machine
•
The engine output is reduced.
•
The engine stops.
Pre-troubleshooting If failure code [CA153] or [CA154] is also shown, do the troubleshooting for that code Associated informafirst. tion Monitoring code Monitoring code The boost temperature can be monitored. (Code: 36401) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The aftercooler is normal.
NO
• YES
2
1.
Check the fan speed, cooling air quantity and aftercooler fins.
2.
Is the aftercooler normal?
Aftercooler
• •
NO
•
Repair or replace the aftercooler.
•
Go to "Confirmation of repair". The turbocharger outlet temperature is normal.
• YES • 3
Turbocharger 1. outlet tempera2. ture
Check the turbocharger outlet temperature.
•
Is the turbocharger outlet temperature normal? NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The aftercooler is defective.
Go to the next inspection item. The XXXX is defective.
•
Repair or replace the XXXX.
•
Go to "Confirmation of repair". 40-297
FAILURE CODE [CA155]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-298
Do the troubleshooting above again.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA187]
FAILURE CODE [CA187] Details of failure
A low voltage error occurs in the sensor 2 power supply (5V) circuit.
Action level
L03
Action of controller
The engine controller ignores the signals from the common rail pressure sensor, charge (boost) pressure sensor, and Bkup speed sensor. The engine controller fixes the values at the one before detecting the error, and runs the engine.
Phenomenon on machine
The engine output is reduced.
Associated informa- tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Ground fault in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, FUEL RAIL PRESS, BOOST PRESS & IMT, CAM SENSOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between ECM (female) (37), FUEL Resist- RAIL PRESS (female) (3), BOOST ance PRESS & IMT (female) (2), or CAM SENSOR (female) (1) and ground
PC210-10M0, PC210LC-10M0
Standard value Min. 100 kΩ
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-299
FAILURE CODE [CA187]
No.
3
40 TROUBLESHOOTING
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, FUEL RAIL PRESS, BOOST PRESS & IMT, CAM SENSOR.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between ECM (female) (37) and ance each pin other than (37)
Standard value
Diagnosis and treatment YES
NO
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The equipment connected to each connector is is normal.
•
Go to the next inspection item.
•
If this failure code is shown for a connector, the equipment connected to that connector is defective.
•
Replace the equipment connected to the connector which caused this failure code.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector SEGR and connector SVGT.
3.
Connect one of the disconnected connectors.
4.
Turn the starting switch to the ON position to troubleshoot.
5.
Check that this failure code is not shown.
6.
Do the steps 1 to 5 again for all the disconnected connectors.
7.
Are all connectors checked for not having a defect to show this failure code?
YES
REMARK 4
Sensor
Since connectors are disconnected, the failure codes for the disconnected devices are shown. Sensor
Common rail pressure sensor
40-300
Connector FUEL RAIL PRESS
Charge (boost) pressure sensor
BOOST PRESS & IMT
Bkup speed sensor
CAM SENSOR
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [CA187]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with sensor 2 power supply
ECM (DRC26-60) Accumulator pressure signal Engine position sensor signal Sensor power (+ 5V) Engine position sensor return
E06
G0024202
PC210-10M0, PC210LC-10M0
40-301
FAILURE CODE [CA221]
40 TROUBLESHOOTING
FAILURE CODE [CA221] Details of failure
A high voltage occurs in the signal circuit of the ambient pressure sensor.
Action level
L03 •
Sets the ambient pressure to a fixed value (52.44 kPa {0.53 kg/cm2}), and runs the engine.
•
Closes the EGR valve.
Action of controller
Phenomenon on machine
The engine output is reduced.
Pre-troubleshooting If failure codes [CA352] and [CA386] are also shown, do the the troubleshooting for them first. Associated informa- Monitoring code tion • The signal voltage from the ambient pressure sensor can be monitored. (Code: 37401) •
No.
The ambient pressure sensed by the ambient pressure sensor can be monitored. (Code: 37400)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Open circuit in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector AMB.AIR PRESSURE.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (38) and ance AMB.AIR PRESSURE (female) (2)
40-302
Max. 10 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [CA221]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector AMB.AIR PRESSURE.
3.
Connect the T-adapter to the female side of connector AMB.AIR PRESSURE.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The ambient pressure sensor is normal.
•
Go to the next inspection item.
•
The ambient pressure sensor is defective.
•
Replace the ambient pressure sensor.
•
Go to "Confirmation of repair".
YES
Does the troubleshooting result agree with the standard value?
Voltage
Ambient pressure sensor
•
Measure the voltage to troubleshoot.
Item
4
Diagnosis and treatment
StandMeasurement position and condition ard value Between AMB.AIR PRESSURE (female) (3) and (2)
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector AMB.AIR PRESSURE.
3.
Turn the starting switch to the ON position.
4.
Troubleshoot the voltage.
5.
Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between AMB.AIR PRESSURE (3) and (2)
NO
YES
NO
0.3 to 4.7V
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-303
FAILURE CODE [CA221]
40 TROUBLESHOOTING
Circuit diagram associated with ambient pressure sensor
ECM (DRC26-60) Air pressure sensor Sensor power (+ 5V) Air pressure sensor return
G0024203
40-304
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA222]
FAILURE CODE [CA222] Details of failure
A low voltage occurs in the signal circuit of the ambient pressure sensor.
Action level
L03 •
Sets the ambient pressure to a fixed value (52.44 kPa {0.53 kg/cm2}), and runs the engine.
•
Closes the EGR valve.
Action of controller
Phenomenon on machine
The engine output is reduced.
Monitoring code
Associated information
•
The signal voltage from the ambient pressure sensor can be monitored. (Code: 37401)
•
The ambient pressure sensed by the ambient pressure sensor can be monitored. (Code: 37400)
Reference information If the sensor connector is disconnected, this failure code is shown. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Open circuit in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector AMB.AIR PRESSURE.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (33) and Resist- AMB.AIR PRESSURE (female) (1) ance Between ECM (female) (3) and AMB.AIR PRESSURE (female) (3)
PC210-10M0, PC210LC-10M0
Max. 10 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 10 Ω
40-305
FAILURE CODE [CA222]
No.
3
40 TROUBLESHOOTING
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector AMB.AIR PRESSURE.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector AMB.AIR PRESSURE.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Ambient pressure sensor
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector AMB.AIR PRESSURE.
3.
Turn the starting switch to the ON position.
4.
Troubleshoot the voltage.
5.
Does the troubleshooting result agree with the standard value?
Voltage
StandMeasurement position and condition ard value Between AMB.AIR PRESSURE (3) and (2)
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The ambient pressure sensor is normal.
•
Go to the next inspection item.
•
The ambient pressure sensor is defective.
•
Replace the ambient pressure sensor.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Item
40-306
YES
StandMeasurement position and condition ard value
Resist- Between ECM (female) (3) and ance each pin other than (3)
NO
•
Min. 100 kΩ
1.
Item
5
YES
StandMeasurement position and condition ard value
Between ECM (female) (3) or ResistAMB.AIR PRESSURE (female) (3) ance and ground
Diagnosis and treatment
0.3 to 4.7V
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA222]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with ambient pressure sensor
ECM (DRC26-60) Air pressure sensor Sensor power (+ 5V) Air pressure sensor return
G0024203
PC210-10M0, PC210LC-10M0
40-307
FAILURE CODE [CA227]
40 TROUBLESHOOTING
FAILURE CODE [CA227] Details of failure
A high voltage error occurs in the sensor power supply 2 (5V) circuit.
Action level
L03
Action of controller
The engine controller ignores the signals from the common rail pressure sensor, charge (boost) pressure sensor, and Bkup speed sensor. The engine controller fixes the values at the one before detecting the error, and runs the engine.
Phenomenon on machine
The engine output is reduced.
Associated informa- tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS, BOOST PRESS & IMT, CAM SENSOR. Connect the T-adapter to one of the female sides.
3.
2
Are the wiring harnesses and connectors normal?
Hot short circuit 4. in wiring harness
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES •
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Turn the starting switch to the ON position to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between FUEL RAIL PRESS (female) (3) and (1), BOOST PRESS & 4.75 to Voltage IMT (female) (2) and (4), or CAM 5.25V SENSOR (female) (1) and (2)
40-308
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [CA227]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS, BOOST PRESS & IMT, CAM SENSOR.
3.
Connect one of the disconnected connectors.
4.
Turn the starting switch to the ON position to troubleshoot.
5.
Check that this failure code is not shown.
6.
Do the steps 1 to 5 again for all the disconnected connectors.
7.
Are all connectors checked for not having a defect to show this failure code?
Diagnosis and treatment •
The equipment connected to each connector is is normal.
•
Go to the next inspection item.
•
If this failure code is shown for a connector, the equipment connected to that connector is defective.
•
Replace the equipment connected to the connector which caused this failure code.
•
Go to "Confirmation of repair".
YES
REMARK 3
Sensor
Since connectors are disconnected, the failure codes for the disconnected devices are shown. Sensor
Common rail pressure sensor
Connector
NO
FUEL RAIL PRESS
Charge (boost) pressure sensor
BOOST PRESS & IMT
Bkup speed sensor
CAM SENSOR
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-309
FAILURE CODE [CA227]
40 TROUBLESHOOTING
Circuit diagram associated with sensor 2 power supply
ECM (DRC26-60) Accumulator pressure signal Engine position sensor signal Sensor power (+ 5V) Engine position sensor return
E06
G0024202
40-310
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA234]
FAILURE CODE [CA234] Details of failure
The engine speed exceeds the operating range.
Action level
L02
Action of controller
Restricts the fuel injection rate until the speed is lowered to within the operating range.
Phenomenon on machine
The engine speed changes.
Pre-troubleshooting Associated informa- If multiple failure codes are shown at the same time, do the troubleshooting for them first. tion Monitoring code The engine speed can be monitored. (Code: 01002) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel is proper.
NO
• YES • 2
Fuel
1.
Drain the fuel from the fuel tank.
2.
Check if the fuel is proper.
3.
Is proper fuel used?
• •
Replace with the specified fuel.
•
Go to "Confirmation of repair". The operating method of the machine is correct.
NO
• YES •
3
Operating method of the machine
1.
Check how the operator used the machine.
2.
Is the operating method of the machine by the operator correct?
•
Go to the next inspection item. The operating method of the machine is incorrect.
•
Instruct the correct operating method of the machine to the operator.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The fuel is improper.
40-311
FAILURE CODE [CA234]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
Confirmation of 3. repair
40-312
Do the preceding troubleshooting again. NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine.
4.
Run the engine at high idle.
5.
Is this failure code shown again?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA238]
FAILURE CODE [CA238] Details of failure
An error occurs in the power supply (5V) circuit of the engine NE speed sensor.
Action level
L01
Action of controller
Controls by the signals from the engine Bkup speed sensor.
Phenomenon on machine
•
The engine stops during operation. (When the engine Bkup (G) speed sensor is also defective)
•
When the engine is stopped, the engine cannot be started. (When the engine Bkup (G) speed sensor is also defective)
Associated informa- tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Ground fault in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CRANK SENSOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (16) or ResistCRANK SENSOR (female) (1) and ance ground
PC210-10M0, PC210LC-10M0
Min. 100 kΩ
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-313
FAILURE CODE [CA238]
No.
3
40 TROUBLESHOOTING
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CRANK SENSOR.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (16) and ance each pin other than (16)
4
Engine NE speed sensor
Diagnosis and treatment YES
NO
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The engine NE speed sensor is normal.
•
Go to the next inspection item. The engine NE speed sensor is defective.
Min. 100 kΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CRANK SENSOR.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again? REMARK Since connectors are disconnected, the failure codes for the disconnected devices are shown.
YES
• NO
•
Replace the engine NE speed sensor.
•
Go to "Confirmation of repair".
YES The repair is completed.
5
Reconfirmation 1. of inspection 2. item
40-314
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA238]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Diagnosis and treatment YES
Return to the first inspection item.
REMARK 6
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
Circuit diagram associated with NE speed sensor
ECM (DRC26-60)
( F R A M AT O M E - 3 )
Sensor power (+ 5V)
return G0024204
PC210-10M0, PC210LC-10M0
40-315
FAILURE CODE [CA271]
40 TROUBLESHOOTING
FAILURE CODE [CA271] Details of failure
A short circuit occurs in the supply pump actuator (IMV) drive circuit.
Action level
L03
Action of controller
Closes the EGR valve.
Phenomenon on machine
•
The engine speed does not increase from low idle speed.
•
The engine output is reduced.
•
The engine startability is degraded.
•
The common rail fuel pressure is higher than the command value.
Reference information Associated informaNormally, while the engine runs, pulses of approximately 24 V are supplied to PCV1 (1). tion The voltage of pulses cannot be measured with a multimeter. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Actuator of supply pump
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of connector CP3 PUMP REGULATOR.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between CP3 PUMP REGULATOR Resist- (1) and (2) ance Between CP3 PUMP REGULATOR (1) and ground
40-316
2.3 to 5.3 Ω Min. 100 kΩ
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The actuator of the supply pump is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The actuator of the supply pump is defective.
•
Replace the actuator of the supply pump.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [CA271]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Diagnosis and treatment YES
NO
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Between ECM (female) (2) or PUMP Min. ResistREGULATOR (female) (1) and 100 kΩ ance ground
4
Short circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (2) and ance each pin other than (2)
5
NO
Min. 100 kΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of connector CP3 PUMP REGULATOR.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
YES
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
PC210-10M0, PC210LC-10M0
StandMeasurement position and condition ard value Between CP3 PUMP REGULATOR (female) (1) and (2)
Max. 3V
NO
40-317
FAILURE CODE [CA271]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with IMV and PCV1
ECM (DRC26-60)
return
Pump regulator valve (IMA)
G0024205
40-318
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA272]
FAILURE CODE [CA272] Details of failure
An open circuit occurs in the actuator (IMV) drive circuit of the supply pump.
Action level
L03
Action of controller
Closes the EGR valve.
Phenomenon on machine
•
The engine output is reduced.
•
The engine startability is degraded.
•
The engine runs but it is not stable.
•
The common rail fuel pressure is higher than the command value.
Reference information Associated information
No.
•
Normally, while the engine runs, pulses of approximately 24 V are supplied to PCV1 (1). The voltage of pulses cannot be measured with a multimeter.
•
The "socket" for troubleshooting this sensor has only a female connector. Since the socket cannot be connected to the female connector on the wiring harness side of the sensor, open circuits cannot be checked. (T-adapter is not provided.)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Actuator of supply pump
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of connector CP3 PUMP REGULATOR.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP3 PUMP REGULATOR ance (female) (1) and (2)
PC210-10M0, PC210LC-10M0
2.3 to 5.3 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The actuator of the supply pump is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The actuator of the supply pump is defective.
•
Replace the actuator of the supply pump.
•
Go to "Confirmation of repair".
40-319
FAILURE CODE [CA272]
No.
3
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
StandMeasurement position and condition ard value
Diagnosis and treatment YES
NO
Between ECM (female) (2) and CP3 Max. 10 Ω PUMP REGULATOR (female) (1)
Resistance Between ECM (female) (32) and CP3 PUMP REGULATOR (female) (2)
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 10 Ω
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with IMV and PCV1
ECM (DRC26-60)
return
Pump regulator valve (IMA)
G0024205
40-320
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA322]
FAILURE CODE [CA322] Details of failure
An open circuit or short circuit occurs in the injector #1 circuit.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
•
The engine output is reduced.
•
The engine does not run stably.
Reference information Associated information
No.
•
While engine runs normally, pulses of approximately 24 V are supplied to the injector (+) side. The voltage of pulses cannot be measured with a multimeter.
•
If a ground fault or hot short circuit is sensed, failure codes [CA322], [CA331], and [CA324] are shown at the same time.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Injector #1
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 1 & 2.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between INJECTOR CYL 1 & 2 Resist- (male) (3) and (4) ance Between INJECTOR CYL 1 & 2 (male) (3) and ground
PC210-10M0, PC210LC-10M0
Max. 2 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Injector #1 is normal.
NO
• YES •
NO
Go to the next inspection item.
•
Injector #1 is defective.
•
Replace injector #1.
•
Go to "Confirmation of repair".
Min. 100 kΩ
40-321
FAILURE CODE [CA322]
No.
3
40 TROUBLESHOOTING
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
YES
NO
Between ECM (female) (45) and IN- Max. 10 Ω Resist- JECTOR CYL 1 & 2 (female) (3) ance Between ECM (female) (53) and IN- Max. 10 JECTOR CYL 1 & 2 (female) (4)
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (45) or INJECTOR CYL 1 & 2 (female) (3) Resist- and ground ance Between ECM (female) (53) or INJECTOR CYL 1 & 2 (female) (4) and ground
40-322
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Ω
1.
Item
•
Min. 100 kΩ
YES
NO
Min. 100 kΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [CA322]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (45) and Resist- each pin other than (45) ance Between ECM (female) (53) and each pin other than (53)
Diagnosis and treatment YES
NO
Min. 100 kΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item. The wiring harness has a hot short circuit.
Min. 100 kΩ
YES
6
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 1 & 2.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
• •
Disconnect connector INJECTOR CYL 1 & 2 and measure the voltage again at the same place.
•
If the voltage is abnormal again, the positive side line is defective.
•
If the voltage returns to the normal range, the negative side line is defective.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between INJECTOR CYL 1 & 2 (female) (3) and (4)
NO
Max. 6V
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-323
FAILURE CODE [CA322]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Confirmation of repair
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
Diagnosis and treatment Return to the first inspection item.
YES
NO The repair is completed.
Circuit diagram associated with injector #1
ECM (DRC26-60) 3
1
4
2
G0024206
40-324
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA323]
FAILURE CODE [CA323] Details of failure
An open circuit or short circuit occurs in the injector #5 circuit.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
•
The engine output is reduced.
•
The engine does not run stably.
Reference information Associated information
No.
•
While engine runs normally, pulses of approximately 24 V are supplied to the injector (+) side. The voltage of pulses cannot be measured with a multimeter.
•
If a ground fault or hot short circuit is sensed, failure codes [CA323], [CA325], and [CA332] are shown at the same time.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Injector #5
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 5 & 6.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between INJECTOR CYL 5 & 6 Resist- (male) (3) and (4) ance Between INJECTOR CYL 5 & 6 (male) (3) and ground
PC210-10M0, PC210LC-10M0
Max. 2 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Injector #5 is normal.
NO
• YES •
NO
Go to the next inspection item.
•
Injector #5 is defective.
•
Replace injector #5.
•
Go to "Confirmation of repair".
Min. 100 kΩ
40-325
FAILURE CODE [CA323]
No.
3
40 TROUBLESHOOTING
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
YES
NO
Between ECM (female) (46) and IN- Max. 10 Ω Resist- JECTOR CYL 5 & 6 (female) (3) ance Between ECM (female) (60) and IN- Max. 10 JECTOR CYL 5 & 6 (female) (4)
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (46) or INJECTOR CYL 5 & 6 (female) (3) Resist- and ground ance Between ECM (female) (60) or INJECTOR CYL 5 & 6 (female) (4) and ground
40-326
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Ω
1.
Item
•
Min. 100 kΩ
YES
NO
Min. 100 kΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [CA323]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (46) and Resist- each pin other than (46) ance Between ECM (female) (60) and each pin other than (60)
Diagnosis and treatment YES
NO
Min. 100 kΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item. The wiring harness has a hot short circuit.
Min. 100 kΩ
YES
6
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 5 & 6.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
• •
Disconnect connector INJECTOR CYL 5 & 6 and measure the voltage again at the same place.
•
If the voltage is abnormal again, the positive side line is defective.
•
If the voltage returns to the normal range, the negative side line is defective.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between INJECTOR CYL 5 & 6 (female) (3) and (4)
NO
Max. 6V
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-327
FAILURE CODE [CA323]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Confirmation of repair
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with injector #5
ECM (DRC26-60) 3
1
4
2
G0024207
40-328
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA324]
FAILURE CODE [CA324] Details of failure
An open circuit or short circuit occurs in the injector #3 circuit.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
•
The engine output is reduced.
•
The engine does not run stably.
Reference information Associated information
No.
•
While engine runs normally, pulses of approximately 24 V are supplied to the injector (+) side. The voltage of pulses cannot be measured with a multimeter.
•
If a ground fault or hot short circuit is sensed, failure codes [CA322], [CA331], and [CA324] are shown at the same time.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Injector #3
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the male side of connector INJECTOR CYL 3 & 4.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between INJECTOR CYL 3 & 4 Resist- (male) (3) and (4) ance Between INJECTOR CYL 3 & 4 (male) (3) and ground
PC210-10M0, PC210LC-10M0
Max. 2 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Injector #3 is normal.
NO
• YES •
NO
Go to the next inspection item.
•
Injector #3 is defective.
•
Replace injector #3.
•
Go to "Confirmation of repair".
Min. 100 kΩ
40-329
FAILURE CODE [CA324]
No.
3
40 TROUBLESHOOTING
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
YES
NO
Between ECM (female) (52) and IN- Max. 10 Ω Resist- JECTOR CYL 3 & 4 (female) (3) ance Between ECM (female) (55) and IN- Max. 10 JECTOR CYL 3 & 4 (female) (4)
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (52) or INJECTOR CYL 3 & 4 (female) (3) Resist- and ground ance Between ECM (female) (55) or INJECTOR CYL 3 & 4 (female) (4) and ground
40-330
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Ω
1.
Item
•
Min. 100 kΩ
YES
NO
Min. 100 kΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [CA324]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (52) and Resist- each pin other than (52) ance Between ECM (female) (55) and each pin other than (55)
Diagnosis and treatment YES
NO
Min. 100 kΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item. The wiring harness has a hot short circuit.
Min. 100 kΩ
YES
6
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 3 & 4.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
• •
Disconnect connector INJECTOR CYL 3 & 4 and measure the voltage again at the same place.
•
If the voltage is abnormal again, the positive side line is defective.
•
If the voltage returns to the normal range, the negative side line is defective.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between INJECTOR CYL 3 & 4 (female) (3) and (4)
NO
Max. 6V
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-331
FAILURE CODE [CA324]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Confirmation of repair
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
Diagnosis and treatment Return to the first inspection item.
YES
NO The repair is completed.
Circuit diagram associated with injector #3
ECM (DRC26-60) 3
1
4
2
G0024208
40-332
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA325]
FAILURE CODE [CA325] Details of failure
An open circuit or short circuit occurs in the injector #6 circuit.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
•
The engine output is reduced.
•
The engine does not run stably.
Reference information Associated information
No.
•
While engine runs normally, pulses of approximately 24 V are supplied to the injector (+) side. The voltage of pulses cannot be measured with a multimeter.
•
If a ground fault or hot short circuit is sensed, failure codes [CA323], [CA325], and [CA332] are shown at the same time.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Injector #6
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 5 & 6.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between INJECTOR CYL 5 & 6 Resist- (male) (2) and (1) ance Between INJECTOR CYL 5 & 6 (male) (2) and ground
PC210-10M0, PC210LC-10M0
Max. 2 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Injector #6 is normal.
NO
• YES •
NO
Go to the next inspection item.
•
Injector #6 is defective.
•
Replace injector #6.
•
Go to "Confirmation of repair".
Min. 100 kΩ
40-333
FAILURE CODE [CA325]
No.
3
40 TROUBLESHOOTING
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
YES
NO
Between ECM (female) (57) and IN- Max. 10 Ω Resist- JECTOR CYL 5 & 6 (female) (2) ance Between ECM (female) (59) and IN- Max. 10 JECTOR CYL 5 & 6 (female) (1)
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (57) or INJECTOR CYL 5 & 6 (female) (2) Resist- and ground ance Between ECM (female) (59) or INJECTOR CYL 5 & 6 (female) (1) and ground
40-334
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Ω
1.
Item
•
Min. 100 kΩ
YES
NO
Min. 100 kΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [CA325]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (57) and Resist- each pin other than (57) ance Between ECM (female) (59) and each pin other than (59)
Diagnosis and treatment YES
NO
Min. 100 kΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item. The wiring harness has a hot short circuit.
Min. 100 kΩ
YES
6
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 5 & 6.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 5 & 6.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
• •
Disconnect connector INJECTOR CYL 5 & 6 and measure the voltage again at the same place.
•
If the voltage is abnormal again, the positive side line is defective.
•
If the voltage returns to the normal range, the negative side line is defective.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between INJECTOR CYL 5 & 6 (female) (2) and (1)
NO
Max. 6V
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-335
FAILURE CODE [CA325]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Confirmation of repair
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
Diagnosis and treatment Return to the first inspection item.
YES
NO The repair is completed.
Circuit diagram associated with injector #6
ECM (DRC26-60) 1
1
2
2
G0024209
40-336
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA331]
FAILURE CODE [CA331] Details of failure
An open circuit or short circuit occurs in the injector #2 circuit.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
•
The engine output is reduced.
•
The engine does not run stably.
Reference information Associated information
No.
•
While engine runs normally, pulses of approximately 24 V are supplied to the injector (+) side. The voltage of pulses cannot be measured with a multimeter.
•
If a ground fault or hot short circuit is sensed, failure codes [CA322], [CA331], and [CA324] are shown at the same time.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Injector #2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 1 & 2.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between INJECTOR CYL 1 & 2 Resist- (male) (2) and (1) ance Between INJECTOR CYL 1 & 2 (male) (2) and ground
PC210-10M0, PC210LC-10M0
Max. 2 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Injector #2 is normal.
NO
• YES •
NO
Go to the next inspection item.
•
Injector #2 is defective.
•
Replace injector #2.
•
Go to "Confirmation of repair".
Min. 100 kΩ
40-337
FAILURE CODE [CA331]
No.
3
40 TROUBLESHOOTING
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
YES
NO
Between ECM (female) (51) and IN- Max. 10 Ω Resist- JECTOR CYL 1 & 2 (female) (2) ance Between ECM (female) (54) and IN- Max. 10 JECTOR CYL 1 & 2 (female) (1)
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (51) or INJECTOR CYL 1 & 2 (female) (2) Resist- and ground ance Between ECM (female) (54) or INJECTOR CYL 1 & 2 (female) (1) and ground
40-338
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Ω
1.
Item
•
Min. 100 kΩ
YES
NO
Min. 100 kΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [CA331]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (51) and Resist- each pin other than (51) ance Between ECM (female) (54) and each pin other than (54)
Diagnosis and treatment YES
NO
Min. 100 kΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item. The wiring harness has a hot short circuit.
Min. 100 kΩ
YES
6
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 1 & 2.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 1 & 2.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
• •
Disconnect connector INJECTOR CYL 1 & 2 and measure the voltage again at the same place.
•
If the voltage is abnormal again, the positive side line is defective.
•
If the voltage returns to the normal range, the negative side line is defective.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between INJECTOR CYL 1 & 2 (female) (2) and (1)
NO
Max. 6V
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-339
FAILURE CODE [CA331]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Confirmation of repair
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
Diagnosis and treatment Return to the first inspection item.
YES
NO The repair is completed.
Circuit diagram associated with injector #2
ECM (DRC26-60) 1
1
2
2
G0024210
40-340
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA332]
FAILURE CODE [CA332] Details of failure
An open circuit or short circuit occurs in the injector #4 circuit.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
•
The engine output is reduced.
•
The engine does not run stably.
Reference information Associated information
No.
•
While engine runs normally, pulses of approximately 24 V are supplied to the injector (+) side. The voltage of pulses cannot be measured with a multimeter.
•
If a ground fault or hot short circuit is sensed, failure codes [CA323], [CA325], and [CA332] are shown at the same time.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Injector #4
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 3 & 4.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between INJECTOR CYL 3 & 4 Resist- (male) (2) and (1) ance Between INJECTOR CYL 3 & 4 (male) (2) and ground
PC210-10M0, PC210LC-10M0
Max. 2 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Injector #4 is normal.
NO
• YES •
NO
Go to the next inspection item.
•
Injector #4 is defective.
•
Replace injector #4.
•
Go to "Confirmation of repair".
Min. 100 kΩ
40-341
FAILURE CODE [CA332]
No.
3
40 TROUBLESHOOTING
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
YES
NO
Between ECM (female) (56) and IN- Max. 10 Ω Resist- JECTOR CYL 3 & 4 (female) (2) ance Between ECM (female) (58) and IN- Max. 10 JECTOR CYL 3 & 4 (female) (1)
4
Ground fault in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (56) or INJECTOR CYL 3 & 4 (female) (2) Resist- and ground ance Between ECM (female) (58) or INJECTOR CYL 3 & 4 (female) (1) and ground
40-342
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Ω
1.
Item
•
Min. 100 kΩ
YES
NO
Min. 100 kΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [CA332]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (56) and Resist- each pin other than (56) ance Between ECM (female) (58) and each pin other than (58)
Diagnosis and treatment YES
NO
Min. 100 kΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item. The wiring harness has a hot short circuit.
Min. 100 kΩ
YES
6
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector INJECTOR CYL 3 & 4.
3.
Connect the T-adapter to the female side of connector INJECTOR CYL 3 & 4.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
• •
Disconnect connector INJECTOR CYL 3 & 4 and measure the voltage again at the same place.
•
If the voltage is abnormal again, the positive side line is defective.
•
If the voltage returns to the normal range, the negative side line is defective.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between INJECTOR CYL 3 & 4 (female) (2) and (1)
NO
Max. 6V
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-343
FAILURE CODE [CA332]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Confirmation of repair
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
Diagnosis and treatment Return to the first inspection item.
YES
NO The repair is completed.
Circuit diagram associated with injector #4
ECM (DRC26-60) 1
1
2
2
G 0 0 2 4 2 11
40-344
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA342]
FAILURE CODE [CA342] Details of failure
A data matching error occurs in the engine controller.
Action level
L04
Action of controller
None in particular.
Phenomenon on machine
The engine operates normally but it can stop during operation, or it cannot be started when it is stopped.
Associated informa- Monitoring code tion The power supply voltage of the engine controller can be monitored. (Code: 03203) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
Check the battery voltage.
2.
Does the battery voltage agree with the standard value? Item
Voltage
3
Alternator
Measuring point and measurement condition Between battery terminals (+) and (-)
Standard value 20 to 30 V
1.
Turn the starting switch to the OFF position.
2.
Start the engine.
3.
Run the engine at a medium speed or above.
4.
Measure the voltage.
5.
Does the troubleshooting result agree with the standard value? Item
Voltage
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between alternator terminal GI and ground
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The battery output voltage is normal.
NO
•
1.
Battery voltage
•
YES
• NO
26 to 30.5 V
NO
Go to the next inspection item. The battery output voltage is low.
•
Charge or replace the battery.
•
Go to "Confirmation of repair". The alternator is normal.
• YES
Standard value
•
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
40-345
FAILURE CODE [CA342]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment • YES •
4
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse No.19 in the fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
•
When it is not blown but it has no resistance, replace the fuse.
•
Go to "Confirmation of repair". The removed engine controller power supply relay is normal.
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors R23 and R24. Replace the relay with same type.
•
Turn the starting switch to the ON position to troubleshoot.
•
Engine controller power sup3. ply relay 4.
Is this failure code cleared?
YES •
NO •
6
Open circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect connectors R23 and R24. Connect the T-adapter to each female side.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CE03 (female) (3) and R23 Max. 1 (female) (5) Ω Between CE03 (female) (3) and R24 Max. 1 (female) (4) Ω
40-346
• YES
Resist- Between R23 (female) (3) and ance F01-19
Max. 1 Ω
Between R24 (female) (3) and F01-19
Max. 1 Ω
Between CE03 (female) (1) and ground
Max. 1 Ω
Go to the next inspection item. If blown, go to "Ground fault of wiring harness".
• NO
•
5
The fuse is normal.
Restore the removed relay. Go to the next inspection item. The removed engine controller power supply relay is defective. Go to "Confirmation of repair". The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
7
FAILURE CODE [CA342]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect connectors CE03, R23 and R24. Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between ground and one of CE03 (female) (3), R23 (female) (5), and Resist- R24 (female) (4) ance Between ground and one of R23 (female) (3), R24 (female) (3), and F01-19
8
Short circuit in wiring harness
Standard value
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect connector CE03. Connect the Tadapter to the female side.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value?
Resist- Between CE03 (female) (3) and ance each pin other than pin (3)
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
Turn the starting switch to the OFF position.
Measuring point and measurement condition
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Standard value Min. 1 MΩ
YES The repair is completed.
9
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Can you identify the cause by reconfirmation?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-347
FAILURE CODE [CA342]
No.
10
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-348
40 TROUBLESHOOTING
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA342]
Circuit diagram associated with engine controller power supply
CE02
CE03 Power (+24V)
Starter B
3
L19 2 J 0 5 16
AC
AC95 8 HK Relay for CM850 (1)
Monitor panel
1 2
15A
3 Relay for CM850 (2)
HJ
4 5 6 T06
S01
CP02
G0024214
PC210-10M0, PC210LC-10M0
40-349
FAILURE CODE [CA351]
40 TROUBLESHOOTING
FAILURE CODE [CA351] Details of failure
An error occurs in the injector drive circuit.
Action level
L03
Action of controller
The engine power is derated. (Restricts the common rail pressure.)
Phenomenon on machine
The engine output is reduced.
Pre-troubleshooting If failure code [CA322], [CA323], [CA324], [CA325], [CA331], [CA332], or [CA441] is also Associated informashown, do the troubleshooting for that code first. tion Monitoring code The power supply voltage of the engine controller can be monitored. (Code: 03203) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-350
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA351]
Cause
Procedures, Measurement, Values, Note
Battery
• YES •
Turn the starting switch to the OFF position.
2.
Check the battery electrolyte level.
3.
Measure the battery voltage.
4.
Measure the specific gravity of the battery electrolyte.
•
5.
Do the electrolyte level, voltage and specific gravity agree with the standard value?
The battery is defective.
•
If the battery electrolyte level is low, add electrolyte. After the electrolyte is refilled, charge the battery.
•
If the battery voltage is low, charge or replace the battery.
•
If the specific gravity of the battery electrolyte is low, charge the battery. If the specific gravity is less than the specified value after the battery is charged, replace the battery.
•
Go to "Confirmation of repair".
•
The alternator is normal.
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
Standard value
Battery Between UPPER LEVEL and LOWER LEVelectroEL lyte level Battery voltage (1 Min. 12V battery)
NO
Battery voltage (2 Min. 24 V batteries in series) Specific gravity of battery Min. 1.26 (electrolyte temperature: 20°C) electrolyte
3
1.
Turn the starting switch to the OFF position.
2.
Start the engine.
3.
Run the engine at a medium speed or above.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Alternator
Item
Voltage
4
Fuse
The battery is normal.
1.
Judged item
2
Diagnosis and treatment
Measuring point and measurement condition Between alternator terminal GI and ground
YES
Standard value 26 to 30.5V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Check if the fuse is blown.
5.
Check the fuse for continuity.
6.
Is the fuse normal?
PC210-10M0, PC210LC-10M0
NO
• YES • •
NO
Go to the next inspection item.
The fuse is normal. Go to the next inspection item. If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair".
40-351
FAILURE CODE [CA351]
No.
5
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Disconnect the connector.CE03, R23, R24
5.
Connect the T-adapter to the female side of the connector.CE03, R23, R24
6.
Measure the resistance to troubleshoot.
7.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Measuring point and measurement condition
Standard value
Between CE03 (female) (3) and R23 Max. 10 (female) (5) Ω
Diagnosis and treatment YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
If the fuse is blown, replace the fuse.
•
Go to "Confirmation of repair".
Between CE03 (female) (3) and R24 Max. 10 (female) (4) Ω
6
Ground fault in wiring harness
Resist- Between R23 (female) (3) and ance F01-19
Max. 10 Ω
Between R24 (female) (3) and F01-19
Max. 10 Ω
Between CE03 (female) (1) and ground
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Disconnect the connector.CE03, R23, R24
5.
Connect the T-adapter to the female side of the connector.CE03, R23, R24
6.
Measure the resistance to troubleshoot.
7.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CE03 (female) (3), R23 Min. (female) (5), or R24 (female) (4) and 100 kΩ Resist- ground ance Between F01-19, R23 (female) (3), Min. or R24 (female) (3) and ground 100 kΩ
40-352
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
7
FAILURE CODE [CA351]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Disconnect the connector.CE03, R23, R24
5.
Connect the T-adapter to the female side of the connector.CE03, R23, R24
6.
Measure the resistance to troubleshoot.
7.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between CE03 (female) (1) and Resist- each pin other than (1) ance Between CE03 (female) (3) and each pin other than (3)
Diagnosis and treatment YES
NO
Standard value
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
If the fuse is blown, replace the fuse.
•
Go to "Confirmation of repair".
Min. 100 kΩ Min. 100 kΩ
YES The repair is completed.
8
9
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-353
FAILURE CODE [CA351]
40 TROUBLESHOOTING
Circuit diagram associated with engine controller power supply
CE02
CE03 Power (+24V)
Starter B
3
L19 2 J 0 5 16
AC
AC95 8 HK Relay for CM850 (1)
Monitor panel
1 2
15A
3 Relay for CM850 (2)
HJ
4 5 6 T06
S01
CP02
G0024214
40-354
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA352]
FAILURE CODE [CA352] Details of failure
A low voltage error occurs in the sensor 1 power supply (5V) circuit.
Action level
L03
Action of controller
The engine controller ignores the signals from the ambient pressure sensor. The engine control sets the ambient pressure to a fixed value (52.44 kPa {0.53 kg/cm2}), and runs the engine.
Phenomenon on machine
The engine output is reduced.
Associated informa- tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Ground fault in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, AMB. AIR PRESSURE.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between ECM (female) (33), or ResistAMB.AIR PRESSURE (female) (1) ance and ground
PC210-10M0, PC210LC-10M0
Standard value Min. 100 kΩ
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-355
FAILURE CODE [CA352]
No.
3
40 TROUBLESHOOTING
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, AMB. AIR PRESSURE.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between ECM (female) (33) and ance each pin other than (33)
4
Ambient pressure sensor
Standard value
Diagnosis and treatment YES
NO
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The removed ambient pressure sensor is normal.
•
Go to the next inspection item. The removed ambient pressure sensor is defective.
Min. 100 kΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectorAMB. AIR PRESSURE, and replace it with the same type of sensor.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
YES
• NO •
Go to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-356
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA352]
Circuit diagram associated with sensor 1 power supply
ECM (DRC26-60) Air pressure sensor Sensor power (+ 5V) Air pressure sensor return
G0024203
PC210-10M0, PC210LC-10M0
40-357
FAILURE CODE [CA386]
40 TROUBLESHOOTING
FAILURE CODE [CA386] Details of failure
A high voltage error occurs in the sensor power supply 1 (5V) circuit.
Action level
L03
Action of controller
The engine controller ignores the signals from the ambient pressure sensor. The engine control sets the ambient pressure to a fixed value (52.44 kPa {0.53 kg/cm2}), and runs the engine.
Phenomenon on machine
The engine output is reduced.
Associated informa- tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector AMB. AIR PRESSURE.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
40-358
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES •
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Voltage
Between AMB.AIR PRESSURE (female) (1) and (2)
4.75 to 5.25V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [CA386]
Cause
Ambient pressure sensor
Procedures, Measurement, Values, Note
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectorAMB. AIR PRESSURE, and replace it with the same type of sensor.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
Diagnosis and treatment •
The removed ambient pressure sensor is normal.
•
Go to the next inspection item. The removed ambient pressure sensor is defective.
YES
• NO •
Go to "Confirmation of repair".
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with sensor 1 power supply
ECM (DRC26-60) Air pressure sensor Sensor power (+ 5V) Air pressure sensor return
G0024203
PC210-10M0, PC210LC-10M0
40-359
FAILURE CODE [CA435]
40 TROUBLESHOOTING
FAILURE CODE [CA435] Details of failure
An error occurs in the signal circuit of the engine oil pressure switch.
Action level
L01
Action of controller
None in particular.
Phenomenon on machine
•
The protection function by the engine oil pressure does not operate.
•
The engine oil pressure monitor is not shown normally.
k
For the check and replacement work of the engine oil pressure switch, open the engine oil filler port. Check that the engine oil temperature is decreased sufficiently to not get burned.
Reference information Associated information
No.
•
The engine oil pressure switch closes (ON) when the oil pressure is low (engine stopped), and opens (OFF) when the oil pressure is high (engine in operation).
•
For this failure code, the engine controller checks if the engine oil pressure switch is closed (ON) or at "GND level" only when the engine is stopped.
•
Error of the engine oil pressure switch during engine operation is checked for failure code [B@BAZG].
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector OIL PRESSURE SWITCH.
3.
Connect the T-adapter to the female side of connector OIL PRESSURE SWITCH.
4.
Measure the resistance to troubleshoot.
Engine oil pres- 5. sure switch
StandMeasurement position and condition ard value
Resist- Between OIL PRESSURE SWITCH ance (male) (1) and ground
40-360
Max. 10 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The engine oil pressure switch is normal.
NO
• YES
Does the troubleshooting result agree with the standard value? Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The engine oil pressure switch is defective.
•
Replace the engine oil pressure switch.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [CA435]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector OIL PRESSURE SWITCH.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (17) and ResistOIL PRESSURE SWITCH (female) ance (1)
4
YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector OIL PRESSURE SWITCH.
3.
Connect the T-adapter to the female side of connector OIL PRESSURE SWITCH.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
StandMeasurement position and condition ard value Between OIL PRESSURE SWITCH (female) (1) and ground
NO
? Max. V
YES The repair is completed.
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-361
FAILURE CODE [CA435]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Diagnosis and treatment YES
Return to the first inspection item.
REMARK 6
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
Circuit diagram associated with engine oil pressure switch
ECM (DRC26-60)
(Low)
G0024213
40-362
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA441]
FAILURE CODE [CA441] Details of failure
A low voltage occurs in the engine controller power supply circuit.
Action level
L04
Action of controller
Sets the power supply voltage to a fixed value (6.0V), and runs the engine.
Phenomenon on machine
•
The engine stops.
•
The engine startability will be degraded.
Associated informa- Monitoring code tion The power supply voltage of the engine controller can be monitored. (Code: 03203) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
Battery
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The battery is normal.
NO
•
1.
Turn the starting switch to the OFF position.
2.
Check the battery electrolyte level.
3.
Measure the battery voltage.
4.
Measure the specific gravity of the battery electrolyte.
•
5.
Do the electrolyte level, voltage and specific gravity agree with the standard value?
The battery is defective.
•
If the battery electrolyte level is low, add electrolyte. After the electrolyte is refilled, charge the battery.
•
If the battery voltage is low, charge or replace the battery.
•
If the specific gravity of the battery electrolyte is low, charge the battery. If the specific gravity is less than the specified value after the battery is charged, replace the battery.
•
Go to "Confirmation of repair".
Judged item
2
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
YES •
Standard value
Battery Between UPPER LEVEL and LOWER LEVelectroEL lyte level Battery voltage (1 Min. 12V battery)
NO
Battery voltage (2 Min. 24 V batteries in series) Specific gravity of battery Min. 1.26 (electrolyte temperature: 20°C) electrolyte
PC210-10M0, PC210LC-10M0
Go to the next inspection item.
40-363
FAILURE CODE [CA441]
No.
3
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Start the engine.
3.
Run the engine at a medium speed or above.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Alternator
Item
Voltage
4
5
Fuse
Open circuit in wiring harness
Measuring point and measurement condition Between alternator terminal GI and ground
YES
Standard value
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Check if the fuse is blown.
5.
Check the fuse for continuity.
6.
Is the fuse normal?
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Disconnect the connector.CE03, R23, R24
5.
Connect the T-adapter to the female side of the connector.CE03, R23, R24
6.
Measure the resistance to troubleshoot.
7.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
The alternator is normal.
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
• YES • •
NO
Standard value
Between CE03 (female) (3) and R23 Max. 10 (female) (5) Ω Between CE03 (female) (3) and R24 Max. 10 (female) (4) Ω
40-364
NO
•
26 to 30.5V
1.
Item
Diagnosis and treatment
Resist- Between R23 (female) (3) and ance F01-19
Max. 10 Ω
Between R24 (female) (3) and F01-19
Max. 10 Ω
Between CE03 (female) (1) and ground
Max. 10 Ω
NO
Go to the next inspection item. If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
• YES
The fuse is normal.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
FAILURE CODE [CA441]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Disconnect the connector.CE03, R23, R24
5.
Connect the T-adapter to the female side of the connector.CE03, R23, R24
6.
Measure the resistance to troubleshoot.
7.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Diagnosis and treatment YES
NO
Between CE03 (female) (3), R23 Min. (female) (5), or R24 (female) (4) and 100 kΩ Resist- ground ance Between F01-19, R23 (female) (3), Min. or R24 (female) (3) and ground 100 kΩ
7
Short circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse in fuse box F01.No.19
4.
Disconnect the connector.CE03, R23, R24
5.
Connect the T-adapter to the female side of the connector.CE03, R23, R24
6.
Measure the resistance to troubleshoot.
7.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between CE03 (female) (1) and Resist- each pin other than (1) ance Between CE03 (female) (3) and each pin other than (3)
YES
NO
Standard value
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
If the fuse is blown, replace the fuse.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
If the fuse is blown, replace the fuse.
•
Go to "Confirmation of repair".
Min. 100 kΩ Min. 100 kΩ
YES The repair is completed.
8
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair". 40-365
FAILURE CODE [CA441]
No.
9
Cause
Confirmation of repair
40-366
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown again?
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA441]
Circuit diagram associated with engine controller power supply
CE02
CE03 Power (+24V)
Starter B
3
L19 2 J 0 5 16
AC
AC95 8 HK Relay for CM850 (1)
Monitor panel
1 2
15A
3 Relay for CM850 (2)
HJ
4 5 6 T06
S01
CP02
G0024214
PC210-10M0, PC210LC-10M0
40-367
FAILURE CODE [CA442]
40 TROUBLESHOOTING
FAILURE CODE [CA442] Details of failure
A high voltage (approximately 36 V or above) occurs in the engine controller power supply circuit.
Action level
L04
Action of controller
Sets the power supply voltage to a fixed value (24 V), and runs the engine.
Phenomenon on machine
The engine operates normally but it can stop during operation, or it cannot be started when it is stopped. Pre-troubleshooting
Check it. For details, see this chapter, "CHECK ELECTRIC EQUIPMENT", "Check of battery terminal for looseness and corrosion" and "Check of alternator terminal for looseAssociated informaness and corrosion". tion Monitoring code The power supply voltage of the engine controller can be monitored. (Code: 03203) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-368
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA442]
Cause
Procedures, Measurement, Values, Note
Battery
• YES •
Turn the starting switch to the OFF position.
2.
Check the battery electrolyte level.
3.
Measure the battery voltage.
4.
Measure the specific gravity of the battery electrolyte.
•
5.
Do the electrolyte level, voltage and specific gravity agree with the standard value?
The battery is defective.
•
If the battery electrolyte level is low, add electrolyte. After the electrolyte is refilled, charge the battery.
•
If the battery voltage is low, charge or replace the battery.
•
If the specific gravity of the battery electrolyte is low, charge the battery. If the specific gravity is less than the specified value after the battery is charged, replace the battery.
•
Go to "Confirmation of repair".
•
The alternator is normal.
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
Standard value
Battery Between UPPER LEVEL and LOWER LEVelectroEL lyte level Battery voltage (1 Min. 12V battery)
NO
Battery voltage (2 Min. 24 V batteries in series) Specific gravity of battery Min. 1.26 (electrolyte temperature: 20°C) electrolyte
3
Alternator
The battery is normal.
1.
Judged item
2
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Start the engine.
3.
Run the engine at a medium speed or above.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Voltage
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between alternator terminal GI and ground
YES
Standard value 26 to 30.5V
NO
Go to the next inspection item.
40-369
FAILURE CODE [CA442]
No.
4
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
ConnectorCE03Insert the T-adapter into the connector.
4.
Turn the battery disconnect switch to the ON position.
Hot short circuit 5. in wiring har6. ness 7.
Diagnosis and treatment •
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Turn the starting switch to the ON position. Measure the voltage. Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
NO
Standard value
Voltage Between CE03 (female) (3) and (1)
20 to 30V
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-370
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA442]
Circuit diagram associated with engine controller power supply
CE02
CE03 Power (+24V)
Starter B
3
L19 2 J 0 5 16
AC
AC95 8 HK Relay for CM850 (1)
Monitor panel
1 2
15A
3 Relay for CM850 (2)
HJ
4 5 6 T06
S01
CP02
G0024214
PC210-10M0, PC210LC-10M0
40-371
FAILURE CODE [CA449]
40 TROUBLESHOOTING
FAILURE CODE [CA449] Details of failure
A high pressure error (exceeding specified maximum level) occurs in the common rail pressure.
Action level
L03
Action of controller
Restricts the common rail pressure.
Phenomenon on machine
•
The engine sound becomes large at no load or light load.
•
The engine output is reduced.
Pre-troubleshooting If failure code [CA451], [CA452] or [CA553] is also shown, do the troubleshooting for that code first. Associated informa- Monitoring code tion • The signal voltage from the common rail pressure sensor can be monitored. (Code: 36401) •
No.
Cause
The common rail pressure sensed by the common rail pressure sensor can be monitored. (Code: 36400) Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
1.
2
Air mix in lowpressure circuit
Are the wiring harnesses and connectors normal?
Remove the pressure pickup plug (outlet side) of the fuel main filter.
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The low-pressure circuit is normal.
NO
• YES
•
Go to the next inspection item.
Is the low-pressure circuit normal?
•
REMARK
Air is mixed in the lowpressure circuit.
•
Bleed air from the lowpressure circuit. For details, see TESTING AND ADJUSTING, "BLEED AIR FROM FUEL SYSTEM".
•
Go to "Confirmation of repair".
2.
Operate the feed pump of the fuel prefilter.
3.
Check how the fuel and air leaks from the pressure pickup plug.
4.
• If this error occurs during air bleeding after replacement of the fuel filter, air could be left in the low-pressure circuit.
NO
• Run the engine at low idle for approximately 3 minutes. • When the air is bled, the engine speed becomes steady and the error indication is cleared.
40-372
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA449]
Cause
Procedures, Measurement, Values, Note 1.
Diagnosis and treatment
Check the pressure of the fuel return circuit. REMARK
2.
Measure the pressure to troubleshoot.
3.
Does the troubleshooting result agree with the standard value?
Fuel return circuit
Item
StandMeasurement position and condition ard value
Pressure of Joint bolt part of fuel refuel return hose turn circuit
4
Open circuit in wiring harness
Engine at low idle or cranking
Max. 18.6 kPa
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value Between ECM (female) (82) and FUEL RAIL PRESS (female) (3)
Max. 10 Ω
Resist- Between ECM (female) (25) and ance FUEL RAIL PRESS (female) (2)
Max. 10 Ω
Between ECM (female) (47) and FUEL RAIL PRESS (female) (1)
Max. 10 Ω
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item.
•
The equipment in the fuel return circuit are defective.
NO
•
Repair or replace the equipment in the fuel return circuit.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
{Min. 0.19 kg/ cm2}
1.
Item
The equipment in the fuel return circuit are normal.
YES
For the checking method, see TESTING AND ADJUSTING, "TEST FUEL PRESSURE".
3
•
YES
NO
40-373
FAILURE CODE [CA449]
No.
5
40 TROUBLESHOOTING
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Diagnosis and treatment YES
NO
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Between ECM (female) (25), or ResistMin. FUEL RAIL PRESS (female) (2) and ance 100 kΩ ground
6
Short circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (25) and ance each pin other than (25)
7
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector FUEL RAIL PRESS.
4.
Turn the starting switch to the ON position.
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
40-374
NO
Min. 100 kΩ
1.
Hot short circuit 5. in wiring har6. ness
YES
StandMeasurement position and condition ard value Between FUEL RAIL PRESS (female) (2) and (1)
Approx. 5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
8
FAILURE CODE [CA449]
Cause
Common rail pressure sensor
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector FUEL RAIL PRESS.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage Between ECM (25) and (47)
1.
Diagnosis and treatment YES
NO
0.2 to 4.8 V
Measure the leakage quantity from the pressure limiter and troubleshoot.
YES
REMARK
•
The common rail pressure sensor is normal.
•
Go to the next inspection item.
•
The common rail pressure sensor is defective.
•
Replace the common rail pressure sensor.
•
Go to "Confirmation of repair".
•
The pressure limiter is normal.
•
Go to the next inspection item.
•
The pressure limiter is defective.
•
Replace the pressure limiter.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE" 2. 9
Does the troubleshooting result agree with the standard value?
Pressure limiter Item Leakage from pressure limiter
PC210-10M0, PC210LC-10M0
StandMeasurement position and condition ard value
Joint bolt part of pressure limiter
At low idle (for 30 Max. 8 seconds) cc
NO
40-375
FAILURE CODE [CA449]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Measure the return rate from the supply pump and troubleshoot.
Diagnosis and treatment YES
REMARK
•
The supply pump is normal.
•
Go to the next inspection item.
•
The supply pump is defective.
•
Repair or replace the supply pump.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL DISCHARGE, RETURN AND LEAKAGE" to troubleshoot. 2.
10 Supply pump
Does the troubleshooting result agree with the standard value? Item
Measurement condition
Standard value
Cranking Return (Min. 150 rpm, for 30 seconds) rate from supply pump Low idle (for 30 seconds)
Max. 575 cc/30 sec
NO
Max. 575 cc/30 sec
YES The repair is completed. Reconfirmation 1. 11 of inspection 2. item
12
Confirmation of repair
40-376
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA449]
Circuit diagram associated with common rail pressure sensor
ECM (DRC26-60) Accumulator pressure signal Sensor power (+5V) Engine position sensor return
E06
G0024215
PC210-10M0, PC210LC-10M0
40-377
FAILURE CODE [CA451]
40 TROUBLESHOOTING
FAILURE CODE [CA451] Details of failure
A high voltage occurs in the signal circuit of the common rail pressure sensor.
Action level
L03
Action of controller
Restricts the common rail pressure.
Phenomenon on machine
The engine output is reduced.
Monitoring code
Associated information
•
The signal voltage from the common rail pressure sensor can be monitored. (Code: 36401)
•
The common rail pressure sensed by the common rail pressure sensor can be monitored. (Code: 36400)
Reference information If the sensor connector is disconnected, this failure code is shown instead of the failure code for low error in this configuration of circuit. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
40-378
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
3
FAILURE CODE [CA451]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Between ECM (female) (82) and FUEL RAIL PRESS (female) (3)
Max. 10 Ω
Resist- Between ECM (female) (25) and ance FUEL RAIL PRESS (female) (2)
Max. 10 Ω
Between ECM (female) (47) and FUEL RAIL PRESS (female) (1)
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector FUEL RAIL PRESS.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
NO
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The common rail pressure sensor is normal.
•
Go to the next inspection item.
•
The common rail pressure sensor is defective.
•
Replace the common rail pressure sensor.
•
Go to "Confirmation of repair".
YES
Does the troubleshooting result agree with the standard value?
Voltage
4
YES
•
Measure the voltage to troubleshoot.
Item
Common rail pressure sensor
StandMeasurement position and condition ard value
Diagnosis and treatment
StandMeasurement position and condition ard value Between FUEL RAIL PRESS (female) (2) and (1)
Approx. 5V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector FUEL RAIL PRESS.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between FUEL RAIL PRESS (2) Voltage and (1)
PC210-10M0, PC210LC-10M0
NO
0.2 to 4.8 V
YES
NO
40-379
FAILURE CODE [CA451]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with common rail pressure sensor
ECM (DRC26-60) Accumulator pressure signal Sensor power (+5V) Engine position sensor return
E06
G0024215
40-380
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA452]
FAILURE CODE [CA452] Details of failure
A low voltage occurs in the signal circuit of the common rail pressure sensor.
Action level
L03
Action of controller
Restricts the common rail pressure.
Phenomenon on machine
The engine output is reduced.
Monitoring code Associated information
No.
•
The signal voltage from the common rail pressure sensor can be monitored. (Code: 36401)
•
The common rail pressure sensed by the common rail pressure sensor can be monitored. (Code: 36400)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Ground fault in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (25), or ResistMin. FUEL RAIL PRESS (female) (2) and ance 100 kΩ ground
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-381
FAILURE CODE [CA452]
No.
3
40 TROUBLESHOOTING
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (25) and ance each pin other than (25)
4
Common rail pressure sensor
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector FUEL RAIL PRESS.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between FUEL RAIL PRESS (2) Voltage and (1)
YES
NO
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The common rail pressure sensor is normal.
•
Go to the next inspection item.
•
The common rail pressure sensor is defective.
•
Replace the common rail pressure sensor.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Item
Diagnosis and treatment
YES
NO
0.2 to 4.8 V
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-382
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA452]
Circuit diagram associated with common rail pressure sensor
ECM (DRC26-60) Accumulator pressure signal Sensor power (+5V) Engine position sensor return
E06
G0024215
PC210-10M0, PC210LC-10M0
40-383
FAILURE CODE [CA488]
40 TROUBLESHOOTING
FAILURE CODE [CA488] Details of failure
The temperature signal from the boot pressure and temperature sensor exceeds the upper control limit.
Action level
L03
Action of controller
-
Phenomenon on machine
The engine output is reduced.
Pre-troubleshooting If failure code [CA153] or [CA154] is also shown, do the troubleshooting for that code Associated informa- first. tion Monitoring code •
No.
Cause
The signal voltage sensed by the common rail pressure sensor can be monitored. (Code: 36401) Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The aftercooler is normal.
NO
• YES
2
1.
Check the fan speed, cooling air quantity and aftercooler fins.
2.
Is the aftercooler normal?
Aftercooler
• NO
40-384
•
Go to the next inspection item. The aftercooler is defective.
•
Repair or replace the aftercooler.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA488]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The turbocharger outlet temperature is normal.
•
Go to the next inspection item. The XXXX is defective.
YES
3
Turbocharger 1. outlet tempera2. ture
Check the turbocharger outlet temperature.
•
Is the turbocharger outlet temperature normal? NO
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector BOOST PRESS & IMT.
3.
Connect the T-adapter to the female side of connector BOOST PRESS & IMT.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
4
Charge air temperature sensor
•
Repair or replace the XXXX.
•
Go to "Confirmation of repair". The charge air temperature sensor is normal.
• YES •
Go to the next inspection item.
•
The charge air temperature sensor is defective.
•
Replace the charge air temperature sensor.
•
Go to "Confirmation of repair".
StandMeasurement position and condition ard value -40℃
41 to 48 kΩ
-20℃
14 to 16 kΩ
0°C
5.4 to 6.1 kΩ
Between BOOST PRESS & IMT 30℃ (male) (3) and Resist- (4) 60℃ ance
1.6 to 1.8 kΩ 500 to 600 Ω
90℃
230 to 250 Ω
130℃
80 to 90 Ω
Between BOOST PRESS & IMT All (male) (3) and ground
NO
Min. 100 kΩ
YES The repair is completed.
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair". 40-385
FAILURE CODE [CA488]
No.
6
40 TROUBLESHOOTING
Cause
Confirmation of repair
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with charge air temperature sensor
ECM (DRC26-60) Sensor power (+5V) ENG position sensor GND
E06
G0024199
40-386
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA553]
FAILURE CODE [CA553] Details of failure
A high pressure error (indicated pressure is higher than expected) of the common rail pressure is sensed.
Action level
L01
Action of controller
None in particular.
Phenomenon on machine
•
The engine sound becomes large at no load or light load.
•
The engine output is reduced.
Pre-troubleshooting •
If failure code [CA451] or [CA452] is also shown, do the troubleshooting for that code first.
Associated informa- Monitoring code tion • The signal voltage from the common rail pressure sensor can be monitored. (Code: 36401) •
No.
Cause
The common rail pressure sensed by the common rail pressure sensor can be monitored. (Code: 36400) Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel is correct.
NO
• YES • 2
Fuel
1.
Drain fuel from the fuel tank.
2.
Check if the correct fuel is used.
3.
Is the correct type of fuel used?
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. The fuel is incorrect.
•
Change the fuel to the correct type.
•
Go to "Confirmation of repair".
NO
40-387
FAILURE CODE [CA553]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1. 3
Ground terminal 2.
4
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between ECM (female) (37) and Resist- FUEL RAIL PRESS (female) (3) ance Between ECM (female) (25) and FUEL RAIL PRESS (female) (2)
5
Ground fault in wiring harness
Standard value
2.
Disconnect connector ECM, FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Standard value
Between ECM (female) (25), or ResistMin. FUEL RAIL PRESS (female) (2) and ance 100 kΩ ground
40-388
•
Clean, retighten and replace the ground terminal which has defective connection or contact.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
YES
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 10 Ω
Turn the starting switch to the OFF position.
Measuring point and measurement condition
Go to the next inspection item. The ground terminal is defective.
•
Max. 10 Ω
1.
Item
•
NO
1.
Open circuit in wiring harness
The ground terminal is normal.
•
Check the connecting condition of the ground terminals on the chassis (battery (-) terminal), engine, engine controller and starting motor. Is the ground terminal normal?
•
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
FAILURE CODE [CA553]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between ECM (female) (25) and ance each pin other than (25)
7
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector FUEL RAIL PRESS.
4.
Turn the starting switch to the ON position.
NO
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The common rail pressure sensor is normal.
•
Go to the next inspection item.
•
The common rail pressure sensor is defective.
•
Replace the common rail pressure sensor.
•
Go to "Confirmation of repair".
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
8
YES
•
Min. 100 kΩ
1.
Hot short circuit 5. in wiring har6. ness
Common rail pressure sensor
Standard value
Diagnosis and treatment
Measuring point and measurement condition Between FUEL RAIL PRESS (female) (2) and (1)
Standard value Approx. 5V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector FUEL RAIL PRESS.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between FUEL RAIL PRESS (2) Voltage and (1)
PC210-10M0, PC210LC-10M0
NO
Standard value 0.2 to 4.8V
YES
NO
40-389
FAILURE CODE [CA553]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
9
Pressure limiter
1.
Remove the common rail pressure limiter.
2.
Check the pressure limiter for mechanical defects.
3.
Is the pressure limiter normal?
•
The pressure limiter is normal.
•
Go to the next inspection item. The pressure limiter is defective.
• NO
•
Replace the pressure limiter.
•
Go to "Confirmation of repair".
YES The repair is completed. Reconfirmation 1. 10 of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
REMARK For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of 11 repair
40-390
5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Start the engine.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA553]
Circuit diagram associated with common rail pressure sensor
ECM (DRC26-60) Accumulator pressure signal Sensor power (+5V) Engine position sensor return
E06
G0024215
PC210-10M0, PC210LC-10M0
40-391
FAILURE CODE [CA559]
40 TROUBLESHOOTING
FAILURE CODE [CA559] Details of failure
A low pressure error (level 1) occurs in the supply pump.
Action level
L01
Action of controller
Closes the EGR valve.
Phenomenon on machine
•
The engine does not start.
•
The engine startability will be degraded.
•
The engine output is reduced.
Monitoring code Associated informaThe common rail pressure sensed by the common rail pressure sensor can be monition tored. (Code: 36400) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel quantity is sufficient.
NO
• YES 2
Fuel level
1.
Turn the starting switch to the ON position.
2.
Check the fuel gauge and check the fuel level.
3.
Is the fuel quantity sufficient?
• •
NO
•
Add fuel.
•
Go to "Confirmation of repair". The fuel type is correct.
• YES
3
Fuel type
1.
Check if unspecified fuel is used.
2.
Is the fuel type correct?
40-392
• •
NO
Go to the next inspection item. The fuel quantity is not sufficient.
Go to the next inspection item. Incorrect type of fuel could be the cause of the failure.
•
Replace with the specified fuel.
•
Go to the next inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA559]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
4
Fuel tank breather
1.
Check the inside of the fuel tank breather for clogging.
2.
Is the fuel tank breather normal?
•
The fuel tank breather is normal.
•
Go to the next inspection item. The fuel tank breather is defective.
• NO
•
Clean or replace the fuel tank breather.
•
Go to "Confirmation of repair". The fuel system piping is normal.
• 1.
Check the fuel system piping for fuel leakage.
YES
REMARK 5
Fuel system piping
For the checking method, see TESTING AND ADJUSTING, "TEST FUEL CIRCUIT FOR LEAKAGE", "TEST FUEL CIRCUIT FOR LEAKAGE". 2.
1.
Is the fuel system piping normal?
Measure the pressure of the equipment in the low-pressure circuit for troubleshooting. REMARK
• •
NO
•
Repair or replace the fuel system piping.
•
Go to "Confirmation of repair". The equipment in the low-pressure circuit are normal.
• YES •
Go to the next inspection item.
•
The equipment in the low-pressure circuit is defective.
•
Repair or replace the equipment in the lowpressure circuit.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL PRESSURE". (Note 1) 2.
Does the troubleshooting result agree with the standard value? Item
6
Go to the next inspection item. The fuel system piping is defective.
StandMeasurement position and condition ard value Negative pressure at inlet of fuel supply pump At high idle (Outlet pressure of fuel prefilter)
Equipment in low-pressure circuit
Pressure
At cranking Fuel main filter inlet pressure At high idle
PC210-10M0, PC210LC-10M0
Max. -40.7 kPa {Max. -305 mmHg} 207 to 500 kPa {2.11 to 5.1 kg/ cm2}
NO
0.15 to 0.3 MPa {1.5 to 3.0kg/ cm2}
40-393
FAILURE CODE [CA559]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Measure the return rate of the injector to troubleshoot.
Diagnosis and treatment •
The inlet connector is normal.
•
Go to the next inspection item.
•
The inlet connector is defective.
•
Replace the inlet connector.
•
Go to "Confirmation of repair".
•
The injector is normal.
YES •
Go to the next inspection item.
YES
REMARK
7
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE".
Inlet connector 2.
Is the inlet connector normal? NO
REMARK When the fuel return rate is large, check the tightening of connection part of the high-pressure piping according to "Note 2" in the attached drawing. 1.
Measure the return rate of the injector to troubleshoot. REMARK For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE".
2. 8
Injector
Does the troubleshooting result agree with the standard value? Item
Measurement condition Cranking
Return (Min. 150 rpm, for 30 seconds) rate from injector Low idle (for 30 seconds)
40-394
Standard value Max. 45 cc/30 sec
NO
•
The injector is defective.
•
Replace the injector.
•
Go to "Confirmation of repair".
Max. 125 cc/30 sec
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA559]
Cause
Procedures, Measurement, Values, Note 1.
Measure the return rate from the supply pump to troubleshoot.
Diagnosis and treatment YES
REMARK
•
The supply pump is normal.
•
Go to the next inspection item.
•
The supply pump is defective.
•
Repair or replace the supply pump.
•
Go to "Confirmation of repair".
•
The pressure limiter is normal.
•
Go to the next inspection item.
•
The pressure limiter is defective.
•
Replace the pressure limiter.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE". 2.
9
Supply pump
Does the troubleshooting result agree with the standard value? Item
Measurement condition
Cranking Return (Min. 150 rpm, for 30 seconds) rate from supply pump Low idle (for 30 seconds)
1.
Standard value Max. 575 cc/30 sec
NO
Max. 575 cc/30 sec
Measure the leakage from the pressure limiter to troubleshoot.
YES
REMARK For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE". 2.
Does the troubleshooting result agree with the standard value?
10 Pressure limiter Item Leakage from pressure limiter
PC210-10M0, PC210LC-10M0
Measurement condition
Joint bolt part of pressure limiter
Standard value
At low idle (for 30 Max. 8 seconds) cc
NO
40-395
FAILURE CODE [CA559]
No.
11
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note
•
The low-pressure circuit is normal.
•
Go to the next inspection item.
Is the low-pressure circuit normal?
•
REMARK
Air is mixed in the lowpressure circuit.
•
Bleed air from the lowpressure circuit. For details, see TESTING AND ADJUSTING, "BLEED AIR FROM FUEL SYSTEM".
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
1.
Remove the pressure pickup plug (outlet side) of the fuel main filter.
2.
Operate the feed pump of the fuel prefilter.
3.
Check how the fuel and air leaks from the pressure pickup plug.
4. Air mix in lowpressure circuit
Diagnosis and treatment
• If this error occurs during air bleeding after replacement of the fuel filter, air could be left in the low-pressure circuit.
YES
NO
• Run the engine at low idle for approximately 3 minutes. • When the air is bled, the engine speed becomes steady and the display of error is cleared.
Open circuit in 12 wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (25) and Resist- FUEL RAIL PRESS (female) (2) ance Between ECM (female) (47) and FUEL RAIL PRESS (female) (1)
13
Ground fault in wiring harness
Max. 10 Ω
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (25), or ResistMin. FUEL RAIL PRESS (female) (2) and ance 100 kΩ ground
40-396
NO
Max. 10 Ω
1.
Item
YES
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA559]
Cause
Short circuit in 14 wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (25) and ance each pin other than (25)
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector FUEL RAIL PRESS.
4.
Turn the starting switch to the ON position.
NO
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The common rail pressure sensor is normal.
•
Go to the next inspection item.
•
The common rail pressure sensor is defective.
•
Replace the common rail pressure sensor.
•
Go to "Confirmation of repair".
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
Common rail 16 pressure sensor
YES
•
Min. 100 kΩ
1.
Hot short circuit 5. 15 in wiring har6. ness
Diagnosis and treatment
StandMeasurement position and condition ard value Between FUEL RAIL PRESS (female) (2) and (1)
Approx. 5V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector FUEL RAIL PRESS.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage Between ECM (25) and (47)
PC210-10M0, PC210LC-10M0
NO
0.2 to 4.8 V
YES
NO
40-397
FAILURE CODE [CA559]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
Reconfirmation 1. 17 of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
REMARK For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of 18 repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Start the engine.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
Circuit diagram associated with common rail pressure sensor
ECM (DRC26-60) Accumulator pressure signal Sensor power (+5V) Engine position sensor return
E06
G0024215
TEST LOW PRESSURE FUEL CIRCUIT DEVICES Note 1: If there is a problem in the low-pressure fuel circuit, check the items that follow.
40-398
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
1.
Clogged fuel tank breather
2.
The low pressure fuel piping has a leak or is clogged.
3.
Clogged fuel prefilter
4.
Clogged fuel main filter
5.
Replace the fuel filter if no restriction is found but the problem is not resolved.
FAILURE CODE [CA559]
Note 2:
The high-pressure pipe from the common rail is connected to the injector via the inlet connection (11) inside of the cylinder head. Since the inlet connection (11) is tightened with the retainer (10), retighten the retainer (10). Retainer: 50±4 Nm {5±0.4 kgm}
PC210-10M0, PC210LC-10M0
40-399
FAILURE CODE [CA689]
40 TROUBLESHOOTING
FAILURE CODE [CA689] Details of failure
Errors occur in the signals from the speed sensor of the engine crank sensor.
Action level
L01
Action of controller
Operates the engine by signals from the engine Bkup speed sensor.
Phenomenon on machine
•
The engine stops during operation. (When the Bkup (CAM) speed sensor is also defective)
•
When the engine is stopped, the engine cannot be started. (When the Bkup (CAM) speed sensor is also defective)
•
The engine hunts.
•
The engine startability will be degraded.
Pre-troubleshooting If failure code [CA238] or [CA239] is also shown, do the troubleshooting for that code first. Monitoring code The engine speed can be monitored. (Code: 01002) Reference information Associated information
No.
•
Because the inside of the speed sensor consists of a hole sensor and electronic circuit instead of a coil, you cannot know whether the sensor is normal or not cannot by taking a measurement of the resistance of the speed sensor with a multimeter.
•
When normal, 5 V pulses are output from the speed sensor. They cannot be measured with a multimeter.
•
When the speed sensing wheel installed to the inside of the crankshaft vibration damper turns by the rotation of the crankshaft, the speed sensor senses the oblong hole in the speed sensing wheel go through the front of the speed sensor.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-400
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [CA689]
Procedures, Measurement, Values, Note 1.
Diagnosis and treatment
Make it possible to visually check the vibration damper. REMARK
2
Installation position of speed sensing wheel on crankshaft side
Align the painted mark (M1) on the vibration damper with the damper mounting bolt (M2).
3.
Is the installation position of speed sensing wheel on crankshaft side correct?
The installation position of the speed sensing wheel on the crankshaft side is correct.
•
Go to the next inspection item.
•
The installation position of the speed sensing wheel on the crankshaft side is incorrect.
•
Adjust the installation position of the speed sensing wheel on the crankshaft side.
•
Go to "Confirmation of repair".
•
The installation condition of the engine NE speed sensor is normal.
•
Go to the next inspection item. The installation condition of the engine NE speed sensor is defective.
YES
For the checking method, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL ENGINE FRONT OIL SEAL". 2.
•
REMARK • If the center of the slotted hole (WS) in the speed sensing wheel is at the top surface (M3) of the engine NE speed sensor, the installation position of the speed sensing wheel on the crankshaft side is correct.
NO
• The specified position is not the compression top dead center of No.1 cylinder. (Approximately 76 to 80° before compression top dead center)
YES
3
1. Installation condition of engine NE speed 2. sensor
•
Check the installation condition of the engine NE speed sensor. Check for damages or looseness. Is the installation condition of the engine NE speed sensor normal?
•
Install the engine NE speed sensor again.
•
If a damage is found, replace the engine NE speed sensor.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40-401
FAILURE CODE [CA689]
No.
4
5
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CRANK SENSOR.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Ground fault in wiring harness
Item
StandMeasurement position and condition ard value Between ECM (female) (16) and CRANK SENSOR (female) (1)
Max. 10 Ω
Resist- Between ECM (female) (27) and ance CRANK SENSOR (female) (3)
Max. 10 Ω
Between ECM (female) (48) and CRANK SENSOR (female) (2)
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CRANK SENSOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (27) or ResistCRANK SENSOR (female) (3) and ance ground
6
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CRANK SENSOR.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between ECM (female) (27) and ance each pin other than (27)
40-402
YES
NO
YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Item
Diagnosis and treatment
Min. 100 kΩ
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
7
8
FAILURE CODE [CA689]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CRANK SENSOR.
3.
Connect the T-adapter to the female side of connector CRANK SENSOR.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Engine NE speed sensor
Diagnosis and treatment •
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The engine NE speed sensor is normal.
•
Go to the next inspection item. The engine NE speed sensor is defective.
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage
Between CRANK SENSOR (female) Max. 1 (3) and (2) V
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CRANK SENSOR.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again? REMARK Since connectors are disconnected, the failure codes for the disconnected devices are shown.
NO
YES
• NO
•
Replace the engine NE speed sensor.
•
Go to "Confirmation of repair".
YES The repair is completed.
9
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-403
FAILURE CODE [CA689]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Diagnosis and treatment YES
Return to the first inspection item.
REMARK For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of 10 repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Start the engine.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
Circuit diagram associated with NE speed sensor
ECM (DRC26-60)
( F R A M AT O M E - 3 )
Sensor power (+ 5V)
return G0024204
40-404
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA731]
FAILURE CODE [CA731] Details of failure
The engine controller senses a phase error by the signals from the engine Bkup speed sensor. (Compared with the signals from NE speed sensor, the phases do not match.)
Action level
L01
Action of controller
Controls by the signals from the engine NE speed sensor.
Phenomenon on machine
Associated information No.
•
The engine stops during operation. (When the engine NE speed sensor is defective at the same time)
•
The engine does not start.
•
The engine startability will be degraded.
•
The engine does not run at idle speed stably.
Pre-troubleshooting •
Cause
If failure code [CA238], [CA352] or [CA386] is also shown, do the troubleshooting for that code first. Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The installation condition of the engine NE speed sensor is normal.
NO
• YES •
2
Engine NE speed sensor
1.
Check the installation condition of the engine NE speed sensor. Check for damages or looseness.
2.
Is the installation condition of the engine NE speed sensor normal?
•
•
Install the engine NE speed sensor again.
•
If a damage is found, replace the engine NE speed sensor.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The installation condition of the engine NE speed sensor is defective.
40-405
FAILURE CODE [CA731]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The installation condition of the engine Bkup speed sensor is normal.
•
Go to the next inspection item. The installation condition of the engine Bkup speed sensor is defective.
YES
3
Engine Bkup speed sensor
1.
Check the installation condition of the engine Bkup speed sensor. Check for damages and looseness.
2.
Is the installation condition of the engine Bkup speed sensor normal?
•
•
Install the engine Bkup speed sensor again.
•
If a damage is found, replace the engine Bkup speed sensor.
•
Go to "Confirmation of repair". The installation position of the speed sensing wheel on the crankshaft side is correct.
NO
1.
•
Make it possible to visually check the vibration damper. REMARK
YES
For the checking method, see DISASSEMBLY AND ASSEMBLY, "REMOVE AND INSTALL ENGINE FRONT OIL SEAL".
4
Installation position of speed sensing wheel on crankshaft side
2.
Align the painted mark (M1) on the vibration damper with the damper mounting bolt (M2).
3.
Is the installation position of speed sensing wheel on crankshaft side correct?
Go to the next inspection item.
•
The installation position of the speed sensing wheel on the crankshaft side is incorrect.
•
Adjust the installation position of the speed sensing wheel on the crankshaft side.
•
Go to "Confirmation of repair".
REMARK • If the center of the slotted hole (WS) in the speed sensing wheel is at the top surface (M3) of the engine NE speed sensor, the installation position of the speed sensing wheel on the crankshaft side is correct. • The specified position is not the compression top dead center of No.1 cylinder. (Approximately 76 to 80° before compression top dead center)
40-406
•
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [CA731]
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The installation position of the speed sensing ring on the camshaft side is normal.
Set the No.1 cylinder to the compression top dead center. (Align stamping mark)
•
Remove the engine Bkup speed sensor.
•
Go to the next inspection item. The installation position of the speed sensing ring on the camshaft side is defective.
YES 1.
5
Installation po- 2. sition of speed 3. sensing ring on camshaft side 4.
Check if the 2 grooves (with 1 rib) (B) on the speed sensing ring is visible through the sensor mounting hole (H). Is the installation of the speed sensing ring on the camshaft side normal?
NO
•
Adjust the installation position of the speed sensing ring on the camshaft side.
•
Go to "Confirmation of repair". The position of the crankshaft and the camshaft are normal to be timed correctly.
• YES •
6
1. Position for 2. matching of timing between crankshaft and 3. camshaft
Remove the engine front cover.
•
Check that the matchmarks on the crank gear and cam gear are matched. Is the position for checking the timing between the crank gear and cam gear normal?
NO
•
Adjust the position for checking the timing between the crank gear and cam gear.
•
Go to "Confirmation of repair". The connecting condition of the ground terminal is normal.
• YES •
7
Ground terminal
1.
Check the connecting condition of the ground terminals on the chassis (battery (-) terminal), engine, engine controller and starting motor.
2.
Is the connecting condition of ground terminals normal?
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The position of the crankshaft and the camshaft are defective and not timed correctly.
•
Go to the next inspection item. The connecting condition of the ground terminal is defective.
•
Clean, retighten or replace the ground terminals which have a defective connection.
•
Go to "Confirmation of repair".
NO
40-407
FAILURE CODE [CA731]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
8
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
REMARK 9
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Start the engine.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
INSTALLATION POINTS OF CRANKSHAFT AND CAMSHAFT SPEED SENSORS ENGINE Ne (CRANKSHAFT) SPEED SENSOR
40-408
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA731]
ENGINE Bkup (CAMSHAFT) SPEED SENSOR
PC210-10M0, PC210LC-10M0
40-409
FAILURE CODE [CA757]
40 TROUBLESHOOTING
FAILURE CODE [CA757] Details of failure
An all data lost error occurs in the engine controller.
Action level
L04
Action of controller
None in particular.
Phenomenon on machine
The engine operates normally but it can stop during operation, or it cannot be started when it is stopped.
Associated informa- Monitoring code tion The power supply voltage of the engine controller can be monitored. (Code: 03203) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
Check the battery voltage.
2.
Does the battery voltage agree with the standard value? Item
Voltage
3
Alternator
Between battery terminals (+) and (-)
Standard value 20 to 30 V
1.
Turn the starting switch to the OFF position.
2.
Start the engine.
3.
Run the engine at a medium speed or above.
4.
Measure the voltage.
5.
Does the troubleshooting result agree with the standard value? Item
Voltage
40-410
Measuring point and measurement condition
Measuring point and measurement condition Between alternator terminal GI and ground
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The battery output voltage is normal.
NO
•
1.
Battery voltage
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
YES
• NO
26 to 30.5 V
NO
Go to the next inspection item. The battery output voltage is low.
•
Charge or replace the battery.
•
Go to "Confirmation of repair". The alternator is normal.
• YES
Standard value
•
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA757]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment • YES •
4
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove the fuse No.19 in the fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
•
When it is not blown but it has no resistance, replace the fuse.
•
Go to "Confirmation of repair". The removed engine controller power supply relay is normal.
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors R23 and R24. Replace the relay with same type.
•
Turn the starting switch to the ON position to troubleshoot.
•
Engine controller power sup3. ply relay 4.
Is this failure code cleared?
YES •
NO •
6
Open circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect connectors CE03, R23 and R24. Connect the T-adapter to each female side.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CE03 (female) (3) and R23 Max. 1 (female) (5) Ω Between CE03 (female) (3) and R24 Max. 1 (female) (4) Ω Resist- Between R23 (female) (3) and ance F01-19
Max. 1 Ω
Between R24 (female) (3) and F01-19
Max. 1 Ω
Between CE03 (female) (1) and ground
Max. 1 Ω
PC210-10M0, PC210LC-10M0
• YES
NO
Go to the next inspection item. If blown, go to "Ground fault of wiring harness".
• NO
•
5
The fuse is normal.
Restore the removed relay. Go to the next inspection item. The removed engine controller power supply relay is defective. Go to "Confirmation of repair". The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-411
FAILURE CODE [CA757]
No.
7
40 TROUBLESHOOTING
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect connectors CE03, R23 and R24. Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between ground and one of CE03 (female) (3), R55 (female) (5), and Resist- R56 (female) (5) ance Between ground and one of R55 (female) (3), R56 (female) (3), and F01-18
8
Short circuit in wiring harness
Standard value
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect connector CE03. Connect the Tadapter to the female side.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value?
Resist- Between CE03 (female) (3) and ance each pin other than pin (3)
NO
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 1 MΩ
Turn the starting switch to the OFF position.
Measuring point and measurement condition
YES
•
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Standard value Min. 1 MΩ
YES The repair is completed.
9
Reconfirmation 1. of inspection 2. item
40-412
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
10
Cause
FAILURE CODE [CA757]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
40-413
FAILURE CODE [CA757]
40 TROUBLESHOOTING
Circuit diagram associated with engine controller power supply
CE02
CE03 Power (+24V)
Starter B
3
L19 2 J 0 5 16
AC
AC95 8 HK Relay for CM850 (1)
Monitor panel
1 2
15A
3 Relay for CM850 (2)
HJ
4 5 6 T06
S01
CP02
G0024214
40-414
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA778]
FAILURE CODE [CA778] Details of failure
An error occurs in the engine Bkup speed sensor circuit.
Action level
L01
Action of controller
Runs the engine by signals from the engine NE speed sensor.
Phenomenon on machine
•
The engine stops during operation. (When the engine NE speed sensor is defective at the same time)
•
When the engine is stopped, the engine cannot be started. (When the engine NE speed sensor is defective at the same time)
•
The engine startability will be degraded.
Pre-troubleshooting If failure code [CA238] is also shown, do the troubleshooting for this code first. Reference information •
Because the inside of the speed sensor consists of a hole sensor and electronic circuit instead of a coil, you cannot know whether the sensor is normal or not cannot by taking a measurement of the resistance of the speed sensor with a multimeter.
•
When normal, 5 V pulses are output from the speed sensor. They cannot be measured with a multimeter.
•
The speed sensor senses the speed by the groove in the speed sensing ring installed to the camshaft.
Associated information
No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-415
FAILURE CODE [CA778]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The installation condition of the speed sensing ring on the camshaft side is normal.
•
Go to the next inspection item. The installation condition of the speed sensing ring on the camshaft side is defective.
YES
2
Installation condition of speed sensing ring on camshaft side
1.
Set the No.1 cylinder to the compression top dead center. (Align stamping mark)
2.
Remove the engine Bkup speed sensor.
3.
Can you see the 2 grooves (with 1 rib) (B) on the speed sensing ring through the sensor mounting hole (H)?
•
•
Adjust the installation position of the speed sensing ring on the camshaft side. For details, see "CHECK CAMSHAFT GEAR FOR LOOSENING" that follows.
•
Go to "Confirmation of repair". The installation condition of the engine Bkup speed sensor is normal.
NO
• YES • 1.
3
Installation condition of engine Bkup 2. speed sensor
•
Check the installation condition of the engine Bkup speed sensor. Check for damages and looseness. Is the installation condition of the engine Bkup speed sensor normal?
•
Install the engine Bkup speed sensor again.
•
If a damage is found, replace the engine Bkup speed sensor.
•
Go to "Confirmation of repair".
NO
40-416
Go to the next inspection item. The installation condition of the engine Bkup speed sensor is defective.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
5
FAILURE CODE [CA778]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Ground fault in wiring harness
Item
StandMeasurement position and condition ard value Between ECM (female) (37) and CAM SENSOR (female) (1)
Max. 10 Ω
Resist- Between ECM (female) (26) and ance CAM SENSOR (female) (3)
Max. 10 Ω
Between ECM (female) (47) and CAM SENSOR (female) (2)
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Diagnosis and treatment YES
NO
YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Resist- Between ECM (female) (26) or CAM Min. ance SENSOR (female) (3) and ground 100 kΩ
6
Short circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector CAM SENSOR.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (26) and ance each pin other than (26)
PC210-10M0, PC210LC-10M0
Min. 100 kΩ
YES
NO
40-417
FAILURE CODE [CA778]
No.
7
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CAM SENSOR.
3.
Connect the T-adapter to the female side of connector CAM SENSOR.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
StandMeasurement position and condition ard value Between CAM SENSOR (female) (3) and (2)
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The engine Bkup speed sensor is normal.
•
Go to the next inspection item. The engine Bkup speed sensor is defective.
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CAM SENSOR.
3.
Turn the starting switch to the ON position to troubleshoot.
4.
The wiring harness has no hot short circuits.
YES
Does the troubleshooting result agree with the standard value?
Voltage
Engine Bkup speed sensor
•
Measure the voltage to troubleshoot.
Item
8
Diagnosis and treatment
YES
•
Is this failure code shown again? REMARK Since connectors are disconnected, the failure codes for the disconnected devices are shown.
NO
•
Replace the engine Bkup speed sensor.
•
Go to "Confirmation of repair".
YES The repair is completed.
9
Reconfirmation 1. of inspection 2. item
40-418
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [CA778]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Diagnosis and treatment YES
Return to the first inspection item.
REMARK For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of 10 repair 5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Start the engine.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
Circuit diagram associated with engine Bkup speed sensor
ECM Engine sensor Sensor Engine sensor
position signal power (+5V) position return
Boost press. & IMT Fuel rail press.
Fuel rail press. Boost press. 4 & IMT
G0024216
PC210-10M0, PC210LC-10M0
40-419
FAILURE CODE [CA778]
40 TROUBLESHOOTING
ENGINE Ne (CRANKSHAFT) SPEED SENSOR
Reference: Inspection of camshaft gear for looseness (107 Engine) Remove the pulley, damper, front seal, front cover, and housing. Check the looseness of the camshaft ring. REMARK Prepare the front seal, gasket, liquid gasket LG-7, and front seal tool (795-799-6400).
REMOVAL 1.
Remove the cooling assembly.
2.
Remove the compressor belt. For details, see DISASSEMBLY AND ASSEMBLY, REMOVE AND INSTALL ENGINE FRONT OIL SEAL.
3.
Remove the damper assembly (1).
DP: Dowel pin 4.
Remove the front cover (2).
5.
Remove the front seal (3).
RING: Ring 6.
Check that the mounting bolt (4) of the camshaft ring (5) is not loose.
40-420
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA778]
Mounting bolt (4): 10 ± 2 Nm {0.98 ± 0.2 kgm}
INSTALLATION REMARK For the figure, see Removal. 1. Install the front cover (2). Housing: Liquid gasket LG-7 2. Install the front seal (3). For details, see DISASSEMBLY AND ASSEMBLY, REMOVE AND INSTALL ENGINE FRONT OIL SEAL. 1) 2) Install the dowel pin (DP). Install the damper assembly (1). 3) Install the compressor belt. 4)
Install the cooling assembly.
PC210-10M0, PC210LC-10M0
40-421
FAILURE CODE [CA2185]
40 TROUBLESHOOTING
FAILURE CODE [CA2185] Details of failure
A high voltage occurs in the throttle sensor power supply (5V) circuit.
Action level
L03 •
engine.
Action of controller •
Phenomenon on machine
If an abnormality is found while the starting switch is in the ON position, the controller fixes the setting to the value before the detection of the abnormality, and runs the If the starting switch is turned to the ON position under the occurrence of abnormality, the controller runs the engine at the value of 100%.
The engine speed cannot be controlled with the fuel control dial.
Associated informa- None in particular. tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P20.
3.
Connect the T-adapter to the female side of connector P20.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES •
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage Between P20 (female) (1) and (3)
40-422
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
4.75 to 5.25V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
Cause
FAILURE CODE [CA2185]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P20.
3. Fuel control di4. al
Diagnosis and treatment YES
Turn the starting switch to the ON position.
Since connectors are disconnected, the failure codes for the disconnected devices are shown.
The fuel control dial is normal.
•
Go to the next inspection item. The fuel control dial is defective.
•
Is this failure code shown again? REMARK
•
NO
•
Replace the fuel control dial.
•
Go to "Confirmation of repair".
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with throttle sensor
CE02
G0024200
PC210-10M0, PC210LC-10M0
40-423
FAILURE CODE [CA2186]
40 TROUBLESHOOTING
FAILURE CODE [CA2186] Details of failure
A low voltage occurs in the throttle sensor power supply (5V) circuit.
Action level
L03 •
engine.
Action of controller •
Phenomenon on machine
If an abnormality is found while the starting switch is in the ON position, the controller fixes the setting to the value before the detection of the abnormality, and runs the If the starting switch is turned to the ON position under the occurrence of abnormality, the controller runs the engine at the value of 100%.
The engine speed cannot be controlled with the fuel control dial.
Associated informa- None in particular. tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Ground fault in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector P20.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CE02 (female) (22) or P20 ance (female) (1) and ground
40-424
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
NO
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [CA2186]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector P20.
4.
Connect the T-adapter to the female side of connector CE02.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Item
4
YES
NO
StandMeasurement position and condition ard value
Resist- Between CE02 (female) (22) and ance each pin other than (22)
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The fuel control dial is normal.
•
Go to the next inspection item. The fuel control dial is defective.
Min. 100 kΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P20.
3. Fuel control di4. al
Diagnosis and treatment
YES
Turn the starting switch to the ON position.
•
Is this failure code shown again? REMARK Since connectors are disconnected, the failure codes for the disconnected devices are shown.
NO
•
Replace the fuel control dial.
•
Go to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
PC210-10M0, PC210LC-10M0
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-425
FAILURE CODE [CA2186]
40 TROUBLESHOOTING
Circuit diagram associated with throttle sensor
CE02
G0024200
40-426
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA2249]
FAILURE CODE [CA2249] Details of failure
A pressure low error occurs in the supply pump. (Pressure lower than the specified value continues for a long time: Level 2)
Action level
L03
Action of controller
-
Phenomenon on machine
The engine output is reduced.
Monitoring code Associated information
No.
•
The signal voltage from the common rail pressure sensor can be monitored. (Code: 36401)
•
The common rail pressure sensed by the common rail pressure sensor can be monitored. (Code: 36400)
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel quantity is sufficient.
NO
• YES 2
Fuel level
1.
Turn the starting switch to the ON position.
2.
Check the fuel gauge and check the fuel level.
3.
Is the fuel quantity sufficient?
• •
NO
•
Add fuel.
•
Go to "Confirmation of repair". The fuel type is correct.
• YES
3
Fuel type
1.
Check if unspecified fuel is used.
2.
Is the fuel type correct?
PC210-10M0, PC210LC-10M0
• •
NO
Go to the next inspection item. The fuel quantity is not sufficient.
Go to the next inspection item. Incorrect type of fuel could be the cause of the failure.
•
Replace with the specified fuel.
•
Go to the next inspection item.
40-427
FAILURE CODE [CA2249]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
4
Fuel tank breather
1.
Check the inside of the fuel tank breather for clogging.
2.
Is the fuel tank breather normal?
•
The fuel tank breather is normal.
•
Go to the next inspection item. The fuel tank breather is defective.
• NO
•
Clean or replace the fuel tank breather.
•
Go to "Confirmation of repair". The fuel system piping is normal.
• 1.
YES
Check the fuel system for fuel leakage. REMARK
5
Fuel system piping
For the check method, see TESTING AND ADJUSTING, "TEST FUEL CIRCUIT FOR LEAKAGE", "TEST FUEL CIRCUIT FOR LEAKAGE". 2.
1.
Is the fuel system piping normal?
Measure the pressure of the equipment in the low-pressure circuit for troubleshooting. REMARK
• •
NO
•
Repair or replace the fuel system piping.
•
Go to "Confirmation of repair". The equipment in the low-pressure circuit are normal.
• YES •
Go to the next inspection item.
•
The equipment in the low-pressure circuit is defective.
•
Repair or replace the equipment in the lowpressure circuit.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL PRESSURE". (Note 1) 2.
Does the troubleshooting result agree with the standard value? Item
6
StandMeasurement position and condition ard value Negative pressure at inlet of fuel supply pump At high idle (Outlet pressure of fuel prefilter)
Equipment in low-pressure circuit
Pressure
At cranking Fuel main filter inlet pressure At high idle
40-428
Go to the next inspection item. The fuel system piping is defective.
Max. -40.7 kPa {Max. -305 mmHg} 207 to 500 kPa {2.11 to 5.1 kg/ cm2}
NO
0.15 to 0.3 MPa {1.5 to 3.0kg/ cm2}
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA2249]
Cause
Procedures, Measurement, Values, Note 1.
Inlet connector
•
The inlet connector is normal.
•
Go to the next inspection item.
•
The inlet connector is defective.
•
Replace the inlet connector.
•
Go to "Confirmation of repair".
•
The injector is normal.
YES •
Go to the next inspection item.
Check the return rate from the injector. YES
REMARK
7
Diagnosis and treatment
For the checking method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE" to troubleshoot. 2.
Is the inlet connector normal? NO
REMARK When the fuel return rate is large, check the tightening of connection part of the high-pressure piping according to "Note 2" in the attached drawing. 1.
Measure the return rate from the injector and troubleshoot. REMARK For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE".
2. 8
Injector
Does the troubleshooting result agree with the standard value? Item
Measurement condition Cranking
Return (Min. 150 rpm, for 30 seconds) rate from injector Low idle (for 30 seconds)
PC210-10M0, PC210LC-10M0
Standard value Max. 45 cc/30 sec
NO
•
The injector is defective.
•
Replace the injector.
•
Go to "Confirmation of repair".
Max. 125 cc/30 sec
40-429
FAILURE CODE [CA2249]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Measure the return rate from the supply pump and troubleshoot.
Diagnosis and treatment YES
REMARK
•
The supply pump is normal.
•
Go to the next inspection item.
•
The supply pump is defective.
•
Repair or replace the supply pump.
•
Go to "Confirmation of repair".
•
The pressure limiter is normal.
•
Go to the next inspection item.
•
The pressure limiter is defective.
•
Replace the pressure limiter.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE". 2.
9
Supply pump
Does the troubleshooting result agree with the standard value? Item
Measurement condition
Cranking Return (Min. 150 rpm, for 30 seconds) rate from supply pump Low idle (for 30 seconds)
1.
Standard value Max. 575 cc/30 sec
NO
Max. 575 cc/30 sec
Measure the leakage from the pressure limiter and troubleshoot.
YES
REMARK For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL DISCHARGED VOLUME, RETURN RATE AND LEAKAGE". 2.
Does the troubleshooting result agree with the standard value?
10 Pressure limiter Item Leakage from pressure limiter
40-430
Measurement condition
At low idle (for 30 seconds)
Standard value
Max. 8 ml
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
11
FAILURE CODE [CA2249]
Cause
Procedures, Measurement, Values, Note
•
The low-pressure circuit is normal.
•
Go to the next inspection item.
Is the low-pressure circuit normal?
•
REMARK
Air is mixed in the lowpressure circuit.
•
Bleed air from the lowpressure circuit. For details, see TESTING AND ADJUSTING, "BLEED AIR FROM FUEL SYSTEM".
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
1.
Remove the pressure pickup plug (outlet side) of the fuel main filter.
2.
Operate the feed pump of the fuel prefilter.
3.
Check how the fuel and air leaks from the pressure pickup plug.
4. Air mix in lowpressure circuit
Diagnosis and treatment
• If this error occurs during air bleeding after replacement of the fuel filter, air could be left in the low-pressure circuit.
YES
NO
• Run the engine at low idle. Continue running it for approximately 3 minutes. • When the air is bled, the engine speed becomes steady and the error indication is cleared.
Open circuit in 12 wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between ECM (female) (25) and Resist- FUEL RAIL PRESS (female) (2) ance Between ECM (female) (47) and FUEL RAIL PRESS (female) (1)
13
Ground fault in wiring harness
Max. 10 Ω
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (25), or ResistMin. FUEL RAIL PRESS (female) (2) and ance 100 kΩ ground
PC210-10M0, PC210LC-10M0
NO
Max. 10 Ω
1.
Item
YES
YES
NO
40-431
FAILURE CODE [CA2249]
No.
40 TROUBLESHOOTING
Cause
Short circuit in 14 wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (25) and ance each pin other than (25)
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector FUEL RAIL PRESS.
4.
Turn the starting switch to the ON position.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The common rail pressure sensor is normal.
•
Go to the next inspection item.
•
The common rail pressure sensor is defective.
•
Replace the common rail pressure sensor.
•
Go to "Confirmation of repair".
YES
Does the troubleshooting result agree with the standard value?
Voltage
StandMeasurement position and condition ard value Between FUEL RAIL PRESS (female) (2) and (1)
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector ECM.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between ECM (25) and (47)
NO
Approx. 5V
1.
Item
40-432
NO
The wiring harness has no short circuits.
Measure the voltage to troubleshoot.
Item
Common rail 16 pressure sensor
YES
•
Min. 100 kΩ
1.
Hot short circuit 5. 15 in wiring har6. ness
Diagnosis and treatment
0.2 to 4.8 V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA2249]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
Reconfirmation 1. 17 of inspection 2. item
18
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with common rail pressure sensor
ECM (DRC26-60) Accumulator pressure signal Sensor power (+5V) Engine position sensor return
E06
G0024215
TEST LOW PRESSURE FUEL CIRCUIT DEVICES Note 1: If there is a problem in the low-pressure fuel circuit, check the items that follow. 1.
Clogged fuel tank breather
2.
The low pressure fuel piping has a leak or is clogged.
3.
Clogged fuel prefilter
4.
Clogged fuel main filter
5.
Replace the fuel filter if no restriction is found but the problem is not resolved.
PC210-10M0, PC210LC-10M0
40-433
FAILURE CODE [CA2249]
40 TROUBLESHOOTING
Note 2:
The high-pressure pipe from the common rail is connected to the injector via the inlet connection (11) inside of the cylinder head. Since the inlet connection (11) is tightened with the retainer (10), retighten the retainer (10). Retainer: 50±4 Nm {5±0.4 kgm}
40-434
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA2311]
FAILURE CODE [CA2311] Details of failure
The resistance value of the supply pump actuator circuit is abnormally high or low. Or, the common rail pressure system is abnormal.
Action level
L03
Action of controller
None in particular.
Phenomenon on machine
The engine output is reduced.
Associated informa- None in particular. tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Actuator of supply pump
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of connector CP3 PUMP REGULATOR.
4.
Start the engine.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between CP3 PUMP REGULATOR Resist- (male) (2) and (1) ance Between CP3 PUMP REGULATOR (male) (2) and ground
PC210-10M0, PC210LC-10M0
2.3 to 5.3 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The actuator of the supply pump is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The actuator of the supply pump is defective.
•
Replace the actuator of the supply pump.
•
Go to "Confirmation of repair".
Min. 100 kΩ
40-435
FAILURE CODE [CA2311]
No.
3
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
StandMeasurement position and condition ard value
Diagnosis and treatment YES
NO
Between ECM (female) (2) and CP3 Max. 10 Ω PUMP REGULATOR (female) (1)
Resistance Between ECM (female) (32) and CP3 PUMP REGULATOR (female) (2)
4
Ground fault in wiring harness
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 10 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
•
StandMeasurement position and condition ard value
YES
NO
Min. Resist- Between ECM (female) (2) and CP3 100 kΩ ance PUMP REGULATOR (female) (1)
5
Short circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM, CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (2) and ance each pin other than (2)
40-436
Min. 100 kΩ
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
FAILURE CODE [CA2311]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP3 PUMP REGULATOR.
3.
Connect the T-adapter to the female side of connector CP3 PUMP REGULATOR.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The fuel low-pressure circuit is normal.
•
Go to the next inspection item. Air is in the fuel lowpressure circuit.
YES
Does the troubleshooting result agree with the standard value?
Voltage
StandMeasurement position and condition ard value Between CP3 PUMP REGULATOR (female) (1) and (2)
NO
Max. 3V
YES
Fuel low-pressure circuit
The wiring harness has no hot short circuits.
Measure the voltage to troubleshoot.
Item
7
•
1.
Remove the pressure pickup plug (outlet side) of the fuel main filter.
•
2.
Operate the feed pump of the fuel prefilter.
•
3.
Check that air does not mix in the fuel low-pressure circuit.
4.
Is the fuel low-pressure circuit normal?
Bleed air from the fuel low-pressure circuit. For details, see TESTING AND ADJUSTING, "BLEEDING AIR FROM FUEL SYSTEM".
•
Go to "Confirmation of repair". The equipment in the fuel return circuit are normal.
1.
Measure the pressure of the fuel return circuit to troubleshoot. REMARK
NO
• YES •
Go to the next inspection item.
•
The equipment in the fuel return circuit are defective.
•
Repair or replace the equipment in the fuel return circuit.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL PRESSURE". 2. 8
Fuel return circuit
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Pressure of Joint bolt part of fuel refuel return hose turn circuit
PC210-10M0, PC210LC-10M0
Engine at low idle or cranking
Max. 18.6 kPa {Min. 0.19 kg/ cm2}
NO
40-437
FAILURE CODE [CA2311]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Measure the leakage from the pressure limiter and troubleshoot.
Diagnosis and treatment YES
REMARK
•
The pressure limiter is normal.
•
Go to the next inspection item.
•
The pressure limiter is defective.
•
Replace the pressure limiter.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL DISCHARGED VOLUME, RETURN RATE AND LEAKAGE". 2. 9
Does the troubleshooting result agree with the standard value?
Pressure limiter Item Leakage from pressure limiter
Open circuit in wiring harness
StandMeasurement position and condition ard value
Joint bolt part of pressure limiter
At low idle (for 30 Max. 8 seconds) cc
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value?
10 (Common rail pressure sensor)
Item
StandMeasurement position and condition ard value
Between ECM (female) (25) and Resist- FUEL RAIL PRESS (female) (2) ance Between ECM (female) (47) and FUEL RAIL PRESS (female) (1)
Ground fault in wiring harness 11 (Common rail pressure sensor)
NO
Max. 10 Ω
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Between ECM (female) (25), or ResistMin. FUEL RAIL PRESS (female) (2) and ance 100 kΩ ground
40-438
YES
Max. 10 Ω
1.
Item
NO
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [CA2311]
Cause
Short circuit in wiring harness 12 (Common rail pressure sensor)
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector ECM and connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector ECM.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between ECM (female) (25) and ance each pin other than (25)
Turn the starting switch to the OFF position.
2.
Disconnect connector FUEL RAIL PRESS.
3.
Connect the T-adapter to the female side of connector FUEL RAIL PRESS.
NO
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The common rail pressure sensor is normal.
•
Go to the next inspection item.
•
The common rail pressure sensor is defective.
•
Replace the common rail pressure sensor.
•
Go to "Confirmation of repair".
YES
Turn the starting switch to the ON position. Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Voltage
Common rail 14 pressure sensor
YES
•
Min. 100 kΩ
1.
Hot short circuit 4. in wiring har5. ness 13 6. (Common rail pressure sensor)
Diagnosis and treatment
StandMeasurement position and condition ard value Between FUEL RAIL PRESS (female) (2) and (1)
Approx. 5V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector ECM.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
PC210-10M0, PC210LC-10M0
YES
StandMeasurement position and condition ard value
Voltage Between ECM (25) and (47)
NO
0.2 to 4.8 V
NO
40-439
FAILURE CODE [CA2311]
No.
40 TROUBLESHOOTING
Cause
Procedures, Measurement, Values, Note 1.
Measure the return rate from the supply pump and troubleshoot.
Diagnosis and treatment YES
REMARK
•
The supply pump is normal.
•
Go to the next inspection item.
•
The supply pump is defective.
•
Repair or replace the supply pump.
•
Go to "Confirmation of repair".
For the measuring method, see TESTING AND ADJUSTING, "TEST FUEL RETURN RATE AND LEAKAGE". 2.
15 Supply pump
Does the troubleshooting result agree with the standard value? Item
Measurement condition
Standard value
Cranking Return (Min. 150 rpm, for 30 seconds) rate from supply pump Low idle (for 30 seconds)
Max. 575 cc/30 sec
NO
Max. 575 cc/30 sec
YES The repair is completed. Reconfirmation 1. 16 of inspection 2. item
17
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown again?
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with IMV and PCV1
ECM (DRC26-60)
return
Pump regulator valve (IMA)
G0024205
40-440
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA2311]
Circuit diagram associated with common rail pressure sensor
ECM (DRC26-60) Accumulator pressure signal Sensor power (+5V) Engine position sensor return
E06
G0024215
PC210-10M0, PC210LC-10M0
40-441
FAILURE CODE [CA2555]
40 TROUBLESHOOTING
FAILURE CODE [CA2555] Details of failure
A short circuit is sensed in the drive circuit (primary side) of the preheating relay.
Action level
L01
Action of controller
None in particular.
Phenomenon on machine
The intake air heater does not operate in auto preheating mode. (degraded startability and emission of white smoke at low temperature)
Associated informa- Reference information tion Only when the relay is off, this failure code is shown. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Preheating relay
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R18.
3.
Connect the T-adapter to the female side of connector R18.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
ResistBetween R18 (male) (1) and (2) ance
40-442
200 to 400 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The preheating relay is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The preheating relay is defective.
•
Replace the preheating relay.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [CA2555]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector R18.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Between CE02 (female) and R18 Resist- (female) (1) ance Between CE02 (female) and R18 (female) (2)
Diagnosis and treatment YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 10 Ω Max. 10 Ω
YES The repair is completed.
4
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
40-443
FAILURE CODE [CA2555]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Check that the charge (boost) temperature is -2°C or above.
2.
Turn the starting switch to the OFF position.
3.
Restore the machine. Install all the configuration equipment and connect them.
4.
Turn the starting switch to the ON position.
5.
Delete the abnormality record of the electrical system.
Diagnosis and treatment YES
Return to the first inspection item.
REMARK 5
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of repair 6.
Turn the starting switch to the OFF position.
7.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
8.
Turn the starting switch to the ON position.
9.
Start the engine.
NO The repair is completed.
10. Check the abnormality record. 11. Is this failure code shown in the record?
40-444
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA2555]
Circuit diagram associated with intake air heater relay CEN2
R16B R16A
Monitor panel
A/C unit MA
CP01 LG
Key switch (ACC) Key switch (ACC) Key switch (C) Key switch (ACC)
61
XE
80
AC95 9 LE
CP02
FP
AC95 (090-22) FT
HJ HK
CP01 AC
1
2
3
4
5
ECM_J3 L19 2 J 0 5 16
6
T06 Relay for starter out (PPC lock)
PC210-10M0, PC210LC-10M0
Relay for starter out (Personal code)
Relay for auto preheat
Relay for CM850 (1)
Relay for CM850 (2)
G0024217
40-445
FAILURE CODE [CA2556]
40 TROUBLESHOOTING
FAILURE CODE [CA2556] Details of failure
A short circuit is sensed in the drive circuit (primary side) of the air intake heater relay.
Action level
L01
Action of controller
None in particular.
Phenomenon on machine
The intake air heater does not operate in auto preheating mode. (degraded startability and emission of white smoke at low temperature)
Associated informa- Reference information tion Only when the relay is on, this failure code is shown. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Preheating relay
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R18.
3.
Connect the T-adapter to the female side of connector R18.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
ResistBetween R18 (male) (1) and (2) ance
40-446
200 to 400 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The preheating relay is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The preheating relay is defective.
•
Replace the preheating relay.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [CA2556]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02 and connector R18.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Item
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CE02 and connector R18.
3.
Connect the T-adapter to the female side of connector CE02.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CE02 (female) (40) and ance each pin other than (40)
5
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
YES
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 100 kΩ
1.
Check that the charge (boost) temperature is -2°C or above.
2.
Turn the starting switch to the OFF position.
3.
Insert the T-adapter into connector R18.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
NO
•
Min. 100 kΩ
1.
Item
YES
StandMeasurement position and condition ard value
Resist- Between CE02 (female) (40) or R18 ance (female) (1) and ground
4
Diagnosis and treatment
YES
Measure the voltage to troubleshoot. Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage Between R18 (1) and (2)
PC210-10M0, PC210LC-10M0
Max. 1 V
NO
40-447
FAILURE CODE [CA2556]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Check that the charge (boost) temperature is -3°C or below.
2.
Turn the starting switch to the OFF position.
3.
Restore the machine. Install all the configuration equipment and connect them.
4.
Turn the starting switch to the ON position.
5.
Delete the abnormality record of the electrical system.
NO
YES
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
REMARK 7
Confirmation of repair
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)". 6.
Turn the starting switch to the OFF position.
7.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
8.
Turn the starting switch to the ON position.
9.
Check the abnormality record.
NO The repair is completed.
10. Is this failure code shown in the record?
40-448
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [CA2556]
Circuit diagram associated with intake air heater relay CEN2
R16B R16A
Monitor panel
A/C unit MA
CP01 LG
Key switch (ACC) Key switch (ACC) Key switch (C) Key switch (ACC)
61
XE
80
AC95 9 LE
CP02
FP
AC95 (090-22) FT
HJ HK
CP01 AC
1
2
3
4
5
ECM_J3 L19 2 J 0 5 16
6
T06 Relay for starter out (PPC lock)
PC210-10M0, PC210LC-10M0
Relay for starter out (Personal code)
Relay for auto preheat
Relay for CM850 (1)
Relay for CM850 (2)
G0024217
40-449
FAILURE CODE [D110KB]
40 TROUBLESHOOTING
FAILURE CODE [D110KB] Details of failure
The pump controller found a ground fault in the battery relay circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops the 24 V output to the primary (coil side) circuit of the battery relay.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
Each controller possibly fails in writing of data into its ROM (non-volatile memory).
Associated informa- Monitoring code tion The output (ON or OFF) to the battery relay can be monitored. (Code: 03700) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Battery relay
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect battery relay terminal R01, R02.
3.
Resistance
4.
Measure the continuity.
5.
Does the measurement result agree with the standard value? Item
Continuity
40-450
Measuring point and measurement condition Between R01 and R02
Standard value Continuity
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The battery relay is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The battery relay is defective.
•
Replace the battery relay.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [D110KB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01.
3.
Connect the T-adapter to the male side of connector D01.
4.
Measure the continuity.
5.
Does the measurement result agree with the standard value?
Diode
Item
Continuity
4
Ground fault in wiring harness
Measuring point and measurement condition
Standard value
Between D01 (male) (2) (+) and (6) (-)
No continuity
Between D01 (male) (6) (+) and (2) (-)
Continuity
1.
Turn the starting switch to the OFF position.
2.
Disconnect battery relay terminal R01.
3.
Disconnect connector CP02, connector D01, connector R43, and connector H15.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition Between H15 (female) (2) or D01 (female) (5) and ground
Resistance Between CP02 (female) (108), D01 (female) (2), or R43 (female) (4) and ground
5
Short circuit in wiring harness
Standard value
Disconnect battery relay terminal R01.
3.
Disconnect connector CP02 and connector D01.
4.
Connect the T-adapter to the female side of connector CP02.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value?
PC210-10M0, PC210LC-10M0
The diode is normal. Go to the next inspection item.
•
The diode is defective.
•
Replace the diode.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
2.
Resist- Between CP02 (female) (108) and ance each pin other than (108)
NO
Min. 1 MΩ
Turn the starting switch to the OFF position.
Measuring point and measurement condition
• YES •
YES
1.
Item
Diagnosis and treatment
YES
Standard value Min. 1 MΩ
NO
40-451
FAILURE CODE [D110KB]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with battery relay
(S-12)
From battery
10A 10A
LD
R17 R08
G0024198
40-452
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [D19JKZ]
FAILURE CODE [D19JKZ] Details of failure
The machine monitor senses an open circuit or a ground fault in the circuit of the personal code relay.
Action level
L03
Action of controller
Phenomenon on machine
•
None in particular. (When an open circuit occurs)
•
Stops to drive the personal code relay. (When a ground fault occurs)
•
If the cause of the failure disappears, the machine becomes normal by itself. (When an open circuit occurs)
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once. (When a ground fault occurs)
•
The start motor operates even after the engine starts. (When an open circuit occurs)
•
The starting motor does not operate. (When a ground fault occurs)
Notice While this failure code is shown, if you turn the key switch to the START position after the Associated informaengine has started, the pinion of starting motor may break. tion Reference information This failure code is shown only when the engine lock function is enabled. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Fuse
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.3 in fuse box F01.
4.
Check if the fuse is blown.
5.
Check the fuse for continuity.
6.
Is the fuse normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". Fuse No.3 is normal.
NO
• YES • •
NO
Go to the next inspection item. FuseNo.3 is defective.
•
It blown, go to "Ground fault in wiring harness".
•
If fuse No.3 is not blown but has no continuity, replace it.
•
Go to "Confirmation of repair".
40-453
FAILURE CODE [D19JKZ]
No.
3
Cause
Personal code relay
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R07.
3.
Connect the T-adapter to the female side of connector R07.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
4
Open circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.3 in fuse box F01.
4.
Disconnect connector CM01 and connector R07.
5.
Connect the T-adapter to the female side of each connector.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Between F01-3 and R07 (female) Resist- (1) ance Between CM01 (female) (6) and R07 (female) (2)
NO
•
The personal code relay is normal.
•
Go to the next inspection item.
•
The personal code relay is defective.
•
Replace the personal code relay.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
200 to 600 Ω
1.
Item
40-454
YES
StandMeasurement position and condition ard value
ResistBetween R07 (male) (1) and (2) ance
Diagnosis and treatment
YES
NO
Max. 1 Ω Max. 1 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [D19JKZ]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.3 in fuse box F01.
4.
Disconnect connector CM01, R07, S14.
5.
Connect the T-adapter to the female side of one of the connectors.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
(female) (2) and ground
Short circuit in wiring harness
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.3 in fuse box F01.
4.
Disconnect connector CM01 and connector H16.
5.
Connect the T-adapter to the female side of connector CM01.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value?
YES
NO
StandMeasurement position and condition ard value
Resist- Between CM01 (female) (6) and ance each pin other than (6)
•
Min. 1 MΩ
1.
Item
YES
StandMeasurement position and condition ard value
Between F01-3, R07 (female) (1), or Resist- S14 (female) (1) and ground ance Between CM01 (female) (6) or R07
6
Diagnosis and treatment
Min. 1 MΩ
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
40-455
FAILURE CODE [D19JKZ]
No.
8
Cause
Confirmation of repair
40-456
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [D19JKZ]
Circuit diagram associated with personal code relay
PC210-10M0, PC210LC-10M0
40-457
FAILURE CODE [D1N0KA]
40 TROUBLESHOOTING
FAILURE CODE [D1N0KA] No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Fuel feed pump relay
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R43. Connect the T-adapter to the male side.
3.
Measure the voltage.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Voltage Between R43 (male) (1) and (2)
3
Standard value
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel feed pump relay is normal.
NO
• YES
NO
200 to 600 Ω
•
Go to the next inspection item.
•
The fuel feed pump relay is defective.
•
Replace the fuel feed pump relay.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, R43. Connect the T- YES • adapter to each female side.
3.
Measure the voltage.
4.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Voltage
Measuring point and measurement condition
Standard value
Between CP02 (female) (98) and R43 (female) (1)
Max. 1 Ω
Between R43 (female) (2) and ground
Max. 1 Ω
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
4
Reconfirmation 1. of inspection 2. item
40-458
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
Cause
FAILURE CODE [D1N0KA]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
Diagnosis and treatment YES
Return to the first inspection item.
Turn the starting switch to the ON position. Set the PPC lock lever to FREE position to do troubleshooting.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40-459
FAILURE CODE [D1N0KB]
40 TROUBLESHOOTING
FAILURE CODE [D1N0KB] No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Fuel feed pump relay
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R43. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
ResistBetween R43 (male) (1) and (2) ance
3
Ground fault in wiring harness
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel feed pump relay is normal.
NO
• YES
NO
200 to 600 Ω
•
Go to the next inspection item.
•
The fuel feed pump relay is defective.
•
Replace the fuel feed pump relay.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, R43. Connect the T- YES • adapter to one of the female sides.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between CP02 (female) (98) or R43 ance (female) (1) and ground
40-460
Standard value
•
Standard value Min. 1 MΩ
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [D1N0KB]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note
Diagnosis and treatment •
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, R43. Connect the T- YES • adapter to the female side of CP02.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between CP02 (female) (98) and ance each pin other than (98)
Standard value
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
The wiring harness has no short circuits.
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position. Set the PPC lock lever to FREE position to do troubleshooting.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40-461
FAILURE CODE [D1N0KY]
40 TROUBLESHOOTING
FAILURE CODE [D1N0KY] No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R43. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position to troubleshoot.
Hot short circuit 4. in wiring harness
•
StandMeasurement position and condition ard value
Voltage Between R43 (female) (1) and (2)
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
• YES
Does the troubleshooting result agree with the standard value? Item
• NO
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 7 Ｖ
YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-462
Do the troubleshooting above again.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [D811MC]
FAILURE CODE [D811MC] Details of failure
The KOMTRAX system does not operate normally.
Action level
-
Action of controller Phenomenon on machine
The KOMTRAX system does not operate normally.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The KOMTRAX terminal can be defective.
•
Replace the KOMTRAX terminal.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-463
FAILURE CODE [D862KA]
40 TROUBLESHOOTING
FAILURE CODE [D862KA] Details of failure
An open circuit is found in the GPS antenna circuit.
Action level
-
Action of controller
If the cause of the failure disappears, the machine becomes normal by itself.
Phenomenon on machine
The GPS positioning system does not work.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The installation condition of the GPS antenna cable is normal.
NO
• YES •
2
Installation condition of GPS antenna cable
1.
Check the installation condition of the GPS antenna cable.
•
2.
Is the installation condition of the GPS antenna cable normal?
•
Connect the GPS antenna cable to the KOMTRAX terminal and the GPS antenna.
•
Go to "Confirmation of repair". The GPS antenna cable is normal.
NO
• YES
3
GPS antenna cable
1.
Check if the GPS antenna cable has an open circuit.
2.
Is thw GPS antenna cable normal?
• •
NO
40-464
Go to the next inspection item. The GPS antenna cable is disconnected.
Go to the next inspection item. The GPS antenna cable has an open circuit.
•
Replace the GPS antenna cable.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
Cause
GPS antenna
FAILURE CODE [D862KA]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Replace the air conditioner controller.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
Diagnosis and treatment
YES
•
The removed GPS antenna is normal.
•
Restore the removed GPS antenna.
•
Go to the next inspection item.
NO The repair is completed.
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Confirmation of 5. repair 6.
NO
YES
•
The KOMTRAX terminal can be defective.
•
Replace the KOMTRAX terminal.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
NO The repair is completed.
Configuration diagram of GPS system
PC210-10M0, PC210LC-10M0
40-465
FAILURE CODE [D8AQKR]
40 TROUBLESHOOTING
FAILURE CODE [D8AQKR] Details of failure
The machine monitor cannot recognize the KOMTRAX terminal over the CAN communication 2 line (KOMNET/c).
Action level
-
Action of controller
None in particular.
Phenomenon on machine
None in particular.
Reference information •
The ACC signal from the starting switch tells the start of CAN communication to each controller.
•
4 different failure codes, [D8AQKR], [DA2QKR], [DAZQKR] and [DB2QKR] are used for defective CAN communications in CAN 2 when they are found by the machine monitor. If all of these failure codes are shown simultaneously, there can be a ground fault, short circuit, or hot short circuit in the wiring harness (CAN communication line).
Associated informaREMARK tion If the air conditioner is operable, there is no possibility of ground fault, short circuit, or hot short circuit occurred in the wiring harness (CAN communication line).
No.
•
One of the CAN2 termination resistors is located in the machine monitor on the cab side. The other is in connector K02 located on the engine side.
•
Since each controller and machine monitor are connected directly to the battery, they are supplied with power even when the starting switch is in the OFF position.
•
Since the signals passing an active CAN communication line are pulse voltages, they cannot be measured by using a multimeter.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-466
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [D8AQKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Insert the T-adapter into connector CK02.
4.
Turn the battery disconnect switch to the ON position.
5. ACC signal cir- 6. cuit of KOM7. TRAX terminal
The ACC signal circuit of the KOMTRAX terminal is normal.
•
Go to check item of "CAN TERMINATING RESISTOR".
•
An error occurs in the ACC signal circuit of the KOMTRAX terminal.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage. Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
Between CK02 (3) and (1)
20 to 30V
Between CK02 (3) and (2)
20 to 30V
Voltage
3
YES
•
Turn the starting switch to the ON position.
Item
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.14 in fuse box F01.
4.
Disconnect connector CK02.
5.
Connect the T-adapter to the female side of connector CK02.
Open circuit in 6. wiring harness 7. (ACC signal circuit of KOMTRAX terminal)
Diagnosis and treatment
NO
YES
Measure the resistance. Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between F01-14 and CK02 (female) (3)
Max. 1 Ω
Resist- Between CK02 (female) (1) and ance ground
Max. 1 Ω
Between CK02 (female) (2) and ground
Max. 1 Ω
PC210-10M0, PC210LC-10M0
NO
40-467
FAILURE CODE [D8AQKR]
No.
4
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector K02.
3.
Connect the T-adapter to the male side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
CAN terminating resistor
Item
Resistance
5
Open circuit in wiring harness (CAN2 communication circuit)
40-468
Measuring point and measurement condition
Standard value
Between CM02 (male) (7) and (9)
120 ± 12 Ω
Between K02 (male) (A) and (B)
120 ± 12 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CK01, connector CM02, and connector K02.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CK01 (female) (10) and CM02 (female) (7)
Max. 1 Ω
Between CK01 (female) (10) and CM02 (female) (8)
Max. 1 Ω
Resist- Between CK01 (female) (11) and ance CM02 (female) (9)
Max. 1 Ω
Between CK01 (female) (10) and K02 (female) (A)
Max. 1 Ω
Between CK01 (female) (11) and K02 (female) (B)
Max. 1 Ω
Diagnosis and treatment YES
NO
YES
•
The CAN terminating resistor is normal.
•
Go to the next inspection item.
•
The CAN terminating resistor is defective.
•
Replace the CAN terminating resistor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
FAILURE CODE [D8AQKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
Ground fault in 6. wiring harness (CAN2 communication circuit)
Diagnosis and treatment YES
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
CM02 (female) (8), CP01 (female) (45), CE02 (female) (46), AC01 (female) (2), N08 (female)(3), CK01 Resist- (female) (10), K02 (female) (A) ance CM02 (female) (9), CP01 (female) (64), CE02 (female) (47), AC01 (female) (1), N08 (female)(10), CK01 (female) (11), K02 (female) (A)
PC210-10M0, PC210LC-10M0
Standard value Min. 1 MΩ
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
40-469
FAILURE CODE [D8AQKR]
No.
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of connector CM02, CP01, CE02, AC01, N08, CK01, K02.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
7
Short circuit in wiring harness (CAN2 communication circuit)
40-470
40 TROUBLESHOOTING
Measuring point and measurement condition
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between CK01 (female) (10) and each pin other than (10)
Min. 1 MΩ
Between CK01 (female) (11) and each pin other than (11)
Min. 1 MΩ
Between CP01 (female) (45) and each pin other than (45)
Min. 1 MΩ
Between CP01 (female) (64) and each pin other than (64)
Min. 1 MΩ
Between AC01 (female) (2) and each pin other than (2)
Min. 1 MΩ
Resist- Between AC01 (female) (1) and ance each pin other than (1)
Min. 1 MΩ
Between CE02 (female) (46) and each pin other than (46)
Min. 1 MΩ
Between CE02 (female) (47) and each pin other than (47)
Min. 1 MΩ
Between CM02 (female) (7) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (8) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (9) and each pin other than (9)
Min. 1 MΩ
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
8
Cause
FAILURE CODE [D8AQKR]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector K02.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
Between K02 (A) and ground
Max. 1 to 4 V
Between K02 (B) and ground
Max. 1 to 4 V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed controller is defective.
•
Replace the defective controller.
•
Go to "Confirmation of repair".
•
The removed controller is normal.
•
Restore the removed controller.
•
Go to the next inspection item.
YES
Hot short circuit 5. Does the measurement result agree with the standard value? in wiring harness (CAN2 StandMeasuring point and measurement communication Item ard valcondition circuit). ue
Voltage
Diagnosis and treatment
NO
YES
Disconnect one of the CAN communication connectors below. KOMTRAX terminal (connectorCK01), pump controller (connectorCP01), air conditioner controller (connectorAC01), engine controller (connectorCE02) REMARK
9
Connector CM02 of the monitor controller is not disconnected. A terminating register is built in the connector. If the connector is disconnected, a CAN2 communication error occurs. You will not be able to troubleshoot.
Controller 4.
Turn the battery disconnect switch to the ON position.
5.
Turn the starting switch to the ON position.
6.
Does the number of shown failure codes decrease from 4?
7.
If the number does not decrease, change the connector to be disconnected. Do the steps again from 1.
NO
REMARK • If all of 4 failure codes, [D8AQKR], [DA2QKR], [DAZQKR], and [DB2QKR] are shown, disconnect the controller one by one and as explained in steps 1 to 6 to find the defective controller.
PC210-10M0, PC210LC-10M0
40-471
FAILURE CODE [D8AQKR]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
Reconfirmation 1. 10 of inspection 2. item
11
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with CAN2 communication
40-472
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [D8AQKR]
Circuit diagram associated with KOMTRAX power supply KOMTRAX controller
AC95 (090-22) XJ
J03 (Green)
CK02 (070-12)
3
1
GND
4
2
GND
5
3
Key switch (ACC)
3 4 5 6
10C
10
20F
20
GC
AC02 4 R21 1
7 FM LG
8
C P 0 1 24
9
C P 0 1 43
10
C P 0 1 80 N08 2 MA
C M 0 1 10 C M 0 1 13
J04 (Green) M 11 3
17 18
M04 2
19 20
T05 G0024196
PC210-10M0, PC210LC-10M0
40-473
FAILURE CODE [D8ALKA]
40 TROUBLESHOOTING
FAILURE CODE [D8ALKA]
Details of failure
The KOMTRAX terminal senses an open circuit because the output line voltage of the system operation lamp is 5 V or below during approximately 3 seconds after the starting switch is turned to the ON position when the KOMTRAX terminal does not output a voltage.
Action level
-
Action of controller
Phenomenon on machine
•
Stops to turn on the system operating lamp.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
None in particular.
Reference information
Associated information
No.
•
Do not turn the battery disconnect switch to the OFF position while the system operating lamp is lit.
•
If the battery disconnect switch is turned to the OFF position while the system operating lamp is lit, the memory data stored in each controller will possibly be destroyed.
•
The system operating lamp cannot be lit from the KOMTRAX terminal.
•
Although the system operating lamp cannot be lit from the KOMTRAX terminal, no trouble will result unless the battery disconnect switch is turned to the OFF position.
•
When the system operating lamp is lit, the output voltage is at low level.
•
Since no controller drives the system operating lamp for approximately 3 seconds after the starting switch is turned to the ON position, an open circuit can be found.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
40-474
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [D8ALKA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off. In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
Fuse 3.
Remove fuse No.16 in fuse box F01.
4.
Check if the fuse is blown.
5.
Check the fuse for continuity.
6.
Is the fuse normal?
1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off.
Diagnosis and treatment • YES •
NO
YES
The fuse is normal. Go to the next inspection item.
•
The fuse is defective.
•
It blown, go to "Ground fault in wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
3
Open circuit in wiring harness
3.
Remove fuse No.16 in fuse box F01.
4.
Disconnect connector CK01 and connector L19.
5.
Connect the T-adapter to the female side of each connector.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Between F01-16 and L19 (female) Resist- (1) ance Between L19 (female) (2) and CK01 (female) (15)
PC210-10M0, PC210LC-10M0
NO
Max. 1 Ω Max. 1 Ω
40-475
FAILURE CODE [D8ALKA]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off.
Diagnosis and treatment YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
4
Ground fault in wiring harness
3.
Remove fuse No.16 in fuse box F01.
4.
Disconnect connector L19, L03, H16, CK01.
5.
Connect the T-adapter to the female side of one of the connectors.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
NO
StandMeasurement position and condition ard value
Between F01-16, L19 (female) (1), ResistL03 (female) (2), or H16 (female) ance (15) and ground
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-476
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The KOMTRAX terminal can be defective.
•
Replace the KOMTRAX terminal.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [D8ALKA]
Circuit diagram associated with system operating lamp
E 30A
From battery
MM
(S-12)
Pump controller
BJ
System operating SIG
(Black) controller
(J-20) 16
AC95 (090-22)
17 18
7
19
20
20
Monitor panel
R24 1
L03 2
PC210-10M0, PC210LC-10M0
G0024195
40-477
FAILURE CODE [D8ALKB]
40 TROUBLESHOOTING
FAILURE CODE [D8ALKB] Details of failure
The KOMTRAX terminal senses a short circuit because the output voltage does not become low level while the KOMTRAX terminal outputs current to the system operating lamp.
Action level
-
Action of controller
Phenomenon on machine
•
Stops to drive the system operating lamp.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
None in particular.
Reference information
Associated information
No.
•
Do not turn the battery disconnect switch to the OFF position while the system operating lamp is lit.
•
If the battery disconnect switch is turned to the OFF position while the system operating lamp is lit, the memory data stored in each controller will possibly be destroyed.
•
The system operating lamp cannot be lit from the KOMTRAX terminal.
•
Although the system operating lamp cannot be lit from the KOMTRAX terminal, no trouble will result unless the battery disconnect switch is turned to the OFF position.
•
When the system operating lamp is lit, the output voltage is at low level.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-478
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [D8ALKB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector L19.
3.
Connect the T-adapter to the female side of connector L19.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Between L19 (female) (2) and Voltage ground
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
Item
•
NO
Max. 1 V
YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The KOMTRAX terminal can be defective.
•
Replace the KOMTRAX terminal.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-479
FAILURE CODE [D8ALKB]
40 TROUBLESHOOTING
Circuit diagram associated with system operating lamp
E 30A
From battery
MM
(S-12)
Pump controller
BJ
System operating SIG
(Black) controller
(J-20) 16
AC95 (090-22)
17 18
7
19
20
20
Monitor panel
R24 1
L03 2
40-480
G0024195
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA20MC]
FAILURE CODE [DA20MC] Details of failure
The pump controller does not operate correctly.
Action level
-
Action of controller Phenomenon on machine
The work equipment, travel, and swing do not operate correctly.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-481
FAILURE CODE [DA22KK]
40 TROUBLESHOOTING
FAILURE CODE [DA22KK] Details of failure
The power supply voltage of the pump controller to drive solenoids is 20 V or below.
Action level
L03 •
While this failure code is active, stops sensing of failures (open circuits and short circuits) in all solenoid systems.
•
If the cause of the failure disappears, the machine becomes normal by itself.
Action of controller
Phenomenon on machine
Since no solenoid valve is energized correctly, the machine does not operate correctly. (Work equipment, swing, and travel systems do not work.) Pre-troubleshooting
If failure code [D110KB] is also shown, do the troubleshooting for this code first. Associated informaReference information tion As the T-adapter for the pump controller connector is a “socket-type box”, the operating voltage cannot be measured at the pump controller connector. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-482
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DA22KK]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check the battery electrolyte level.
3.
Measure the battery voltage.
4.
Measure the specific gravity of the battery electrolyte.
5.
Do the electrolyte level, voltage and specific gravity agree with the standard value? Judged item
2
Battery
Diagnosis and treatment • YES • •
Standard value
Battery electrolyte level
Between UPPER LEVEL and LOWER LEVEL
Battery voltage (1 battery)
Min. 12 V
Battery voltage (2 batteries in series)
Min. 24V
Specific gravity of battery electrolyte
Min. 1.26 (electrolyte temperature: 20°C)
NO
3
Fusible link
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fusible link F04.
4.
Check if the fusible link is blown.
5.
Check the fusible link for continuity.
6.
Is the fusible link normal?
If the battery electrolyte level is low, add electrolyte. After the electrolyte is refilled, charge the battery.
•
If the battery voltage is low, charge or replace the battery.
•
If the specific gravity of the battery electrolyte is low, charge the battery. After charging, if the specific gravity is lower than the specified value, replace the battery.
•
Go to "Confirmation of repair". The fusible link is normal.
•
NO
4
Fuse
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.2 in fuse box F01.
4.
Check if the fuse is blown.
It blown, go to "Ground fault in wiring harness".
•
If the fusible link is not blown but has no continuity, replace it.
•
Go to "Confirmation of repair". The fuse is normal.
5.
Check the fuse for continuity.
6.
Is the fuse normal?
PC210-10M0, PC210LC-10M0
YES • •
NO
Go to the next inspection item. The fusible link is defective.
•
• 1.
Go to the next inspection item. The battery is defective.
•
YES • 1.
The battery is normal.
Go to the next inspection item. The fuse is defective.
•
It blown, go to "Ground fault in wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair".
40-483
FAILURE CODE [DA22KK]
No.
5
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.2 in fuse box F01.
4.
Disconnect connector CP02.
5.
Connect the T-adapter to the female side of connector CP02.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
6
Ground fault in wiring harness
40 TROUBLESHOOTING
StandMeasurement position and condition ard value Between F01-2 and CP02 (female) (116)
Max. 1 Ω
Resist- Between F01-2 and CP02 (female) ance (118)
Max. 1 Ω
Between F01-2 and CP02 (female) (121)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.2 in fuse box F01.
4.
Disconnect connector CP02.
5.
Connect the T-adapter to the female side of connector CP02.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between F01-2, CP02 (female) ance (116), (118) or (121) and ground
40-484
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
7
FAILURE CODE [DA22KK]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.2 in fuse box F01.
4.
Disconnect connector CP02.
5.
Connect the T-adapter to the female side of connector CP02.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value?
Short circuit in wiring harness
Item
StandMeasurement position and condition ard value Between CP02 (female) (116) and each pin other than (116), (118), or (121)
Min. 1 MΩ
Between CP02 (female) (118) and Resisteach pin other than (116), (118), or ance (121)
Min. 1 MΩ
Between CP02 (female) (121) and each pin other than (116), (118), or (121)
Min. 1 MΩ
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
8
9
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-485
FAILURE CODE [DA22KK]
40 TROUBLESHOOTING
Circuit diagram associated with pump controller solenoid power supply
40-486
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA25KP]
FAILURE CODE [DA25KP] Details of failure
The voltage of the 5 V sensor power supply output 1 circuit is 2.5 V or below or 6.0 V or above.
Action level
-
Action of controller
Phenomenon on machine
•
Stops the output of power from 5 V sensor power supply output 1.
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
•
Signals from the pressure sensor are not input correctly.
•
The error code for the pressure sensor is shown at the same time.
•
Travel and work equipment speeds are slow.
•
The travel automatic transmission function does not operate.
•
The auto-decelerator function stays activated or the fine control performance of the work equipment is low.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Ground fault in wiring harness
Are the wiring harnesses and connectors normal?
Disconnect connector CP01, P09, P10, P11, P12. YES
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Between CP01 (female) (6), P09 Resist- (female) (3), P10 (female) (3), P11 ance (female) (3), or P12 (female) and ground
PC210-10M0, PC210LC-10M0
Min. 1 MΩ
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
•
2.
Standard value
Go to the next inspection item. A wiring harness or connector is defective.
NO
Turn the starting switch to the OFF position.
Measuring point and measurement condition
• •
1.
Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-487
FAILURE CODE [DA25KP]
No.
3
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, P09, P10, P11, P12. YES
3.
Connect the T-adapter to the female side of connector CP01.
4.
Measure the resistance.
5.
Does the measuring result meet the standard value for the connector? Item
Measuring point and measurement condition
Resist- Between C P01 (female) (6) and ance each pin other than (6)
4
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connector P09, P10, P11, P12.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Turn the starting switch to the ON position.
5.
Measure the voltage.
Measuring point and measurement condition
Between P09 (female) (3) and (1), P10 (female) (3) and (1), P11 (feVoltage male) (3) and (1), P12 (female)(3) and (1)
Standard value 4.5 to 5.5V
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Does the measuring result meet the standard value for the connector? Item
•
NO
Min. 1 MΩ
1.
Hot short circuit 6. in wiring harness
40-488
Diagnosis and treatment
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
Cause
FAILURE CODE [DA25KP]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P09, P10, P11, P12.
3.
Connect one of the disconnected connectors.
4.
Turn the starting switch to the ON position to troubleshoot.
5.
Check that this failure code is not shown.
6.
Do the steps 1 to 5 again for all the disconnected connectors.
7.
Are all connectors checked for not having a defect to show this failure code?
Sensor
Diagnosis and treatment •
The equipment connected to each connector is is normal.
•
Go to the next inspection item.
•
If this failure code is shown for a connector, the equipment connected to that connector is defective.
•
Replace the equipment connected to the connector (indicated by the failure code).
•
Go to "Confirmation of repair".
YES
REMARK Since connectors are disconnected, the failure codes for the disconnected devices are shown. Sensor
NO
Connector
Travel forward LEFT pressure sensor
P09
Travel reverse LEFT pressure sensor
P10
Travel forward RIGHT pressure sensor
P11
Travel reverse RIGHT pressure sensor
P12
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-489
FAILURE CODE [DA25KP]
40 TROUBLESHOOTING
Circuit diagram associated with pump controller 5 V sensor power supply
40-490
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA26KP]
FAILURE CODE [DA26KP] Details of failure
The voltage of the 5 V sensor power supply output 2 circuit is 2.5 V or below or 6.0 V or above.
Action level
-
Action of controller
Phenomenon on machine
•
Stops the output of power from 5 V sensor power supply output 2.
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
•
Signals from the pressure sensor are not input correctly.
•
The error code for the pressure sensor is shown at the same time.
•
Travel and work equipment speeds are slow.
•
The travel automatic transmission function does not operate.
•
The auto-decelerator function stays activated or the fine control performance of the work equipment is low.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-491
FAILURE CODE [DA26KP]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, A20, P01, P02, P03, P04, P05, P06, P07, P08, P25, P26, P27, P28, P47, P57, P67, M16.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Ground fault in wiring harness
Item
Measuring point and measurement condition
CP01 (female) (63), A20 (female) (3), P01 (female) (3), P02 (female) (3), P03 (female) (3), P04 (female) (3), P05 (female) (3), P06 (female) Resist- (3), P07 (female) (3), P08 (female) ance (3), P25 (female)(3), P26 (female) (3), P27 (female) (A), P28 (female) (A), P47 (female) (1), P57 (female) (1), P67 (female) (A), M16 (female) (5)
3
Short circuit in wiring harness
40-492
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Min. 1 MΩ
2.
Disconnect connector CP01, A20, P01, P02, P03, P04, P05, P06, P07, P08, P25, P26, P27, P28, P47, P57, P67, M16.
3.
Connect the T-adapter to the female side of connector CP01.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Resist- Between CP01 (female) (63) and ance each pin other than (63)
•
NO
Turn the starting switch to the OFF position.
Measuring point and measurement condition
YES
Standard value
1.
Item
Diagnosis and treatment
Standard value Min. 1 MΩ
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [DA26KP]
Cause
Hot short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector A20, P01, P02, P03, P04, P05, P06, P07, P08, P25, P26, P27, P28, P47, P57, P67, M16.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Turn the starting switch to the ON position.
5.
Measure the voltage.
6.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Between A20 (female) (3) and (1), P01 (female) (3) and (1), P02 (female) (3) and (1), P03 (female) (3) and (1), P04 (female) (3) and (1), P05 (female) (3) and (1), P06 (female) (3) and (1), , P07 (female) (3) Voltage and (1), P08 (female) (3) and (1), P25 (female) (3) and (1), P26 (female) (3) and (1), P27 (female) (A) and (B), P28 (female) (A) and (B), Ｐ 47 (female) (1) and (2), P57 (female) (1) and (2), P67 (female) (A) and (B), or M16 (female) (5) and (2)
PC210-10M0, PC210LC-10M0
Diagnosis and treatment •
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Standard value
NO
4.5 to 5.5V
40-493
FAILURE CODE [DA26KP]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector Y09, connector Y11, connector Y12, and connector Y13.
3.
Connect one of the disconnected connectors.
4.
Turn the starting switch to the ON position to troubleshoot.
5.
Check that this failure code is not shown.
6.
Do the steps 1 to 5 again for all the disconnected connectors.
7.
Are all connectors checked for not having a defect to show this failure code?
Diagnosis and treatment •
The equipment connected to each connector is is normal.
•
Go to the next inspection item.
•
If this failure code is shown for a connector, the equipment connected to that connector is defective.
•
Replace the equipment connected to the connector (indicated by the failure code).
•
Go to "Confirmation of repair".
YES
REMARK Since connectors are disconnected, the failure codes for the disconnected devices are shown. Sensor
5
Sensor, potentiometer
Connector
Service pressure sensor
A20
Bucket CURL pressure sensor
P01
Boom LOWER pressure sensor
P02
Swing (LEFT) pressure sensor
P03
Arm IN pressure sensor
P04
Bucket DUMP pressure sensor
P05
Boom RAISE pressure sensor
P06
Swing (RIGHT) pressure sensor
P07
Arm OUT pressure sensor
P08
Front pump pressure sensor
P25
Rear pump pressure sensor
P26
Front pump swash plate sensor
P27
Rear pump swash plate sensor
P28
Water-in-fuel sensor
P47
Blowby pressure sensor (option)
P57
Clogging sensor for hydraulic oil return filter
P67
Fan clutch M16
M16
NO
YES The repair is completed.
6
Reconfirmation 1. of inspection 2. item
40-494
Do the inspection above again. Have you identified the cause when the inspection is done again?
NO
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
7
Cause
Confirmation of repair
FAILURE CODE [DA26KP]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
40-495
FAILURE CODE [DA26KP]
40 TROUBLESHOOTING
Circuit diagram associated with pump controller 5 V sensor power supply
40-496
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA29KQ]
FAILURE CODE [DA29KQ] Details of failure
A model code signal for a model which is not registered in the controller is input.
Action level
L01
Action of controller
Phenomenon on machine
•
Controls the machine by regarding the machine as a default model (standard specification machine).
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
No problem is shown if the machine specification is standard.
Monitoring code •
The assembly part number of the pump controller can be monitored. (Code: 20229)
•
The state (ON or OFF) of the machine model selection signal can be monitored. (Code: 02201)
Associated informaMachine Model Select 1: OFF tion Machine Model Select 2: OFF Machine Model Select 3: ON Machine Model Select 4: OFF Machine Model Select 5: OFF No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-497
FAILURE CODE [DA29KQ]
No.
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S30.
3.
Connect the T-adapter to the female side of connector S30.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
2
Model selection connector
40-498
40 TROUBLESHOOTING
Measuring point and measurement condition
Diagnosis and treatment YES
•
The model selection connector is normal.
•
Go to the next inspection item.
•
The model selection connector is defective.
•
Replace the machine model select connector.
•
Go to "Confirmation of repair".
Standard value
Between S30 (female) (1) and (2)
Min. 1 MΩ
Between S30 (female) (1) and (3)
Max. 1 Ω
Between S30 (female) (1) and (4)
Min. 1 MΩ
Between S30 (female) (1) and (7)
Min. 1 MΩ
Between S30 (female) (1) and (8)
Max. 1 Ω
Between S30 (female) (2) and (3)
Min. 1 MΩ
Between S30 (female) (2) and (4)
Min. 1 MΩ
ResistBetween S30 (female) (2) and (7) ance
Min. 1 MΩ
Between S30 (female) (2) and (8)
Min. 1 MΩ
Between S30 (female) (3) and (4)
Min. 1 MΩ
Between S30 (female) (3) and (7)
Min. 1 MΩ
Between S30 (female) (3) and (8)
Max. 1 Ω
Between S30 (female) (4) and (7)
Min. 1 MΩ
Between S30 (female) (4) and (8)
Min. 1 MΩ
Between S30 (female) (7) and (8)
Min. 1 MΩ
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DA29KQ]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01 and connector S30.
3.
Connect the T-adapter to the female side of connector CP01 and the male side of connector S30.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
3
Max. 1 Ω
Between CP01 (female) (40) and S30 (male) (2)
Max. 1 Ω
Between CP01 (female) (58) and Resist- S30 (male) (7) ance Between CP01 (female) (59) and S30 (male) (1)
Max. 1 Ω
Between CP01 (female) (77) and S30 (male) (4)
Max. 1 Ω
Between S30 (male) (8) and ground
Max. 1 Ω
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01 and connector S30.
3.
Connect the T-adapter to the female side or male side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
Between CP01 (female) (21) or S30 (male) (3) and ground
Min. 1 MΩ
Between CP01 (female) (40) or S30 (male) (2) and ground
Min. 1 MΩ
Resist- Between CP01 (female) (58) or S30 ance (male) (7) and ground
Min. 1 MΩ
Between CP01 (female) (59) or S30 (male) (1) and ground
Min. 1 MΩ
Between CP01 (female) (77) or S30 (male) (4) and ground
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
1.
Ground fault in wiring harness
YES
•
Standard value
Between CP01 (female) (21) and S30 (male) (3)
Open circuit in wiring harness
Item
4
Measuring point and measurement condition
Diagnosis and treatment
YES
NO
40-499
FAILURE CODE [DA29KQ]
No.
5
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector S30.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value?
Short circuit in wiring harness
Item
Measuring point and measurement condition
Diagnosis and treatment YES
Standard value
Between CM01 (female) (21) and each pin other than (21)
Min. 1 MΩ
Between CM01 (female) (40) and each pin other than (40)
Min. 1 MΩ
Resist- Between CM01 (female) (58) and ance each pin other than (58)
Min. 1 MΩ
Between CM01 (female) (59) and each pin other than (59)
Min. 1 MΩ
Between CM01 (female) (77) and each pin other than (77)
Min. 1 MΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-500
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA29KQ]
Circuit diagram associated with machine model setting system
PC210-10M0, PC210LC-10M0
40-501
FAILURE CODE [DA2LKA]
40 TROUBLESHOOTING
FAILURE CODE [DA2LKA] Details of failure
The pump controller senses an open circuit because the output line voltage of the system operating lamp is 5 V or below for approximately 3 seconds after the start switch is turned to the ON position while the pump controller does not output a current.
Action level
-
Action of controller
Phenomenon on machine
•
Stops to turn on the system operating lamp.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
None in particular.
Reference information
Associated information
No.
•
Do not turn the battery disconnect switch to the OFF position while the system operating lamp is lit.
•
If the battery disconnect switch is turned to the OFF position while the system operating lamp is lit, the memory data stored in each controller will possibly be destroyed.
•
The system operating lamp cannot be lit from the pump controller.
•
Although the system operating lamp cannot be lit from the pump controller, no trouble will result unless the battery disconnect switch is turned to the OFF position.
•
When the system operating lamp is lit, the output voltage is at low level.
•
Since no controller drives the system operating lamp for approximately 3 seconds after the starting switch is turned to the ON position, an open circuit can be found.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-502
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DA2LKA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off. In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
Fuse
3.
Check if the fuse is blown.
4.
Check the fuse for continuity.
5.
Is the fuse normal?
1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off.
Diagnosis and treatment • YES • •
NO
Go to the next inspection item. The fuse is defective.
•
It blown, go to "Ground fault in wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
• YES
The fuse is normal.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
3
Open circuit in wiring harness
3.
Remove fuse No.16 in fuse box F01.
4.
Disconnect connector CP02 and connector L19.
5.
Connect the T-adapter to the female side of each connector.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Between F01-16 and L19 (female) Resist- (1) ance Between L19 (female) (2) and CP02 (female) (15)
PC210-10M0, PC210LC-10M0
NO
Max. 1 Ω Max. 1 Ω
40-503
FAILURE CODE [DA2LKA]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off.
Diagnosis and treatment YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
4
Ground fault in wiring harness
3.
Remove fuse No.16 in fuse box F01.
4.
Disconnect connector L19, L03, H16, CK01.
5.
Connect the T-adapter to the female side of one of the connectors.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
NO
StandMeasurement position and condition ard value
Between F01-16, L19 (female) (1), ResistL03 (female) (2), H16 (female) (1), ance or CK01 (female) (15) and ground
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-504
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA2LKA]
Circuit diagram associated with system operating lamp
E 30A
From battery
MM
(S-12)
Pump controller
BJ
System operating SIG
(Black) controller
(J-20) 16
AC95 (090-22)
17 18
7
19
20
20
Monitor panel
R24 1
L03 2
PC210-10M0, PC210LC-10M0
G0024195
40-505
FAILURE CODE [DA2LKB]
40 TROUBLESHOOTING
FAILURE CODE [DA2LKB] Details of failure
The pump controller senses a short circuit because the voltage of the output circuit does not become low level while the pump controller outputs current to the system operating lamp.
Action level
-
Action of controller
Phenomenon on machine
•
Stops to drive the system operating lamp.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
None in particular.
Reference information
Associated information
No.
•
Do not turn the battery disconnect switch to the OFF position while the system operating lamp is lit.
•
If the battery disconnect switch is turned to the OFF position while the system operating lamp is lit, the memory data stored in each controller will possibly be destroyed.
•
The system operating lamp cannot be lit from the pump controller.
•
Although the system operating lamp cannot be lit from the pump controller, no trouble will result unless the battery disconnect switch is turned to the OFF position.
•
When the system operating lamp is lit, the output voltage is at low level.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-506
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DA2LKB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector L19.
3.
Connect the T-adapter to the female side of connector L19.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Between L19 (female) (2) and Voltage ground
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
Item
•
NO
Max. 1 V
YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-507
FAILURE CODE [DA2LKB]
40 TROUBLESHOOTING
Circuit diagram associated with system operating lamp
E 30A
From battery
MM
(S-12)
Pump controller
BJ
System operating SIG
(Black) controller
(J-20) 16
AC95 (090-22)
17 18
7
19
20
20
Monitor panel
R24 1
L03 2
40-508
G0024195
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA2QKR]
FAILURE CODE [DA2QKR] Details of failure
The machine monitor cannot recognize the pump controller in the CAN2 communication line (KOMNET/c).
Action level
L03
Action of controller
Keeps information when an error occurs.
Phenomenon on machine
The information from the pump controller are not shown. Special functions do not operate. Received data do not update. (Failure code sent by pump controller, monitoring code, or such) Reference information •
The ACC signal from the starting switch tells the start of CAN communication to each controller.
•
4 different failure codes, [D8AQKR], [DA2QKR], [DAZQKR] and [DB2QKR] are used for defective CAN communications in CAN 2 when they are found by the machine monitor. If all of these failure codes are shown simultaneously, there can be a ground fault, short circuit, or hot short circuit in the wiring harness (CAN communication line).
Associated informaREMARK tion If the air conditioner is operable, there is no possibility of ground fault, short circuit, or hot short circuit occurred in the wiring harness (CAN communication line).
No.
•
One of the CAN2 termination resistors is located in the machine monitor on the cab side. The other is in connector K02 located on the engine side.
•
Since each controller and machine monitor are connected directly to the battery, they are supplied with power even when the starting switch is in the OFF position.
•
Since the signals passing an active CAN communication line are pulse voltages, they cannot be measured by using a multimeter.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-509
FAILURE CODE [DA2QKR]
No.
2
Cause
Pump controller power supply circuit
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Turn the starting switch to the ON position.
6.
Measure the voltage.
7.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition Between CP01 (female) (1) and (2)
20 to 30V
Between CP01 (female) (4) and (5)
20 to 30V
Voltage
3
Open circuit in wiring harness (Pump controller power supply circuit)
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01.
4.
Disconnect connector CP01.
5.
Connect the T-adapter to the female side of connector CP01.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
Between F01-17 and CP01 (female) (1)
Max. 1 Ω
Between F01-17 and CP01 (female) Resist- (4) ance Between CP01 (female) (2) and ground
Max. 1 Ω
Item
Between CP01 (female) (5) and ground
40-510
Standard value
Diagnosis and treatment
YES
•
The power supply circuit of the pump controller is normal.
•
Go to inspection item of "ACC signal circuit of pump controller".
•
The pump controller power supply circuit is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Max. 1 Ω Max. 1 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [DA2QKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Turn the battery disconnect switch to the ON position.
6.
Turn the starting switch to the ON position.
ACC signal cir- 7. cuit of pump 8. controller
Diagnosis and treatment
YES
•
The ACC signal circuit of the pump controller is normal.
•
Go to check item of "CAN TERMINATING RESISTOR".
•
The ACC signal circuit of the pump controller is defective.
•
Go to the next inspection item.
Measure the voltage. Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
Between CP01 (female) (24) and (2)
20 to 30V
Voltage Between CP01 (female) (43) and (5)
20 to 30V
Between CP01 (female) (80) and (2)
20 to 30V
Item
PC210-10M0, PC210LC-10M0
NO
40-511
FAILURE CODE [DA2QKR]
No.
5
6
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.10 and 20 in fuse box F01.
4.
Disconnect connector CP01.
5.
Connect the T-adapter to the female side of connector CP01.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value?
Open circuit in wiring harness (ACC signal circuit of pump controller)
CAN terminating resistor
40 TROUBLESHOOTING
Item
Standard value
Between F01-10 and CP01 (female) (24)
Max. 1 Ω
Between F01-20 and CP01 (female) (43)
Max. 1 Ω
Resist- Between F01-20 and CP01 (female) ance (80)
Max. 1 Ω
Between CP01 (female) (2) and ground
Max. 1 Ω
Between CP01 (female) (5) and ground
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector K02.
3.
Connect the T-adapter to the male side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
40-512
Measuring point and measurement condition
Measuring point and measurement condition
Standard value
Between CM02 (male) (7) and (9)
120 ± 12 Ω
Between K02 (male) (A) and (B)
120 ± 12 Ω
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The CAN terminating resistor is normal.
•
Go to the next inspection item.
•
The CAN terminating resistor is defective.
•
Replace the CAN terminating resistor.
•
Go to "Confirmation of repair".
NO
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
7
8
FAILURE CODE [DA2QKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CM02, and connector K02.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value?
Open circuit in wiring harness (CAN2 communication circuit)
Item
Measuring point and measurement condition
Standard value
Between CP01 (female) (45) and CM02 (female) (7)
Max. 1 Ω
Between CP01 (female) (45) and CM02 (female) (8)
Max. 1 Ω
Resist- Between CP01 (female) (64) and ance CM02 (female) (9)
Max. 1 Ω
Between CP01 (female) (45) and K02 (female) (A)
Max. 1 Ω
Between CP01 (female) (64) and K02 (female) (B)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
Ground fault in 6. wiring harness (CAN2 communication circuit)
Diagnosis and treatment YES
Measuring point and measurement condition
CM02 (female) (8), CP01 (female) (45), CE02 (female) (46), AC01 (female) (2), N08 (female)(3), CK01 Resist- (female) (10), K02 (female) (A) ance CM02 (female) (9), CP01 (female) (64), CE02 (female) (47), AC01 (female) (1), N08 (female)(10), CK01 (female) (11), K02 (female) (A)
PC210-10M0, PC210LC-10M0
Standard value Min. 1 MΩ
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
Does the measurement result agree with the standard value? Item
•
NO
Min. 1 MΩ
40-513
FAILURE CODE [DA2QKR]
No.
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of connector CM02, CP01, CE02, AC01, N08, CK01, K02.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
9
Short circuit in wiring harness (CAN2 communication circuit)
40-514
40 TROUBLESHOOTING
Measuring point and measurement condition
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between CK01 (female) (10) and each pin other than (10)
Min. 1 MΩ
Between CK01 (female) (11) and each pin other than (11)
Min. 1 MΩ
Between CP01 (female) (45) and each pin other than (45)
Min. 1 MΩ
Between CP01 (female) (64) and each pin other than (64)
Min. 1 MΩ
Between AC01 (female) (2) and each pin other than (2)
Min. 1 MΩ
Resist- Between AC01 (female) (1) and ance each pin other than (1)
Min. 1 MΩ
Between CE02 (female) (46) and each pin other than (46)
Min. 1 MΩ
Between CE02 (female) (47) and each pin other than (47)
Min. 1 MΩ
Between CM02 (female) (7) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (8) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (9) and each pin other than (9)
Min. 1 MΩ
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DA2QKR]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector K02.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
Between K02 (A) and ground
Max. 1 to 4 V
Between K02 (B) and ground
Max. 1 to 4 V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed controller is defective.
•
Replace the defective controller.
•
Go to "Confirmation of repair".
•
The removed controller is normal.
•
Restore the removed controller.
•
Go to the next inspection item.
YES
Hot short circuit 5. Does the measurement result agree with the standard value? in wiring har10 ness (CAN2 StandMeasuring point and measurement communication Item ard valcondition circuit). ue
Voltage
Diagnosis and treatment
NO
YES
Disconnect one of the CAN communication connectors below. KOMTRAX terminal (connectorCK01), pump controller (connectorCP01), air conditioner controller (connectorAC01), engine controller (connectorCE02) REMARK Connector CM02 of the monitor controller is not disconnected. A terminating register is built in the connector. If the connector is disconnected, a CAN2 communication error occurs. You will not be able to troubleshoot.
11 Controller 4.
Turn the battery disconnect switch to the ON position.
5.
Turn the starting switch to the ON position.
6.
Does the number of shown failure codes decrease from 4?
7.
If the number does not decrease, change the connector to be disconnected. Do the steps again from 1.
NO
REMARK • If all of 4 failure codes, [D8AQKR], [DA2QKR], [DAZQKR], and [DB2QKR] are shown, disconnect the controller one by one and as explained in steps 1 to 6 to find the defective controller.
PC210-10M0, PC210LC-10M0
40-515
FAILURE CODE [DA2QKR]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
Reconfirmation 1. 12 of inspection 2. item
13
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with CAN2 communication
40-516
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA2QKR]
Circuit diagram associated with pump controller power supply
PC210-10M0, PC210LC-10M0
40-517
FAILURE CODE [DA2RKR]
40 TROUBLESHOOTING
FAILURE CODE [DA2RKR] Details of failure
The machine monitor cannot recognize the pump controller in the CAN1 communication line (KOMNET/c).
Action level
L04
Action of controller
Phenomenon on machine
•
Keeps the working mode.
•
Keeps the current selection of auto-deceleration.
•
Keeps the travel speed (Hi/Lo).
•
Keeps information when an error occurs.
•
The information from the pump controller is not shown. Special functions do not operate. Received data do not update.
•
Pump control is disabled.
•
The Hydraulic oil temperature gauge pointer is not shown on the machine monitor.
•
Windshield wiper operation is disabled.
•
Windshield washer operation is disabled.
•
The flow rate of the attachment oil pressure line cannot be controlled.
Reference information • The ACC signal from the starting switch tells the start of CAN communication to each controller.
Associated information
No.
•
If this failure code is shown, there can be a ground fault, short circuit, or hot short circuit in the wiring harness (CAN communication line).
•
One of the CAN1 termination resistors is located in the machine monitor on the cab side. The other is in connector B_RES located on the engine side.
•
Since each controller and machine monitor are connected directly to the battery, they are supplied with power even when the starting switch is in the OFF position.
•
Since the signals passing an active CAN communication line are pulse voltages, they cannot be measured by using a multimeter.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
40-518
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DA2RKR]
Cause
Pump controller power supply circuit
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Turn the starting switch to the ON position.
6.
Measure the voltage.
7.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition Between CP01 (female) (1) and (2)
20 to 30V
Between CP01 (female) (4) and (5)
20 to 30V
Voltage
3
Open circuit in wiring harness (Pump controller power supply circuit)
Standard value
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01.
4.
Disconnect connector CP01.
5.
Connect the T-adapter to the female side of connector CP01.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
Between F01-17 and CP01 (female) (1)
Max. 1 Ω
Between F01-17 and CP01 (female) Resist- (4) ance Between CP01 (female) (2) and ground
Max. 1 Ω
Item
Between CP01 (female) (5) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment
YES
•
The power supply circuit of the pump controller is normal.
•
Go to inspection item of "ACC signal circuit of pump controller".
•
The pump controller power supply circuit is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Max. 1 Ω Max. 1 Ω
40-519
FAILURE CODE [DA2RKR]
No.
4
5
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01.
3.
Connect the T-adapter to the female side of connector CP01.
4.
Turn the starting switch to the ON position.
5.
Measure the voltage.
6.
Does the measurement result agree with the standard value?
ACC signal circuit of pump controller
Open circuit in wiring harness (ACC signal circuit of pump controller)
40-520
40 TROUBLESHOOTING
Measuring point and measurement condition
Standard value
Between CP01 (female) (24) and (2)
20 to 30V
Voltage Between CP01 (female) (43) and (5)
20 to 30V
Between CP01 (female) (80) and (2)
20 to 30V
Item
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.10 and 20 in fuse box F01.
4.
Disconnect connector CP01.
5.
Connect the T-adapter to the female side of connector CP01.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between F01-10 and CP01 (female) (24)
Max. 1 Ω
Between F01-20 and CP01 (female) (43)
Max. 1 Ω
Resist- Between F01-20 and CP01 (female) ance (80)
Max. 1 Ω
Between CP01 (female) (2) and ground
Max. 1 Ω
Between CP01 (female) (5) and ground
Max. 1 Ω
Diagnosis and treatment
YES
•
The ACC signal circuit of the pump controller is normal.
•
Go to check item of "CAN TERMINATING RESISTOR".
•
The ACC signal circuit of the pump controller is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
FAILURE CODE [DA2RKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector K13.
3.
Connect the T-adapter to the male side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
CAN terminating resistor
Item
Resistance
7
Open circuit in wiring harness (CAN1 communication circuit)
Measuring point and measurement condition
Standard value
Between CM02 (male) (10) and (12)
120 ± 12 Ω
Between K13 (male) (A) and (B)
120 ± 12 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CM02, and connector K13.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CP01 (female) (7) and CM02 (female) (10)
Max. 1 Ω
Between CP01 (female) (7) and CM02 (female) (11)
Max. 1 Ω
Resist- Between CP01 (female) (26) and ance CM02 (female) (12)
Diagnosis and treatment YES
NO
YES
•
The CAN terminating resistor is normal.
•
Go to the next inspection item.
•
The CAN terminating resistor is defective.
•
Replace the CAN terminating resistor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
Between CP01 (female) (7) and K13 Max. 1 (female) (A) Ω Between CP01 (female) (26) and K13 (female) (B)
PC210-10M0, PC210LC-10M0
Max. 1 Ω
40-521
FAILURE CODE [DA2RKR]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CM02, and connector K13.
4.
Connect the T-adapter to the female side of one of the connectors.
Ground fault in 5. wiring harness 6. (CAN1 communication circuit)
Does the measuring result meet the standard value for the connector? Measuring point and measurement condition
Between CP01 (female) (7), CM02 (female) (10), CM02 (female) (11), Resist- or K13 (female) (15) and ground ance Between CP01 (female) (26), CM02 (female) (12), or K13 (female) (B) and ground
9
40-522
YES
Measure the resistance.
Item
Short circuit in wiring harness (CAN1 communication circuit)
Diagnosis and treatment
Standard value
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CM02, and connector K13.
4.
Connect the T-adapter to the female side of connector CP01 and connector CM02.
5.
Measure the resistance.
6.
Does the measuring result meet the standard value for the connector? Item
The wiring harness has no ground faults.
Min. 1 MΩ
1.
Measuring point and measurement condition
•
Standard value
Between CP01 (female) (7) and each pin other than (7)
Min. 1 MΩ
Between CP01 (female) (26) and each pin other than (26)
Min. 1 MΩ
Resist- Between CM02 (female) (10) and ance each pin other than (10), or (11)
Min. 1 MΩ
Between CM02 (female) (11) and each pin other than (10), or (11)
Min. 1 MΩ
Between CM02 (female) (12) and each pin other than (12)
Min. 1 MΩ
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DA2RKR]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector K13.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
11 Controller
Between K13 (A) and ground
Max. 1 to 4 V
Between K13 (B) and ground
Max. 1 to 4 V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect the pump controller (connector CP01).
4.
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The pump controller is defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair". The pump controller is normal.
YES
Hot short circuit 5. Does the measurement result agree with the standard value? in wiring har10 ness (CAN1 StandMeasuring point and measurement communication Item ard valcondition circuit). ue
Voltage
Diagnosis and treatment
Turn the battery disconnect switch to the ON position.
5.
Turn the starting switch to the ON position.
6.
Is the shown failure code cleared?
NO
YES
• NO
•
Restore the pump controller.
•
Go to the next inspection item.
YES The repair is completed. Reconfirmation 1. 12 of inspection 2. item
13
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-523
FAILURE CODE [DA2RKR]
40 TROUBLESHOOTING
Circuit diagram associated with CAN1 communication
40-524
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DA2RKR]
Circuit diagram associated with pump controller power supply
PC210-10M0, PC210LC-10M0
40-525
FAILURE CODE [DAF0MB]
40 TROUBLESHOOTING
FAILURE CODE [DAF0MB] Details of failure
The machine monitor program is rewritten. (Program error)
Action level
-
Action of controller
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
Phenomenon on machine
•
The machine monitor display is unreliable.
•
It cannot send the data to controllers or receive the data from them.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Confirmation of 5. repair 6.
40-526
Do the preceding troubleshooting again. NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DAF0MC]
FAILURE CODE [DAF0MC] Details of failure
The machine monitor does not operate correctly.
Action level
-
Action of controller
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
Phenomenon on machine
•
The machine monitor display is unreliable.
•
It cannot send the data to controllers or receive the data from them.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Confirmation of 5. repair 6.
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-527
FAILURE CODE [DAF9KQ]
40 TROUBLESHOOTING
FAILURE CODE [DAF9KQ] Details of failure Action level
The pump controller is not the model specified in the machine monitor program. (The replaced machine monitor or pump controller has a wrong part number.) L03
Action of controller Phenomenon on machine
The machine does not operate correctly.
Monitoring code •
The assembly part number of the machine monitor can be monitored. (Code: 20227)
•
The assembly part number of the pump controller can be monitored. (Code: 20229)
•
The state (ON or OFF) of the machine model selection signal can be monitored. (Code: 02201)
Associated information
Machine Model Select 1: OFF Machine Model Select 2: OFF Machine Model Select 3: ON Machine Model Select 4: OFF Machine Model Select 5: OFF
No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The machine monitor is correct.
NO
• YES 1. 2
Part number of 2. machine monitor 3.
40-528
Check the part number of the replaced machine monitor.
•
Check the correct part number with monitoring code 20227. Is the part number of the machine monitor correct?
•
Go to the next inspection item. The machine monitor is incorrect.
•
Replace the machine monitor with the correct one.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DAF9KQ]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1. 3
Part number of 2. pump controller 3.
Check the part number of the replaced pump controller.
The pump controller is correct.
•
Go to the next inspection item. The pump controller is incorrect.
•
Check the correct part number with monitoring code 20229. Is the part number of the pump controller correct?
•
•
Replace the pump controller with the correct one.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-529
FAILURE CODE [DAFGMC]
40 TROUBLESHOOTING
FAILURE CODE [DAFGMC] Details of failure
No position data is sent from the GPS module (inside the machine monitor) to the KOMTRAX communication modem for more than 50 seconds since the startup of KOMTRAX.
Action level
-
Action of controller
If the cause of the failure disappears, the machine becomes normal by itself.
Phenomenon on machine Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
5. Confirmation of 6. repair
40-530
Do the preceding troubleshooting again. NO
YES
•
The KOMTRAX terminal can be defective.
•
Replace the KOMTRAX terminal.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record. (At 50 seconds or more after turning the starting switch to the ON position)
9.
Is this failure code displayed in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DAFLKA]
FAILURE CODE [DAFLKA]
Details of failure
For approximately 3 seconds after the starting switch is turned to the ON position and the machine monitor is not driving, the voltage of the output line of the system operating lamp is approximately 5 V or below. The machine monitor senses that there is an open circuit.
Action level
Action of controller
Phenomenon on machine
•
Stops to turn on the system operating lamp.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
None in particular.
Reference information
Associated information
No.
•
Do not turn the battery disconnect switch to the OFF position while the system operating lamp is lit.
•
If the battery disconnect switch is turned to the OFF position while the system operating lamp is lit, the memory data stored in each controller will possibly be destroyed.
•
The system operating lamp cannot be lit from the machine monitor.
•
Although the system operating lamp cannot be lit from the machine monitor, no trouble will result unless the battery disconnect switch is turned to the OFF position.
•
When the system operating lamp is lit, the output voltage is at low level.
•
Since no controller drives the system operating lamp for approximately 3 seconds after the starting switch is turned to the ON position, an open circuit can be found.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-531
FAILURE CODE [DAFLKA]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off. In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
Fuse 3.
Remove fuse No.16 in fuse box F01.
4.
Check if the fuse is blown.
5.
Check the fuse for continuity.
6.
Is the fuse normal?
1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off.
Diagnosis and treatment • YES •
NO
YES
The fuse is normal. Go to the next inspection item.
•
The fuse is defective.
•
It blown, go to "Ground fault in wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
3
Open circuit in wiring harness
3.
Remove fuse No.16 in fuse box F01.
4.
Disconnect connector CM01 and connector L19.
5.
Connect the T-adapter to the female side of each connector.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Between F01-16 and L19 (female) Resist- (1) ance Between L19 (female) (2) and CM01 (female) (8)
40-532
NO
Max. 1 Ω Max. 1 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DAFLKA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
When this failure code is active or left in the abnormality record, you cannot check whether the controller shuts down normally even if the system operating lamp is turned off.
Diagnosis and treatment YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
In this case, turn the starting switch to the OFF position. Wait for 8 minutes or more. Then turn the battery disconnect switch to the OFF position.
4
Ground fault in wiring harness
3.
Remove fuse No.16 in fuse box F01.
4.
Disconnect connector L19, L03, H16, CK01.
5.
Connect the T-adapter to the female side of one of the connectors.
6.
Measure the resistance.
7.
Does the measuring result meet the standard value for the connector? Item
NO
StandMeasurement position and condition ard value
Between F01-16, L19 (female) (1), ResistL03 (female) (2), H16 (female) (1), ance or CK01 (female) (15) and ground
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-533
FAILURE CODE [DAFLKA]
40 TROUBLESHOOTING
Circuit diagram associated with system operating lamp
E 30A
From battery
MM
(S-12)
Pump controller
BJ
System operating SIG
(Black) controller
(J-20) 16
AC95 (090-22)
17 18
7
19
20
20
Monitor panel
R24 1
L03 2
40-534
G0024195
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DAFLKB]
FAILURE CODE [DAFLKB] Details of failure
The machine monitor senses a short circuit because the voltage of the output circuit does not become low level while the machine monitor outputs current to the system operating lamp.
Action level
-
Action of controller
Phenomenon on machine
•
Stops to drive the system operating lamp.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
None in particular.
Reference information
Associated information
No.
•
Do not turn the battery disconnect switch to the OFF position while the system operating lamp is lit.
•
If the battery disconnect switch is turned to the OFF position while the system operating lamp is lit, the memory data stored in each controller will possibly be destroyed.
•
The system operating lamp cannot be lit from the machine monitor.
•
Although the system operating lamp cannot be lit from the machine monitor, no trouble will result unless the battery disconnect switch is turned to the OFF position.
•
When the system operating lamp is lit, the output voltage is at low level.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-535
FAILURE CODE [DAFLKB]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector L19.
3.
Connect the T-adapter to the female side of connector L19.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Between L19 (female) (2) and Voltage ground
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
Item
•
NO
Max. 1 V
YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-536
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DAFLKB]
Circuit diagram associated with system operating lamp
E 30A
From battery
MM
(S-12)
Pump controller
BJ
System operating SIG
(Black) controller
(J-20) 16
AC95 (090-22)
17 18
7
19
20
20
Monitor panel
R24 1
L03 2
PC210-10M0, PC210LC-10M0
G0024195
40-537
FAILURE CODE [DAFQKR]
40 TROUBLESHOOTING
FAILURE CODE [DAFQKR] Details of failure
The KOMTRAX terminal cannot recognize the machine monitor in the CAN2 communication line (KOMNET/c).
Action level
-
Action of controller
None in particular.
Phenomenon on machine
The system can possibly not operate correctly.
Reference information
Associated information
No.
•
The ACC signal from the starting switch tells the start of CAN communication to each controller.
•
The failure code is shown on the machine monitor by CAN communication. If CAN communication with the machine monitor fails, failure code [DAFQKR] is not shown on the machine monitor and it can be confirmed only through the KOMTRAX system.
•
One of the CAN2 termination resistors is located in the machine monitor on the cab side. The other is in connector K02 located on the engine side.
•
Since each controller and machine monitor are connected directly to the battery, they are supplied with power even when the starting switch is in the OFF position.
•
Since the signals passing an active CAN communication line are pulse voltages, they cannot be measured by using a multimeter.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-538
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DAFQKR]
Cause
Machine monitor power supply circuit
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM01.
4.
Connect the T-adapter to the female side of the connector.
5.
Turn the starting switch to the ON position.
6.
Measure the voltage.
7.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CM01 (female) (1) and (3)
20 to 30V
Between CM01 (female) (2) and (4)
20 to 30V
Voltage
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01.
4.
Disconnect connector CM01.
5.
Connect the T-adapter to the female side of the connector.
YES
•
The power supply circuit of the machine monitor is normal.
•
Go to inspection item of "ACC signal circuit of machine monitor".
•
The machine monitor power supply circuit is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
6.
3
Measure the resistance. Open circuit in 7. Does the measurement result agree with the wiring harness standard value? (Machine moniStandtor power supMeasuring point and measurement Item ard valply circuit) condition ue
Between F01-17 and CM01 (female) Max. 1 (1) Ω
NO
Between F01-17 and CM01 (female) Max. 1 Ω Resist- (2) ance Between CM01 (female) (3) and Max. 1 ground Ω Between CM01 (female) (4) and ground
PC210-10M0, PC210LC-10M0
Max. 1 Ω
40-539
FAILURE CODE [DAFQKR]
No.
4
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM01.
4.
Connect the T-adapter to the female side of the connector.
5. ACC signal cir- 6. cuit of machine 7. monitor
The ACC signal circuit of the machine monitor is normal.
•
Go to check item of "CAN TERMINATING RESISTOR".
•
The ACC signal circuit of the machine monitor is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage. Does the measurement result agree with the standard value?
Voltage
5
YES
•
Turn the starting switch to the ON position.
Item
Open circuit in wiring harness (ACC signal circuit of machine monitor)
Diagnosis and treatment
Measuring point and measurement condition
Standard value
Between CM01 (female) (10) and (3)
20 to 30V
Between CM01 (female) (13) and (4)
20 to 30V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.10 and 20 in fuse box F01.
4.
Disconnect connector CM01.
5.
Connect the T-adapter to the female side of the connector.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between F01-10 and CM01 (female) Max. 1 (10) Ω
NO
YES
NO
Between F01-20 and CM01 (female) Max. 1 Ω Resist- (20) ance Between CM01 (female) (3) and Max. 1 ground Ω Between CM01 (female) (4) and ground
40-540
Max. 1 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
FAILURE CODE [DAFQKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector K02.
3.
Connect the T-adapter to the male side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
CAN terminating resistor
Item
Resistance
7
Open circuit in wiring harness (CAN2 communication circuit)
Measuring point and measurement condition
Standard value
Between CM02 (male) (7) and (9)
120 ± 12 Ω
Between K02 (male) (A) and (B)
120 ± 12 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector K02.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CM02 (female) (7) and K02 (female) (A)
Max. 1 Ω
Resist- Between CM02 (female) (8) and ance K02 (female) (A)
Max. 1 Ω
Between CM02 (female) (9) and K02 (female) (B)
Max. 1 Ω
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
NO
YES
•
The CAN terminating resistor is normal.
•
Go to the next inspection item.
•
The CAN terminating resistor is defective.
•
Replace the CAN terminating resistor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-541
FAILURE CODE [DAFQKR]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
Ground fault in 6. wiring harness (CAN2 communication circuit)
YES
Does the measuring result meet the standard value for the connector? Item
Measuring point and measurement condition
CM02 (female) (8), CP01 (female) (45), CE02 (female) (46), AC01 (female) (2), N08 (female)(3), CK01 Resist- (female) (10), K02 (female) (A) ance CM02 (female) (9), CP01 (female) (64), CE02 (female) (47), AC01 (female) (1), N08 (female)(10), CK01 (female) (11), K02 (female) (A)
40-542
Diagnosis and treatment
Standard value Min. 1 MΩ
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DAFQKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of connector CM02, CP01, CE02, AC01, N08, CK01, K02.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
9
Measuring point and measurement condition
Min. 1 MΩ
Between CK01 (female) (11) and each pin other than (11)
Min. 1 MΩ
Between CP01 (female) (45) and each pin other than (45)
Min. 1 MΩ
Between CP01 (female) (64) and each pin other than (64)
Min. 1 MΩ
Between AC01 (female) (2) and each pin other than (2)
Min. 1 MΩ
Resist- Between AC01 (female) (1) and ance each pin other than (1)
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between CK01 (female) (10) and each pin other than (10)
Short circuit in wiring harness (CAN2 communication circuit)
Diagnosis and treatment
Between CE02 (female) (46) and each pin other than (46)
Min. 1 MΩ
Between CE02 (female) (47) and each pin other than (47)
Min. 1 MΩ
Between CM02 (female) (7) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (8) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (9) and each pin other than (9)
Min. 1 MΩ
NO
40-543
FAILURE CODE [DAFQKR]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector K02.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
Between K02 (A) and ground
Max. 1 to 4 V
Between K02 (B) and ground
Max. 1 to 4 V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed controller is normal.
•
Restore the removed controller.
•
Go to the next inspection item.
•
The removed controller is defective.
•
Replace the defective controller.
•
Go to "Confirmation of repair".
YES
Hot short circuit 5. Does the measurement result agree with the standard value? in wiring har10 ness (CAN2 StandMeasuring point and measurement communication Item ard valcondition circuit). ue
Voltage
Diagnosis and treatment
NO
YES
Disconnect one of the CAN communication connectors below. KOMTRAX terminal (connectorCK01), pump controller (connectorCP01), air conditioner controller (connectorAC01), engine controller (connectorCE02) REMARK Connector CM02 of the monitor controller is not disconnected. A terminating register is built in the connector. If the connector is disconnected, a CAN2 communication error occurs. You will not be able to troubleshoot.
11 Controller 4.
Turn the battery disconnect switch to the ON position.
5.
Turn the starting switch to the ON position.
6.
Does the number of shown failure codes decrease from 4?
7.
If the number does not decrease, change the connector to be disconnected. Do the steps again from 1.
NO
REMARK • If all of 4 failure codes, [D8AQKR], [DA2QKR], [DAZQKR], and [DB2QKR] are shown, disconnect the controller one by one and as explained in steps 1 to 6 to find the defective controller.
40-544
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DAFQKR]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
Reconfirmation 1. 12 of inspection 2. item
13
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with CAN2 communication
PC210-10M0, PC210LC-10M0
40-545
FAILURE CODE [DAFQKR]
40 TROUBLESHOOTING
Circuit diagram associated with monitor controller power supply
40-546
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DAZ9KQ]
FAILURE CODE [DAZ9KQ] Details of failure Action level
The air conditioner controller is not the model specified in the machine monitor program. (The replaced machine monitor or air conditioner controller has a wrong part number.) -
Action of controller Phenomenon on machine
The machine does not operate correctly.
Monitoring code
Associated information
•
The machine model code of the machine monitor program can be monitored. (Code: 00500)
•
The air conditioner control data of the machine monitor can be monitored. (Code: 55200)
•
The control data of the air conditioner controller can be monitored. (Code: 55201)
•
The state (ON or OFF) of the machine model selection signal can be monitored. (Code: 02201)
Machine Model Select 1: OFF Machine Model Select 2: OFF Machine Model Select 3: ON Machine Model Select 4: OFF Machine Model Select 5: OFF No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-547
FAILURE CODE [DAZ9KQ]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1. 2
Part number of machine moni- 2. tor 3.
Check the part number of the replaced machine monitor.
The machine monitor is correct.
•
Go to the next inspection item. The machine monitor is incorrect.
•
Check the correct part number check with the monitoring code 20227. Is the part number of machine monitor correct?
•
•
Replace the machine monitor with the correct one.
•
Go to "Confirmation of repair". The air conditioner controller is correct.
NO
• YES
3
1. Part number of air conditioner 2. controller
Check the part number of the replaced air conditioner controller. Is the part number of the air conditioner controller correct?
• •
Go to the next inspection item. The air conditioner controller is incorrect.
•
Replace it with the correct air conditioner controller.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
Confirmation of 5. repair 6.
40-548
Do the preceding troubleshooting again. NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the OFF position. Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code displayed in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DAZQKR]
FAILURE CODE [DAZQKR] Details of failure
The machine monitor cannot recognize the air conditioner controller in the CAN2 communication line (KOMNET/c).
Action level
L01
Action of controller
Keeps information when an error occurs.
Phenomenon on machine
•
The information from the engine controller is not shown. (Such as failure codes and monitoring codes sent from the engine controller)
•
The air conditioner cannot be operated. (No air comes out )
•
The air conditioner control screen of the machine monitor is not shown correctly.
Reference information •
The ACC signal from the starting switch tells the start of CAN communication to each controller.
•
4 different failure codes, [D8AQKR], [DA2QKR], [DAZQKR] and [DB2QKR] are used for defective CAN communications in CAN 2 when they are found by the machine monitor. If all of these failure codes are shown simultaneously, there can be a ground fault, short circuit, or hot short circuit in the wiring harness (CAN communication line).
Associated informaREMARK tion If the air conditioner is operable, there is no possibility of ground fault, short circuit, or hot short circuit occurred in the wiring harness (CAN communication line).
No.
•
One of the CAN2 termination resistors is located in the machine monitor on the cab side. The other is in connector K02 located on the engine side.
•
Since each controller and machine monitor are connected directly to the battery, they are supplied with power even when the starting switch is in the OFF position.
•
Since the signals passing an active CAN communication line are pulse voltages, they cannot be measured by using a multimeter.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-549
FAILURE CODE [DAZQKR]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector AC02.
3.
Connect the T-adapter to the female side of connector AC02.
4. ACC signal cir- 5. cuit for air con6. ditioner controller
Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
•
Go to check item of "CAN TERMINATING RESISTOR".
•
The ACC signal circuit of the air conditioner controller is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.10 in fuse box F01.
4.
Disconnect connector AC02.
5.
Connect the T-adapter to the female side of connector AC02.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Measuring point and measurement condition
•
Go to "Confirmation of repair".
Between F01-10 and AC02 (female) Resist- (4) ance Between AC02 (female) (1) and ground
NO
20 to 30V
1.
Item
40-550
The ACC signal circuit of the air conditioner controller is normal.
Measure the voltage.
Voltage Between AC02 (female) (4) and (1)
3
YES
•
Turn the starting switch to the ON position.
Item
Open circuit in wiring harness (ACC signal circuit of air conditioner controller)
Diagnosis and treatment
Standard value
YES
NO
Max. 1 Ω Max. 1 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [DAZQKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector K02.
3.
Connect the T-adapter to the male side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
CAN terminating resistor
Item
Resistance
5
Open circuit in wiring harness (CAN2 communication circuit)
Measuring point and measurement condition
Standard value
Between CM02 (male) (7) and (9)
120 ± 12 Ω
Between K02 (male) (A) and (B)
120 ± 12 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector AC01, connector CM02, and connector K02.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between AC01 (female) (2) and CM02 (female) (7)
Max. 1 Ω
Between AC01 (female) (2) and CM02 (female) (8)
Max. 1 Ω
Resist- Between AC01 (female) (1) and ance CM02 (female) (9)
Max. 1 Ω
Diagnosis and treatment YES
NO
YES
•
The CAN terminating resistor is normal.
•
Go to the next inspection item.
•
The CAN terminating resistor is defective.
•
Replace the CAN terminating resistor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Between AC01 (female) (2) and K02 Max. 1 (female) (A) Ω Between AC01 (female) (1) and K02 Max. 1 (female) (B) Ω
PC210-10M0, PC210LC-10M0
40-551
FAILURE CODE [DAZQKR]
No.
6
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
Ground fault in 6. wiring harness (CAN2 communication circuit)
YES
Does the measuring result meet the standard value for the connector? Item
Measuring point and measurement condition
CM02 (female) (8), CP01 (female) (45), CE02 (female) (46), AC01 (female) (2), N08 (female)(3), CK01 Resist- (female) (10), K02 (female) (A) ance CM02 (female) (9), CP01 (female) (64), CE02 (female) (47), AC01 (female) (1), N08 (female)(10), CK01 (female) (11), K02 (female) (A)
40-552
Diagnosis and treatment
Standard value Min. 1 MΩ
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DAZQKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of connector CM02, CP01, CE02, AC01, N08, CK01, K02.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
7
Measuring point and measurement condition
Min. 1 MΩ
Between CK01 (female) (11) and each pin other than (11)
Min. 1 MΩ
Between CP01 (female) (45) and each pin other than (45)
Min. 1 MΩ
Between CP01 (female) (64) and each pin other than (64)
Min. 1 MΩ
Between AC01 (female) (2) and each pin other than (2)
Min. 1 MΩ
Resist- Between AC01 (female) (1) and ance each pin other than (1)
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between CK01 (female) (10) and each pin other than (10)
Short circuit in wiring harness (CAN2 communication circuit)
Diagnosis and treatment
Between CE02 (female) (46) and each pin other than (46)
Min. 1 MΩ
Between CE02 (female) (47) and each pin other than (47)
Min. 1 MΩ
Between CM02 (female) (7) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (8) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (9) and each pin other than (9)
Min. 1 MΩ
NO
40-553
FAILURE CODE [DAZQKR]
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector K02.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
Between K02 (A) and ground
Max. 1 to 4 V
Between K02 (B) and ground
Max. 1 to 4 V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed controller is defective.
•
Replace the defective controller.
•
Go to "Confirmation of repair".
•
The removed controller is normal.
•
Restore the removed controller.
•
Go to the next inspection item.
YES
Hot short circuit 5. Does the measurement result agree with the standard value? in wiring harness (CAN2 StandMeasuring point and measurement communication Item ard valcondition circuit). ue
Voltage
Diagnosis and treatment
NO
YES
Disconnect one of the CAN communication connectors below. KOMTRAX terminal (connectorCK01), pump controller (connectorCP01), air conditioner controller (connectorAC01), engine controller (connectorCE02) REMARK
9
Connector CM02 of the monitor controller is not disconnected. A terminating register is built in the connector. If the connector is disconnected, a CAN2 communication error occurs. You will not be able to troubleshoot.
Controller 4.
Turn the battery disconnect switch to the ON position.
5.
Turn the starting switch to the ON position.
6.
Does the number of shown failure codes decrease from 4?
7.
If the number does not decrease, change the connector to be disconnected. Do the steps again from 1.
NO
REMARK • If all of 4 failure codes, [D8AQKR], [DA2QKR], [DAZQKR], and [DB2QKR] are shown, disconnect the controller one by one and as explained in steps 1 to 6 to find the defective controller.
40-554
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DAZQKR]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
Reconfirmation 1. 10 of inspection 2. item
11
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with CAN2 communication
PC210-10M0, PC210LC-10M0
40-555
FAILURE CODE [DAZQKR]
40 TROUBLESHOOTING
Circuit diagram associated with air conditioner controller power supply
unit
J03 (Green) 3
AC95 5
4 5 6
10C
10
20F
20
GC
7 FM LG
8
R21 1
C P 0 1 24
9
C P 0 1 43
10
C P 0 1 80 N08 2 MA
C M 0 1 10 C M 0 1 13
T07
G0024194
40-556
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DB2QKR]
FAILURE CODE [DB2QKR] Details of failure
The machine monitor cannot recognize the engine controller on the CAN2 communication line (KOMNET/c).
Action level
L03
Action of controller
Keeps information when an error occurs.
Phenomenon on machine
The information from the engine controller are not shown. Special functions do not operate. Received data do not update. (Such as failure codes and monitoring codes sent from the engine controller) Reference information •
The ACC signal from the starting switch tells the start of CAN communication to each controller.
•
4 different failure codes, [D8AQKR], [DA2QKR], [DAZQKR] and [DB2QKR] are used for defective CAN communications in CAN 2 when they are found by the machine monitor. If all of these failure codes are shown simultaneously, there can be a ground fault, short circuit, or hot short circuit in the wiring harness (CAN communication line).
Associated informaREMARK tion If the air conditioner is operable, there is no possibility of ground fault, short circuit, or hot short circuit occurred in the wiring harness (CAN communication line).
No.
•
One of the CAN2 termination resistors is located in the machine monitor on the cab side. The other is in connector K02 located on the engine side.
•
Since each controller and machine monitor are connected directly to the battery, they are supplied with power even when the starting switch is in the OFF position.
•
Since the signals passing an active CAN communication line are pulse voltages, they cannot be measured by using a multimeter.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-557
FAILURE CODE [DB2QKR]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE03.
4.
Connect the T-adapter to the female side of the connector.
Engine control- 5. ler power sup- 6. ply circuit 7.
Measure the voltage. Does the measurement result agree with the standard value? Measuring point and measurement condition
Voltage Between CE03 (female) (3) and (1)
3
YES
•
The power supply circuit of the engine controller is normal.
•
Go to inspection item of "ACC signal circuit of engine controller".
•
The engine controller power supply circuit is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Turn the starting switch to the ON position.
Item
Open circuit in wiring harness (power supply circuit of engine controller)
Diagnosis and treatment
Standard value 20 to 30V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.19 in fuse box F01.
4.
Disconnect connector CE03.
5.
Connect the T-adapter to the female side of connector CE03.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
NO
Standard value
Between F01-19 and R23 (female) (3)
Max. 1 Ω
Between F01-19 and R24 (female) (3)
Max. 1 Ω
YES
NO
Resist- Between R23 (female) (5) and CE03 Max. 1 Ω ance (female) (2) Between R24 (female) (4) and CE03 Max. 1 (female) (2) Ω Between CE03 (female) (1) and ground
40-558
Max. 1 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [DB2QKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02.
4.
Connect the T-adapter to the female side of connector CE02.
5. ACC signal circuit of engine 6. controller 7.
Turn the battery disconnect switch to the ON position.
8.
Measure the voltage. Does the measurement result agree with the standard value?
Voltage
5
YES
Turn the starting switch to the ON position.
Item
Measuring point and measurement condition Between CE02 (female) (39) and (33)
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.20 in fuse box F01.
4.
Disconnect connector CE02.
YES
Measure the resistance. Does the measurement result agree with the standard value?
Between F01-20 and CE02 (female) Resist- (39) ance Between CE02 (female) (33) and ground
PC210-10M0, PC210LC-10M0
•
Go to check item of "CAN TERMINATING RESISTOR".
•
The ACC signal circuit of the engine controller is defective.
•
Go to the next inspection item.
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Connect the T-adapter to the female side of connector CE02.
Measuring point and measurement condition
The ACC signal circuit of the engine controller is normal.
20 to 30V
Turn the starting switch to the OFF position.
Item
•
Standard value
1.
5. Open circuit in wiring harness 6. (ACC signal 7. circuit of engine controller)
Diagnosis and treatment
Standard value
NO
Max. 1 Ω Max. 1 Ω
40-559
FAILURE CODE [DB2QKR]
No.
6
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02 and connector K02.
3.
Connect the T-adapter to the male side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
CAN terminating resistor
Item
Resistance
7
Open circuit in wiring harness (CAN2 communication circuit)
40-560
Measuring point and measurement condition
Standard value
Between CM02 (male) (7) and (9)
120 ± 12 Ω
Between K02 (male) (A) and (B)
120 ± 12 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CE02, connector CM02, and connector K02.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measuring result meet the standard value for the connector? Item
Measuring point and measurement condition
Standard value
Between CE02 (female) (46) and CM02 (female) (7)
Max. 1 Ω
Between CE02 (female) (46) and CM02 (female) (8)
Max. 1 Ω
Resist- Between CE02 (female) (47) and ance CM02 (female) (9)
Max. 1 Ω
Between CE02 (female) (46) and K02 (female) (A)
Max. 1 Ω
Between CE02 (female) (47) and K02 (female) (B)
Max. 1 Ω
Diagnosis and treatment YES
NO
YES
•
The CAN terminating resistor is normal.
•
Go to the next inspection item.
•
The CAN terminating resistor is defective.
•
Replace the CAN terminating resistor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
8
FAILURE CODE [DB2QKR]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
Ground fault in 6. wiring harness (CAN2 communication circuit)
Diagnosis and treatment YES
Does the measuring result meet the standard value for the connector? Item
Measuring point and measurement condition
CM02 (female) (8), CP01 (female) (45), CE02 (female) (46), AC01 (female) (2), N08 (female)(3), CK01 Resist- (female) (10), K02 (female) (A) ance CM02 (female) (9), CP01 (female) (64), CE02 (female) (47), AC01 (female) (1), N08 (female)(10), CK01 (female) (11), K02 (female) (A)
PC210-10M0, PC210LC-10M0
Standard value Min. 1 MΩ
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
40-561
FAILURE CODE [DB2QKR]
No.
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CM02, CP01, CE02, AC01, N08, CK01, K02.
4.
Connect the T-adapter to the female side of connector CM02, CP01, CE02, AC01, N08, CK01, K02.
5.
Measure the resistance.
6.
Does the measuring result meet the standard value for the connector? Item
9
Short circuit in wiring harness (CAN2 communication circuit)
40-562
40 TROUBLESHOOTING
Measuring point and measurement condition
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between CK01 (female) (10) and each pin other than (10)
Min. 1 MΩ
Between CK01 (female) (11) and each pin other than (11)
Min. 1 MΩ
Between CP01 (female) (45) and each pin other than (45)
Min. 1 MΩ
Between CP01 (female) (64) and each pin other than (64)
Min. 1 MΩ
Between AC01 (female) (2) and each pin other than (2)
Min. 1 MΩ
Resist- Between AC01 (female) (1) and ance each pin other than (1)
Min. 1 MΩ
Between CE02 (female) (46) and each pin other than (46)
Min. 1 MΩ
Between CE02 (female) (47) and each pin other than (47)
Min. 1 MΩ
Between CM02 (female) (7) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (8) and each pin other than (7), or (8)
Min. 1 MΩ
Between CM02 (female) (9) and each pin other than (9)
Min. 1 MΩ
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DB2QKR]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector K02.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
Between K02 (A) and ground
Max. 1 to 4 V
Between K02 (B) and ground
Max. 1 to 4 V
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The removed controller is defective.
•
Replace the defective controller.
•
Go to "Confirmation of repair".
•
The removed controller is normal.
•
Restore the removed controller.
•
Go to the next inspection item.
YES
Hot short circuit 5. Does the measurement result agree with the standard value? in wiring har10 ness (CAN2 StandMeasuring point and measurement communication Item ard valcondition circuit). ue
Voltage
Diagnosis and treatment
NO
YES
Disconnect one of the CAN communication connectors below. KOMTRAX terminal (connectorCK01), pump controller (connectorCP01), air conditioner controller (connectorAC01), engine controller (connectorCE02) REMARK Connector CM02 of the monitor controller is not disconnected. A terminating register is built in the connector. If the connector is disconnected, a CAN2 communication error occurs. You will not be able to troubleshoot.
11 Controller 4.
Turn the battery disconnect switch to the ON position.
5.
Turn the starting switch to the ON position.
6.
Does the number of shown failure codes decrease from 4?
7.
If the number does not decrease, change the connector to be disconnected. Do the steps again from 1.
NO
REMARK • If all of 4 failure codes, [D8AQKR], [DA2QKR], [DAZQKR], and [DB2QKR] are shown, disconnect the controller one by one and as explained in steps 1 to 6 to find the defective controller.
PC210-10M0, PC210LC-10M0
40-563
FAILURE CODE [DB2QKR]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
Reconfirmation 1. 12 of inspection 2. item
13
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with CAN2 communication
40-564
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DB2QKR]
Circuit diagram associated with engine controller power supply
CE02
CE03 Power (+24V)
Starter B
3
L19 2 J 0 5 16
AC
AC95 8 HK Relay for CM850 (1)
Monitor panel
1 2
15A
3 Relay for CM850 (2)
HJ
4 5 6 T06
S01
CP02
G0024214
PC210-10M0, PC210LC-10M0
40-565
FAILURE CODE [DDPAKA]
40 TROUBLESHOOTING
FAILURE CODE [DDPAKA] Details of failure
When the machine is not in a breaker work in B mode, an open circuit of the clogging switch for additional hydraulic oil filter or open switch contacts is sensed.
Action level
L01
Action of controller
If the phenomenon of the failure no longer exists, the machine becomes normal by itself.
Phenomenon on machine
If the machine is used as it is, the detection function for a clogged additional hydraulic oil filter does not operate. Monitoring code
The input state (ON/OFF) from the clogging switch of the additional hydraulic oil filter can Associated informabe monitored. (Code: 02203) tion Reference information This failure code shows a failure only when the working mode is set in B mode. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The hydraulic oil additional filter element is normal.
NO
• YES •
2
Hydraulic oil additional filter element
1.
Visually check the hydraulic oil additional filter element.
2.
Is the hydraulic oil additional filter element normal?
•
NO
40-566
Go to the next inspection item. The hydraulic oil additional filter element is defective.
•
Replace the hydraulic oil additional filter element.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DDPAKA]
Cause
Clogging switch for hydraulic oil additional filter
Procedures, Measurement, Values, Note
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P68. Connect the T-adapter to the male side to troubleshoot.
3.
Item
Measuring point and measurement condition
Standard value Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01, P68 CP01 and P68. Connect the T-adapter to each female side to troubleshoot.
3.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Measuring point and measurement condition
Between CP01 (female) (17) and Resist- P68 (female) (1) ance Between P68 (female) (2) and ground
Standard value
•
The clogging switch for the hydraulic oil additional filter is normal.
•
Go to the next inspection item. The clogging switch for the hydraulic oil additional filter is defective.
YES
Does the troubleshooting result agree with the standard value?
ResistBetween P68 (male) (1) and (2) ance
4
Diagnosis and treatment
•
NO
•
Replace the clogging switch for the hydraulic oil additional filter.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
• YES
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω Max. 1 Ω
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position to troubleshoot.
4.
Set the working mode to B mode.
5.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-567
FAILURE CODE [DDPAKA]
40 TROUBLESHOOTING
Circuit diagram associated with clogging switch for hydraulic oil additional filter
40-568
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DGH2KA]
FAILURE CODE [DGH2KA] Details of failure
The pump controller senses an open circuit in the hydraulic oil temperature sensor circuit.
Action level
L01
Action of controller
When the cause of failure no longer exists, the machine returns to normal. •
While the hydraulic oil temperature rises normally, the hydraulic oil temperature gauge does not move from the top end of the white range (bottom end of the green range).
•
The fan speed reaches maximum speed.
Phenomenon on machine
Monitoring code Associated informaThe signal voltage of the hydraulic oil temperature sensor can be monitored. (Code: tion 04402) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-569
FAILURE CODE [DGH2KA]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P22.
3.
Connect the T-adapter to the male side of connector P22.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Hydraulic oil temperature sensor
Measuring point and measurement condition
Between P22 Resist(male) (2) and ance (1)
3
Open circuit in wiring harness
38.1 to 47.8 kΩ
30℃
31.0 to 40.0 kΩ
80℃
6.1 to 7.0 kΩ
90℃
4.6 to 5.2 kΩ
100℃
3.6 to 4.0 kΩ
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P22.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value?
Between CP01 (female) (28) and Resist- P22 (female) (2) ance Between CP01 (female) (46) and P22 (female) (1)
40-570
Standard value
25℃
Measuring point and measurement condition
•
The hydraulic oil temperature sensor is normal.
•
Go to the next inspection item.
•
The hydraulic oil temperature sensor is defective.
•
Replace the hydraulic oil temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
1.
Item
Diagnosis and treatment
Standard value Max. 1 Ω
NO
YES
NO
Max. 1 Ω
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
FAILURE CODE [DGH2KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P22.
3.
Connect the T-adapter to the female side of connector P22.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
Does the measurement result agree with the standard value? Measuring point and measurement condition
Voltage Between P22 (female) (2) and (1)
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
Item
•
Standard value
NO
4.5 to 5.5V
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Start the engine to troubleshoot.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with hydraulic oil temperature sensor
PC210-10M0, PC210LC-10M0
40-571
FAILURE CODE [DGH2KB]
40 TROUBLESHOOTING
FAILURE CODE [DGH2KB] Details of failure
The pump controller senses a ground fault in the hydraulic oil temperature sensor circuit.
Action level
L01
Action of controller
When the cause of failure no longer exists, the machine returns to normal.
Phenomenon on machine
•
The hydraulic oil temperature gauge shows approximately 50°C.
•
The fan speed reaches maximum speed.
Monitoring code Associated informaThe signal voltage of the hydraulic oil temperature sensor can be monitored. (Code: tion 04402) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-572
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DGH2KB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P22.
3.
Connect the T-adapter to the male side of connector P22.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
2
Measuring point and measurement condition
Hydraulic oil temperature sensor Between P22 (male) (2) and Resist- (1) ance
Between P22 (male) (2) and ground
3
Ground fault in wiring harness
38.1 to 47.8 kΩ
30℃
31.0 to 40.0 kΩ
80℃
6.1 to 7.0 kΩ
90℃
4.6 to 5.2 kΩ
100℃
3.6 to 4.0 kΩ
All
Min. 100 kΩ
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P22.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value?
Resist- Between CP01 (female) (28) or P22 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
The hydraulic oil temperature sensor is normal.
•
Go to the next inspection item.
•
The hydraulic oil temperature sensor is defective.
•
Replace the hydraulic oil temperature sensor.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Standard value
25℃
Measuring point and measurement condition
• YES
1.
Item
Diagnosis and treatment
Standard value
NO
YES
NO
Min. 1 MΩ
40-573
FAILURE CODE [DGH2KB]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector P22.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between CP01 (female) (28) and ance each pin other than (28)
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Standard value Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Start the engine.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with hydraulic oil temperature sensor
40-574
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DHA4KA]
FAILURE CODE [DHA4KA] Details of failure
The machine monitor senses a clogged air cleaner (sensor contacts "OPEN"), because the signal voltage of the air cleaner clogging switch is no longer 1 V or below when the start switch is turned to the ON position.
Action level
L01
Action of controller
Shows the air cleaner clogging monitor in yellow on the machine monitor.
Phenomenon on machine
If machine is used as it is, the engine can be damaged.
Associated informa- Monitoring code tion The input (ON or OFF) from air cleaner clogging switch can be monitored. (Code: 04501) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The air cleaner is normal.
NO
• YES
2
Air cleaner
1.
Check the air cleaner for clogging.
2.
Is the air cleaner normal?
• NO
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. The air cleaner is defective.
•
Clean or replace the air cleaner.
•
Go to "Confirmation of repair".
40-575
FAILURE CODE [DHA4KA]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P23.
3.
Connect the T-adapter to the female side of connector P23.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Air cleaner clogging switch
Item
4
YES
StandMeasurement position and condition ard value
Between P23 Resist(male) (1) and ance (2)
Filter normal
Max. 1 Ω
Filter clogged
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM02, connector P23.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Open circuit in wiring harness
Item
Diagnosis and treatment
StandMeasurement position and condition ard value
Between CM02 (female) (4) and Resist- P23 (female) (1) ance Between P23 (female) (2) and ground
NO
YES
•
The air cleaner clogging switch is normal.
•
Go to the next inspection item.
•
The air cleaner clogging switch is defective.
•
Replace the air cleaner clogging switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω Max. 1 Ω
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-576
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DHA4KA]
Circuit diagram associated with air cleaner clogging switch
PC210-10M0, PC210LC-10M0
40-577
FAILURE CODE [DHE5MA]
40 TROUBLESHOOTING
FAILURE CODE [DHE5MA] Details of failure
The signal voltage of the blowby pressure sensor circuit is 0.3 V or below or 4.74 V or above.
Action level
L00
Action of controller
Phenomenon on machine
•
Cannot recognize the blowby pressure.
•
If the phenomenon of the failure no longer exists, the machine becomes normal by itself.
None in particular.
Notice If the connection of the 5 V circuit (1) and ground circuit (3) of the blowby pressure sensor are inverted, the sensor will break. Take extreme care when checking. Associated informa- Monitoring code tion The blowby pressure can be monitored. (Code: 42830) Reference information As the T-adapter for the pump controller connector is a “socket-type box”, the operating voltage cannot be measured at the pump controller connector. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
40-578
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
3
FAILURE CODE [DHE5MA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and P57. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Ground fault in wiring harness
Item
Measuring point and measurement condition
Max. 1 Ω
Resist- Between CP01 (female) (55) and ance P57 (female) (3)
Max. 1 Ω
Between CP01 (female) (18) and P57 (female) (2)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and P57. Connect the T-adapter to the female side of one of the connectors.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Resist- Between ground and one of CP01 ance (female) (55) and P57 (female) (3)
4
Short circuit in wiring harness
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and P57. Connect the T-adapter to the female side of CP01.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Resist- Between CP01 (female) (55) and ance each pin other than pin (55)
PC210-10M0, PC210LC-10M0
Standard value Min. 1 MΩ
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
1.
Item
YES
Standard value
Between CP01 (female) (63) and P57 (female) (1)
Item
Diagnosis and treatment
YES
NO
40-579
FAILURE CODE [DHE5MA]
No.
5
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P57. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position to troubleshoot.
Hot short circuit 4. in wiring harness
Measuring point and measurement condition
Voltage Between P57 (female) (3) and (2)
Standard value
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P57.
3.
Turn the starting switch to the ON position.
4.
Does the troubleshooting result agree with the standard value?
Blowby pressure sensor
Item
Measuring point and measurement condition
Voltage Between P57 (2) and (1)
YES
Standard value
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The blowby pressure sensor is normal.
•
Go to the next inspection item.
•
The blowby pressure sensor is defective.
•
Replace the blowby pressure sensor.
•
Go to "Confirmation of repair".
NO
Max 1V
1.
• YES
Does the troubleshooting result agree with the standard value? Item
6
Diagnosis and treatment
NO
0.5 to 4.5 V
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-580
Do the troubleshooting above again.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DHE5MA]
Circuit diagram associated with blowby pressure sensor
A20 3
M16 5 AT
P47 1
AT
P67 A
Blow by P57 pressure ( F R A M AT O M E - 3 ) sensor
18 Blow by pressure sensor
55
PD
AS
63 SIG P08
3
XM
P02
3
XM
P03
3
P06
3
P05
3
P04
3
P25
3
P26
3
P07
3
P01
3
NE
AR
P27 A P28 A
ND NC NB DD DD NA
G0024219
PC210-10M0, PC210LC-10M0
40-581
FAILURE CODE [DHPAMA]
40 TROUBLESHOOTING
FAILURE CODE [DHPAMA] Details of failure
The signal voltage of the front pump pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the front pump pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The travel automatic transmission function does not operate.
•
Straight travel performance becomes low or it becomes hard to steer.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The front pump pressure can be monitored. (Code: 01100) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-582
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHPAMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P25.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P25 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (11) and ance P25 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P25 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P25.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (11) or P25 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-583
FAILURE CODE [DHPAMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P25.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P25.
3.
Connect the T-adapter to the female side of the connector.
4.
Turn the starting switch to the ON position.
6
StandMeasurement position and condition ard value
40-584
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The front pump pressure sensor is normal.
•
Go to the next inspection item.
•
The front pump pressure sensor is defective.
•
Replace the front pump pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P25.
3.
Turn the starting switch to the ON position.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P25 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P25 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
Front pump pressure sensor
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (11) and ance each pin other than (11)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHPAMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with front pump pressure sensor
PC210-10M0, PC210LC-10M0
40-585
FAILURE CODE [DHPBMA]
40 TROUBLESHOOTING
FAILURE CODE [DHPBMA] Details of failure
The signal voltage of the rear pump pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the rear pump pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The travel automatic transmission function does not operate.
•
Straight travel performance becomes low or it becomes hard to steer.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The rear pump pressure can be monitored. (Code: 01101) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-586
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHPBMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P26.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P26 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (30) and ance P26 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P26 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P26.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (30) or P26 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-587
FAILURE CODE [DHPBMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P26.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P26.
3.
Connect the T-adapter to the female side of connector P26.
4.
Turn the starting switch to the ON position.
6
StandMeasurement position and condition ard value
40-588
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The rear pump pressure sensor is normal.
•
Go to the next inspection item.
•
The rear pump pressure sensor is defective.
•
Replace the rear pump pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P26.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P26 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P26 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
Rear pump pressure sensor
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (30) and ance each pin other than (30)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHPBMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with rear pump pressure sensor
PC210-10M0, PC210LC-10M0
40-589
FAILURE CODE [DHS3MA]
40 TROUBLESHOOTING
FAILURE CODE [DHS3MA] Details of failure
The signal voltage of the arm IN PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the arm IN PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of arm IN.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The arm IN PPC pressure can be monitored. (Code: 07200) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-590
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHS3MA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P04.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P04 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (14) and ance P04 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P04 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P04.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (14) or P04 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-591
FAILURE CODE [DHS3MA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P04.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P04.
3.
Connect the T-adapter to the female side of connector P04.
4.
Turn the starting switch to the ON position.
Arm IN PPC pressure sensor
StandMeasurement position and condition ard value
40-592
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The arm IN PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The arm IN PPC pressure sensor is defective.
•
Replace the arm IN PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P04.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P04 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P04 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (14) and ance each pin other than (14)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHS3MA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with arm IN PPC pressure sensor
PC210-10M0, PC210LC-10M0
40-593
FAILURE CODE [DHS4MA]
40 TROUBLESHOOTING
FAILURE CODE [DHS4MA] Details of failure
The signal voltage of the bucket CURL PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the bucket CURL PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of bucket CURL.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The bucket CURL PPC pressure can be monitored. (Code: 07300) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-594
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHS4MA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P01.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P01 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (69) and ance P01 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P01 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P01.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (69) or P01 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-595
FAILURE CODE [DHS4MA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P01.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P01.
3.
Connect the T-adapter to the female side of connector P01.
4.
Turn the starting switch to the ON position.
Bucket CURL PPC pressure sensor
StandMeasurement position and condition ard value
40-596
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The bucket CURL PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The bucket CURL PPC pressure sensor is defective.
•
Replace the bucket CURL PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P01.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P01 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P01 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (69) and ance each pin other than (69)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHS4MA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with bucket CURL PPC pressure sensor
PC210-10M0, PC210LC-10M0
40-597
FAILURE CODE [DHS8MA]
40 TROUBLESHOOTING
FAILURE CODE [DHS8MA] Details of failure
The signal voltage of the boom RAISE PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the boom RAISE PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of boom RAISE.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The boom RAISE PPC pressure can be monitored. (Code: 07400) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-598
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHS8MA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P06.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P06 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (32) and ance P06 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P06 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P06.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (32) or P06 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-599
FAILURE CODE [DHS8MA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P06.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P06.
3.
Connect the T-adapter to the female side of the connector.
4.
Turn the starting switch to the ON position.
Boom RAISE PPC pressure sensor
StandMeasurement position and condition ard value
40-600
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The boom RAISE PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The boom RAISE PPC pressure sensor is defective.
•
Replace the boom RAISE PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P06.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P06 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P06 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (32) and ance each pin other than (32)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHS8MA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with boom RAISE PPC pressure sensor
PC210-10M0, PC210LC-10M0
40-601
FAILURE CODE [DHS9MA]
40 TROUBLESHOOTING
FAILURE CODE [DHS9MA] Details of failure
The signal voltage of the boom LOWER PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the boom LOWER PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of boom LOWER.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The boom LOWER PPC pressure can be monitored. (Code: 07500) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-602
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHS9MA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P02.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P02 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (13) and ance P02 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P02 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P02.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (13) or P02 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-603
FAILURE CODE [DHS9MA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P02.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P02.
3.
Connect the T-adapter to the female side of connector P02.
4.
Turn the starting switch to the ON position.
Boom LOWER PPC pressure sensor
StandMeasurement position and condition ard value
40-604
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The boom LOWER PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The boom LOWER PPC pressure sensor is defective.
•
Replace the boom LOWER PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P02.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P02 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P02 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (13) and ance each pin other than (13)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHS9MA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with boom LOWER PPC pressure sensor
PC210-10M0, PC210LC-10M0
40-605
FAILURE CODE [DHSAMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSAMA] Details of failure
The signal voltage of the swing RIGHT PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the swing RIGHT PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of swing RIGHT.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The swing right PPC pressure can be monitored. (Code: 09002) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-606
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSAMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P07.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P07 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (12) and ance P07 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P07 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P07.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (12) or P07 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-607
FAILURE CODE [DHSAMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P07.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P07.
3.
Connect the T-adapter to the female side of connector P07.
4.
Turn the starting switch to the ON position.
Swing RIGHT PPC pressure sensor
StandMeasurement position and condition ard value
40-608
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The swing RIGHT PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The swing RIGHT PPC pressure sensor is defective.
•
Replace the swing RIGHT PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P07.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P07 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P07 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (12) and ance each pin other than (12)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSAMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with swing RIGHT PPC pressure sensor
PC210-10M0, PC210LC-10M0
40-609
FAILURE CODE [DHSBMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSBMA] Details of failure
The signal voltage of the swing LEFT PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the swing LEFT PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of swing LEFT.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The swing left PPC pressure can be monitored. (Code: 09901) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-610
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSBMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P03.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P03 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (31) and ance P03 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P03 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P03.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (31) or P03 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-611
FAILURE CODE [DHSBMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P03.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P03.
3.
Connect the T-adapter to the female side of connector P03.
4.
Turn the starting switch to the ON position.
Swing LEFT PPC pressure sensor
StandMeasurement position and condition ard value
40-612
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The swing LEFT PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The swing LEFT PPC pressure sensor is defective.
•
Replace the swing LEFT PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P03.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P03 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P03 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (31) and ance each pin other than (31)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSBMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with swing LEFT PPC pressure sensor
PC210-10M0, PC210LC-10M0
40-613
FAILURE CODE [DHSCMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSCMA] Details of failure
The signal voltage of the arm OUT PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the arm OUT PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of arm OUT.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The arm OUT PPC pressure can be monitored. (Code: 07600) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-614
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSCMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P08.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P08 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (51) and ance P08 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P08 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P08.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (51) or P08 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-615
FAILURE CODE [DHSCMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P08.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P08.
3.
Connect the T-adapter to the female side of connector P08.
4.
Turn the starting switch to the ON position.
Arm OUT PPC pressure sensor
StandMeasurement position and condition ard value
40-616
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The arm OUT PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The arm OUT PPC pressure sensor is defective.
•
Replace the arm OUT PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P08.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P08 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P08 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (51) and ance each pin other than (51)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSCMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with arm OUT PPC pressure sensor Pump ontroller
CP01 (AMP-81) Output
63
P57 AR
PD
XM
AS
NE
AR
ND NC
P47 A67 A20
AT
NB
AT
DD
G0024191
PC210-10M0, PC210LC-10M0
40-617
FAILURE CODE [DHSDMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSDMA] Details of failure
The signal voltage of the bucket DUMP PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller Phenomenon on machine
•
Controls the machine by regarding the bucket DUMP PPC pressure as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of bucket DUMP.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The bucket DUMP PPC pressure can be monitored. (Code: 07301) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-618
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSDMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P05.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P05 (female) (3)
Max. 1 Ω
Resist- Between CP01 (female) (50) and ance P05 (female) (2)
Max. 1 Ω
Between CP01 (female) (18) and P05 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P05.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (50) or P05 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-619
FAILURE CODE [DHSDMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P05.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector P05.
4.
Connect the T-adapter to the female side of connector P05.
Does the measurement result agree with the standard value?
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The bucket DUMP PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The bucket DUMP PPC pressure sensor is defective.
•
Replace the bucket DUMP PPC pressure sensor.
•
Go to "Confirmation of repair".
YES
NO
StandMeasurement position and condition ard value Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P05.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value? Item
YES
StandMeasurement position and condition ard value
Voltage Between P05 (2) and (1)
40-620
•
Measure the voltage.
Voltage Between P05 (female) (2) and (1)
Bucket DUMP PPC pressure sensor
The wiring harness has no short circuits.
NO
Turn the starting switch to the ON position.
Item
6
•
Min. 1 MΩ
1.
Hot short circuit 5. in wiring har6. ness 7.
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (50) and ance each pin other than (50)
5
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSDMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with bucket DUMP PPC pressure sensor Pump controller
18 50
Output
63
PD XM NE ND NC
NB DD
M16 5 P57 AR
P47 P67 A20
PD
DD
AS
NA
AS
AT AT
XM G0024189
PC210-10M0, PC210LC-10M0
40-621
FAILURE CODE [DHSFMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSFMA] Details of failure
The signal voltage of the travel forward left PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01 •
Controls the machine by regarding the travel forward left PPC pressure sensor as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of travel.
Action of controller
Phenomenon on machine
Notice If the connection of the 5V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA25KP] is also shown, do the troubleshooting for this code first. Monitoring code The Travel Forward Left PPC pressure can be monitored. (Code: 07102) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-622
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSFMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P09.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value Between CP01 (female) (6) and P09 (female) (3)
3
Ground fault in wiring harness
Max. 1 Ω
Between CP01 (female) (18) and P09 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P09.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP01 (female) (34) or P09 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
Resist- Between CP01 (female) (34) and ance P09 (female) (2)
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
40-623
FAILURE CODE [DHSFMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P09.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P09.
3.
Connect the T-adapter to the female side of connector P09.
4.
Turn the starting switch to the ON position.
Travel forward left PPC pressure sensor
StandMeasurement position and condition ard value
40-624
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The travel forward left PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The travel forward left PPC pressure sensor is defective.
•
Replace the travel forward left PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P09.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P09 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P09 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (34) and ance each pin other than (34)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSFMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with travel PPC pressure sensor
XR
Pump controller
XT
XS
XU
XS
XU
G0024192
PC210-10M0, PC210LC-10M0
40-625
FAILURE CODE [DHSGMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSGMA] Details of failure
The signal voltage of the travel forward right PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01 •
Controls the machine by regarding the travel forward right PPC pressure sensor as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of travel.
Action of controller
Phenomenon on machine
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA25KP] is also shown, do the troubleshooting for this code first. Monitoring code The Travel Forward Right PPC pressure can be monitored. (Code: 07103) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-626
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSGMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P11.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value Between CP01 (female) (6) and P11 (female) (3)
3
Ground fault in wiring harness
Max. 1 Ω
Between CP01 (female) (18) and P11 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P11.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP01 (female) (72) or P11 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
Resist- Between CP01 (female) (72) and ance P11 (female) (2)
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
40-627
FAILURE CODE [DHSGMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P11.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P11.
3.
Connect the T-adapter to the female side of connector P11.
4.
Turn the starting switch to the ON position. Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
2.
Insert the T-adapter into connector P11.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
40-628
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The travel forward right PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The travel forward right PPC pressure sensor is defective.
•
Replace the travel forward right PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
YES
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between P11 (2) and (1)
Go to the next inspection item.
Max. 1 V
Turn the starting switch to the OFF position.
Item
•
YES
1.
Travel forward 5. right PPC pressure sensor
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P11 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (72) and ance each pin other than (72)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSGMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with travel PPC pressure sensor
XR
Pump controller
XT
XS
XU
XS
XU
G0024192
PC210-10M0, PC210LC-10M0
40-629
FAILURE CODE [DHSHMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSHMA] Details of failure
The signal voltage of the travel reverse left PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01 •
Controls the machine by regarding the travel reverse left PPC pressure sensor as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of travel.
Action of controller
Phenomenon on machine
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA25KP] is also shown, do the troubleshooting for this code first. Monitoring code The Travel Reverse Left PPC pressure can be monitored. (Code: 07104) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-630
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSHMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P10.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value Between CP01 (female) (6) and P10 (female) (3)
3
Ground fault in wiring harness
Max. 1 Ω
Between CP01 (female) (18) and P10 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P10.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP01 (female) (15) or P10 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
Resist- Between CP01 (female) (15) and ance P10 (female) (2)
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
40-631
FAILURE CODE [DHSHMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P10.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P10.
3.
Connect the T-adapter to the female side of the connector.
4.
Turn the starting switch to the ON position.
Travel reverse left PPC pressure sensor
StandMeasurement position and condition ard value
40-632
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The travel reverse left PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The travel reverse left PPC pressure sensor is defective.
•
Replace the travel reverse left PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P10.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P10 (2) and (1)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P10 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (15) and ance each pin other than (15)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSHMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with travel PPC pressure sensor
XR
Pump controller
XT
XS
XU
XS
XU
G0024192
PC210-10M0, PC210LC-10M0
40-633
FAILURE CODE [DHSJMA]
40 TROUBLESHOOTING
FAILURE CODE [DHSJMA] Details of failure
The signal voltage of the travel reverse right PPC pressure sensor circuit becomes 0.3 V or below or 4.5 V and above.
Action level
L01 •
Controls the machine by regarding the travel reverse right PPC pressure sensor as 0 MPa.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The auto-deceleration function cannot be canceled.
•
Degraded operability of travel.
Action of controller
Phenomenon on machine
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the pressure sensor are inverted, the pressure sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA25KP] is also shown, do the troubleshooting for this code first. Monitoring code The Travel Reverse Right PPC pressure can be monitored. (Code: 07105) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
40-634
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DHSJMA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P12.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value Between CP01 (female) (6) and P12 (female) (3)
3
Ground fault in wiring harness
Max. 1 Ω
Between CP01 (female) (18) and P12 (female) (1)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P12.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP01 (female) (53) or P12 ance (female) (2) and ground
PC210-10M0, PC210LC-10M0
YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
Resist- Between CP01 (female) (53) and ance P12 (female) (2)
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
40-635
FAILURE CODE [DHSJMA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P12.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P12.
3.
Connect the T-adapter to the female side of connector P12.
4.
Turn the starting switch to the ON position. Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
2.
Insert the T-adapter into connector P12.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
40-636
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The travel reverse right PPC pressure sensor is normal.
•
Go to the next inspection item.
•
The travel reverse right PPC pressure sensor is defective.
•
Replace the travel reverse right PPC pressure sensor.
•
Go to "Confirmation of repair".
NO
YES
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between P12 (2) and (1)
Go to the next inspection item.
Max. 1 V
Turn the starting switch to the OFF position.
Item
•
YES
1.
Travel reverse 5. right PPC pressure sensor
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P12 (female) (2) and (1)
•
Min. 1 MΩ
1.
Item
6
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (53) and ance each pin other than (53)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DHSJMA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with travel PPC pressure sensor
XR
Pump controller
XT
XS
XU
XS
XU
G0024192
PC210-10M0, PC210LC-10M0
40-637
FAILURE CODE [DJG1KX]
40 TROUBLESHOOTING
FAILURE CODE [DJG1KX] Details of failure
The voltage of the signal circuit for the water sensor in the fuel prefilter is 0.3 V or below or 4.7 V or above.
Action level
L01
Action of controller
None in particular.
Phenomenon on machine
The water separator monitor does not operate normally.
Associated information No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P47.
3.
Connect the T-adapter to the female side of connector P47.
4.
Measure the resistance to troubleshoot.
5. Water sensor for fuel prefilter
Measuring point and measurement condition
ResistBetween P47 (female) (1) and (2) ance
40-638
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The water sensor for the fuel prefilter is normal.
NO
• YES
Does the troubleshooting result agree with the standard value? Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
Standard value 10 to 100 kΩ
NO
•
Go to the next inspection item.
•
The water sensor for the fuel prefilter is defective.
•
Replace the water sensor for the fuel prefilter.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DJG1KX]
Cause
Dummy resistance
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector K05.
3.
Connect the T-adapter to the female side of connector K05.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
ResistBetween K05 (male) (1) and (2) ance
4
Open circuit in wiring harness
YES
Standard value
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, P47, K05.
4.
Connect the T-adapter to the female side of connector CP01 and the male side of connector CP01.
5.
Measure the resistance to troubleshoot.
6.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition Between CP01 (female) (63) and P47 (female) (1)
NO
•
The dummy resistance is normal.
•
Go to the next inspection item.
•
The dummy resistance is defective.
•
Replace the dummy resistance.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
50 to 70 kΩ
1.
Item
Diagnosis and treatment
Standard value Max. 10 Ω
YES
NO
Resist- Between CP01 (female) (9) and P47 Max. 10 ance (male) (2) Ω Between CP01 (female) (9) and K05 Max. 10 (female) (1) Ω
PC210-10M0, PC210LC-10M0
40-639
FAILURE CODE [DJG1KX]
No.
5
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, P47, K05.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between CP01 (female) (9) and ance each pin other than (9)
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Standard value Min. 1 MΩ
YES The repair is completed.
6
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Restore the machine. Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Delete the abnormality record of the electrical system.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
REMARK 7
For the operating method, see TESTING AND ADJUSTING, "SETTING AND OPERATION OF MACHINE MONITOR", "CHECK ABNORMALITY RECORD (ELECTRICAL SYSTEMS)".
Confirmation of repair
40-640
5.
Turn the starting switch to the OFF position.
6.
Shut down the engine controller. (See "PROCEDURE FOR TROUBLESHOOTING" in this chapter.)
7.
Turn the starting switch to the ON position.
8.
Check the abnormality record.
9.
Is this failure code shown in the record?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DJG1KX]
Circuit diagram associated with water sensor
XR
Pump controller
XT
XS
XU
XS
XU
G0024192
PC210-10M0, PC210LC-10M0
40-641
FAILURE CODE [DKR0MA]
40 TROUBLESHOOTING
FAILURE CODE [DKR0MA] Details of failure
The signal voltage of the front pump swash plate sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller
If the cause of the failure disappears, the machine becomes normal by itself.
Phenomenon on machine
The engine control function does not work to lower the low load matching speed.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the swash plate sensor are inverted, the swash plate sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The voltage from the front pump swash plate sensor can be monitored. (Code: 01138) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
40-642
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DKR0MA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P27.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P27 (female) (A)
Max. 1 Ω
Resist- Between CP01 (female) (49) and ance P27 (female) (C)
Max. 1 Ω
Between CP01 (female) (18) and P27 (female) (B)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P27.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (49) or P27 ance (female) (C) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-643
FAILURE CODE [DKR0MA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P27.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P27.
3.
Connect the T-adapter to the female side of connector P27.
4.
Turn the starting switch to the ON position.
6
StandMeasurement position and condition ard value
40-644
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The front pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The front pump swash plate sensor is defective.
•
Replace the front pump swash plate sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P27.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P27 (C) and (B)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P27 (female) (C) and (B)
•
Min. 1 MΩ
1.
Item
Front pump swash plate sensor
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (49) and ance each pin other than (49)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DKR0MA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with front and rear pump swash plate sensor
P57
F pump cradle sensor
AS
PD
M16 5
R pump cradle sensor
PD
63
AT XM NE
P47 A20 P67 A
ND NC NB
DD NA
G0024190
PC210-10M0, PC210LC-10M0
40-645
FAILURE CODE [DKR1MA]
40 TROUBLESHOOTING
FAILURE CODE [DKR1MA] Details of failure
The signal voltage of the rear pump swash plate sensor circuit becomes 0.3 V or below or 4.5 V or above.
Action level
L01
Action of controller
If the cause of the failure disappears, the machine becomes normal by itself.
Phenomenon on machine
The engine control function does not work to lower the low load matching speed.
Notice If the connection of the 5 V circuit (3) and ground circuit (1) of the swash plate sensor are inverted, the swash plate sensor will break. Take extreme care when checking. Associated informaPre-troubleshooting tion If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Monitoring code The voltage from the rear pump swash plate sensor can be monitored. (Code: 01140) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
40-646
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DKR1MA]
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P28.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
3
Ground fault in wiring harness
StandMeasurement position and condition ard value Between CP01 (female) (63) and P28 (female) (A)
Max. 1 Ω
Resist- Between CP01 (female) (68) and ance P28 (female) (C)
Max. 1 Ω
Between CP01 (female) (18) and P28 (female) (B)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P28.
4.
Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (68) or P28 ance (female) (C) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
40-647
FAILURE CODE [DKR1MA]
No.
4
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector P28.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P28.
3.
Connect the T-adapter to the female side of connector P28.
4.
Turn the starting switch to the ON position.
6
StandMeasurement position and condition ard value
40-648
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The rear pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The rear pump swash plate sensor is defective.
•
Replace the rear pump swash plate sensor.
•
Go to "Confirmation of repair".
NO
Max. 1 V
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P28.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the measurement result agree with the standard value?
YES
StandMeasurement position and condition ard value
Voltage Between P28 (C) and (B)
•
YES
Does the measurement result agree with the standard value?
Item
The wiring harness has no short circuits.
NO
Measure the voltage.
Voltage Between P28 (female) (C) and (B)
•
Min. 1 MΩ
1.
Item
Rear pump swash plate sensor
YES
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (68) and ance each pin other than (68)
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
0.5 to 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DKR1MA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with front and rear pump swash plate sensor
P57
F pump cradle sensor
AS
PD
M16 5
R pump cradle sensor
PD
63
AT XM NE
P47 A20 P67 A
ND NC NB
DD NA
G0024190
PC210-10M0, PC210LC-10M0
40-649
FAILURE CODE [DKR2MA]
40 TROUBLESHOOTING
FAILURE CODE [DKR2MA] Details of failure
The signal voltage of the stroke sensor 1 circuit of the return filter bypass valve is 0.3 V or below or 4.5 V or above.
Action level
-
Action of controller
None in particular
Phenomenon on machine
If the machine is used as is, the hydraulic components can be damaged.
Pre-troubleshooting If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Associated informaMonitoring code tion • The return filter pressure can be monitored. (Code: 97000) • No.
The voltage of the return filter pressure sensor can be monitored. (Code: 97001)
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Open circuit in wiring harness
40-650
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, P67. Connect the Tadapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
•
Max. 1 Ω
Resist- Between CP01 (female) (63) and ance P67 (female) (A)
Max. 1 Ω
Between CP01 (female) (74) and P67 (female) (C)
Max. 1 Ω
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
• YES
StandMeasurement position and condition ard value Between CP01 (female) (18) and P67 (female) (B)
• NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DKR2MA]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, P67. Connect the Tadapter to one of the female sides.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (74) or P67 ance (female) (C) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, P67. Connect the Tadapter to the female side of CP01.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP01 (female) (74) and ance each pin other than (74)
5
Turn the starting switch to the OFF position.
2.
Disconnect connector P67. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position.
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
1.
4. Hot short circuit 5. in wiring harness
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
Measure the voltage. Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage Between P67 (female) (C) and (B)
PC210-10M0, PC210LC-10M0
Max. 1 V
NO
40-651
FAILURE CODE [DKR2MA]
No.
6
Cause
Stroke sensor 1 for return filter bypass valve
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector P67.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the troubleshooting result agree with the standard value? Item
•
The stroke sensor 1 for the return filter bypass valve is normal.
•
Go to the next inspection item. The stroke sensor 1 for the return filter bypass valve is defective.
YES
StandMeasurement position and condition ard value
Voltage Between P67 (C) and (B)
Diagnosis and treatment
•
NO
0.5 to 4.8 V
•
Replace the stroke sensor 1 for the return filter bypass valve.
•
Go to "Confirmation of repair".
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-652
Do the troubleshooting above again.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DKR2MA]
Circuit diagram associated with stroke sensor 1 for return filter bypass valve
PC210-10M0, PC210LC-10M0
40-653
FAILURE CODE [DKR2NX]
40 TROUBLESHOOTING
FAILURE CODE [DKR2NX] Details of failure
The pump controller senses a clogged return filter.
Action level
-
Action of controller
None in particular
Phenomenon on machine
If the machine is used as is, the hydraulic components can be damaged.
Pre-troubleshooting If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Associated informaMonitoring code tion • The return filter pressure can be monitored. (Code: 97000) • No.
Cause
The voltage of the return filter pressure sensor can be monitored. (Code: 97001) Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The return filter is normal.
NO
• YES
2
Return filter
1.
Check if the return filter is clogged.
2.
Is the return filter normal?
• •
NO
•
Clean or replace the return filter.
•
Go to "Confirmation of repair". The return filter bypass valve is normal.
• YES
3
Return filter by- 1. pass valve 2.
Is the return filter bypass valve normal? NO
40-654
• •
Check the return filter bypass valve.
Go to the next inspection item. The return filter is defective.
Go to the next inspection item. The return filter bypass valve is defective.
•
Replace the return filter bypass valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DKR2NX]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3.
Start the engine.
Confirmation of 4. repair 5.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Set the fuel control dial to Hi. Increase the oil temperature to 50 ° C or higher.
6.
Operate the work equipment relief approximately 15 times to troubleshoot.
7.
Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with stroke sensor 1 for return filter bypass valve
PC210-10M0, PC210LC-10M0
40-655
FAILURE CODE [DLM5KA]
40 TROUBLESHOOTING
FAILURE CODE [DLM5KA] Details of failure
The pump controller senses an open circuit in the fan speed sensor circuit.
Action level
L01
Action of controller
None in particular.
Phenomenon on machine
The fan speed control does not operate correctly. The fan speed becomes the maximum speed allowed by the engine speed. Pre-troubleshooting
Associated informa- If failure code [DA26KP] is also shown, do the troubleshooting for this code first. tion Monitoring code The input speed from fan speed sensor can be monitored. (Code: 10007) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Open circuit in wiring harness
40-656
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, M16. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
•
Max. 1 Ω
Resist- Between CP01 (female) (38) and ance M16 (female) (1)
Max. 1 Ω
Between CP01 (female) (44) and M16 (female) (2)
Max. 1 Ω
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
• YES
Standard value
Between CP01 (female) (63) and M16 (female) (5)
• NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DLM5KA]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, M16. Connect the T-adapter to one of the female sides.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between CP01 (female) (38) or M16 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, M16. Connect the T-adapter to the female side of CP01.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Resist- Between CP01 (female) (38) and ance each pin other than (38)
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connector M16. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position.
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
Min. 1 MΩ
1.
4. Hot short circuit 5. in wiring harness
YES
Min. 1 MΩ
1.
Item
5
Standard value
Diagnosis and treatment
YES
Measure the voltage. Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Voltage Between M16 (female) (1) and (2)
PC210-10M0, PC210LC-10M0
Standard value 4.5 to 5.5V
NO
40-657
FAILURE CODE [DLM5KA]
No.
6
Cause
Fan speed sensor
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M16. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
ResistBetween M16 (male) (1) and (2) ance
Standard value
Diagnosis and treatment YES
NO
2 to 3 kΩ
•
The fan speed sensor is normal.
•
Go to the next inspection item.
•
The fan speed sensor is defective.
•
Replace the fan speed sensor.
•
Go to "Confirmation of repair".
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
1. 8
Confirmation of 2. repair 3. 4.
40-658
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
Turn the starting switch to the OFF position. Connect all the configuration equipment.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine to troubleshoot. Is this failure code shown?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DLM5KA]
Circuit diagram associated with fan clutch
PC210-10M0, PC210LC-10M0
40-659
FAILURE CODE [DLM5MB]
40 TROUBLESHOOTING
FAILURE CODE [DLM5MB] Details of failure
The pump controller senses the difference between the fan speed and the speed sensed by the fan speed sensor.
Action level
-
Action of controller
None in particular.
Phenomenon on machine
The fan speed control does not operate correctly. The fan speed becomes the maximum speed allowed by the engine speed. Pre-troubleshooting
If failure code [DA26KP] is also shown, do the troubleshooting for this code first. Associated informaMonitoring code tion • The fan speed instructed by the pump controller can be monitored. (Code: 10010) • No.
Cause
The fan speed can be monitored. (Code: 10007) Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
40-660
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DLM5MB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, M16. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
2
3
Open circuit in wiring harness
Ground fault in wiring harness
Measuring point and measurement condition Between CP01 (female) (63) and M16 (female) (5)
Max. 1 Ω
Between CP01 (female) (38) and M16 (female) (1)
Max. 1 Ω Max. 1 Ω
Resist- Between CP01 (female) (44) and ance M16 (female) (2)
Max. 1 Ω
Between CP02 (female) (115) and M16 (female) (3)
Max. 1 Ω
Between CP02 (female) (117) and M16 (female) (3)
Max. 1 Ω
Between CP02 (female) (120) and M16 (female) (3)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, M16. Connect the T-adapter to one of the female sides.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Between CP01 (female) (38) or M16 Resist- (female) (1) and ground ance Between CP02 (female) (99) or M16 (female) (4) and ground
PC210-10M0, PC210LC-10M0
YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between CP02 (female) (99) and M16 (female) (4)
Item
Diagnosis and treatment
Standard value Min. 1 MΩ Min. 1 MΩ
NO
YES
NO
40-661
FAILURE CODE [DLM5MB]
No.
4
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01, M16. Connect the T-adapter to the female side of CP01, CP02.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Short circuit in wiring harness
Item
Measuring point and measurement condition
Between CP01 (female) (38) and Resist- each pin other than (38) ance Between CP02 (female) (99) and each pin other than (99)
5
Hot short circuit in wiring harness
2.
Disconnect connector M16. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Fan clutch
Between M16 (female) (1) and (2)
Max 1 V
Between M16 (female) (4) and (3)
4.5 to 5.5V
Turn the starting switch to the OFF position.
2.
Disconnect connector M16. Connect the T-adapter to the male side.
3.
Measure the voltage.
4.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The fan clutch is normal.
•
Go to the next inspection item.
•
The fan clutch is defective.
•
Replace the fan clutch.
•
Go to "Confirmation of repair".
NO
YES
NO
YES
Standard value
Between M16 (male) (1) and (2)
2 to 3 kΩ
Voltage Between M16 (male) (3) and (4)
20 to 32 Ω
Between M16 (male) (4) and ground
40-662
Standard value
1.
Item
•
Min. 1 MΩ
Turn the starting switch to the OFF position.
Item
YES
Min. 1 MΩ
1.
Voltage
6
Standard value
Diagnosis and treatment
NO
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DLM5MB]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
1. 8
Confirmation of 2. repair 3. 4.
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
Turn the starting switch to the OFF position. Connect all the configuration equipment.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with fan clutch
PC210-10M0, PC210LC-10M0
40-663
FAILURE CODE [DR21KX]
40 TROUBLESHOOTING
FAILURE CODE [DR21KX] Details of failure
A voltage that is different from the output voltage of the machine monitor occurs in the camera 2 picture reverse output line (pin 6 of connector CM04).
Action level
L01
Action of controller
Camera 2 images are not shown.
Phenomenon on machine
Camera 2 images are not shown.
Reference information Associated informa- The camera 2 image will be normal when the image reverse output line (pin 6 of connection tor CM04) is 0 V. Mirror images will be shown when the line is 8 V. (The mirror image command is 8 V because the camera power supply is 8 V.) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Open circuit in wiring harness
40-664
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM04 and connector A40.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Standard value
Between CM04 (female) (1) and A40 (female) (1)
Max. 1 Ω
Resist- Between CM04 (female) (6) and ance A40 (female) (6)
Max. 1 Ω
Between CM04 (female) (4) and A40 (female) (4)
Max. 1 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
NO
• YES
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DR21KX]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CM04 and connector A40.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between CM04 (female) (6) or A40 ance (female) (6) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CM04 and connector A40.
3.
Connect the T-adapter to the female side of connector CM04.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Measuring point and measurement condition
Resist- Between CM04 (female) (6) and ance each pin other than (6)
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connector A40.
3.
Connect the T-adapter to the female side of connector A40.
4.
Turn the starting switch to the ON position.
YES
Does the measurement result agree with the standard value?
Voltage Between A40 (female) (6) and (4)
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
Measuring point and measurement condition
The wiring harness has no ground faults.
NO
Check that the camera 2 setting is normal image.
Item
•
NO
Min. 1 MΩ
1.
5. Hot short circuit 6. in wiring harness 7.
YES
Min. 1 MΩ
1.
Item
5
Standard value
Diagnosis and treatment
Standard value
NO
Max 1V
40-665
FAILURE CODE [DR21KX]
No.
6
Cause
Camera 2
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector A40.
3.
Replace the camera with the same model.
4.
Turn the starting switch to the ON position.
5.
Is this failure code shown?
Diagnosis and treatment •
The removed camera 2 is normal.
•
Install the removed camera 2 back to the initial position.
•
Go to the next inspection item. The removed camera 2 is defective.
YES
• NO
•
Go to "Confirmation of repair".
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-666
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DR31KX]
FAILURE CODE [DR31KX] Details of failure
-
Action level
-
Action of controller
-
Phenomenon on machine
-
Reference information Since this machine is not equipped with camera 3, this failure code is not shown. This Associated informafailure code is prepared as a spare in case camera 3 is equipped in the future. tion If this failure code is shown, follow the procedure in "Procedure for troubleshooting" to clear the failure code. No.
Cause
Procedures, Measurement, Values, Note
PC210-10M0, PC210LC-10M0
Diagnosis and treatment
40-667
FAILURE CODE [DV20KB]
40 TROUBLESHOOTING
FAILURE CODE [DV20KB] Details of failure
When the pump controller drives the travel alarm circuit, an abnormal current flows.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops to drive the travel alarm circuit.
•
Even if the cause of the failure is naturally resolved, the machine does not become normal until the starting switch is turned to the OFF position once.
The travel alarm does not sound.
Associated informa- tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Ground fault in wiring harness
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector M14.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (107) or ance M14 (female) (1) and ground
40-668
Min. 1 MΩ
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
NO
• YES
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DV20KB]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector M14.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (107) and ance each pin other than (107)
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector M14.
3.
Turn the starting switch to the ON position.
4.
Operate the travel lever to measure the voltage.
5.
Does the measurement result agree with the standard value?
Travel alarm Item
YES
YES
Do not go under the machine to measure when the machine travels. StandMeasurement position and condition ard value
Travel lever: Between M14 (1) NEUTRAL Voltage and (2) Travel lever: At
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The travel alarm is normal.
•
Go to the next inspection item.
•
The travel alarm is defective.
•
Replace the travel alarm.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
k
4
Diagnosis and treatment
NO
Max. 1 V
operation
20 to 30V
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-669
FAILURE CODE [DV20KB]
40 TROUBLESHOOTING
Circuit diagram associated with travel speed Hi/Lo solenoid
Pump controller
GR FH FL
G0024188
40-670
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW43KA]
FAILURE CODE [DW43KA] Details of failure
The pump controller senses an open circuit in the travel speed selector solenoid circuit.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular. (The solenoid does not operate since no current flows.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
The machine travels slow in Hi travel speed setting. (The machine monitor shows Hi setting but the speed is kept at around Lo.) Monitoring code
The command (ON or OFF) from the controller to the travel speed selector solenoid can Associated informabe monitored. (As long as the command from the controller is ON, the indication on the tion monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02300) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Travel speed selector solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V04.
3.
Connect the T-adapter to the female side of connector V04.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The travel speed selector solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
ResistBetween V04 (male) (1) and (2) ance
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
20 to 60 Ω
NO
•
Go to the next inspection item.
•
The travel speed selector solenoid is defective.
•
Replace the travel speed selector solenoid.
•
Go to "Confirmation of repair".
40-671
FAILURE CODE [DW43KA]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V04.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (93) and V04 (female) (1)
Between CP02 (female) (115) and Resist- V04 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
Max. 1 Ω
Between CP02 (female) (120) and V04 (female) (2)
Max. 1 Ω
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
V04 (female) (2)
•
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4.
40-672
Do the preceding troubleshooting again. NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Set the travel speed to Hi.
5.
Operate the travel lever.
6.
Is this failure code shown?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW43KA]
Circuit diagram associated with travel speed Hi/Lo solenoid Pup controller Solenoid valve travel speed GR FH FL
G0024187
PC210-10M0, PC210LC-10M0
40-673
FAILURE CODE [DW43KB]
40 TROUBLESHOOTING
FAILURE CODE [DW43KB] Details of failure
The pump controller senses a ground fault in the travel speed selector solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops to drive the travel speed selector solenoid.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The machine travels slow in Hi travel speed setting. (The machine monitor shows Hi setting but the speed is kept at around Lo.) Monitoring code
The command (ON or OFF) from the controller to the travel speed selector solenoid can Associated informabe monitored. (As long as the command from the controller is ON, the indication on the tion monitor is ON even if the solenoid is not energized because there is a short circuit.) (Code: 02300) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Travel speed selector solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V04.
3.
Connect the T-adapter to the female side of connector V04.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
40-674
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The travel speed selector solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value Between V04 (male) (1) and (2)
20 to 60 Ω
Between V04 (male) (1) and ground
Min. 1 MΩ
NO
•
Go to the next inspection item.
•
The travel speed selector solenoid is defective.
•
Replace the travel speed selector solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DW43KB]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V04.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (93) or V04 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V04.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (93) and ance each pin other than (93)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Set the travel speed to Hi.
5.
Operate the travel lever.
6.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-675
FAILURE CODE [DW43KB]
40 TROUBLESHOOTING
Circuit diagram associated with travel speed Hi/Lo solenoid Pup controller Solenoid valve travel speed GR FH FL
G0024187
40-676
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW43KY]
FAILURE CODE [DW43KY] Details of failure
The pump controller senses a hot short circuit in the travel speed selector solenoid circuit.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The machine travels fast in Lo travel speed setting. (The machine monitor shows Lo setting but the speed is kept at around Hi.) Monitoring code
The command (ON or OFF) from the controller to the travel speed selector solenoid can Associated informabe monitored. (As long as the command from the controller is ON, the indication on the tion monitor is ON even if the solenoid is not energized because there is a short circuit.) (Code: 02300) No.
Cause
Procedures, Measurement, Values, Note
1.
Diagnosis and treatment
Check the wiring harnesses and connectors.
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V04.
3.
Connect the T-adapter to the female side of connector V04.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Voltage Between V04 (female) (1) and (2)
PC210-10M0, PC210LC-10M0
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES
Does the measurement result agree with the standard value? Measuring point and measurement condition
• •
Measure the voltage.
Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
Standard value Max 4.5V
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-677
FAILURE CODE [DW43KY]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with travel speed Hi/Lo solenoid Pup controller Solenoid valve travel speed GR FH FL
G0024187
40-678
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW45KA]
FAILURE CODE [DW45KA] Details of failure
The pump controller senses an open circuit in the swing parking brake solenoid circuit.
Action level
L03 •
None in particular. (The solenoid does not operate since no current flows.) That is, the swing parking brake is kept applied.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
Action of controller
Phenomenon on machine
The machine does not swing. (The swing parking brake is not released)
Monitoring code The command (ON or OFF) from the controller to the swing parking brake solenoid can be monitored. (As long as the command from the controller is ON, the indication on the monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02300) Associated informaReference information tion • When the solenoid and wiring harness are normal, swing operation is possible if the swing parking brake cancel switch is set to the RELEASE position. (Note that the swing parking brake is applied when the starting switch is in the OFF position.) •
No.
Cause
Power for the swing parking brake solenoid is supplied from pin (101) of pump controller CP02 or fuse No.1 in fuse box F01. Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-679
FAILURE CODE [DW45KA]
No.
2
Cause
Swing parking brake solenoid
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V03.
3.
Connect the T-adapter to the female side of connector V03.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
3
Turn the starting switch to the OFF position.
2.
Disconnect connector S04.
3.
Connect the T-adapter to the female side of connector S04.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
(male) (3) and (4)
4
Diode
Swing lock switch: OFF
Max. 1 Ω
Swing lock switch: ON
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01.
3.
Connect the T-adapter to the female side of connector D01.
4.
Measure the continuity.
5.
Does the measurement result agree with the standard value? Item
Continuity
40-680
YES
StandMeasurement position and condition ard value
Between S04 (male) (3) and Resist- (4) ance Between S04
NO
20 to 60 Ω
1.
Swing lock switch
•
The swing parking brake solenoid is normal.
•
Go to the next inspection item.
•
The swing parking brake solenoid is defective.
•
Replace the swing parking brake solenoid.
•
Go to "Confirmation of repair".
•
The swing lock switch is normal.
•
Go to the next inspection item.
•
The swing lock switch is defective.
•
Replace the swing lock switch.
•
Go to "Confirmation of repair".
YES
StandMeasurement position and condition ard value
ResistBetween V03 (male) (1) and (2) ance
Diagnosis and treatment
StandMeasurement position and condition ard value Between D01 (male) (3) (+) and (7) (-)
No continuity
Between D01 (male) (7) (+) and (3) (-)
Continuity
NO
• YES •
NO
The diode is normal. Go to the next inspection item.
•
The diode is defective.
•
Replace the diode.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [DW45KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CP02, connector D01, connector V03, and connector S04.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value?
Open circuit in wiring harness
Item
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (101) and D01 (female) (7)
Max. 1 Ω
Between D01 (female) (3) and S04 (female) (3)
Max. 1 Ω
Between S04 (female) (4) and V03 Resist- (female) (1) ance Between V03 (female) (2) and CP02 (female) (115)
Max. 1 Ω
Between V03 (female) (2) and CP02 (female) (117)
Max. 1 Ω
Between V03 (female) (2) and CP02 (female) (120)
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-681
FAILURE CODE [DW45KA]
40 TROUBLESHOOTING
Circuit diagram associated with swing parking brake
LE FD FD
H15 6
9
FP
GS
J02 (J-20)(Orange)
J04 4
1 2 3
(J-20) 1
C M 0 1 14 J04 7
2 3 4
T07
GR
R05 2 R10 2
5
CP01 2 S30 8
7
R08 2 R12 2
GF
6
8 9 10
FH
R43 2 FL
G0024193
40-682
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW45KB]
FAILURE CODE [DW45KB] Details of failure
The pump controller senses a ground fault in the swing parking brake solenoid circuit.
Action level
L03 •
Stops to drive the swing parking brake solenoid. (The solenoid does not operate since no current flows.) That is, the swing parking brake is kept applied.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
Action of controller
Phenomenon on machine
The machine does not swing. (The swing parking brake is not released)
Monitoring code The command (ON or OFF) from the controller to the swing parking brake solenoid can be monitored. (As long as the command from the controller is ON, the indication on the monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02300) Associated informaReference information tion • When the solenoid and wiring harness are normal, swing operation is possible if the swing parking brake cancel switch is set to the RELEASE position. (Note that the swing parking brake is applied when the starting switch is in the OFF position.) •
No.
Cause
Power for the swing parking brake solenoid is supplied from pin (101) of pump controller CP02 or fuse No.1 in fuse box F01. Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-683
FAILURE CODE [DW45KB]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V03.
3.
Connect the T-adapter to the female side of connector V03.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Swing parking brake solenoid
Item
Resistance
3
StandMeasurement position and condition ard value Between V03 (male) (1) and (2)
20 to 60 Ω
Between V03 (male) (1) and ground
Min. 1 MΩ
Turn the starting switch to the OFF position.
2.
Disconnect connector S04.
3.
Connect the T-adapter to the female side of connector S04.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
(male) (3) and (4)
4
Diode
Max. 1 Ω
Swing lock switch: ON
Min. 1 MΩ
Turn the starting switch to the OFF position.
2.
Disconnect connector D03.
3.
Connect the T-adapter to the female side of connector D03.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Continuity
40-684
Swing lock switch: OFF
1.
Item
NO
YES
StandMeasurement position and condition ard value
Between S04 (male) (3) and Resist- (4) ance Between S04
•
The swing parking brake solenoid is normal.
•
Go to the next inspection item.
•
The swing parking brake solenoid is defective.
•
Replace the swing parking brake solenoid.
•
Go to "Confirmation of repair".
•
The swing lock switch is normal.
•
Go to the next inspection item.
•
The swing lock switch is defective.
•
Replace the swing lock switch.
•
Go to "Confirmation of repair".
•
The diode is normal.
YES
1.
Swing lock switch
Diagnosis and treatment
StandMeasurement position and condition ard value Between D03 (male) (3) (+) and (7) (-)
No continuity
Between D03 (male) (7) (+) and (3) (-)
Continuity
NO
YES •
Go to the next inspection item.
•
The diode is defective.
•
Replace the diode.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [DW45KB]
Cause
Procedures, Measurement, Values, Note Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, connector D01, con- YES • nector D03, connector S04, connector S25, and connector V03.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measuring result meet the standard value for the connector?
Ground fault in wiring harness
Short circuit in wiring harness
•
1.
Item
StandMeasurement position and condition ard value Between CP02 (female) (101) or D01 (female) (7) and ground
6
Diagnosis and treatment
Min. 1 MΩ
Between D01 (female) (3), S04 (feResist- male) (3), or S25 (female) (14) and ance ground
Min. 1 MΩ
Between S04 (female) (4), D03 (female) (3), or V03 (female) (1) and ground
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector D01.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (101) and ance each pin other than (101)
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
Go to the next inspection item.
•
NO
YES
The wiring harness has no ground faults.
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
PC210-10M0, PC210LC-10M0
NO
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
40-685
FAILURE CODE [DW45KB]
No.
8
Cause
Confirmation of repair
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
YES
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with swing parking brake
LE FD FD
H15 6
9
FP
GS
J02 (J-20)(Orange)
J04 4
1 2 3
(J-20) 1
C M 0 1 14 J04 7
2 3 4
T07
GR
R05 2 R10 2
5
CP01 2 S30 8
7
R08 2 R12 2
GF
6
8 9 10
FH
R43 2 FL
G0024193
40-686
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW45KY]
FAILURE CODE [DW45KY] Details of failure
The pump controller senses a hot short circuit in the swing parking brake solenoid circuit.
Action level
L03
Action of controller Phenomenon on machine
•
None in particular.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The swing parking brake does not work.
Monitoring code The command (ON or OFF) from the controller to the swing parking brake solenoid can be monitored. (As long as the command from the controller is ON, the indication on the monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02300) Associated informaReference information tion • When the solenoid and wiring harness are normal, swing operation is possible if the swing parking brake cancel switch is set to the RELEASE position. (Note that the swing parking brake is applied when the starting switch is in the OFF position.) •
No.
Cause
Power for the swing parking brake solenoid is supplied from pin (101) of pump controller CP02 or fuse No.1 in fuse box F01. Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
Are the wiring harnesses and connectors normal?
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
40-687
FAILURE CODE [DW45KY]
No.
2
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01.
3.
Connect the T-adapter to the male side of connector D01.
4.
Measure the continuity.
5.
Does the measurement result agree with the standard value?
Diode
Item
Continuity
3
Measuring point and measurement condition
Standard value
Between D01 (male) (3) (+) and (7) (-)
No continuity
Between D01 (male) (7) (+) and (3) (-)
Continuity
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01.
3.
Connect the T-adapter to the female side of connector D01.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment • YES •
NO
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Between D01 (female) (7) and Voltage ground
Standard value
Go to the next inspection item.
•
The diode is defective.
•
Replace the diode.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
The diode is normal.
NO
? Max. V
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-688
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW45KY]
Circuit diagram associated with swing parking brake
LE FD FD
H15 6
9
FP
GS
J02 (J-20)(Orange)
J04 4
1 2 3
(J-20) 1
C M 0 1 14 J04 7
2 3 4
T07
GR
R05 2 R10 2
5
CP01 2 S30 8
7
R08 2 R12 2
GF
6
8 9 10
FH
R43 2 FL
G0024193
PC210-10M0, PC210LC-10M0
40-689
FAILURE CODE [DW91KA]
40 TROUBLESHOOTING
FAILURE CODE [DW91KA] Details of failure
The pump controller senses an open circuit in the travel junction solenoid circuit.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
It is hard to steer during machine travel.
Monitoring code The command (ON or OFF) from the controller to the travel junction solenoid can be monitored. (As long as the command from the controller is ON, the indication on the Associated informamonitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02300) Reference information Setting the solenoid to OFF interconnects the travel junction circuit. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Travel junction solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V05.
3.
Connect the T-adapter to the female side of connector V05.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
ResistBetween V05 (male) (1) and (2) ance
40-690
20 to 60 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The travel junction solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
NO
•
Go to the next inspection item.
•
The travel junction solenoid is defective.
•
Replace the travel junction solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DW91KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V05.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (85) and V05 (female) (1)
Between CP02 (female) (115) and Resist- V05 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
Max. 1 Ω
Between CP02 (female) (120) and V05 (female) (2)
Max. 1 Ω
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
V05 (female) (2)
•
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Operate the R.H. and L.H. travel levers to steer the machine.
NO The repair is completed.
Is this failure code shown?
Circuit diagram associated with travel junction solenoid
PC210-10M0, PC210LC-10M0
40-691
FAILURE CODE [DW91KB]
40 TROUBLESHOOTING
FAILURE CODE [DW91KB] Details of failure
The pump controller senses a ground fault in the travel junction solenoid circuit.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
It is hard to steer during machine travel.
Monitoring code The command (ON or OFF) from the controller to the travel junction solenoid can be monitored. (As long as the command from the controller is ON, the indication on the Associated informamonitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02300) Reference information Setting the solenoid to OFF interconnects the travel junction circuit. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Travel junction solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V05.
3.
Connect the T-adapter to the female side of connector V05.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
40-692
Between V05 (male) (1) and (2)
20 to 60 Ω
Between V05 (male) (1) and ground
Min. 1 MΩ
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The travel junction solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
NO
•
Go to the next inspection item.
•
The travel junction solenoid is defective.
•
Replace the travel junction solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DW91KB]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V05.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (85) or V05 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V05.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (85) and ance each pin other than (85)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Operate the R.H. and L.H. travel levers to steer the machine.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40-693
FAILURE CODE [DW91KB]
40 TROUBLESHOOTING
Circuit diagram associated with travel junction solenoid
40-694
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW91KY]
FAILURE CODE [DW91KY] Details of failure
The pump controller senses a hot short circuit in the travel junction solenoid circuit.
Action level
L01
Action of controller
Stops to drive the travel junction solenoid.
Phenomenon on machine
It is hard to steer during machine travel.
Monitoring code The command (ON or OFF) from the controller to the travel junction solenoid can be monitored. (As long as the command from the controller is ON, the indication on the Associated informamonitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02300) Reference information Setting the solenoid to OFF interconnects the travel junction circuit. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V05.
3.
Connect the T-adapter to the female side of connector V05.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
PC210-10M0, PC210LC-10M0
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between V05 (female) (1) and (2)
• •
Measure the voltage.
Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
Max. 4.5V
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-695
FAILURE CODE [DW91KY]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Operate the R.H. and L.H. travel levers to steer the machine.
NO The repair is completed.
Is this failure code shown?
Circuit diagram associated with travel junction solenoid
40-696
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW97KA]
FAILURE CODE [DW97KA] Details of failure
The pump controller senses an open circuit in the circuit of the swing stroke control solenoid.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
When E1, E2, E3 or E4 mode is selected, the swing speed is not controlled. The swing speed will be that when the E0 mode is selected. Monitoring code
The command (ON or OFF) from the controller to the swing stroke control solenoid can Associated informabe monitored. (As long as the command from the controller is ON, the indication on the tion monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02302) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Swing stroke control solenoid
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector . Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition
Standard value 20 to 60 Ω
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The swing stroke control solenoid is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The swing stroke control solenoid is defective.
•
Replace the swing stroke control solenoid.
•
Go to "Confirmation of repair".
40-697
FAILURE CODE [DW97KA]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector . Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Open circuit in wiring harness
Measuring point and measurement condition
YES
Standard value Max. 1 Ω
Resistance
Diagnosis and treatment •
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω Max. 1 Ω Max. 1 Ω
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3. Confirmation of 4. repair 5. 6.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Select E1 mode. Turn the swing lock switch to the ON position. Put the system in the swing relief state.
NO The repair is completed.
Is this failure code shown?
Circuit diagram associated with swing stroke control solenoid system
40-698
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW97KB]
FAILURE CODE [DW97KB] Details of failure
The pump controller senses a ground fault in the circuit of the swing stroke control solenoid.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops to drive the swing stroke control solenoid.
•
Even if the cause of the failure is resolved, the machine does not become normal until the starting switch is turned to the OFF position once.
When E1, E2, E3 or E4 mode is selected, the swing speed is not controlled. The swing speed will be that when the E0 mode is selected. Monitoring code
f Associated informa- The command (ON or OFF) from the controller to the swing stroke control solenoid can tion be monitored. (As long as the command from the controller is ON, the sensor state shown on the monitoring screen is ON even if solenoid is not energized because there is an open circuit.) (Code: 02302 Solenoid 2) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Swing stroke control solenoid
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V08. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition
Standard value
Between V08 (male) (1) and (2)
20 to 60 Ω
Between V08 (male) (1) and ground
Min. 1 MΩ
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The swing stroke control solenoid is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The swing stroke control solenoid is defective.
•
Replace the swing stroke control solenoid.
•
Go to "Confirmation of repair".
40-699
FAILURE CODE [DW97KB]
No.
3
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, V08. Connect the Tadapter to one of the female sides.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resist- Between CP02 (female) (106) or ance V08 (female) (1) and ground
4
Short circuit in wiring harness
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, V08. Connect the Tadapter to the female side of CP02.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Resist- Between CP02 (female) (106) and ance each pin other than (106)
YES
Standard value
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Measuring point and measurement condition
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3. Confirmation of 4. repair 5. 6.
40-700
Do the inspection above again.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Select E1 mode. Turn the swing lock switch to the ON position. Troubleshoot in the swing relief state.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DW97KB]
Circuit diagram associated with swing stroke control solenoid system
PC210-10M0, PC210LC-10M0
40-701
FAILURE CODE [DW97KY]
40 TROUBLESHOOTING
FAILURE CODE [DW97KY] Details of failure
The pump controller senses a hot short circuit in the circuit of the swing stroke control solenoid.
Action level
L01
Action of controller
Stops to drive the swing stroke control solenoid.
Phenomenon on machine
When E1, E2, E3 or E4 mode is selected, the swing speed is not controlled. The swing speed will be that when the E0 mode is selected. Monitoring code
The command (ON or OFF) from the controller to the swing stroke control solenoid can Associated informabe monitored. (As long as the command from the controller is ON, the indication on the tion monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02302) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V08. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position.
4. Hot short circuit 5. in wiring harness
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES •
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage. Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Voltage Between V08 (female) (1) and (2)
40-702
•
Standard value Max 4.5 V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DW97KY]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3. Confirmation of 4. repair 5. 6.
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Select E1 mode. Turn the swing lock switch to the ON position. Troubleshoot in the swing relief state.
NO The repair is completed.
Is this failure code shown?
Circuit diagram associated with swing stroke control solenoid system
PC210-10M0, PC210LC-10M0
40-703
FAILURE CODE [DWA2KA]
40 TROUBLESHOOTING
FAILURE CODE [DWA2KA] Details of failure
The pump controller senses an open circuit in the attachment single or 2-way change solenoid circuit.
Action level
L03
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
The hydraulic circuit for attachment does not become a single-acting circuit.
Monitoring code The command (ON or OFF) from the controller to the attachment single or 2-way change Associated informasolenoid can be monitored. (As long as the command from the controller is ON, the indition cation on the monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02301) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The attachment single or 2-way change solenoid is normal.
NO
•
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V07.
3.
Connect the T-adapter to the female side of connector V07.
•
Go to the next inspection item.
Measure the resistance.
•
The attachment single or 2-way change solenoid is defective.
•
Replace the attachment single or 2-way change selector solenoid.
•
Go to "Confirmation of repair".
4. Attachment sin5. gle or 2-way change solenoid
YES
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
ResistBetween V07 (male) (1) and (2) ance
40-704
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
20 to 60 Ω
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DWA2KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V07.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (86) and V07 (female) (1)
Between CP02 (female) (115) and Resist- V07 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
Max. 1 Ω
Between CP02 (female) (120) and V07 (female) (2)
Max. 1 Ω
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
V07 (female) (2)
•
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Set to other than breaker mode (B).
5.
Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with ATT single/multiple selector solenoid
PC210-10M0, PC210LC-10M0
40-705
FAILURE CODE [DWA2KB]
40 TROUBLESHOOTING
FAILURE CODE [DWA2KB] Details of failure
The pump controller senses a ground fault in the attachment single or 2-way change solenoid circuit.
Action level
L03
Action of controller
Phenomenon on machine
•
Stops to drive the attachment single or 2-way change solenoid.
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The hydraulic circuit for attachment does not become a single-acting circuit.
Monitoring code The command (ON or OFF) from the controller to the attachment single or 2-way change Associated informasolenoid can be monitored. (As long as the command from the controller is ON, the indition cation on the monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02301) No.
Cause
Procedures, Measurement, Values, Note
1.
Diagnosis and treatment
Check the wiring harnesses and connectors. For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Are the wiring harnesses and connectors normal?
Turn the starting switch to the OFF position.
2.
Disconnect connector V07.
3.
Connect the T-adapter to the female side of connector V07.
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The attachment single or 2-way change solenoid is normal.
NO
4.
Measure the resistance.
YES
Attachment sin- 5. Does the measurement result agree with the standard value? gle or 2-way change soleStandnoid Item Measurement position and condition ard value
40-706
•
•
1.
Resistance
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
Between V07 (male) (1) and (2)
20 to 60 Ω
Between V07 (male) (1) and ground
Min. 1 MΩ
•
Go to the next inspection item.
•
The attachment single or 2-way change solenoid is defective.
•
Replace the attachment single or 2-way change selector solenoid.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DWA2KB]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V07.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (86) or V07 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V07.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (86) and ance each pin other than (86)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Set to breaker mode (B).
5.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-707
FAILURE CODE [DWA2KB]
40 TROUBLESHOOTING
Circuit diagram associated with ATT single/multiple selector solenoid
40-708
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWA2KY]
FAILURE CODE [DWA2KY] Details of failure
The pump controller senses a hot short circuit in the attachment single or 2-way change solenoid circuit.
Action level
L03
Action of controller Phenomenon on machine
•
None in particular.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The hydraulic circuit for attachment does not become a double-acting circuit.
Monitoring code The command (ON or OFF) from the controller to the attachment single or 2-way change Associated informasolenoid can be monitored. (As long as the command from the controller is ON, the indition cation on the monitor is ON even if the solenoid is not energized because there is an open circuit.) (Code: 02301) No.
Cause
Procedures, Measurement, Values, Note
1.
Diagnosis and treatment
Check the wiring harnesses and connectors.
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V07.
3.
Connect the T-adapter to the female side of connector V07.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Voltage Between V07 (female) (1) and (2)
PC210-10M0, PC210LC-10M0
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES
Does the measurement result agree with the standard value? Measuring point and measurement condition
• •
Measure the voltage.
Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
Standard value Max 4.5V
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-709
FAILURE CODE [DWA2KY]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Set to breaker mode (B).
5.
Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with ATT single/multiple selector solenoid
40-710
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWK0KA]
FAILURE CODE [DWK0KA] Details of failure
The pump controller senses an open circuit in the 2-stage relief solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
When the cause of failure is resolved naturally, the machine returns to normal.
•
The traveling force becomes weak. (The main relief valve is not switched to high pressure setting.)
•
The one-touch power maximizing function does not operate.
Monitoring code The command (ON or OFF) from the controller to the 2-stage relief solenoid can be monitored. (As long as the command from the controller is ON, the indication on the Associated informamonitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02300) Reference information The controller senses an open circuit when the solenoid output is OFF. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
2-stage relief solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V02.
3.
Connect the T-adapter to the female side of connector V02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
ResistBetween V02 (male) (1) and (2) ance
PC210-10M0, PC210LC-10M0
20 to 60 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The 2-stage relief solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The 2-stage relief solenoid is defective.
•
Replace the 2-stage relief solenoid.
•
Go to "Confirmation of repair".
40-711
FAILURE CODE [DWK0KA]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, V02.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (109) and V02 (female) (1)
Max. 1 Ω
Between CP02 (female) (115) and Resist- V02 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
V02 (female) (2)
Max. 1 Ω
Between CP02 (female) (120) and V02 (female) (2)
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with 2-stage relief solenoid system
40-712
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWK0KB]
FAILURE CODE [DWK0KB] Details of failure
The pump controller senses a ground fault in the 2-stage relief solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops to drive the 2-stage relief solenoid.
•
Even if the cause of the failure is naturally resolved, the machine does not become normal until the starting switch is turned to the OFF position once.
•
The traveling force becomes weak. (The main relief valve is not switched to high pressure setting.)
•
The one-touch power maximizing function does not operate.
Monitoring code The command (ON or OFF) from the controller to the 2-stage relief solenoid can be monitored. (As long as the command from the controller is ON, the indication on the Associated informamonitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02300) Reference information The controller senses an open circuit when the solenoid output is OFF. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
2-stage relief solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V02.
3.
Connect the T-adapter to the female side of connector V02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Between V02 (male) (1) and (2)
20 to 60 Ω
Between V02 (male) (1) and ground
Min. 1 MΩ
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The 2-stage relief solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The 2-stage relief solenoid is defective.
•
Replace the 2-stage relief solenoid.
•
Go to "Confirmation of repair".
40-713
FAILURE CODE [DWK0KB]
No.
3
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V02.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (109) or ance V02 (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V02.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (109) and ance each pin other than (109)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-714
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWK0KB]
Circuit diagram associated with 2-stage relief solenoid system
PC210-10M0, PC210LC-10M0
40-715
FAILURE CODE [DWK0KY]
40 TROUBLESHOOTING
FAILURE CODE [DWK0KY] Details of failure
The pump controller senses a hot short circuit in the 2-stage relief solenoid circuit.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The relief pressure becomes high also by operations other than travel and one-touch power maximizing. Monitoring code
The command (ON or OFF) from the controller to the 2-stage relief solenoid can be monitored. (As long as the command from the controller is ON, the indication on the Associated informamonitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02300) Reference information The controller senses an open circuit when the solenoid output is OFF. No.
Cause
Procedures, Measurement, Values, Note
1.
Diagnosis and treatment
Check the wiring harnesses and connectors. For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V02.
3.
Connect the T-adapter to the female side of connector V02.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Voltage Between V02 (female) (1) and (2)
40-716
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES
Does the measurement result agree with the standard value? Measuring point and measurement condition
• •
Measure the voltage.
Item
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
Standard value Max 4.5V
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DWK0KY]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with 2-stage relief solenoid system
PC210-10M0, PC210LC-10M0
40-717
FAILURE CODE [DWK2KA]
40 TROUBLESHOOTING
FAILURE CODE [DWK2KA] Details of failure
The pump controller senses an open circuit in the variable back pressure solenoid circuit.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
The fuel consumption is degraded.
Monitoring code The command (ON or OFF) from the controller to the variable back pressure solenoid can be monitored. (As long as the command from the controller is ON, the indication on Associated informathe monitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02301) Reference information When the solenoid is ON, the back pressure valve set pressure decreases. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Variable back pressure solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V25.
3.
Connect the T-adapter to the female side of connector V25.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
40-718
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The variable back pressure solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
ResistBetween V25 (male) (1) and (2) ance
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
20 to 60 Ω
NO
•
Go to the next inspection item.
•
The variable back pressure solenoid is defective.
•
Replace the variable back pressure solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DWK2KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V25.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (113) and V25 (female) (1)
Max. 1 Ω
Between CP02 (female) (115) and Resist- V25 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
V25 (female) (2)
Max. 1 Ω
Between CP02 (female) (120) and V25 (female) (2)
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with variable back pressure solenoid
PC210-10M0, PC210LC-10M0
40-719
FAILURE CODE [DWK2KB]
40 TROUBLESHOOTING
FAILURE CODE [DWK2KB] Details of failure
The pump controller senses a ground fault in the variable back pressure solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops to drive the variable back pressure solenoid.
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The fuel consumption is degraded.
Monitoring code The command (ON or OFF) from the controller to the variable back pressure solenoid can be monitored. (As long as the command from the controller is ON, the indication on Associated informathe monitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02301) Reference information When the solenoid is ON, the back pressure valve set pressure decreases. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Variable back pressure solenoid
40-720
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V25.
3.
Connect the T-adapter to the female side of connector V25.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The variable back pressure solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
ResistBetween V25 (male) (1) and (2) ance
20 to 60 Ω
ResistBetween V25 (male) (1) and ground ance
Min. 1 MΩ
NO
•
Go to the next inspection item.
•
The variable back pressure solenoid is defective.
•
Replace the variable back pressure solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DWK2KB]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V25.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (113) or ance V25 (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V25.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (113) and ance each pin other than (113)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-721
FAILURE CODE [DWK2KB]
40 TROUBLESHOOTING
Circuit diagram associated with variable back pressure solenoid
40-722
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWK2KY]
FAILURE CODE [DWK2KY] Details of failure
The pump controller senses a hot short circuit in the variable back pressure solenoid circuit.
Action level
L01
Action of controller
Stops to drive the variable back pressure solenoid.
Phenomenon on machine
The fuel consumption is degraded.
Monitoring code The command (ON or OFF) from the controller to the variable back pressure solenoid can be monitored. (As long as the command from the controller is ON, the indication on Associated informathe monitor is ON even if the solenoid is not energized because there is an open circuit.) tion (Code: 02301) Reference information When the solenoid is ON, the back pressure valve set pressure decreases. No.
Cause
Procedures, Measurement, Values, Note
1.
Diagnosis and treatment
Check the wiring harnesses and connectors. For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V25.
3.
Connect the T-adapter to the female side of connector V25.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Voltage Between V25 (female) (1) and (2)
PC210-10M0, PC210LC-10M0
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES
Does the measurement result agree with the standard value? Measuring point and measurement condition
• •
Measure the voltage.
Item
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
Standard value Max 4.5V
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-723
FAILURE CODE [DWK2KY]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with variable back pressure solenoid
40-724
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWK8KA]
FAILURE CODE [DWK8KA] Details of failure
The pump controller senses an open circuit in the swing cut-off solenoid circuit.
Action level
L01
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
Degraded swing acceleration.
Monitoring code The command (ON or OFF) from the controller to the swing pressure cut off (2-stage relief) solenoid can be monitored. (As long as the command from the controller is ON, the Associated informaindication on the monitor is ON even if the solenoid is not energized because there is an tion open circuit.) (Code: 02301) Reference information When the solenoid is ON, the swing motor relief pressure becomes "Hi". No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Swing cut-off solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V06.
3.
Connect the T-adapter to the female side of connector V06.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
ResistBetween V06 (male) (1) and (2) ance
PC210-10M0, PC210LC-10M0
20 to 60 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The swing cut-off solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
NO
•
Go to the next inspection item.
•
The swing cut-off solenoid is defective.
•
Replace the swing cut-off solenoid.
•
Go to "Confirmation of repair".
40-725
FAILURE CODE [DWK8KA]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, V06.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (94) and V06 (female) (1)
Between CP02 (female) (115) and Resist- V06 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
Max. 1 Ω
Between CP02 (female) (120) and V06 (female) (2)
Max. 1 Ω
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
V06 (female) (2)
•
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Turn the swing lock switch to the OFF position. Put the system in the swing relief state.
NO The repair is completed.
Is this failure code shown?
Circuit diagram associated with swing C/O solenoid system
40-726
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWK8KB]
FAILURE CODE [DWK8KB] Details of failure
The pump controller senses a ground fault in the swing cut-off solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops to drive the swing cut-off (2-stage relief) solenoid.
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
Degraded swing acceleration.
Monitoring code The command (ON or OFF) from the controller to the swing pressure cut off (2-stage relief) solenoid can be monitored. (As long as controller's command to solenoid is "ON", the Associated informaindication on the monitor is "ON" even if solenoid is not energized because there is an tion open circuit.) (Code: 02301 Solenoid 2) Reference information When the solenoid is ON, the swing motor relief pressure becomes "Hi". No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Swing cut-off solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V06.
3.
Connect the T-adapter to the female side of connector V06.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Between V06 (male) (1) and (2)
20 to 60 Ω
Between V06 (male) (1) and ground
Min. 1 MΩ
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The swing cut-off solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The swing cut-off solenoid is defective.
•
Replace the swing cut-off solenoid.
•
Go to "Confirmation of repair".
40-727
FAILURE CODE [DWK8KB]
No.
3
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V06.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (94) or V06 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V06.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (94) and ance each pin other than (94)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
40-728
Do the preceding troubleshooting again. NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Turn the swing lock switch to the OFF position. Put the system in the swing relief state.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWK8KB]
Circuit diagram associated with swing C/O solenoid system
PC210-10M0, PC210LC-10M0
40-729
FAILURE CODE [DWK8KY]
40 TROUBLESHOOTING
FAILURE CODE [DWK8KY] Details of failure
The pump controller senses a hot short circuit in the swing cut-off solenoid circuit.
Action level
L01
Action of controller
Stops to drive the swing cut-off (2-stage relief) solenoid.
Phenomenon on machine
Degraded swing acceleration.
Monitoring code The command (ON or OFF) from the controller to the swing pressure cut off (2-stage relief) solenoid can be monitored. (As long as the command from the controller is ON, the Associated informaindication on the monitor is ON even if the solenoid is not energized because there is an tion open circuit.) (Code: 02301) Reference information When the solenoid is ON, the swing motor relief pressure becomes "Hi". No.
Cause
Procedures, Measurement, Values, Note
1.
Diagnosis and treatment
Check the wiring harnesses and connectors.
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V06.
3.
Connect the T-adapter to the female side of connector V06.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Voltage Between V06 (female) (1) and (2)
40-730
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES
Does the measurement result agree with the standard value? Measuring point and measurement condition
• •
Measure the voltage.
Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
Standard value Max 4.5V
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DWK8KY]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine. Turn the swing lock switch to the OFF position. Put the system in the swing relief state.
NO The repair is completed.
Is this failure code shown?
Circuit diagram associated with swing C/O solenoid system
PC210-10M0, PC210LC-10M0
40-731
FAILURE CODE [DWN5KA]
40 TROUBLESHOOTING
FAILURE CODE [DWN5KA] Details of failure
The pump controller senses an open circuit in the fan clutch solenoid.
Action level
L03
Action of controller
Phenomenon on machine
•
None in particular.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The fan speed is not controlled. The fan operates at the maximum speed allowed by the engine speed.
Associated informa- Monitoring code tion The fan speed can be monitored. (Code: 10007) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Open circuit in wiring harness
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, M16. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Between CP02 (female) (99) and M16 (female) (4)
Max. 1 Ω Max. 1 Ω
M16 (female) (3)
Max. 1 Ω
Between CP02 (female) (120) and M16 (female) (3)
Max. 1 Ω
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
NO
• YES
StandMeasurement position and condition ard value
Between CP02 (female) (115) and Resist- M16 (female) (3) ance Between CP02 (female) (117) and
40-732
•
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DWN5KA]
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M16. Connect the diagnos- YES • tic circuit to the male side.
The fan clutch solenoid is normal. Go to the next inspection item.
REMARK • Supply voltage of 5 ~ 24 V to troubleshoot failure of fan clutch solenoid. Because the measurement is possible if the voltage is in this range, it is not necessary to change the voltage. • Please supply voltage as shown below. A resistance of 100 Ω (rated power 5 W or more) is required for the diagnostic circuit. 3. 3
Fan clutch solenoid
Measure the power supply voltage between point a, point b in the diagnostic circuit. REMARK Measure with the supply voltage connected to the diagnostic circuit.
4.
Measure the voltage between point c, point d in the diagnostic circuit.
5.
Does the troubleshooting result agree with the standard value? Item
NO
•
The fan clutch solenoid is defective.
•
Replace the fan clutch solenoid.
•
Go to "Confirmation of repair".
StandMeasurement position and condition ard value
Power supply Between point c in circuit for diagnoVoltage voltage sis and point d × 0.6 to 0.9 V
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
PC210-10M0, PC210LC-10M0
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-733
FAILURE CODE [DWN5KA]
40 TROUBLESHOOTING
Circuit diagram associated with fan clutch
40-734
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DWN5KB]
FAILURE CODE [DWN5KB] Details of failure
The pump controller senses a ground fault in the circuit of fan clutch solenoid.
Action level
L03
Action of controller
Phenomenon on machine
•
Stops to drive the fan clutch solenoid.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The fan speed is not controlled. The fan operates at the maximum speed allowed by the engine speed.
Associated informa- Monitoring code tion The fan speed can be monitored. (Code: 10007) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Ground fault in wiring harness
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, M16. Connect the T-adapter to one of the female sides.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (99) or M16 ance (female) (4) and ground
PC210-10M0, PC210LC-10M0
Min. 1 MΩ
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no ground faults.
NO
• YES
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-735
FAILURE CODE [DWN5KB]
No.
3
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, M16. Connect the T-adapter to the female side of CP02.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (99) and ance each pin other than (99)
Diagnosis and treatment YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The fan clutch solenoid is normal.
NO
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M16. Connect the diagnos- YES • tic circuit to the male side.
Go to the next inspection item.
REMARK • Supply voltage of 5 ~ 24 V to troubleshoot failure of fan clutch solenoid. Because the measurement is possible if the voltage is in this range, it is not necessary to change the voltage. • Please supply voltage as shown below. A resistance of 100 Ω (rated power 5 W or more) is required for the diagnostic circuit. 3. 4
Fan clutch solenoid
Measure the power supply voltage between in the diagnostic circuit. REMARK Measure with the supply voltage connected to the diagnostic circuit.
4.
Measure the voltage between in the diagnostic circuit.
5.
Does the troubleshooting result agree with the standard value? Item
NO
•
The fan clutch solenoid is defective.
•
Replace the fan clutch solenoid.
•
Go to "Confirmation of repair".
StandMeasurement position and condition ard value
Power supply Between point c in circuit for diagnovoltage Voltage sis and point d × 0.6 to 0.9 V
40-736
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DWN5KB]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Can you identify the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with fan clutch
PC210-10M0, PC210LC-10M0
40-737
FAILURE CODE [DWN5KY]
40 TROUBLESHOOTING
FAILURE CODE [DWN5KY] Details of failure
The pump controller senses a hot short circuit in the circuit of the fan clutch solenoid.
Action level
L03
Action of controller
Phenomenon on machine
•
Stops to drive the fan clutch solenoid.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The fan speed is not controlled. The fan operates at the maximum speed allowed by the engine speed.
Associated informa- Monitoring code tion The fan speed can be monitored. (Code: 10007) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M16. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position to troubleshoot.
Hot short circuit 4. in wiring harness
•
Measuring point and measurement condition
ResistBetween M16 (female) (4) and (3) ance
Standard value
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
• YES
Does the troubleshooting result agree with the standard value? Item
• NO
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max 1 V
YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
40-738
Do the inspection above again. Can you identify the cause by reconfirmation? NO
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
Cause
FAILURE CODE [DWN5KY]
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
Diagnosis and treatment YES
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with fan clutch
PC210-10M0, PC210LC-10M0
40-739
FAILURE CODE [DXA8KA]
40 TROUBLESHOOTING
FAILURE CODE [DXA8KA] Details of failure
The pump controller senses an open circuit in the front pump PC-EPC solenoid circuit.
Action level
L03
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
If the pump load increases, the engine speed decreases largely. The engine can stop.
Monitoring code The drive current to the front pump PC-EPC solenoid can be monitored. (Code: 01300) Associated informaReference information tion When the solenoid and wiring harness are normal, the engine can be prevented from stopping by setting the pump drive secondary switch to the ON position. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Front pump PC-EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V11.
3.
Connect the T-adapter to the female side of connector V11.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
40-740
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The front pump PCEPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
ResistBetween V11 (male) (1) and (2) ance
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
3 to 14 Ω
NO
•
Go to the next inspection item.
•
The front pump PCEPC valve is defective.
•
Replace the front pump PC-EPC solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DXA8KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S25.
3.
Connect the T-adapter to the female side of connector S25.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
3
Pump secondary drive switch
Resistance Between S25 (male) (6) and (5)
4
YES
StandMeasurement position and condition ard value
Between S25 (male) (3) and (2)
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, connector S25, and connector V11.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
NO
YES
StandMeasurement position and condition ard value Between CP02 (female) (96) and S25 (female) (3)
Max. 1 Ω
Between S25 (female) (2) and V11 (female) (1)
Max. 1 Ω
Between S25 (female) (5) and V11 Resist- (female) (2) ance Between CP02 (female) (115) and
Max. 1 Ω
PC210-10M0, PC210LC-10M0
Diagnosis and treatment
S25 (female) (6)
Max. 1 Ω
Between CP02 (female) (117) and S25 (female) (6)
Max. 1 Ω
Between CP02 (female) (120) and S25 (female) (6)
Max. 1 Ω
•
The pump secondary drive switch is normal.
•
Go to the next inspection item.
•
The pump secondary drive switch is defective.
•
Replace the pump secondary drive switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
40-741
FAILURE CODE [DXA8KA]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with PC-EPC solenoid system
40-742
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXA8KB]
FAILURE CODE [DXA8KB] Details of failure
The pump controller senses a ground fault or hot short circuit in the front pump PC-EPC solenoid circuit.
Action level
L03
Action of controller
Phenomenon on machine
•
Stops to drive the front pump PC-EPC solenoid.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
If the pump load increases, the engine speed decreases largely. The engine can stop.
Monitoring code The drive current to the front pump PC-EPC solenoid can be monitored. (Code: 01300) Associated informaReference information tion When the solenoid and wiring harness are normal, the engine can be prevented from stopping by setting the pump drive secondary switch to the ON position. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Front pump PC-EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V11.
3.
Connect the T-adapter to the female side of connector V11.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The front pump PCEPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value Between V11 (male) (1) and (2)
3 to 14 Ω
Between V11 (male) (1) and ground
Min. 1 MΩ
NO
•
Go to the next inspection item.
•
The front pump PCEPC valve is defective.
•
Replace the front pump PC-EPC solenoid.
•
Go to "Confirmation of repair".
40-743
FAILURE CODE [DXA8KB]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S25.
3.
Connect the T-adapter to the female side of connector S25.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
3
Pump secondary drive switch
Between S25 (male) (3) and (2)
Between S25 (male) (6) and (5)
4
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, connector connector V11, and connector S25.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Between CP02 (female) (96) or S25 Resist- (female) (3) and ground ance Between S25 (female) (2) or V11 (female) (1) and ground
40-744
YES
StandMeasurement position and condition ard value
Resistance
Ground fault in wiring harness
Diagnosis and treatment
Min. 1 MΩ
NO
YES
•
The pump secondary drive switch is normal.
•
Go to the next inspection item.
•
The pump secondary drive switch is defective.
•
Replace the pump secondary drive switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
5
FAILURE CODE [DXA8KB]
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V11.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (96) and ance each pin other than (96)
6
YES
Turn the starting switch to the OFF position.
2.
Disconnect connector V11.
3.
Connect the T-adapter to the female side of connector V11.
4.
Turn the starting switch to the ON position. Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between V11 (female) (1) and (2)
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
Item
•
NO
Min. 1 MΩ
1.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
NO
Max. 4.5V
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
40-745
FAILURE CODE [DXA8KB]
40 TROUBLESHOOTING
Circuit diagram associated with PC-EPC solenoid system
40-746
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXA9KA]
FAILURE CODE [DXA9KA] Details of failure
The pump controller senses an open circuit in the rear pump PC-EPC solenoid circuit.
Action level
L03
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
If the pump load increases, the engine speed decreases largely. The engine can stop.
Monitoring code The drive current to the rear pump PC-EPC solenoid can be monitored. (Code: 01302) Associated informaReference information tion When the solenoid and wiring harness are normal, the engine can be prevented from stopping by setting the pump drive secondary switch to the ON position. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V12.
3.
Connect the T-adapter to the female side of connector V12.
4.
Measure the resistance.
Rear pump PC- 5. EPC solenoid
PC210-10M0, PC210LC-10M0
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The rear pump PCEPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
ResistBetween V12 (male) (1) and (2) ance
• •
Does the measurement result agree with the standard value? Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
3 to 14 Ω
NO
•
Go to the next inspection item.
•
The rear pump PCEPC solenoid is defective.
•
Replace the rear pump PC-EPC solenoid.
•
Go to "Confirmation of repair".
40-747
FAILURE CODE [DXA9KA]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S25.
3.
Connect the T-adapter to the female side of connector S25.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
3
Pump secondary drive switch
Resistance Between S25 (male) (11) and (12)
4
Open circuit in wiring harness
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, connector S25, and connector V12.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
NO
YES
StandMeasurement position and condition ard value Between CP02 (female) (104) and S25 (female) (9)
Max. 1 Ω
Between S25 (female) (9) and V12 (female) (1)
Max. 1 Ω
Between S25 (female) (11) and V12 Resist- (female) (2) ance Between CP02 (female) (115) and
40-748
YES
StandMeasurement position and condition ard value
Between S25 (male) (9) and (8)
Item
Diagnosis and treatment
Max. 1 Ω
S25 (female) (12)
Max. 1 Ω
Between CP02 (female) (117) and S25 (female) (12)
Max. 1 Ω
Between CP02 (female) (120) and S25 (female) (12)
Max. 1 Ω
•
The pump secondary drive switch is normal.
•
Go to the next inspection item.
•
The pump secondary drive switch is defective.
•
Replace the pump secondary drive switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DXA9KA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with PC-EPC solenoid system
PC210-10M0, PC210LC-10M0
40-749
FAILURE CODE [DXA9KB]
40 TROUBLESHOOTING
FAILURE CODE [DXA9KB] Details of failure
The pump controller senses a ground fault or hot short circuit in the rear pump PC-EPC solenoid circuit.
Action level
L03
Action of controller
Phenomenon on machine
•
Stops to drive the rear pump PC-EPC solenoid.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
If the pump load increases, the engine speed decreases largely. The engine can stop.
Monitoring code The drive current to the rear pump PC-EPC solenoid can be monitored. (Code: 01302) Associated informaReference information tion When the solenoid and wiring harness are normal, the engine can be prevented from stopping by setting the pump drive secondary switch to the ON position. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Rear pump PCEPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V12.
3.
Connect the T-adapter to the female side of connector V12.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
40-750
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The rear pump PCEPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value Between V12 (male) (1) and (2)
3 to 14 Ω
Between V12 (male) (1) and ground
Min. 1 MΩ
NO
•
Go to the next inspection item.
•
The rear pump PCEPC solenoid is defective.
•
Replace the rear pump PC-EPC solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
FAILURE CODE [DXA9KB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S25.
3.
Connect the T-adapter to the female side of connector S25.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
3
Pump secondary drive switch
Between S25 (male) (9) and (8)
Between S25 (male) (11) and (12)
4
YES
StandMeasurement position and condition ard value
Resistance
Ground fault in wiring harness
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
Pump secondary drive switch: Normal
Max. 1 Ω
Pump secondary drive switch: Drive
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, connector V12, and connector S25.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Between CP02 (female) (104) or Resist- S25 (female) (9) and ground ance Between S25 (female) (8) or V12 (female) (1) and ground
PC210-10M0, PC210LC-10M0
Diagnosis and treatment
Min. 1 MΩ
NO
YES
•
The pump secondary drive switch is normal.
•
Go to the next inspection item.
•
The pump secondary drive switch is defective.
•
Replace the pump secondary drive switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
40-751
FAILURE CODE [DXA9KB]
No.
5
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V12.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (104) and ance each pin other than (104)
6
YES
Turn the starting switch to the OFF position.
2.
Disconnect connector V12.
3.
Connect the T-adapter to the female side of connector V12.
4.
Turn the starting switch to the ON position. Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between V12 (female) (1) and (2)
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage.
Item
•
NO
Min. 1 MΩ
1.
Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
NO
Max. 4.5V
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Confirmation of repair
40-752
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXA9KB]
Circuit diagram associated with PC-EPC solenoid system
PC210-10M0, PC210LC-10M0
40-753
FAILURE CODE [DXE0KA]
40 TROUBLESHOOTING
FAILURE CODE [DXE0KA] Details of failure
The pump controller senses an open circuit in the LS-EPC solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The machine travels fast in the Lo or Mi travel speed setting.
•
The operation speed of the work equipment and swing becomes high in fine control mode (L).
Associated informa- Monitoring code tion The drive current to the LS-EPC solenoid can be monitored. (Code: 01500) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
LS-EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V19.
3.
Connect the T-adapter to the female side of connector V19.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
ResistBetween V19 (male) (1) and (2) ance
40-754
3 to 14 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The LS-EPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
NO
•
Go to the next inspection item.
•
The LS-EPC solenoid is defective.
•
Replace the LS-EPC solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DXE0KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V19.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (88) and V19 (female) (1)
Between CP02 (female) (115) and Resist- V19 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
Max. 1 Ω
Between CP02 (female) (120) and V19 (female) (2)
Max. 1 Ω
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
V19 (female) (2)
•
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with LS-EPC solenoid system
PC210-10M0, PC210LC-10M0
40-755
FAILURE CODE [DXE0KB]
40 TROUBLESHOOTING
FAILURE CODE [DXE0KB] Details of failure
The pump controller senses a ground fault or hot short circuit in the LS-EPC solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops to drive the LS-EPC solenoid.
•
If the cause of the failure disappears, the machine becomes normal by itself.
•
The machine travels fast in the Lo or Mi travel speed setting.
•
The operation speed of the work equipment and swing becomes high in fine control mode (L).
Associated informa- Monitoring code tion The drive current to the LS-EPC solenoid can be monitored. (Code: 01500) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
LS-EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V19.
3.
Connect the T-adapter to the female side of connector V19.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
40-756
Between V19 (male) (1) and (2)
3 to 14 Ω
Between V19 (male) (1) and ground
Min. 1 MΩ
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The LS-EPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The LS-EPC solenoid is defective.
•
Replace the LS-EPC solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DXE0KB]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V19.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (88) or V19 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V19.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (88) and ance each pin other than (88)
5
Turn the starting switch to the OFF position.
2.
Disconnect connector V19.
3.
Connect the T-adapter to the female side of the connector.
4.
Turn the starting switch to the ON position.
YES
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between V19 (female) (1) and (2)
The wiring harness has no ground faults.
NO
Measure the voltage.
Item
•
NO
Min. 1 MΩ
1.
Hot short circuit 5. in wiring har6. ness
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
Max. 2.5 V
NO
40-757
FAILURE CODE [DXE0KB]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with LS-EPC solenoid system
40-758
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXE4KA]
FAILURE CODE [DXE4KA] Details of failure
The pump controller senses an open circuit in the attachment flow rate adjustment EPC solenoid circuit.
Action level
-
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
The attachment does not operate.
Monitoring code Associated informaThe drive current to the attachment flow rate adjustment EPC solenoid can be monitored. tion (Code: 01700) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Attachment flow rate adjustment EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V30.
3.
Connect the T-adapter to the female side of connector V30.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The attachment flow rate adjustment EPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
ResistBetween V30 (male) (1) and (2) ance
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
3 to 14 Ω
NO
•
Go to the next inspection item.
•
The attachment flow rate adjustment EPC solenoid is defective.
•
Replace the attachment flow rate adjustment EPC solenoid.
•
Go to "Confirmation of repair".
40-759
FAILURE CODE [DXE4KA]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V30.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (97) and V30 (female) (1)
Between CP02 (female) (115) and Resist- V30 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
Max. 1 Ω
Between CP02 (female) (120) and V30 (female) (2)
Max. 1 Ω
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
V30 (female) (2)
•
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Set to other than breaker mode (B).
5.
Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with ATT flow regulating EPC
40-760
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXE4KB]
FAILURE CODE [DXE4KB] Details of failure
The pump controller senses a ground fault in the attachment flow rate adjustment EPC solenoid circuit.
Action level
-
Action of controller Phenomenon on machine
•
None in particular. (Since no current flows, the solenoid is not energized.)
•
If the cause of the failure disappears, the machine becomes normal by itself.
The attachment does not operate.
Monitoring code Associated informaThe drive current to the attachment flow rate adjustment EPC solenoid can be monitored. tion (Code: 01700) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Attachment flow rate adjustment EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V30.
3.
Connect the T-adapter to the female side of connector V30.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The attachment flow rate adjustment EPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value Between V30 (male) (1) and (2)
3 to 14 Ω
Between V30 (male) (1) and ground
Min. 1 MΩ
NO
•
Go to the next inspection item.
•
The attachment flow rate adjustment EPC solenoid is defective.
•
Replace the attachment flow rate adjustment EPC solenoid.
•
Go to "Confirmation of repair".
40-761
FAILURE CODE [DXE4KB]
No.
3
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V30.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (97) or V30 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02, V30.
3.
CP02Connect the T-adapter to the female side of XXX.
4.
Does the measurement result agree with the standard value?
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (97) and ance each pin other than (97)
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
40-762
Do the preceding troubleshooting again. NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Set to other than breaker mode (B).
5.
Is this failure code shown?
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXE4KB]
Circuit diagram associated with ATT flow regulating EPC
PC210-10M0, PC210LC-10M0
40-763
FAILURE CODE [DXE4KY]
40 TROUBLESHOOTING
FAILURE CODE [DXE4KY] Details of failure
The pump controller senses a hot short circuit in the attachment flow rate adjustment EPC solenoid circuit.
Action level
-
Action of controller
Phenomenon on machine
•
Stops to drive the attachment flow rate adjustment EPC solenoid.
•
Even if the cause of the failure is resolved, the machine does not become normal until the starting switch is turned to the OFF position once.
When the attachment is operated, flow rate adjustment does not work. The flow rate becomes maximum.
Monitoring code Associated informaThe drive current to the attachment flow rate adjustment EPC solenoid can be monitored. tion (Code: 01700) No.
Cause
Procedures, Measurement, Values, Note
1.
Diagnosis and treatment
Check the wiring harnesses and connectors.
1
For details of the inspection method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V30.
3.
Connect the T-adapter to the female side of connector V30.
4.
Turn the starting switch to the ON position.
Hot short circuit 5. in wiring har6. ness
Voltage Between V30 (female) (1) and (2)
40-764
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES
Does the measurement result agree with the standard value? Measuring point and measurement condition
• •
Measure the voltage.
Item
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
Standard value Max 4.5V
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DXE4KY]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Do the inspection above again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Set to other than breaker mode (B).
5.
Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with ATT flow regulating EPC
PC210-10M0, PC210LC-10M0
40-765
FAILURE CODE [DXE5KA]
40 TROUBLESHOOTING
FAILURE CODE [DXE5KA] Details of failure
The pump controller senses an open circuit in the merge-divider main EPC solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops the output command to the merge-divider main EPC solenoid and the mergedivider LS-EPC solenoid. The pump is put in a constantly merging condition.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
•
The single operation speed of the work equipment and swing becomes high in fine control mode (L).
•
It will be not easy to steer while traveling.
Monitoring code Associated informaThe drive current to the merge-divider main EPC solenoid can be monitored. (Code: tion 08000) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V23.
3.
Connect the T-adapter to the female side of connector V23.
4. Merge-divider 5. main EPC solenoid
40-766
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The merge-divider main EPC solenoid is normal.
NO
• YES
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
ResistBetween V23 (male) (1) and (2) ance
• •
Measure the resistance.
Item
The wiring harnesses and connectors are normal.
YES
REMARK 1
•
3 to 14 Ω
NO
•
Go to the next inspection item.
•
The merge-divider main EPC solenoid is defective.
•
Replace the merge-divider main EPC solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DXE5KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V23.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (112) and V23 (female) (1)
Max. 1 Ω
Between CP02 (female) (115) and Resist- V23 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
V23 (female) (2)
Max. 1 Ω
Between CP02 (female) (120) and V23 (female) (2)
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with merge-divider main solenoid
PC210-10M0, PC210LC-10M0
40-767
FAILURE CODE [DXE5KB]
40 TROUBLESHOOTING
FAILURE CODE [DXE5KB] Details of failure
The pump controller senses a ground fault or hot short circuit in the merge-divider main EPC solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops the output command to the merge-divider main EPC solenoid and the mergedivider LS-EPC solenoid. The pump is put in a constantly merging condition.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
•
The single operation speed of the work equipment and swing becomes high in fine control mode (L).
•
It will be not easy to steer while traveling.
Monitoring code Associated informaThe drive current to the merge-divider main EPC solenoid can be monitored. (Code: tion 08000) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Merge-divider main EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V23.
3.
Connect the T-adapter to the female side of connector V23.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
40-768
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The merge-divider main EPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value Between V23 (male) (1) and (2)
3 to 14 Ω
Between V23 (male) (1) and ground
Min. 1 MΩ
NO
•
Go to the next inspection item.
•
The merge-divider main EPC solenoid is defective.
•
Replace the merge-divider main EPC solenoid.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DXE5KB]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V23.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (112) or ance V23 (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V23.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (112) and ance each pin other than (112)
5
Turn the starting switch to the OFF position.
2.
Disconnect connector V23.
3.
Connect the T-adapter to the female side of connector V23.
4.
Turn the starting switch to the ON position.
YES
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
YES
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between V23 (female) (1) and (2)
The wiring harness has no ground faults.
NO
Measure the voltage.
Item
•
NO
Min. 1 MΩ
1.
Hot short circuit 5. in wiring har6. ness
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
Max. 4.5V
NO
40-769
FAILURE CODE [DXE5KB]
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Confirmation of repair
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
3.
Turn the starting switch to the ON position.
4.
Is this failure code shown?
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
NO The repair is completed.
Circuit diagram associated with merge-divider main solenoid
40-770
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXE6KA]
FAILURE CODE [DXE6KA] Details of failure
The pump controller senses an open circuit in the merge-divider LS-EPC solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops the output command to the merge-divider main EPC solenoid and the mergedivider LS-EPC solenoid. The pump is put in a constantly merging condition.
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
•
The single operation speed of the work equipment and swing becomes high in fine control mode (L).
•
It will be not easy to steer while traveling.
Monitoring code Associated informaThe drive current to the merge-divider LS-EPC solenoid can be monitored. (Code: tion 08001) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Merge-divider LS-EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V24.
3.
Connect the T-adapter to the female side of connector V24.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The merge-divider LSEPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value
ResistBetween V24 (male) (1) and (2) ance
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
3 to 14 Ω
NO
•
Go to the next inspection item.
•
The merge-divider LSEPC solenoid is defective.
•
Replace the merge-divider LS-EPC solenoid.
•
Go to "Confirmation of repair".
40-771
FAILURE CODE [DXE6KA]
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V24.
3.
Connect the T-adapter to the female side of each connector.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Diagnosis and treatment YES
StandMeasurement position and condition ard value Between CP02 (female) (89) and V24 (female) (1)
Between CP02 (female) (115) and Resist- V24 (female) (2) ance Between CP02 (female) (117) and
Max. 1 Ω
Max. 1 Ω
Between CP02 (female) (120) and V24 (female) (2)
Max. 1 Ω
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
V24 (female) (2)
•
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine.
4.
Do a single operation of travel.
5.
Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with merge-divider LS solenoid
40-772
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DXE6KB]
FAILURE CODE [DXE6KB] Details of failure
The pump controller senses a ground fault or hot short circuit in the merge-divider LSEPC solenoid circuit.
Action level
L01
Action of controller
Phenomenon on machine
•
Stops the output command to the merge-divider main EPC solenoid and the mergedivider LS-EPC solenoid. The pump is put in a constantly merging condition.
•
After the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
•
The single operation speed of the work equipment and swing becomes high in fine control mode (L).
•
It will be not easy to steer while traveling.
Monitoring code Associated informaThe drive current to the merge-divider LS-EPC solenoid can be monitored. (Code: tion 08001) No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
2
Merge-divider LS-EPC solenoid
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V24.
3.
Connect the T-adapter to the female side of connector V24.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The merge-divider LSEPC solenoid is normal.
NO
• YES
StandMeasurement position and condition ard value Between V24 (male) (1) and (2)
3 to 14 Ω
Between V24 (male) (1) and ground
Min. 1 MΩ
NO
•
Go to the next inspection item.
•
The merge-divider LSEPC solenoid is defective.
•
Replace the merge-divider LS-EPC solenoid.
•
Go to "Confirmation of repair".
40-773
FAILURE CODE [DXE6KB]
No.
3
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V24.
3.
Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (89) or V24 ance (female) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector V24.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (89) and ance each pin other than (89)
5
Turn the starting switch to the OFF position.
2.
Disconnect connector V24.
3.
Connect the T-adapter to the female side of connector V24.
4.
Turn the starting switch to the ON position.
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
YES
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Voltage Between V24 (female) (1) and (2)
40-774
YES
Measure the voltage.
Item
•
NO
Min. 1 MΩ
1.
Hot short circuit 5. in wiring har6. ness
YES
Min. 1 MΩ
1.
Item
Diagnosis and treatment
Max. 4.5V
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DXE6KB]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Start the engine.
4.
Do a single operation of travel.
5.
Is this failure code shown?
NO The repair is completed.
Circuit diagram associated with merge-divider LS solenoid
PC210-10M0, PC210LC-10M0
40-775
FAILURE CODE [DY20KA]
40 TROUBLESHOOTING
FAILURE CODE [DY20KA] Details of failure
The W signal at the top end of the wiper motor working area is not input during operation of the wiper.
Action level
-
Action of controller Phenomenon on machine
•
Stops the output for operation to the wiper motor.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The wiper motor does not operate.
Monitoring code The signal input (ON/OFF) of the W contact at the wiper working area can be monitored. Associated informa- (Code: 02204) tion Reference information As the T-adapter for the pump controller connector is a “socket-type box”, the operating voltage cannot be measured at the pump controller connector. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment".
Wiring harness and connector 2.
40-776
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK 1
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
FAILURE CODE [DY20KA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M05.
3.
Connect the T-adapter to the female side of connector M05.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Wiper motor
Between M05 (female) (1) and (3)
3
YES
StandMeasurement position and condition ard value
Between M05 (female) (6) and Resist- (5) ance
Open circuit in wiring harness
Wiper position: Working area top end
Max. 1 Ω
Wiper position: Other than working area top end
Min. 1 MΩ
Wiper position: All
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CP02, and connector M05.
4.
Connect the T-adapter to the female side of connector CP01 and connector CP02 and the male side of connector M05.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value Between CP01 (female) (56) and M05 (male) (6)
Max. 1 Ω
Between M05 (male) (5) and ground
Max. 1 Ω
Resistance Between CP02 (female) (119) and M05 (male) (3)
Between CP02 (female) (114) and M05 (male) (1)
PC210-10M0, PC210LC-10M0
NO
•
The wiper motor is normal.
•
Go to the next inspection item.
•
The wiper motor is defective.
•
Replace the wiper motor.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Max. 20 Ω
1.
Item
Diagnosis and treatment
YES
NO
Max. 1 Ω Max. 1 Ω
40-777
FAILURE CODE [DY20KA]
No.
4
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CP02, and connector M05.
4.
Connect the T-adapter to the female or male side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value Between CP01 (female) (56) or M05 (male) (6) and ground
5
Short circuit in wiring harness
Min. 1 MΩ
Between CP02 (female) (114) or M05 (male) (1) and ground
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CP02, and connector M05.
4.
Connect the T-adapter to the female side of connector CP01 and connector CP02.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value Between CP01 (female) (56) and each pin other than (56)
40-778
YES
Min. 1 MΩ
Resist- Between CP02 (female) (119) and ance each pin other than (119)
Min. 1 MΩ
Between CP02 (female) (114) and each pin other than (114)
Min. 1 MΩ
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
Resist- Between CP02 (female) (119) or ance M05 (male) (3) and ground
Item
Diagnosis and treatment
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
FAILURE CODE [DY20KA]
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position. Turn the wiper switch from the INT or ON position to the OFF position.
NO The repair is completed.
Is this failure code shown?
Circuit diagram associated with windshield wiper
PC210-10M0, PC210LC-10M0
40-779
FAILURE CODE [DY20MA]
40 TROUBLESHOOTING
FAILURE CODE [DY20MA] Details of failure
When the wiper is stowed, the P signal for the wiper motor stowage area is not input.
Action level
-
Action of controller Phenomenon on machine
•
Stops the output for stowing to the wiper motor.
•
If the cause of the failure disappears, the machine becomes normal by itself.
The wiper is not stowed.
Monitoring code The signal state of the P contact at the wiper stowage area can be monitored. (Code: Associated informa- 02204) tion Reference information As the T-adapter for the pump controller connector is a “socket-type box”, the operating voltage cannot be measured at the pump controller connector. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Wiper motor
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M05.
3.
Connect the T-adapter to the female side of connector M05.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Between M05 (female) (4) and Resist- (5) ance Between M05 (female) (1) and (3)
40-780
Wiper position: Working area
Min. 1 MΩ
Wiper position: All
Max. 20 Ω
Go to the next inspection item. A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiper motor is normal.
NO
•
StandMeasurement position and condition ard value Max. 1 Ω
• •
YES
Wiper position: Stowage area
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The wiper motor is defective.
•
Replace the wiper motor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DY20MA]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CP02, and connector M05.
4.
Connect the T-adapter to the female side of connector CP01 and connector CP02 and the male side of connector M05.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value?
Open circuit in wiring harness
Item
StandMeasurement position and condition ard value Between CP01 (female) (75) and M05 (male) (4)
Max. 1 Ω
Between M05 (male) (5) and ground
Max. 1 Ω
Resistance Between CP02 (female) (119) and M05 (male) (3)
Between CP02 (female) (114) and M05 (male) (1)
4
Ground fault in wiring harness
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CP02, and connector M05.
4.
Connect the T-adapter to the female or male side of one of the connectors.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value Min. 1 MΩ
Resist- Between CP02 (female) (119) or ance M05 (male) (3) and ground
Min. 1 MΩ
Between CP02 (female) (114) or M05 (male) (1) and ground
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Max. 1 Ω
Turn the starting switch to the OFF position.
Between CP01 (female) (75) or M05 (male) (4) and ground
YES
•
Max. 1 Ω
1.
Item
Diagnosis and treatment
YES
NO
40-781
FAILURE CODE [DY20MA]
No.
5
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector CP02, and connector M05.
4.
Connect the T-adapter to the female side of connector CP01 and connector CP02.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value Between CP01 (female) (75) and each pin other than (75)
Diagnosis and treatment YES
Min. 1 MΩ
Between CP02 (female) (114) and each pin other than (114)
Min. 1 MΩ
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
Resist- Between CP02 (female) (119) and ance each pin other than (119)
•
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
40-782
Do the preceding troubleshooting again. NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position. Turn the wiper switch from the INT or ON position to the OFF position.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DY20MA]
Circuit diagram associated with windshield wiper
PC210-10M0, PC210LC-10M0
40-783
FAILURE CODE [DY2CKB]
40 TROUBLESHOOTING
FAILURE CODE [DY2CKB] Details of failure
When driving the window washer drive circuit (grounded), a short circuit was sensed when an abnormal current flowed in the circuit.
Action level
-
Action of controller
Phenomenon on machine
•
Stops the output to the window washer motor.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The window washer does not operate.
Associated informa- None in particular. tion No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
Are the wiring harnesses and connectors normal?
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
REMARK Wiring harness and connector
•
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
•
2
Fuse
40-784
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.4 in fuse box F01.
4.
Check if the fuse is blown.
5.
Check the fuse for continuity.
6.
Is the fuse normal?
YES • •
NO
Go to the next inspection item. The fuse is defective.
•
It blown, go to "Ground fault in wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DY2CKB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M06.
3.
Connect the T-adapter to the female side of connector M06.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Window washer motor
Item
Resistance Between M06 (male) (1) or (2) and ground
4
2.
Disconnect connector D02.
3.
Connect the T-adapter to the female side of connector D02.
4.
Measure the continuity.
5.
Does the measurement result agree with the standard value?
Continuity
Open circuit in wiring harness
YES
StandMeasurement position and condition ard value Between D02 (male) (3) (+) and (7) (-)
Continuity
Between D02 (male) (7) (+) and (3) (-)
No continuity
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01 and connector M06.
4.
Connect the T-adapter to the female side of each connector.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP01 (female) (3) and ance M06 (female) (1)
PC210-10M0, PC210LC-10M0
•
The window washer motor is normal.
•
Go to the next inspection item.
•
The window washer motor is defective.
•
Replace the window washer motor.
•
Go to "Confirmation of repair".
•
The diode array is normal.
•
Go to the next inspection item.
•
The diode array is defective.
•
Replace the diode array.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Min. 1 MΩ
Turn the starting switch to the OFF position.
Diode array
NO
5 to 20 Ω
1.
Item
5
YES
StandMeasurement position and condition ard value Between M06 (male) (1) and (2)
Diagnosis and treatment
NO
YES
NO
Max. 1 Ω
40-785
FAILURE CODE [DY2CKB]
No.
6
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.4 in fuse box F01.
4.
Disconnect connector M06, connector CP01, and connector D02.
5.
Connect the T-adapter to the female side of one of the connectors.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value? Item
Resistance Between CP01 (female) (3), M06 (female) (1), or D02 (female) (7) and ground
Short circuit in wiring harness
40-786
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
Min. 1 MΩ
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector CP01, connector M06, and connector D02.
4.
Connect the T-adapter to the female side of connector CP01.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP01 (female) (3) and ance each pin other than (3)
•
NO
Min. 1 MΩ
1.
Item
YES
StandMeasurement position and condition ard value Between F01-4, M06 (female) (2), or D02 (female) (3) and ground
7
Diagnosis and treatment
YES
NO
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
8
FAILURE CODE [DY2CKB]
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.4 in fuse box F01.
4.
Disconnect connector CP01 and connector M06.
5.
Connect the T-adapter to the female side of connector CP01.
6. Hot short circuit in wiring har7. ness 8.
Turn the battery disconnect switch to the ON position.
9.
Diagnosis and treatment
Voltage
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Does the measurement result agree with the standard value? Item
The wiring harness has no hot short circuits.
YES
Turn the starting switch to the ON position. Measure the voltage.
•
StandMeasurement position and condition ard value Between CP01 (female) (3) and ground
Max. 1 V
YES The repair is completed.
9
10
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position.
4.
Turn the washer switch to the ON position.
5.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
NO The repair is completed.
40-787
FAILURE CODE [DY2CKB]
40 TROUBLESHOOTING
Circuit diagram associated with windshield wiper
40-788
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DY2DKB]
FAILURE CODE [DY2DKB] Details of failure
When the normal rotation side of the wiper motor drive circuit is driven, a short circuit is sensed because an abnormal current flows in the circuit.
Action level
-
Action of controller
Phenomenon on machine
•
Stops the output to the window washer motor drive normal rotation side.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The wiper does not operate.
Reference information Associated informaAs the T-adapter for the pump controller connector is a “socket-type box”, the operating tion voltage cannot be measured at the pump controller connector. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Wiper motor
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M05.
3.
Connect the T-adapter to the female side of connector M05.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Between M05 (female) (3) and (1)
Resistance Between M05 (female) (3) and ground
PC210-10M0, PC210LC-10M0
Max. 20 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiper motor is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The wiper motor is defective.
•
Replace the wiper motor.
•
Go to "Confirmation of repair".
Min. 1 MΩ
40-789
FAILURE CODE [DY2DKB]
No.
3
Cause
Ground fault in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector M05.
3.
Connect the T-adapter to the female or male side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (119) or ance M05 (male) (3) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector M05.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (119) and ance each pin other than (119)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
40-790
Do the preceding troubleshooting again. NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position. Turn the wiper switch to the INT or ON position to troubleshoot.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [DY2DKB]
Circuit diagram associated with windshield wiper
PC210-10M0, PC210LC-10M0
40-791
FAILURE CODE [DY2EKB]
40 TROUBLESHOOTING
FAILURE CODE [DY2EKB] Details of failure
When the reverse rotation side of the wiper motor drive circuit is driven, a short circuit is sensed because an abnormal current flows in the circuit.
Action level
-
Action of controller
Phenomenon on machine
•
Stops the output to the wiper motor drive reverse side.
•
Even if the cause of the failure is removed, the machine does not become normal until the starting switch is turned to the OFF position once.
The wiper does not operate.
Reference information Associated informaAs the T-adapter for the pump controller connector is a “socket-type box”, the operating tion voltage cannot be measured at the pump controller connector. No.
Cause
Procedures, Measurement, Values, Note
1.
Check the wiring harnesses and connectors.
Diagnosis and treatment
1
For details of checking method, see "RELATED INFORMATION TO TROUBLESHOOT", "CHECKS BEFORE TROUBLESHOOTING", "Electrical equipment". 2.
2
Wiper motor
Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M05.
3.
Connect the T-adapter to the female side of connector M05.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Between M05 (female) (1) and (3)
Resistance Between M05 (female) (1) and ground
40-792
Max. 20 Ω
•
Go to the next inspection item. A wiring harness or connector is defective.
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiper motor is normal.
NO
• YES
StandMeasurement position and condition ard value
The wiring harnesses and connectors are normal.
YES
REMARK Wiring harness and connector
•
NO
•
Go to the next inspection item.
•
The wiper motor is defective.
•
Replace the wiper motor.
•
Go to "Confirmation of repair".
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
FAILURE CODE [DY2EKB]
Cause
Ground fault in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector M05.
3.
Connect the T-adapter to the female or male side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
StandMeasurement position and condition ard value
Resist- Between CP02 (female) (114) or ance M05 (male) (1) and ground
4
Short circuit in wiring harness
Turn the starting switch to the OFF position.
2.
Disconnect connector CP02 and connector M05.
3.
Connect the T-adapter to the female side of connector CP02.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? StandMeasurement position and condition ard value
Resist- Between CP02 (female) (114) and ance each pin other than (114)
YES
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the defective wiring harness.
•
Go to "Confirmation of repair".
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
YES
NO
Min. 1 MΩ
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the preceding troubleshooting again. Have you identified the cause when the inspection is done again?
1.
Turn the starting switch to the OFF position.
2.
Install all the configuration equipment and connect them.
Confirmation of 3. repair 4. 5.
NO
YES
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position. Turn the wiper switch to the INT or ON position to troubleshoot.
NO The repair is completed.
Is this failure code shown?
PC210-10M0, PC210LC-10M0
40-793
FAILURE CODE [DY2EKB]
40 TROUBLESHOOTING
Circuit diagram associated with windshield wiper
40-794
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [F@BBZL]
FAILURE CODE [F@BBZL] Details of failure
The pressure sensed by the blowby pressure sensor is 1.96 kPa or above.
Action level
L00a
Action of controller
None in particular.
Phenomenon on machine
If the machine is used as it is, the engine can be damaged.
Pre-troubleshooting Associated informa- If failure code [DHE5MA] is also shown, do the troubleshooting for this code first. tion Monitoring code The blowby pressure can be monitored. (Code: 42803) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The blowby pressure sensor is normal.
NO
• 1. 2
Blowby pressure sensor
2.
Check if the block on which the blowby pressure sensor is installed, tube and squeezed part of tip are clogged. Are the block on which the blowby pressure sensor is installed, tube and squeezed part of tip normal?
PC210-10M0, PC210LC-10M0
YES
• •
NO
Go to the next inspection item. The blowby pressure sensor is abnormal.
•
Replace the blowby pressure sensor.
•
Go to "Confirmation of repair".
40-795
FAILURE CODE [F@BBZL]
No.
3
Cause
Pump controller
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector .
3.
Start the engine. Turn the starting switch to the ON position.
4.
Measure the voltage.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Voltage
Diagnosis and treatment YES
Standard value
NO
•
The pump controller is normal.
•
Go to the next inspection item.
•
The pump controller is defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
0.3 to 3.6V
YES The repair is completed. 4
5
Reconfirmation 1. of inspection 2. item
NO
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
4.
•
The engine controller can be defective.
•
Replace the engine.
•
Go to "Confirmation of repair".
Can you identify the cause by reconfirmation?
1. Confirmation of 3. repair
40-796
Do the inspection above again.
Turn the starting switch to the ON position to troubleshoot. Is this failure code shown?
YES
Return to the first inspection item.
NO The repair is completed.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
FAILURE CODE [F@BBZL]
Circuit diagram associated with blowby pressure sensor
PC210-10M0, PC210LC-10M0
40-797
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
40 TROUBLESHOOTING
TROUBLESHOOTING MODE)
SYSTEM
OF
ELECTRICAL
(E-
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) Failure
The engine does not start. (The engine does not crank.) Pre-troubleshooting •
If a failure code is shown, troubleshoot for that code first.
•
If the operation sound of battery relay is not heard when the starting switch is turned to the ON position, troubleshoot with this procedure as well.
•
If the machine monitor does not light up when the starting switch is turned to the ON position, the main power supply system can be defective. Troubleshoot for WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.
Associated information
Reference information The engine start circuit is equipped with 2 systems of start lock structure as follows.
No.
1.
Start lock by password of machine monitor
2.
Start lock by lock lever
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The battery is normal.
NO
• YES • 1. 2
Battery 2.
40-798
Check the battery. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Is the battery normal?
•
Go to the next inspection item. The battery is defective.
•
Resolve the problem. For details, see Electrical equipment.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
3
•
The fusible link is normal.
•
Go to the next inspection item. The fusible link is defective.
1.
Turn the starting switch to the OFF position.
•
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
•
3.
Remove fusible link F05. Check if it is blown.
4.
Ifs blown, go to "Ground fault of wiring harness of continuous power supply".
Is the fusible link normal?
•
If the fusible link is not blown but has no continuity, replace it.
•
Go to "Confirmation of repair". The fuse is normal.
Fusible link
NO
• YES •
4
1.
Turn the starting switch to the OFF position.
•
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
•
3.
Remove fuse No.17 in fuse box F01. Check if the fuse is blown. Check the resistance.
Ifs blown, go to "Ground fault of wiring harness of continuous power supply".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
Fuse
4.
5
Open circuit in wiring harness (continuous power supply circuit)
Go to the next inspection item. The fuse is defective.
NO
Is the fuse normal?
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector H15. Connect the T-adapter to the female side.
4.
Measure the resistance.
5.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resistance
Between battery terminal and H15 (female) (1)
PC210-10M0, PC210LC-10M0
Standard value
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 1 Ω
40-799
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
No.
6
Cause
Ground fault in wiring harness (continuous power supply circuit)
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuses No.16, 17, 18 and 19 in fuse box F01.
4.
Disconnect connector H15. Connect the T-adapter to the female side.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Resistance
Measuring point and measurement condition Between H15 (female) (1) and ground
2.
Disconnect connector H15 to troubleshoot.
3.
After troubleshooting, turn the starting switch to the ON and START position to troubleshoot again.
4.
Does the measurement result agree with the standard value?
Starting Between H15 switch OFF (male) (1) and Starting (2) switch ON
Starting switch
Starting switch OFF
Resistance
Between H15 (male) (1) and Starting (5) switch ON
Starting switch OFF
YES
NO
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The starting switch is normal.
•
Go to the next inspection item.
•
The starting switch is defective.
•
Repair or replace the starting switch.
•
Go to "Confirmation of repair".
Min. 1 MΩ
Turn the starting switch to the OFF position.
Measuring point and measurement condition
Diagnosis and treatment
Standard value
1.
Item
7
40 TROUBLESHOOTING
YES
Standard value Min. 1 MΩ Max. 1 Ω
NO Min. 1 MΩ Max. 1 Ω Min. 1 MΩ
Between H15 (male) (1) and Turn the starting switch to (4) Max. 1 Ω the START position.
40-800
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
8
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
Cause
Diode (between starting switch and battery relay)
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01. Connect the T-adapter to the male side.
3.
Measure the continuity.
4.
Does the troubleshooting result agree with the standard value? Item
Continuity
9
Open circuit in wiring harness (battery relay primary side)
Measuring point and measurement condition
No continuity
Between D01 (male) (5) (+) and (1) (-)
Continuity
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connectors H15 and D01. Connect the T-adapter to each female side.
4.
Measure the resistance.
5.
Does the troubleshooting result agree with the standard value?
Resistance
PC210-10M0, PC210LC-10M0
•
The diode between the starting switch and the battery relay is normal.
•
Go to the next inspection item. The diode between the starting switch and the battery relay is defective.
YES
•
Standard value
Between D01 (male) (1) (+) and (5) (-)
Item
Diagnosis and treatment
Standard value
Between H15 (female) (2) and D01 (female) (5)
Max. 1 Ω
Between D01 (female) (1) and terminal R02 of battery relay
Max. 1 Ω
Between terminal R01 of battery relay and ground
Max. 1 Ω
NO
•
Replace the diode between the starting switch and the battery relay.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
• YES
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-801
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
No.
Cause
Ground fault in wiring harness 10 (battery relay primary side)
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect the battery relay terminal R02.
4.
Disconnect connectors H15 and D01. Connect the T-adapter to each female side.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value? Item
Resistance
11 Battery relay
Standard value
Between ground and one of D01 (female) (1) and battery relay terminal R02
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
NO
YES
NO
Between terminal R02 of battery relay and terminal R01 of 200 to 600 Ω battery relay
1.
Turn the starting switch to the OFF position.
2.
Measure the resistance.
3.
Does the measurement result agree with the standard value?
Resistance
YES
Measuring point and measurement condition Between terminal R03 of battery relay and terminal SB of starting motor
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The battery relay is normal.
•
Go to the next inspection item.
•
The battery relay is defective.
•
Replace the battery relay.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 1 MΩ
2.
Item
Diagnosis and treatment
Between ground and one of H15 (female) (2) and D01 (fe- Min. 1 MΩ male) (5)
Turn the starting switch to the OFF position.
Resistance
40-802
Measuring point and measurement condition
1.
Item
Open circuit in wiring harness 12 (between battery relay and starting motor)
40 TROUBLESHOOTING
YES
Standard value Max. 1 Ω
Between terminal R03 of battery relay and terminal R29 of Max. 1 Ω safety relay
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
Cause
Ground fault in wiring harness 13 (between battery relay and starting motor)
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect terminal R03 of the battery relay and terminal SB of the starting motor.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
Starting motor 14 cut-off relay
Measuring point and measurement condition Between ground and one of terminal R03 of battery relay and terminal SB of starting motor
Standard value
Diagnosis and treatment YES
NO
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The starting motor cutoff relay is normal.
•
Go to the next inspection item. The starting motor cutoff relay is defective.
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Replace the cut-off relay R06 of the starting motor with an other relay.
3.
Start the engine to troubleshoot.
4.
Is the phenomenon reproduced in the same way?
YES
• NO
•
Replace the starting motor cut-off relay.
•
Go to "Confirmation of repair". The personal code relay is normal.
•
Personal Code 15 Relay
1.
Turn the starting switch to the OFF position.
2.
Replace personal code relay R07 with an other relay.
3.
Start the engine to troubleshoot.
4.
Is the phenomenon reproduced in the same way?
PC210-10M0, PC210LC-10M0
YES
• •
NO
Go to the next inspection item. The personal code relay is defective.
•
Replace the personal code relay.
•
Go to "Confirmation of repair".
40-803
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
No.
Cause
Open circuit in wiring harness (between start16 ing switch and starting motor safety relay)
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors H15, R06, R07 and R17. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Resistance
Measuring point and measurement condition Between H15 (female) (4) and R06 (female) (5)
Max. 1 Ω
Between R06 (female) (3) and R07 (female) (4)
Max. 1 Ω
Between R07 (female) (3) and R17 (female) (1)
Max. 1 Ω
Turn the starting switch to the OFF position.
2.
Disconnect connectors H15, R06, R07 and R17. Connect the T-adapter to the female side of one of the connectors.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
NO
YES
Standard value
Between ground and one of H15 (female) (4) and R06 (fe- Min. 1 MΩ male) (5) Resistance
YES
Standard value
1.
Ground fault in wiring harness (between start17 ing switch and starting motor safety relay)
Diagnosis and treatment
NO
Between ground and one of R06 (female) (3) and R07 (fe- Min. 1 MΩ male) (4)
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The starting motor safety relay is normal.
•
Go to the next inspection item.
•
The starting motor safety relay is defective.
•
Replace the starting motor safety relay.
•
Go to "Confirmation of repair".
Between ground and one of R07 (female) (3) and R17 (fe- Min. 1 MΩ male) (1)
Starting motor 18 safety relay
1.
Turn the starting switch to the START position to troubleshoot.
2.
Measure the voltage.
3.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between terminal R28 of Voltage starting motor safety relay and ground
40-804
Standard value 20 to 30V
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Measure the resistance.
YES
Open circuit in 3. Does the troubleshooting result agree with the standard value? wiring harness (between startMeasuring point and meas- Standard val19 Item ing motor safeurement condition ue ty relay and Between terminal R28 of starting motor) Resistance
starting motor safety relay and terminal SC of starting motor
NO
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
1.
Turn the starting switch to the OFF position.
2.
YES Disconnect terminal R28 of the starting motor • safety relay and terminal SC of the starting motor.
3. Measure the resistance. Ground fault in wiring harness 4. Does the troubleshooting result agree with the standard value? (between start20 ing motor safeMeasuring point and meas- Standard valItem ty relay and urement condition ue starting motor) Resistance
Diode (between starting 21 motor safety relay and battery relay)
Diagnosis and treatment
Between ground and terminal R28 of starting motor safety Min. 1 MΩ relay or terminal SC of starting motor
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01. Connect the T-adapter to the male side.
3.
Measure the continuity.
4.
Does the troubleshooting result agree with the standard value? Item
Continuity
PC210-10M0, PC210LC-10M0
NO
Measuring point and measurement condition
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The diode between the starting motor safety relay and the battery relay is normal.
•
Go to the next inspection item. The diode between the starting motor safety relay and the battery relay is defective.
YES
•
Standard value
Between D01 (male) (2) (+) and (6) (-)
No continuity
Between D01 (male) (6) (+) and (2) (-)
Continuity
NO
Go to the next inspection item.
•
Replace the diode between the starting motor safety relay and the battery relay.
•
Go to "Confirmation of repair".
40-805
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R17. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage.
Hot short circuit 5. in wiring harness (between 22 starting motor safety relay and alternator)
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The starting motor is normal.
•
Go to the next inspection item.
•
The starting motor is defective.
•
Replace the starting motor.
•
Go to "Confirmation of repair".
YES
Does the troubleshooting result agree with the standard value? REMARK If there is a hot short in charge circuit, the starting motor operation is prohibited by the starting motor safety relay. Item
Voltage
Measuring point and measurement condition Between R17 (female) (2) and ground
Max 1V
Turn the starting switch to the START position to troubleshoot.
2.
Measure the voltage.
3.
Does the troubleshooting result agree with the standard value? Item
Voltage
Measuring point and measurement condition Between terminal SB of starting motor and ground
NO
Standard value
1.
23 Starting motor
Diagnosis and treatment
YES
Standard value 20 to 30V
NO
Between terminal SC of start20 to 30V ing motor and ground
YES The repair is completed.
Reconfirmation 1. 24 of inspection 2. item
25
40-806
The machine monitor, pump controller or engine controller can be defective.
•
Replace each controller in the order of replacement. Go to "Confirmation of repair" each time.
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
YES The repair is completed.
Turn the starting switch to the ON position. The engine does not start. Is the (ENGINE DOES NOT CRANK) problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
Circuit diagram associated with engine starting system
PC210-10M0, PC210LC-10M0
40-807
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK
40 TROUBLESHOOTING
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK Details of failure
The manual preheating system does not work. Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaReference information tion This troubleshooting describes the procedures for the case that the area where the electrical intake air heater is mounted is not warmed by the manual preheat function. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
3
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
Diode
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D02. Connect the T-adapter to the male side.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value? Item
Continuity
40-808
Measuring point and measurement condition
Standard value
Between D02 (male) (1) (+) and (5) (-)
No continuity
Between D02 (male) (5) (+) and (1) (-)
Continuity
•
NO
Go to the next inspection item. The fuse is defective.
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The diode is normal.
• YES •
Go to the next inspection item.
•
The diode is defective.
•
Repair or replace the diode.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
5
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK
Cause
Electric intake air heater
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect terminal E01 of the electric intake air heater.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Continuity
Between terminal E01 of the electric intake air heater and ground
Turn the starting switch to the OFF position.
2.
Disconnect the battery ground.
3.
Disconnect connector H15.
4.
Turn the starting switch to the OFF and HEAT positions to troubleshoot.
5.
Does the measurement result agree with the standard value?
Starting switch
Item
Measuring point and measurement condition
Resistance
Starting Between H15 switch OFF (male) (1) and Starting (3) switch: HEAT
Standard value
NO
Min. 1 MΩ
2.
Disconnect connector H15. Connect the T-adapter to the female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
YES
Resistance
Between battery relay terminal R03 and heater relay terminal R16B
The electric intake air heater is normal.
•
Go to the next inspection item.
•
The electric intake air heater is defective.
•
Replace the electric intake air heater.
•
Go to "Confirmation of repair".
•
The starting switch is normal.
•
Go to the next inspection item.
•
The starting switch is defective.
•
Repair or replace the starting switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between H15 (female) (3) Max. 1 Ω and heater relay terminal R15 Between heater relay terminals and ground
•
Max. 1 Ω
Turn the starting switch to the OFF position.
Open circuit in wiring harness
NO
YES
1.
Measuring point and measurement condition
YES
Continuity
1.
Item
6
Standard value
Diagnosis and treatment
Max. 1 Ω
Max. 1 Ω
NO
Between heater relay terminal R16B and heater terminal Max. 1 Ω E01
PC210-10M0, PC210LC-10M0
40-809
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK
No.
7
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect heater relay terminal R15 and heater terminal E01.
4.
Disconnect connectors H15, CM01, R18 and D02. Connect the T-adapter to the female side of one of the connectors.
5.
Measure the resistance.
6.
Does the troubleshooting result agree with the standard value?
Ground fault in wiring harness
Item
Resistance
Measuring point and measurement condition
Diagnosis and treatment YES
Standard value
NO
Between ground and one of H15 (female) (3), CM01 (female) (12), R18 (female) (5), D02 (female) (1) and heater relay R15
Min. 1 MΩ
Between ground and one of battery relay terminal R03 and heater relay terminal R16B
Min. 1 MΩ
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The heater relay is normal.
•
Go to the next inspection item. The heater relay is defective.
Between ground and one of heater relay terminal E01 and Min. 1 MΩ heater terminal R16A
YES 1. 8
Heater relay
2.
Turn the start switch to the HEAT position to troubleshoot. Can you hear a clicking sound from the heater relay when it activates?
• NO
•
Repair or replace the heater relay.
•
Go to "Confirmation of repair".
YES The repair is completed. 9
Reconfirmation 1. of inspection 2. item
40-810
Do the troubleshooting above again.
•
The heater can be defective.
•
Replace the heater.
•
Go to "Confirmation of repair".
Have you identified the cause by reconfirmation? NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
10
Cause
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair
Turn the starting switch to the ON position. Start the manual preheating function.
4.
Is the MANUAL PREHEATING SYSTEM DOES NOT WORK problem resolved?
Diagnosis and treatment YES The repair is completed.
NO
Return to the first inspection item.
Circuit diagram associated with engine preheating
PC210-10M0, PC210LC-10M0
40-811
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK
40 TROUBLESHOOTING
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK Details of failure
The automatic preheating system does not work. Pre-troubleshooting
Associated information
•
If a failure code is shown, do the troubleshooting for that code first.
•
If automatic preheating function does not operate, check if the manual preheating function operates first.
•
If the manual preheating function does not work, do the troubleshooting for the manual preheating function first.
Monitoring code The charge air (boost) temperature can be monitored. (Code: 18500) Reference information When the boost temperature is -4°C or below, the automatic preheating function operates.
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.6 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
40-812
•
NO
Go to the next inspection item. The fuse is defective.
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
3
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK
Cause
Preheating relay
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R18. Replace the relay with the same type.
3.
Turn the starting switch to the ON position.
4.
Is this failure phenomenon cleared?
Open circuit in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.6 in fuse box F01.
4.
Disconnect connector R18. Connect the T-adapter to the female side.
5.
Measure the resistance.
6.
Does the measurement result agree with the standard value? Item
Resistance
5
Ground fault in wiring harness
YES
REMARK Operate the automatic preheating function to troubleshoot. If there is no abnormalities, it is normal. When the boost temperature is -4°C or below, the automatic preheating function operates.
4
Diagnosis and treatment
Measuring point and measurement condition Between F01-6 and R18 (female) (3)
Standard value
NO
YES
NO
•
The preheating relay is normal.
•
Go to the next inspection item.
•
The preheating relay is defective.
•
Replace the preheating relay.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
Max. 1 Ω
Between R18 (female) (5) Max. 1 Ω and heater relay terminal R15
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.6 in fuse box F01.
4.
Disconnect connector R18. Connect the T-adapter to the female side.
•
The wiring harness has a ground fault.
5.
Measure the resistance.
•
6.
Does the measurement result agree with the standard value?
Repair or replace the wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
Item Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between ground and one of R18 (female) (3) and F01-6
Standard value Min. 1 MΩ
YES
NO
40-813
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-814
Do the troubleshooting above again.
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Activate the automatic preheating system. Is the AUTOMATIC PREHEATING SYSTEM DOES NOT WORK problem resolved?
•
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK
Circuit diagram associated with engine preheating
PC210-10M0, PC210LC-10M0
40-815
E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP
40 TROUBLESHOOTING
E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP Details of failure
While preheating is in operation, the preheating monitor does not light up.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
3
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
Diode array
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D02. Connect the T-adapter to the male side.
3.
Measure the continuity.
4.
Does the troubleshooting result agree with the standard value? Item
Continuity
40-816
Measuring point and measurement condition
Standard value
Between D02 (male) (1) (+) and (5) (-)
No continuity
Between D02 (male) (5) (+) and (1) (-)
Continuity
•
NO
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The diode array is normal.
• YES
NO
Go to the next inspection item. The fuse is defective.
•
Go to the next inspection item.
•
The diode array is defective.
•
Replace the diode array.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP
40 TROUBLESHOOTING
No.
4
5
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect the battery ground.
3.
Disconnect connector H15.
4.
Turn the starting switch to the OFF and HEAT positions to troubleshoot.
5.
Does the measurement result agree with the standard value?
Starting switch
Open circuit in wiring harness
Item
Measuring point and measurement condition
Resistance
Starting Between H15 switch OFF (male) (1) and Starting (3) switch: HEAT
YES
Standard value
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01.
4.
Disconnect relay terminal R15 of the intake air heater.
5.
Disconnect connectors CM01, D02, H15 and R18. Connect the T-adapter to each female side.
6.
Measure the resistance.
7.
Does the measurement result agree with the standard value?
PC210-10M0, PC210LC-10M0
YES
Standard value
Between F01-17 and H15 (feMax. 1 Ω male) (1)
Resistance
•
The starting switch is normal.
•
Go to the next inspection item.
•
The starting switch is defective.
•
Repair or replace the starting switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Max. 1 Ω
Turn the starting switch to the OFF position.
Item
NO
Min. 1 MΩ
1.
Measuring point and measurement condition
Diagnosis and treatment
Between CM01 (female) (12) and H15 (female) (3)
Max. 1 Ω
Between CM01 (female) (12) and R18 (male) (5)
Max. 1 Ω
Between CM01 (female) (12) and D02 (male) (1)
Max. 1 Ω
Between CM01 (female) (12) and relay terminal R15 of intake air heater
Max. 1 Ω
NO
40-817
E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP
No.
6
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01.
4.
Disconnect the relay terminal R15 of the intake air heater.
5.
Disconnect connectors CM01, D02, H15 and R18. Connect the T-adapter to the female side of one of the connectors.
6.
Measure the resistance.
7.
Does the troubleshooting result agree with the standard value?
Ground fault in wiring harness
Item
Resistance
7
Short circuit in wiring harness
40-818
40 TROUBLESHOOTING
Measuring point and measurement condition
Standard value
Between ground and one of F01-17 and H15 (female) (1)
Min. 1 MΩ
Between ground and one of CM01 (female) (12), D02 (female) (1), H15 (female) (3), R18 (female) (5) and relay terminal R15 of intake air heater relay
Min. 1 MΩ
Between ground and one of D02 (female) (2) and ground terminal T05
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.17 in fuse box F01.
4.
Disconnect the relay terminal R15 of the intake air heater.
5.
Disconnect connectors CM01, D02, H15 and R18. Connect the T-adapter to the female side of CM01.
6.
Measure the resistance.
7.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resistance
Between CM01 (female) (12) and each pin other than pin (12)
Standard value
Diagnosis and treatment YES
NO
YES
NO
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
8
9
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-819
E-4 WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP
40 TROUBLESHOOTING
Circuit diagram associated with engine preheating
40-820
PC210-10M0, PC210LC-10M0
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING
40 TROUBLESHOOTING
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING Details of failure
When the starting switch is turned to the ON position, the machine monitor displays nothing. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first. Reference information
Associated information
No.
•
When the starting switch is turned to the ON position, the KOMATSU logo, screen to input password (if set), screen to check the breaker mode (if set), screen of check before starting, screen to check the working mode, screen to check the travel speed, and the standard screen are shown in order.
•
Battery voltage can drop sharply at the starting of engine, under some ambient temperature and battery conditions. Under such conditions, machine monitor display can disappear temporarily. This phenomenon is not abnormal.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
•
YES 1.
2
Battery discon2. nect switch
Turn the starting switch to the OFF position. Is the battery disconnect switch in the ON position?
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair".
NO
Go to the next inspection item. •
Battery disconnect switch is left in OFF.
•
Turn the battery disconnect switch to the ON position.
•
Go to "Confirmation of repair". The battery is normal.
NO
• YES • 1. 3
Battery 2.
Check the battery. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Is the battery normal?
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. The battery is defective.
•
Resolve the problem. For details, see Electrical equipment.
•
Go to "Confirmation of repair".
NO
40-821
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
4
•
The fusible link is normal.
•
Go to the next inspection item. The fusible link is defective.
1.
Turn the starting switch to the OFF position.
•
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
•
3.
Remove fusible link F05. Check if it is blown.
4.
Ifs blown, go to "Ground fault of wiring harness of continuous power supply".
Is the fusible link normal?
•
If the fusible link is not blown but has no continuity, replace it.
•
Go to "Confirmation of repair". The fuse is normal.
Fusible link
NO
• YES •
5
Fuse
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuses No.10, 17 and 20 in fuse box F01. Check if the fuses are blown. Check the continuity.
4.
6
Starting switch
NO
•
Ifs blown, go to "Ground fault of wiring harness of continuous power supply".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The starting switch is normal.
Is the fuse normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector H15. Connect the T-adapter to the male side.
3.
Turn the starting switch to the ON position.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
40-822
•
Measuring point and measurement condition Starting Between H15 switch OFF (male) (1) and Starting (5) switch ON
Standard value Min. 1 MΩ
• YES
NO
Go to the next inspection item. The fuse is defective.
•
Go to the next inspection item.
•
The starting switch is defective.
•
Repair or replace the starting switch.
•
Go to "Confirmation of repair".
Max. 1 Ω
PC210-10M0, PC210LC-10M0
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fusible link F05.
4.
Remove fuses No.10, 17 and 20 in fuse box F01.
5.
Disconnect connectors CP01 and H15. Connect the T-adapter to each female side.
6.
Measure the resistance.
7.
Does the troubleshooting result agree with the standard value? Item
7
Open circuit in wiring harness
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition
Diagnosis and treatment YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Standard value
Between battery (+) and F05 (male) (2)
Max. 1 Ω
Between F05 (male) (1) and F01-16E
Max. 1 Ω
Between F01-17 and each of CP01 (female) (1) and (4)
Max. 1 Ω
Between ground and each of CP01 (female) (2) and (5)
Max. 1 Ω
NO
Between F01-17 and H15 (feMax. 1 Ω male) (1) Between H15 (female) (5) and F01-10C
Max. 1 Ω
Between H15 (female) (5) and F01-20F
Max. 1 Ω
Between H15 (female) (5) and CP01 (female) (24)
Max. 1 Ω
Between H15 (female) (5) and CP01 (female) (43)
Max. 1 Ω
Between H15 (female) (5) and CP01 (female) (80)
Max. 1 Ω
40-823
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fusible link F05.
4.
Remove fuses No.10, 17 and 20 in fuse box F01.
5.
Disconnect connectors CP01 and H15. Connect the T-adapter to the female side of one of the connectors.
6.
Measure the resistance.
7.
Does the troubleshooting result agree with the standard value?
Ground fault in wiring harness
Item
Measuring point and measurement condition
YES
Standard value
Between ground and one of Min. 1 MΩ battery (+) and F05 (male) (2)
Resistance
Diagnosis and treatment
Between ground and one of F05 (male) (1) and F01-16E
Min. 1 MΩ
Between ground and one of F01-17, CP01 (female) (1), (4) and H15 (female) (1)
Min. 1 MΩ
NO
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
If the fusible link is blown, replace it.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
Between ground and one of F01-10C, F01-20F, H15 (feMin. 1 MΩ male) (5), CP01 (female) (24), (43) and (80)
YES The repair is completed.
9
10
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-824
Do the troubleshooting above again.
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING
Circuit diagram associated with machine monitor
PC210-10M0, PC210LC-10M0
40-825
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW
40 TROUBLESHOOTING
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW Details of failure
When the starting switch is turned to the ON position (with the engine stopped), the engine oil level monitor lights up in yellow.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The engine oil level is normal.
NO
• YES 1. 2
Engine oil level 2.
Check the engine oil level.
•
Is the engine oil level between marks H and L of the dipstick? NO
3
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P44. Connect the T-adapter to the male side.
3.
Measure the resistance.
Engine oil level 4. sensor
Resistance
40-826
YES
Measuring point and measurement condition Between P44 (male) (1) and ground
Standard value Max. 1 Ω
NO
Go to the next inspection item. The engine oil level is incorrect.
•
Add engine oil to the correct level.
•
Go to "Confirmation of repair". The engine oil level sensor is normal.
•
Does the troubleshooting result agree with the standard value? Item
•
•
Go to the next inspection item.
•
The engine oil level sensor is defective.
•
Replace the engine oil level sensor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW
40 TROUBLESHOOTING
No.
4
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM02 and P44. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Item Resistance
Between CM02 (female) (2) and P44 (female) (1)
Standard value
Diagnosis and treatment YES
NO
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
Is the WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW problem resolved?
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
Circuit diagram associated with engine oil level Monitor panel
CM01 (070-18) Battery (GND) Battery (GND)
CM02 (070-12) Engine oil level
P44 ( D T- 2 )
Engine oil level sensor AEX
G0024184
PC210-10M0, PC210LC-10M0
40-827
E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW
40 TROUBLESHOOTING
E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW Details of failure
When the starting switch is turned to the ON position (with the engine stopped), the radiator coolant level caution lamp lights up in yellow.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The radiator coolant level is normal.
NO
• YES 1. 2
3
Radiator coolant level
Radiator coolant level sensor
2.
Check the radiator for the coolant level and leakage. Is the radiator coolant level between FULL and LOW of the sub-tank?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P24. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Resistance
40-828
Measuring point and measurement condition Between P24 (male) (1) and (2)
Standard value Max. 1 Ω
• •
NO
•
Add radiator coolant to the correct level.
•
Go to "Confirmation of repair". The radiator coolant level sensor is normal.
• YES
NO
Go to the next inspection item. The radiator coolant level is incorrect.
•
Go to the next inspection item.
•
The radiator coolant level sensor is defective.
•
Replace the radiator coolant level sensor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW
40 TROUBLESHOOTING
No.
4
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM02 and P24. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Resistance
Measuring point and measurement condition Between CM02 (female) (3) and P24 (female) (1)
Standard value
Diagnosis and treatment YES
NO
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Between P24 (female) (2) and Max. 1 Ω ground
YES The repair is completed.
5
6
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. 4. repair
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with radiator coolant level switch Monitor panel
Battery (GND) Battery (GND) Radiator water level sensor Radiator water level
T10 G0024185
PC210-10M0, PC210LC-10M0
40-829
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION Details of failure
The engine coolant temperature monitor lights up in white while the engine runs. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
The engine coolant temperature can be monitored. (Code: 04107) Associated informaReference information tion
No.
•
Signals from the engine coolant temperature sensor are input to the engine controller. The information is sent to the machine monitor by CAN communication.
•
When the engine coolant temperature becomes approximately 30°C or below, the coolant temperature monitor lights up in white.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The warm-up operation of the machine is not sufficient.
YES •
Do a warm-up operation of the machine.
• •
1. 1
Engine coolant temperature 2.
Check the engine coolant temperature with the monitoring function. (Code: 04107)
•
Is the engine coolant temperature 30°C or below? NO
Go to "Confirmation of repair". The engine coolant temperature gauge system can be defective. Do the troubleshooting for COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM and ENGINE COOLANT TEMPERATURE GAUGE INDICATES INCORRECT VALUE (AT VALUES OTHER THAN MINIMUM AND MAXIMUM) in E mode.
YES The repair is completed.
2
Reconfirmation 1. of inspection 2. item
40-830
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
No.
3
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
Is the ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION problem resolved?
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES The repair is completed.
NO
Return to the first inspection item.
40-831
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION Details of failure
The hydraulic oil temperature monitor lights up in white while the engine runs. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
The hydraulic oil temperature can be monitored. (Code: 04401) Associated informaReference information tion
No.
•
Signals from the hydraulic oil temperature sensor are input to the pump controller. The information is sent to the machine monitor through CAN communication.
•
When the hydraulic oil temperature becomes approximately 20°C or below, the hydraulic oil temperature monitor lights up in white.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The warm-up operation of the machine is not sufficient.
YES •
Do a warm-up operation of the machine.
• •
1
Hydraulic oil temperature
1.
Check the hydraulic oil temperature with the monitoring function. (Code: 04401)
2.
Is the hydraulic oil temperature 20°C or below?
Go to "Confirmation of repair". The hydraulic oil temperature gauge system can be defective.
•
Do the troubleshooting for HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM, and HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT VALUE (AT VALUES OTHER THAN MINIMUM AND MAXIMUM) in E mode.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
Reconfirmation 1. of inspection 2. item
40-832
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
No.
3
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
Is the HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION problem resolved?
PC210-10M0, PC210LC-10M0
Diagnosis and treatment YES The repair is completed.
NO
Return to the first inspection item.
40-833
E-10 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-10 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION Details of failure
The air cleaner clogging monitor lights up in yellow while the engine is in operation. Pre-troubleshooting
Associated informa- If a failure code is shown, do the troubleshooting for that code first. tion Monitoring code The signal voltage of the air cleaner clogging switch can be monitored. (Code: 04501) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The air cleaner is normal.
NO
• YES
2
Air cleaner
1.
Check if the air cleaner is clogged.
2.
Is the air cleaner normal?
• NO
3
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P23. Connect the T-adapter to the male side.
3.
Measure the resistance.
4. Air cleaner clogging switch
Resistance
40-834
YES
Measuring point and measurement condition Between P23 (male) (1) and (2)
Standard value Max. 1 Ω
NO
Go to the next inspection item. The air cleaner is defective.
•
Clean or replace the air cleaner.
•
Go to "Confirmation of repair". The air cleaner clogging switch is normal.
•
Does the troubleshooting result agree with the standard value? Item
•
•
Go to the next inspection item.
•
The air cleaner clogging switch is defective.
•
Replace the air cleaner clogging switch.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-10 AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
No.
4
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM02 and P23. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Open circuit in wiring harness
Item
Resistance
Measuring point and measurement condition Between CM02 (female) (4) and P23 (female) (1)
Standard value
Diagnosis and treatment YES
NO
Max. 1 Ω
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Between P23 (female) (2) and Max. 1 Ω ground
YES The repair is completed.
5
Reconfirmation 1. of inspection 2. item
1. 6
2. Confirmation of 3. repair
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
Turn the starting switch to the OFF position. Turn the starting switch to the ON position. Is the AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION problem resolved?
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
Circuit diagram associated with air cleaner clogging switch
PC210-10M0, PC210LC-10M0
40-835
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION Details of failure
The charge level monitor lights up in red while the engine is in operation. Pre-troubleshooting
Associated informa- If a failure code is shown, do the troubleshooting for that code first. tion Monitoring code The state of the alternator generating signal can be monitored. (Code: 04300) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector D01. Connect the T-adapter to the male side.
3.
Measure the continuity.
4.
Does the troubleshooting result agree with the standard value?
Diode
Item
Continuity
3
Open circuit in wiring harness
40-836
Measuring point and measurement condition
Standard value
Between D01 (male) (6) (+) and (2) (-)
Continuity
Between D01 (male) (2) (+) and (6) (-)
No continuity
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM01 and E12. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resistance
Between CM01 (female) (16) and E12 (female) (1)
Standard value Max. 1 Ω
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The diode is normal.
NO
• YES •
Go to the next inspection item.
•
The diode is defective.
•
Replace the diode.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
NO
YES
NO
PC210-10M0, PC210LC-10M0
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
No.
4
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM01, CK02, R17, E12 and D01. Connect the T-adapter to the female side of one of the connectors.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value?
Ground fault in wiring harness
Item
Resistance
5
6
Short circuit in wiring harness
Alternator
Measuring point and measurement condition
Standard value
YES
NO
Between ground and one of CM01 (female) (16), CK02 (female) (4), R17 (female) (2), Min. 1 MΩ E12 (female) (1) and D01 (female) (6)
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM01, CK02, R17, E12 and D01. Connect the T-adapter to the female side of CM01.
3.
Measure the resistance.
4.
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Resistance
Between CM01 (female) (16) and each pin other than pin (16)
Standard value
YES
NO
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The alternator is normal.
•
Go to the next inspection item.
•
The alternator is defective.
•
Replace the alternator.
•
Go to "Confirmation of repair".
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector E12.
3.
Start the engine.
4.
Run the engine at a medium speed or above.
5.
Measure the voltage.
6.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Standard value
Voltage Between E12 (1) and ground
27.5 to 29.5 V
Item
Diagnosis and treatment
YES
NO
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation?
PC210-10M0, PC210LC-10M0
NO
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair". 40-837
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
No.
8
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-838
40 TROUBLESHOOTING
Diagnosis and treatment YES The repair is completed.
Start the engine to troubleshoot. Is the CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
Circuit diagram associated with battery charging system
PC210-10M0, PC210LC-10M0
40-839
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION Details of failure
The fuel level monitor lights up in red while the engine runs. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The signal voltage from the fuel sensor can be monitored. (Code: 04200) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment • YES • • •
1
Fuel tank
1.
Check the fuel tank.
2.
Is the fuel level low?
The fuel is not sufficient. Refill with fuel. Go to "Confirmation of repair". The fuel gauge system can be defective.
•
Do the troubleshooting for FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM and FUEL GAUGE INDICATES INCORRECT LEVEL (AT LEVELS OTHER THAN MINIMUM AND MAXIMUM).
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
40-840
Do the troubleshooting above again.
Is the FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION problem resolved?
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION Details of failure
The water separator monitor lights up in red while the engine is in operation. Pre-troubleshooting
Associated informa- If a failure code is shown, do the troubleshooting for that code first. tion Monitoring code The state of the water sensed by the fuel filter sensor can be monitored. (Code: 05604) No.
1
Cause
Water separator
Procedures, Measurement, Values, Note
1.
Check with the monitoring function (Code: 05604).
2.
Is water found in the water separator?
Diagnosis and treatment •
The water level in the water separator can be high.
YES •
Drain the water separator.
•
Go to "Confirmation of repair". The fuel filter sensor system can be defective.
•
NO
•
Do a troubleshooting for failure code [DJG1KX].
•
Go to "Confirmation of repair".
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
Is the WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION problem resolved?
PC210-10M0, PC210LC-10M0
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
40-841
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION Details of failure
The engine coolant temperature monitor lights up in red while the engine runs. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the water sensed by the fuel filter sensor can be monitored. (Code: 18800) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The engine coolant can be overheated.
•
After doing COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT) in S mode, do the troubleshooting for DECREASE THE HYDRAULIC OIL TEMPERATURE (RUN THE ENGINE AT LOW IDLE OR STOP THE ENGINE.
•
Go to "Confirmation of repair". The engine coolant temperature gauge system can be defective.
YES
1
Engine coolant temperature
1.
Check the engine coolant temperature with the monitoring function. (Code: 04107)
2.
Is the hydraulic oil temperature 102°C or above?
•
•
Do the troubleshooting for COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM and ENGINE COOLANT TEMPERATURE GAUGE INDICATES INCORRECT VALUE (AT VALUES OTHER THAN MINIMUM AND MAXIMUM) in E mode.
•
Go to "Confirmation of repair".
NO
40-842
PC210-10M0, PC210LC-10M0
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
Is the ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION problem resolved?
PC210-10M0, PC210LC-10M0
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
40-843
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION Details of failure
The engine oil pressure monitor lights up in red while the engine runs. If a failure code of Check before starting is shown, do the troubleshooting for that code first.
Associated informa- Monitoring code tion The engine oil pressure can be monitored. (Code: 37200) Reference information The engine controller inputs the signals from the oil pressure switch of the engine. This information is sent to the machine monitor through CAN communication. No.
1
Cause
Procedures, Measurement, Values, Note
1.
Do a test. For details, see TESTING AND ADJUSTING, TEST ENGINE OIL PRESSURE.
2.
Does the troubleshooting result agree with the standard value? Item
Engine oil pressure
Measurement position and condition
Engine Engine oil oil pres- pressure picksure up port
Diagnosis and treatment YES
Min. 0.29 MPa {Min. 3.0 kg/cm2}
Low idle
Min. 0.10 MPa {Min. 1.0 kg/cm2}
The engine oil pressure is normal.
•
Go to the next inspection item. The engine oil pressure is abnormal.
•
Standard value
High idle
•
NO
•
Do the troubleshooting for OIL PRESSURE DROPS in S mode.
•
When the engine oil consumption is high, do the troubleshooting for ENGINE OIL CONSUMPTION IS EXCESSIVE.
•
Go to "Confirmation of repair".
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
40-844
Do the troubleshooting above again.
Is the ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION problem resolved?
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
40 TROUBLESHOOTING
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION Details of failure
The hydraulic oil temperature monitor lights up in red while the engine runs. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first.
Monitoring code Associated informaThe hydraulic oil temperature can be monitored. (Code: 04401) tion Reference information Signals from the hydraulic oil temperature sensor are input to the pump controller and then the data is sent to the machine monitor by CAN communication. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The hydraulic oil can be overheated.
•
Decrease the hydraulic oil temperature (run the engine at low idle or stop the engine).
•
Go to "Confirmation of repair". The hydraulic oil temperature gauge system can be defective.
YES
•
1
Hydraulic oil temperature
1.
Check the hydraulic oil temperature with the monitoring function. (Code: 04401)
2.
Is the hydraulic oil temperature 102°C or above?
•
Do the troubleshooting for HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM, and HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT VALUE (AT VALUES OTHER THAN MINIMUM AND MAXIMUM) in E mode.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation?
PC210-10M0, PC210LC-10M0
NO
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
40-845
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION
No.
3
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
40-846
40 TROUBLESHOOTING
Is the HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP INRED WHILE ENGINE IS IN OPERATION problem resolved?
Diagnosis and treatment YES The repair is completed.
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-17 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
E-17 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM Details of failure
•
When refueled the indication stays in the red range (E).
•
When the fuel level lowers the indication stays at the upper end (F) of the green range.
Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code Associated informa- The signal voltage from the fuel sensor can be monitored. (Code: 04200) tion Reference information Signals from the engine oil pressure switch are input to the engine controller. When the engine oil pressure switch turns on while the engine runs, the engine controller sends failure code [B@BAZG] to the machine monitor through CAN communication. No.
Cause
Procedures, Measurement, Values, Note
1.
1
Wiring harness and connector 2.
2
Fuel level sensor
See RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Check according to the descriptions of wiring harnesses and connectors. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P21. Connect the T-adapter to the male side to troubleshoot.
3.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measurement position and condition Fuel level FULL
Between P21 (male) (1) and Fuel level ground EMPTY
Diagnosis and treatment
85 to 110 Ω
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel level sensor is normal.
NO
• YES
Standard value Approximately 12 Ω
•
NO
•
Go to the next inspection item.
•
The fuel level sensor is defective.
•
Repair or replace the fuel level sensor.
•
Go to "Confirmation of repair".
40-847
E-17 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
No.
3
4
5
Cause
Open circuit in wiring harness
Ground fault in wiring harness
Short circuit in wiring harness
40-848
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM01 and P21. Connect the T-adapter to each female side to troubleshoot.
3.
Does the measurement result agree with the standard value? Item
Measurement position and condition
Resistance
Between CM01 (female) (15) and P21 (female) (1)
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM01 and P21. Connect the T-adapter to the female side of one connector to troubleshoot.
3.
Does the measurement result agree with the standard value? Measurement position and condition
Resistance
Between ground and CM01 (female) (15) or P21 (female) (1)
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM01 and P21. Connect the T-adapter to the female side of CM01 to troubleshoot.
3.
Does the measurement result agree with the standard value? Measurement position and condition
Resistance
Between CM01 (female) (15) and each pin other than pin (15)
NO
YES
NO
Min. 1 MΩ
1.
Item
YES
Max. 1 Ω
1.
Item
Diagnosis and treatment
Standard value Min. 1 MΩ
YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CM01 and P21. Connect the T-adapter to the female side of one of the connectors.
3. 6
E-17 FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
Hot short circuit 4. in wiring harness
Diagnosis and treatment •
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Turn the starting switch to the ON position to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Measurement position and condition
Between ground and one of Voltage CM01 (15) and P21 (female) (1)
Standard value
NO
Max. 1 V
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated to fuel level sensor
PC210-10M0, PC210LC-10M0
40-849
E-18 FUEL GAUGE INDICATES INCORRECT LEVEL
40 TROUBLESHOOTING
E-18 FUEL GAUGE INDICATES INCORRECT LEVEL Details of failure
The indication of the fuel gauge is different from the actual fuel level. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The signal voltage from the fuel sensor can be monitored. (Code: 04200) No.
Cause
Procedures, Measurement, Values, Note
1.
1
Wiring harness and connector 2.
2
See RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Check according to the descriptions of wiring harnesses and connectors. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P21. Connect the T-adapter to the male side to troubleshoot.
3.
Does the measurement result agree with the standard value?
Fuel level sensor
Item
Resistance
Measurement position and condition Fuel level FULL
Between P21 (male) (1) and Fuel level ground EMPTY
Diagnosis and treatment The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuel level sensor is normal.
NO
• YES
Standard value Approximately 12 Ω
•
NO
•
Go to the next inspection item.
•
The fuel level sensor is defective.
•
Repair or replace the fuel level sensor.
•
Go to "Confirmation of repair".
85 to 110 Ω
YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-850
Do the troubleshooting above again.
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the FUEL GAUGE INDICATES INCORRECT LEVEL problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-18 FUEL GAUGE INDICATES INCORRECT LEVEL
Circuit diagram associated to fuel level sensor
PC210-10M0, PC210LC-10M0
40-851
E-19 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
40 TROUBLESHOOTING
E-19 COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM Details of failure
The indication of the engine coolant temperature gauge does not move from minimum or maximum. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
The engine coolant temperature can be monitored. (Code: 04107) Associated informaAssociated information tion
No.
•
Signals from the engine coolant temperature sensor are input to the engine controller. The information is sent to the machine monitor by CAN communication.
•
When the engine coolant temperature becomes approximately 30°C or below, the coolant temperature monitor lights up in white.
Cause
Procedures, Measurement, Values, Note
1. 1
Engine coolant temperature 2.
Diagnosis and treatment •
The warm-up operation of the machine is not sufficient.
YES •
Do a warm-up operation of the machine.
•
Check the engine coolant temperature with the monitoring function. (Code: 04107)
•
Is the engine coolant temperature 30°C or below? NO
Go to "Confirmation of repair". The engine coolant temperature gauge system can be defective.
•
Do the troubleshooting for failure codes [CA144] and [CA145].
•
Go to "Confirmation of repair".
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Turn the starting switch to the ON position.
Confirmation of 3. repair
40-852
Do the troubleshooting above again.
Is the COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM problem resolved?
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-20 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE
40 TROUBLESHOOTING
E-20 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE Details of failure
The coolant temperature gauge shows an incorrect temperature. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first.
Monitoring code Associated informaThe engine coolant temperature can be monitored. (Code: 04107) tion Associated information Signals from the engine coolant temperature sensor are input to the engine controller. The information is sent to the machine monitor by CAN communication. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Coolant temperature sensor
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The coolant temperature sensor is normal.
NO
•
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector COOLANT TEMP. Connect YES • the T-adapter to the male side to troubleshoot.
3.
Does the troubleshooting result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between COOLANT TEMP (male) (B) and (A) (thermal characteristics of coolant temperature sensor)
Standard value
0℃
0 to 37 kΩ
25℃
9.3 to 10.7 kΩ
50℃
3.2 to 3.8 kΩ
80℃
1.0 to 1.3 kΩ
95℃
700 to 800 Ω
NO
Go to the next inspection item.
•
The coolant temperature sensor is defective.
•
Replace the coolant temperature sensor.
•
Go to "Confirmation of repair".
40-853
E-20 COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
3
4
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE problem resolved?
NO
Return to the first inspection item.
Electrical circuit diagram associated with coolant temperature sensor
water
ECM (DRC26-60) AIR Pressure sensor GND
G0024201
40-854
PC210-10M0, PC210LC-10M0
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
40 TROUBLESHOOTING
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM Details of failure
The hydraulic oil temperature gauge indication does not move from minimum or maximum. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first.
Monitoring code Associated informaThe hydraulic oil temperature can be monitored. (Code: 04401) tion Associated information Signals from the hydraulic oil temperature sensor are input to the pump controller and then the data is sent to the machine monitor by CAN communication. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P22. Connect the T-adapter to the male side to troubleshoot.
3.
Does the measurement result agree with the standard value? Item
2
Measuring point and measurement condition 10℃
Hydraulic oil temperature sensor Resistance
Between P22 30℃ (male) (2) and (1) 80℃ 100℃ Between P22 (male) (2) and All ground
PC210-10M0, PC210LC-10M0
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The hydraulic oil temperature sensor is normal.
NO
• YES •
Go to the next inspection item.
•
The hydraulic oil temperature sensor is defective.
•
Repair or replace the hydraulic oil temperature sensor.
•
Go to "Confirmation of repair".
Standard value Approximately 90 kΩ Approximately 35 kΩ Approximately 6.5 kΩ Approximately 3.5 kΩ
NO
Min. 1 MΩ
40-855
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
No.
3
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and P22. Connect the T-adapter to one of the female sides to troubleshoot.
3.
Does the measurement result agree with the standard value?
Open circuit in wiring harness
Item
Resistance
4
Ground fault in wiring harness
40-856
Standard value
Between CP01 (female) (28) and P22 (female) (2)
Max. 1 Ω
Between CP01 (female) (46) and P22 (female) (1)
Max. 1 Ω
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and P22. Connect the T-adapter to one of the female sides to troubleshoot.
3.
Does the measurement result agree with the standard value?
Resistance
5
Measuring point and measurement condition
1.
Item
Short circuit in wiring harness
40 TROUBLESHOOTING
Measuring point and measurement condition Between ground and one of CP01 (female) (28) and P22 (female) (2)
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and P22. Connect the T-adapter to the female side of CP01 to troubleshoot.
3.
Does the measurement result agree with the standard value? Measuring point and measurement condition
Continuity
Between CP01 (female) (28) and each pin other than pin (28)
YES
NO
YES
NO
Min. 1 MΩ
1.
Item
Diagnosis and treatment
Standard value Min. 1 MΩ
YES
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and P22. Connect the T-adapter to the female side of one of the connectors.
3. 6
Hot short circuit 4. in wiring harness
Diagnosis and treatment •
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Turn the starting switch to the ON position to troubleshoot. Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition
Between ground and one of Voltage CP01 (28) and P22 (female) (2)
Standard value
NO
Approx. 5 V
YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with hydraulic oil temperature sensor
PC210-10M0, PC210LC-10M0
40-857
E-22 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE
40 TROUBLESHOOTING
E-22 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE Details of failure
The hydraulic oil temperature gauge indicates an incorrect temperature. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first.
Monitoring code Associated informaThe hydraulic oil temperature can be monitored. (Code: 04401) tion Associated information Signals from the hydraulic oil temperature sensor are input to the pump controller and then the data is sent to the machine monitor by CAN communication. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector P22. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
2
Hydraulic oil temperature sensor
Measuring point and measurement condition 10℃
Resistance
Between P22 30℃ (male) (2) and (1) 80℃ 100℃ Between P22 (male) (2) and All ground
40-858
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The hydraulic oil temperature sensor is normal.
NO
• YES •
Go to the next inspection item.
•
The hydraulic oil temperature sensor is defective.
•
Repair or replace the hydraulic oil temperature sensor.
•
Go to "Confirmation of repair".
Standard value Approximately 90 kΩ Approximately 35 kΩ Approximately 6.5 kΩ Approximately 3.5 kΩ
NO
Min. 1 MΩ
PC210-10M0, PC210LC-10M0
E-22 HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
3
4
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with hydraulic oil temperature sensor
PC210-10M0, PC210LC-10M0
40-859
E-23 MACHINE MONITOR SHOWS INCORRECT MODEL
40 TROUBLESHOOTING
E-23 MACHINE MONITOR SHOWS INCORRECT MODEL Details of failure
The details shown on the machine monitor are not for the machine on which the monitor is installed.
Associated informa- If a failure code is shown, troubleshoot for that code first. tion No.
1
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the ON position.
2.
Monitoring code: 00201 Check by switch input 2.
3.
Does the shown result agree with the standard value? Item
Machine model code signal
Measuring point and measurement condition
2
Reconfirmation 1. of inspection 2. item
1. 3
Confirmation of 2. repair 3. 4.
40-860
YES
Standard value
Model selection 1
OFF
Model selection 2
OFF
Resistance Model selection 3
Diagnosis and treatment
NO
ON
Model selection 4
OFF
Model selection 5
OFF
Do the troubleshooting above again. Have you identified the cause by reconfirmation?
Turn the starting switch to the OFF position. Connect all the configuration equipment.
NO
The machine monitor setting is normal.
•
Go to the next inspection item.
•
The machine monitor setting is defective.
•
Make the setting same as the standard value.
•
Go to "Confirmation of repair".
•
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the screen on the machine monitor normal?
•
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED
40 TROUBLESHOOTING
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED Details of failure
Some areas of the machine monitor screen are not shown.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The liquid crystal panel of the machine monitor is normal. Go to the next inspection item. The liquid crystal panel of the machine monitor is defective.
YES
1
Liquid crystal panel of machine monitor
1.
Turn the starting switch to the ON position.
•
2.
Push the switches [4] and [F2] at the same time to troubleshoot.
•
3.
Does the liquid crystal display panel light up fully (all white)?
NO
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-861
E-25 FUNCTION SWITCH DOES NOT OPERATE
40 TROUBLESHOOTING
E-25 FUNCTION SWITCH DOES NOT OPERATE Details of failure
The function switch does not operate. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the function switch signal can be monitored. (Code: 04503) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-862
Do a reconfirmation of the failure symptom.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the FUNCTION SWITCH DOES NOT OPERATE problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER)
40 TROUBLESHOOTING
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) Details of failure
The automatic warm-up system does not operate (in cold weather). Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Reference information
Associated information
No.
•
When the engine coolant temperature is lower than 30°C, the automatic warm-up operation raises the engine speed up to 1200 rpm.
•
When the starting switch is turned to the ON position or after the engine is started, if the fuel control dial opening is held at 70% or more for 3 seconds or longer, the automatic warm-up operation is canceled.
•
The heater warm-up function is a feature of the air conditioner. When the blower is turned to the ON position, the ambient temperature is 5°C or lower and the engine coolant temperature is lower than 55°C, this function increases the engine speed up to 1300 rpm. When the engine coolant temperature becomes 60°C, the heater warm-up function is canceled.
•
When the engine oil pressure is lower than 50 kPa {0.51 kg/cm2}, the turbo protect function operates to keep the engine speed at 1050 rpm or lower for up to 20 seconds after the engine is started.
•
If a failure code is displayed, do the troubleshooting for that code first.
Cause
Procedures, Measurement, Values, Note 1.
Measure the engine coolant temperature with the monitoring function. (code: 04107).
2.
Decrease or increase the engine coolant temperature to troubleshoot.
3.
Does the measurement result agree with the standard value? Item
1
Measurement position and condition Engine coolant temperature: 100 to 105℃
Engine coolant temperature signal Engine coolant temperaLighting ture gauge up color shown on the monitor
PC210-10M0, PC210LC-10M0
Diagnosis and treatment •
The engine coolant temperature signal is normal.
•
Go to the next inspection item. The engine coolant temperature signal is abnormal.
YES
•
Standard value
•
Do the troubleshooting for COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM and ENGINE COOLANT TEMPERATURE GAUGE INDICATES INCORRECT VALUE (AT VALUES OTHER THAN MINIMUM AND MAXIMUM) in E mode.
•
Go to "Confirmation of repair".
Red
NO
Engine coolant temperature: 60 to 100°C
Blue
Engine coolant temperature: 30 to 60℃
White
40-863
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER)
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-864
Do the troubleshooting above again.
•
The engine controller can be defective.
•
Replace the engine controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-27 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED
40 TROUBLESHOOTING
E-27 AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED Details of failure
When the auto-deceleration switch is operated, the auto-deceleration monitor does not light up or go out. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the auto-deceleration switch signal can be monitored. (Code: 04504) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. 4. repair
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-865
E-28 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION
40 TROUBLESHOOTING
E-28 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION Details of failure
When the lever is operated, the auto-deceleration function does not operate or is not canceled. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first.
Monitoring code Associated informaThe state of the auto-deceleration switch signal can be monitored. (Code: 04504) tion Reference information The auto-deceleration is not activated or canceled unless the fuel control dial is set higher than the set speed of auto-deceleration.
40-866
PC210-10M0, PC210LC-10M0
E-28 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
•
The PPC pressure signal is normal.
•
Go to the next inspection item.
Lever operated: ON
•
The PPC pressure signal is abnormal.
Lever in NEUTRAL: OFF
•
Do the troubleshooting for *** IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION in E mode.
•
Go to "Confirmation of repair".
Troubleshoot the signals of the pressure switch with the monitoring function. (Code: 01900), (Code: 01901)
YES
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
PPC pressure signal
Measurement position and condition
Swing signal
Monitoring code: 01900
Travel signal
Monitoring code: 01900
Boom LOWER signal
Monitoring code: 01900
Boom RAISE signal
Monitoring code: 01900
Monitor Arm IN signal display
Monitoring code: 01900
Arm OUT sig- Monitoring nal code: 01900
Bucket CURL Monitoring signal code: 01901
Bucket DUMP Monitoring signal code: 01901
Service signal
PC210-10M0, PC210LC-10M0
Monitoring code: 01901
Standard value Lever operated: ON Lever in NEUTRAL: OFF Lever operated: ON Lever in NEUTRAL: OFF Lever operated: ON Lever in NEUTRAL: OFF
Lever operated: ON Lever in NEUTRAL: OFF Lever operated: ON
NO
Lever in NEUTRAL: OFF Lever operated: ON Lever in NEUTRAL: OFF Lever operated: ON Lever in NEUTRAL: OFF Lever operated: ON Lever in NEUTRAL: OFF
40-867
E-28 AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
40-868
The machine monitor, pump controller or engine controller can be defective.
•
Replace one of the controllers.
•
Go to "Confirmation of repair".
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
YES The repair is completed.
Turn the starting switch to the ON position. Is the AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-29 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED
40 TROUBLESHOOTING
E-29 WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED Details of failure
The work mode selector screen is not shown when the work mode switch is operated. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the work mode switch signal can be monitored. (Code: 04504) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-869
E-30 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED
40 TROUBLESHOOTING
E-30 ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED Details of failure
The engine and hydraulic pump settings do not change when the work mode is changed.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
40-870
•
The machine monitor, pump controller or engine controller can be defective.
•
Replace one of the controllers.
•
Go to "Confirmation of repair".
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first.
YES The repair is completed.
Turn the starting switch to the ON position. Is the ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-31 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED
40 TROUBLESHOOTING
E-31 TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED Details of failure
When the travel speed switch is operated, the travel speed monitor does not change. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the travel speed switch signal can be monitored. (Code: 04504) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-871
E-32 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED
40 TROUBLESHOOTING
E-32 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED Details of failure
The travel speed does not change when it is changed. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first. Monitoring code The signal of the travel speed can be monitored. (Code: 04504)
Associated information
No.
Reference information •
If a hot short circuit occurs in the wiring harness, the travel speed does not lower when the travel speed setting is Lo.
•
As the T-adapter for the pump controller connector is a socket-type box, the operating voltage cannot be measured at the pump controller connector.
•
When the fuel control dial is throttled, the travel speed does not change when the travel speed setting is changed.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP02 and V04. Connect the T-adapter to the female side of CP01.
3.
Turn the starting switch to the ON position.
4. Hot short circuit 5. in wiring harness
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
NO
• YES •
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Measure the voltage. Does the measurement result agree with the standard value? Item
Voltage
40-872
•
Measuring point and measurement condition Between CP02 (93) and ground
Standard value Max 1V
NO
PC210-10M0, PC210LC-10M0
E-32 TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED
40 TROUBLESHOOTING
No.
3
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP02 and V04. Connect the T-adapter to the female side of CP02.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Continuity
Between CP02 (female) (93) and each pin other than pin (93)
Standard value
Diagnosis and treatment YES
NO
Min. 1 MΩ
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES The repair is completed.
4
5
Reconfirmation 1. of inspection 2. item
The machine monitor or the pump controller can be defective.
•
Replace one of the controllers.
•
Go to "Confirmation of repair".
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
• Do the troubleshooting above again.
YES The repair is completed.
Turn the starting switch to the ON position. Is the TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with travel speed solenoid
Pup controller Solenoid valve travel speed GR FH FL
G0024187
PC210-10M0, PC210LC-10M0
40-873
E-33 ALARM BUZZER DOES NOT STOP
40 TROUBLESHOOTING
E-33 ALARM BUZZER DOES NOT STOP Details of failure
The alarm buzzer cannot be stopped. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the alarm buzzer stop switch signal can be monitored. (Code: 04504) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-874
Do a reconfirmation of the failure symptom.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the ALARM BUZZER DOES NOT STOP problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-34 SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION
40 TROUBLESHOOTING
E-34 SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION Details of failure
The service meter is not shown when the starting switch is in the OFF position. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the alarm buzzer stop switch signal can be monitored. (Code: 04504) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The auxiliary power supply system is normal.
•
Go to the next inspection item. The auxiliary power supply system is abnormal.
YES
•
1
Auxiliary power 1. supply circuit 2.
Turn the starting switch to the ON position. Is something shown on the machine monitor?
•
Do the troubleshooting for WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING in E mode.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
2
3
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
The machine monitor can be defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Push the function switches [4] and [1] at the same time. Is the SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-875
E-35 MACHINE DOES NOT CHANGE TO SERVICE MODE
40 TROUBLESHOOTING
E-35 MACHINE DOES NOT CHANGE TO SERVICE MODE Details of failure
The machine does not change to service mode.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3. Confirmation of 4. repair 5.
40-876
Do a reconfirmation of the failure symptom.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. While pushing down the switch [4], push down the switches [1], [2] and [3] in order. Is the MACHINE DOES NOT CHANGE TO SERVICE MODE problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-36 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE
40 TROUBLESHOOTING
E-36 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE Details of failure
All work equipment, swing or travel do not operate.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
3
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.3 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
Lock lever switch
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S14. Connect the T-adapter to the female side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between S14 (female) (1) and (2)
Standard value
Lock lever: LOCK
Min. 1 MΩ
Lock lever: FREE
Max. 1 Ω
•
NO
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The lock lever switch is normal.
• YES
NO
Go to the next inspection item. The fuse is defective.
•
Go to the next inspection item.
•
The lock lever switch is defective.
•
Replace the lock lever switch.
•
Go to "Confirmation of repair".
40-877
E-36 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE
No.
4
Cause
PPC lock relay
Procedures, Measurement, Values, Note
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R48. Replace the relay with the same type.
3.
Turn the starting switch to the ON position to troubleshoot.
4.
5
Does the failure occur again?
Turn the starting switch to the OFF position.
2.
Disconnect connector V01. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value?
PPC lock solenoid
Item
Diode
Standard value
Between V01 (male) (1) and (2)
20 to 60 Ω
Between V01 (male) (1) and ground
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Remove diode D01. Connect the T-adapter to the male side.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value? Item
Continuity
40-878
Measuring point and measurement condition
Measuring point and measurement condition
Diagnosis and treatment
YES
Standard value
Between D01 (male) (8) (+) and (4) (-)
Continuity
Between D01 (male) (4) (+) and (8) (-)
No continuity
•
The removed PPC lock relay is normal.
•
Restore the removed PPC lock relay.
•
Go to the next inspection item. The removed PPC lock relay is defective.
• NO
1.
Resistance
6
40 TROUBLESHOOTING
• •
YES
NO
•
Go to the next inspection item.
•
The PPC lock solenoid is defective.
•
Replace the PPC lock solenoid.
•
Go to "Confirmation of repair".
• YES •
NO
The repair is completed. The PPC lock solenoid is normal.
The diode is normal. Go to the next inspection item.
•
The diode is defective.
•
Replace the diode.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-36 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE
40 TROUBLESHOOTING
No.
7
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Remove fuse No.3 in fuse box F01.
3.
Disconnect connectors S14 and V01. Connect Tadapter to the female side of S14 and the male side of V01.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Open circuit in wiring harness
Item
Resistance
Measuring point and measurement condition
Diagnosis and treatment YES
Standard value
Between F01-3 and S14 (male) (1)
Max. 1 Ω
Between S14 (male) (2) and V01 (female) (1)
Max. 1 Ω
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
Between V01 (female) (2) and Max. 1 Ω ground (T09)
8
1.
Turn the starting switch to the OFF position.
2.
Remove fuse No.3 in fuse box F01.
3.
Disconnect connectors S14, V01 and D01. Connect the T-adapter to the male side of S14 or female side of V01 and D01.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Ground fault in wiring harness
Item
Resistance
9
Measuring point and measurement condition
YES
Standard value
Between ground and one of F01-3 and S14 (male) (1)
Min. 1 MΩ
Between ground and one of F01-3 and S14 (male) (1)
Min. 1 MΩ
Between ground and one of S14 (male) (2) and V01 (female) (1)
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3. Confirmation of 4. repair 5.
NO
YES The repair is completed.
Start the engine. Operate the lever. Is the ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-879
E-36 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE
40 TROUBLESHOOTING
Circuit diagram associated with PPC lock switch
40-880
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-37 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK
E-37 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK Details of failure
All work equipment, swing and travel cannot be locked.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S14. Connect the T-adapter to the female side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value?
Lock lever switch
Item
Resistance
3
Measuring point and measurement condition Between S14 (female) (1) and (2)
Standard value
Lock lever: LOCK
Min. 1 MΩ
Lock lever: FREE
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V01. Connect the T-adapter to the male side to troubleshoot.
3.
Turn the starting switch to the ON position.
4. Hot short circuit 5. in wiring harness
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The lock lever switch is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The lock lever switch is defective.
•
Repair or replace the lock lever switch.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage. Does the measurement result agree with the standard value? Item
Voltage
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition
Standard value
Between V01 (female) (1) and Max 1V (2)
NO
40-881
E-37 ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK
No.
4
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
Diagnosis and treatment YES The repair is completed.
Start the engine. Operate the lock lever. Is the ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with PPC lock switch
40-882
PC210-10M0, PC210LC-10M0
E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED
40 TROUBLESHOOTING
E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED Details of failure
The machine does not swing when the swing parking brake cancel switch is released. Pre-troubleshooting
Associated informa- If a failure code is shown, do the troubleshooting for that code first. tion Monitoring code The state of the swing lock switch signal can be monitored. (Code: 02200) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.1 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
PC210-10M0, PC210LC-10M0
•
NO
Go to the next inspection item. The fuse is defective.
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair".
40-883
E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED
No.
3
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S25. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value?
Swing parking brake cancel switch
Item
Resistance
Between S25 (male) (13) and (14)
Swing parking brake cancel Min. 1 MΩ switch: NORMAL
Disconnect connectors D01 and D03. Connect the T-adapter to each diode.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value? Measuring point and measurement condition
NO
Continuity
Between D01 (male) (3) (+) and (7) (-)
No continuity
Between D03 (male) (3) (+) and (7) (-)
Continuity
Between D03 (male) (7) (+) and (3) (-)
No continuity
The swing parking brake switch is normal.
•
Go to the next inspection item.
•
The swing parking brake switch is defective.
•
Replace the swing parking brake switch.
•
Go to "Confirmation of repair".
• YES •
Standard value
Between D01 (male) (7) (+) and (3) (-)
• YES
Swing parking brake cancel Max. 1 Ω switch: CANCEL
2.
Continuity
Diagnosis and treatment
Standard value
Turn the starting switch to the OFF position.
Diode
40-884
Measuring point and measurement condition
1.
Item
4
40 TROUBLESHOOTING
The diode is normal. Go to the next inspection item.
•
The diode is defective.
•
Repair or replace the diode.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED
40 TROUBLESHOOTING
No.
5
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect the connectors V03 and S25. Connect the T-adapter to each female side.
3.
Set the swing lock switch to the OFF position.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
6
Disconnect connectors V03, S04, S25, D01 and D03. Connect the T-adapter to the female side of one of the connectors.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Measuring point and measurement condition
YES
Standard value
Between ground and one of D03 (female) (3), S04 (female) (4), and V03 (female) (1)
Min. 1 MΩ
Between ground and one of D01 (female) (1), S04 (female) (3), and S25 (female) (14)
Min. 1 MΩ
NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3.
Turn the starting switch to the ON position. Set the swing parking brake cancel switch to the CANCEL position.
4.
Is the MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED problem resolved?
PC210-10M0, PC210LC-10M0
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
Between V03 (female) (2) and Max. 1 Ω ground
2.
Item
YES
Between V03 (female) (1) and Max. 1 Ω S25 (female) (14)
Turn the starting switch to the OFF position.
Resistance
7
Standard value
1.
Ground fault in wiring harness
Confirmation of repair
Measuring point and measurement condition
Diagnosis and treatment
YES The repair is completed.
NO
Return to the first inspection item.
40-885
E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED
40 TROUBLESHOOTING
Circuit diagram associated with swing parking brake
40-886
PC210-10M0, PC210LC-10M0
E-39 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON
40 TROUBLESHOOTING
E-39 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON Details of failure
The swing brake does not operate when the swing parking brake cancel switch is set to the normal position.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Swing parking brake cancel switch
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S25. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition
Between S25 (male) (13) and (14)
•
Swing parking brake cancel Max. 1 Ω switch: CANCEL
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The swing parking brake switch is normal.
• YES
Standard value
Swing parking brake cancel Min. 1 MΩ switch: NORMAL
• NO
NO
•
Go to the next inspection item.
•
The swing parking brake switch is defective.
•
Replace the swing parking brake switch.
•
Go to "Confirmation of repair".
40-887
E-39 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON
No.
3
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V03. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position.
4. Hot short circuit 5. in wiring har6. ness
Diagnosis and treatment
Measure the voltage. Does the measurement result agree with the standard value? Measuring point and measurement condition
Standard value
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
5.
40-888
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
NO
Between V03 (female) (1) and Voltage Max 1V ground
4
The wiring harness has no hot short circuits.
Set the swing lock switch to the ON position.
Item
3. Confirmation of 4. repair
•
YES The repair is completed.
Turn the starting switch to the ON position. Set the swing parking brake cancel switch to NORMAL position. Is the MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-39 MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON
Circuit diagram associated with swing parking brake
PC210-10M0, PC210LC-10M0
40-889
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY
40 TROUBLESHOOTING
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY Details of failure
The one-touch power maximizing function does not operate normally or the monitor does not show information. Pre-troubleshooting
Associated information
No.
•
If a failure code is shown, do the troubleshooting for that code first.
•
When the engine coolant monitor lights up in red or the hydraulic oil temperature sensor lights up in red, the one-touch power maximizing function does not operate.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
3
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.8 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
L.H. knob switch
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S11. Connect the T-adapter to the female side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
40-890
Measuring point and measurement condition Between S11 (female) (1) and (2)
•
NO
Standard value
NO
L.H. knob switch: Release
Min. 1 MΩ
L.H. knob switch: Push
Max. 1 Ω
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The L.H. knob switch is normal.
• YES
Go to the next inspection item. The fuse is defective.
•
Go to the next inspection item.
•
The L.H. knob switch is defective.
•
Replace the L.H. knob switch.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY
40 TROUBLESHOOTING
No.
4
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V02. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value?
2-stage relief solenoid
Item
Resistance
5
Open circuit in wiring harness
Between V02 (male) (1) and (2)
20 to 60 Ω
Between V02 (male) (1) and ground
Min. 1 MΩ
Turn the starting switch to the OFF position.
2.
Remove fuse No.8 in fuse box F01.
3.
Disconnect connectors CP01 and S11. Connect the T-adapter to each female side.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Resistance
Ground fault in wiring harness
Standard value
1.
Item
6
Measuring point and measurement condition
Measuring point and measurement condition Between F01-8 and S11 (female) (1)
Standard value
NO
•
The 2-stage relief solenoid is normal.
•
Go to the next inspection item.
•
The 2-stage relief solenoid is defective.
•
Replace the 2-stage relief solenoid.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Between S11 (female) (2) and Max. 1 Ω CP01 (female) (42)
2.
Remove fuse No.8 in fuse box F01.
3.
Disconnect connectors CP01, S11, H16 and M23. Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
PC210-10M0, PC210LC-10M0
NO
Max. 1 Ω
Turn the starting switch to the OFF position.
Resistance
YES
YES
1.
Item
Diagnosis and treatment
Measuring point and measurement condition
YES
Standard value
Between ground and one of F01-8, H16 (female) (2) and (4)
Min. 1 MΩ
Between ground and one of S11 (female) (1), H16 (male) (4), or M23 (female) (1)
Min. 1 MΩ
NO
40-891
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY
No.
7
Cause
Short circuit in wiring harness
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Remove fuse No.8 in fuse box F01.
3.
Disconnect connectors CP01 and S11. Connect the T-adapter to the female side of CP01.
4.
Measure the continuity.
5.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Continuity
Between CP01 (female) (42) and each pin other than pin (42)
Diagnosis and treatment YES
Standard value
NO
Machine monitor
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The machine monitor is normal.
•
Go to the next inspection item. The machine monitor is defective.
Min. 1 MΩ
YES
8
•
1.
Turn the starting switch to the ON position.
2.
Push the L.H. knob switch.
3.
When the power of the work equipment is increased, is it shown in the machine monitor?
• NO
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
9
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Stop the engine.
2.
Connect all the configuration equipment.
3.
Start the engine.
Confirmation of 4. 10 repair 5.
40-892
Do the troubleshooting above again.
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
Push the L.H. knob switch. Is the ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY
Circuit diagram associated with 2-stage relief solenoid system
Circuit diagram associated with one-touch power maximizing switch
PC210-10M0, PC210LC-10M0
40-893
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED
40 TROUBLESHOOTING
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED Details of failure
The one-touch power maximizing function cannot be canceled.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V02. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position to troubleshoot.
Hot short circuit 4. in wiring harness
•
Voltage
Measuring point and measurement condition
Standard value
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
• YES
Does the measurement result agree with the standard value? Item
• NO
NO
Between V02 (female) (1) and Max 4.5V (2)
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES The repair is completed.
3
4
Reconfirmation 1. of inspection 2. item
40-894
The machine monitor or pump controller is defective.
•
Replace the machine monitor or the pump controller.
•
Go to "Confirmation of repair".
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
YES The repair is completed.
Turn the starting switch to the ON position. Set the L.H. knob switch to OFF. Is the ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED
Circuit diagram associated with 2-stage relief solenoid
PC210-10M0, PC210LC-10M0
40-895
E-42 TRAVEL ALARM DOES NOT SOUND
40 TROUBLESHOOTING
E-42 TRAVEL ALARM DOES NOT SOUND Details of failure
The travel alarm does not sound.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors M14 and CP02. Connect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Measuring point and measurement condition
Between CP02 (female) (115) Max. 1 Ω and M14 (female) (2)
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no open circuits.
NO
• YES
Standard value
Between CP02 (female) (107) Max. 1 Ω and M14 (female) (1) Resistance
•
NO
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Between CP02 (female) (117) Max. 1 Ω and M14 (female) (2) Between CP02 (female) (120) Max. 1 Ω and M14 (female) (2)
3
Ground fault in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP02 and M14. Connect the T-adapter to the female side of one of the connectors.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
40-896
Measuring point and measurement condition
Standard value
Between ground and one of CP02 (female) (107) and M14 Min. 1 MΩ (female) (1)
YES
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
E-42 TRAVEL ALARM DOES NOT SOUND
Cause
Short circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP02 and M14. Connect the T-adapter to the female side of CP02.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
5
Travel alarm
Measuring point and measurement condition Between CP02 (107) and each pin other than (107)
Standard value
Diagnosis and treatment YES
NO
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M14. Replace the travel alarm with the same type.
3.
Start the engine. Drive the machine.
4.
Does the TRAVEL ALARM DOES NOT SOUND problem occur?
YES
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The removed travel alarm is normal.
•
Restore the removed travel alarm.
•
Go to the next inspection item. The removed travel alarm is defective.
• NO
•
The repair is completed.
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Drive the machine. Is the TRAVEL ALARM DOES NOT SOUND problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-897
E-42 TRAVEL ALARM DOES NOT SOUND
40 TROUBLESHOOTING
Circuit diagram associated with travel alarm
Pump controller
GR FH FL
G0024188
40-898
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-43 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS
E-43 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS Details of failure
E-42 The travel alarm sound does not stop while the machine is stopped.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M14. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position to troubleshoot.
Hot short circuit 4. in wiring harness
Voltage
Measuring point and measurement condition Between M14 (female) (1) and ground
Standard value
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3. Confirmation of 4. repair 5. 6.
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
• YES
NO
Max 1V
1.
• NO
Does the measurement result agree with the standard value? Item
3
•
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Start the engine. Drive the machine. Stop the machine. Is the TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-899
E-43 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS
40 TROUBLESHOOTING
Circuit diagram associated with travel alarm
Pump controller
GR FH FL
G0024188
40-900
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-44 HORN DOES NOT SOUND
E-44 HORN DOES NOT SOUND Details of failure
The horn does not sound.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
3
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.5 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
Horn switch
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector S10. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between S10 Switch: OFF (male) (1) and Switch: ON (2)
Standard value Min. 1 MΩ Max. 1 Ω
•
NO
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The horn switch is normal.
• YES
NO
Go to the next inspection item. The fuse is defective.
•
Go to the next inspection item.
•
The horn switch is defective.
•
Replace the horn switch.
•
Go to "Confirmation of repair".
40-901
E-44 HORN DOES NOT SOUND
No.
4
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors M07 and M08. Connect the T-adapter to the male side.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value?
Horn
Item
Continuity
5
Open circuit in wiring harness
Measuring point and measurement condition
Standard value
Between M07 (male) (1) and (2)
Continuity
Between M08 (male) (1) and (2)
Continuity
1.
Turn the starting switch to the OFF position.
2.
Remove fuse No.5 in fuse box F01.
3.
Disconnect connectors R08 and S10. Connect the T-adapter to each female side.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition Between F01-5 and S10 (female) (1)
Resistance
40-902
40 TROUBLESHOOTING
Diagnosis and treatment • YES •
NO
YES
Standard value Max. 1 Ω
Between S10 (female) (2) and Max. 1 Ω R08 (female) (1) Between R08 (female) (2) and ground
Max. 1 Ω
Between R08 (female) (3) and F01-5
Max. 1 Ω
NO
The horn is normal. Go to the next inspection item.
•
The horn is defective.
•
Replace the horn.
•
Go to "Confirmation of repair".
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
6
E-44 HORN DOES NOT SOUND
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Remove fuse No.5 in fuse box F01.
3.
Disconnect connectors R08, M07, M08 and H15. Connect the T-adapter to the female side of R08.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value?
Ground fault in wiring harness
Item
Resistance
7
8
Horn relay
Measuring point and measurement condition
YES
Standard value
Between R08 (female) (1) and ground
Min. 1 MΩ
Between R08 (female) (3) and ground
Min. 1 MΩ
Between R08 (female) (5) and ground
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R08. Replace the relay with the same type.
3.
Turn the starting switch to the ON position.
4.
Push the L.H. knob switch to troubleshoot.
5.
Is the phenomenon reproduced in the same way?
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Diagnosis and treatment
NO
YES
PC210-10M0, PC210LC-10M0
The wiring harness has no ground faults.
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
•
The horn relay is normal.
•
Go to the next inspection item. The horn relay is defective.
• NO
•
Replace the horn relay.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Push the horn switch. Is the HORN DOES NOT SOUND problem resolved?
•
NO
Return to the first inspection item.
40-903
E-44 HORN DOES NOT SOUND
40 TROUBLESHOOTING
Circuit diagram associated with horn
40-904
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-45 HORN DOES NOT STOP
E-45 HORN DOES NOT STOP Details of failure
The horn does not stop.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Hot short circuit in wiring harness
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors M07 and M08. Connect the T-adapter to each female side.
3.
Turn the starting switch to the ON position to troubleshoot.
4.
Does the measurement result agree with the standard value? Item
Voltage
3
4
Horn relay
Measuring point and measurement condition
Standard value
Between M07 (female) (2) and (1)
Max 1V
Between M08 (female) (2) and (1)
Max 1V
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector R08. Replace the relay with same type.
3.
Turn the starting switch to the ON position.
4.
Push the L.H. knob switch to troubleshoot.
5.
Is the phenomenon reproduced in the same way?
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
PC210-10M0, PC210LC-10M0
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The wiring harness has no hot short circuits.
• YES
NO
YES
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The horn relay is normal.
•
Go to the next inspection item. The horn relay is defective.
• NO
•
Replace the horn relay.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Push the horn. Is the HORN DOES NOT STOP problem resolved?
• NO
NO
Return to the first inspection item.
40-905
E-45 HORN DOES NOT STOP
40 TROUBLESHOOTING
Circuit diagram associated with horn
40-906
PC210-10M0, PC210LC-10M0
E-46 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED
40 TROUBLESHOOTING
E-46 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED Details of failure
When the wiper switch is operated, the wiper monitor does not light up or go out. Pre-troubleshooting
Associated informa- If a failure code is displayed, do the troubleshooting for that code first. tion Monitoring code The state of the wiper switch signal can be monitored. (Code: 04504) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
3. Confirmation of 4. repair 5.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Operate the wiper switch. Is the WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-907
E-47 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED
40 TROUBLESHOOTING
E-47 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED Details of failure
The wiper does not operate when the wiper switch is operated. Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The state of the wiper switch signal can be monitored. (Code: 04504) • No.
The state of the window rear limit switch signal can be monitored. (Code: 02204)
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
•
Go to "Confirmation of repair". The window rear limit switch is normal.
•
2.
Disconnect connector W03. Connect the T-adapt- YES • er to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
Front window: Mounted at Min. 1 MΩ Between W03 front (male) (1) and Front window: (2) Stowed at Max. 1 Ω rear
Turn the starting switch to the OFF position.
2.
Disconnect connector M05. Connect the T-adapter to the female side.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value?
Continuity
Measuring point and measurement condition Between M05 (female) (1) and (3)
Standard value Continuity
Go to the next inspection item.
•
The window rear limit switch is defective.
•
Replace the window rear limit switch.
•
Go to "Confirmation of repair".
• YES •
Wiper motor is normal.
•
The wiper motor is defective.
•
Replace the wiper motor.
•
Go to "Confirmation of repair".
Standard value
1.
Item
40-908
Repair or replace the defective wiring harness or connector.
Turn the starting switch to the OFF position.
Window rear limit switch
Wiper motor
• NO
1.
Resistance
3
•
NO
NO
Go to the next inspection item.
PC210-10M0, PC210LC-10M0
E-47 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED
40 TROUBLESHOOTING
No.
4
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Disconnect connector CP01. Connect the Tadapter to the female side.
3.
Stow the front window at the rear.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
5
Ground fault in wiring harness
2.
Disconnect connectors CP01 and W03. Connect the T-adapter to the female side of CP01.
3.
Mount the front window at the front.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Measuring point and measurement condition Between CP01 (female) (76) and ground
Standard value
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01 and W03. Connect the T-adapter to the female side of CP01.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value?
Resistance
Measuring point and measurement condition
NO
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
YES
•
Go to the next inspection item.
•
The wiring harness has a ground fault.
NO
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
•
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Min. 1 MΩ
1.
Item
YES
•
Max. 1 Ω
Turn the starting switch to the OFF position.
Resistance
Short circuit in wiring harness
Between CP01 (female) (76) and ground
Standard value
1.
Item
6
Measuring point and measurement condition
Diagnosis and treatment
Standard value
YES
NO
Between CP01 (76) and each Min. 1 MΩ pin other than (76)
YES The repair is completed.
7
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation?
PC210-10M0, PC210LC-10M0
NO
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
40-909
E-47 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED
No.
8
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Diagnosis and treatment YES The repair is completed.
Turn the starting switch to the ON position. Operate the wiper switch. Is the WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with windshield wiper
40-910
PC210-10M0, PC210LC-10M0
E-48 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED
40 TROUBLESHOOTING
E-48 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED Details of failure
The window washer does not operate when the window washer switch is operated. Pre-troubleshooting
Associated informa- If a failure code is shown, do the troubleshooting for that code first. tion Monitoring code The state of the window washer switch signal can be monitored. (Code: 04504) No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES 1. 1
Wiring harness and connector 2.
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Are the wiring harnesses and connectors normal?
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The fuse is normal.
NO
• YES •
2
3
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Remove fuse No.4 in fuse box F01. Check if the fuse is blown. Check the resistance.
4.
Is the fuse normal?
Fuse
Window washer motor
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector M06. Connect the T-adapter to the female side.
3.
Measure the continuity.
4.
Does the measurement result agree with the standard value? Item
Continuity
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between M06 (female) (1) and (2)
Standard value Continuity
•
NO
•
If blown, go to "Ground fault of wiring harness".
•
If the fuse is not blown but has no continuity, replace the fuse.
•
Go to "Confirmation of repair". The window washer motor is normal.
• YES
NO
Go to the next inspection item. The fuse is defective.
•
Go to the next inspection item.
•
The window washer motor is defective.
•
Replace the window washer motor.
•
Go to "Confirmation of repair".
40-911
E-48 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED
No.
4
Cause
Open circuit in wiring harness
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Remove fuse No.4 in fuse box F01.
3.
Disconnect connectors CP01 and M06. Connect the T-adapter to the female side.
4.
Measure the resistance.
5.
Does the measurement result agree with the standard value? Item
Resistance
5
Ground fault in wiring harness
40 TROUBLESHOOTING
Measuring point and measurement condition
Diagnosis and treatment YES
Standard value
Between F01-4 and M06 (female) (2)
Max. 1 Ω
Between CP01 (female) (3) and M06 (female) (1)
Max. 1 Ω
NO
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
•
Go to the next inspection item.
1.
Turn the starting switch to the OFF position.
2.
Remove fuse No.4 in fuse box F01.
3.
Disconnect connectors M04, M06 and D02. Connect the T-adapter to the female side of one of the connectors.
4.
Measure the resistance.
•
5.
Does the measurement result agree with the standard value?
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Replace the fuse if it is blown.
•
Go to "Confirmation of repair".
Item
Measuring point and measurement condition
Resistance
Between ground and one of F01-4, M04 (female) (1), D02 (female) (3), and M06 (female) (2)
YES
Standard value
NO
Min. 1 MΩ
YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-912
Do the troubleshooting above again.
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Operate the wiper switch. Is the WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-48 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED
Circuit diagram associated with windshield wiper
PC210-10M0, PC210LC-10M0
40-913
E-49 BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-49 BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION Details of failure
Boom RAISE is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-914
Do a reconfirmation of the failure symptom.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the "Boom RAISE is not shown normally with the monitoring function" problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-50 BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-50 BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION Details of failure
Boom LOWER is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is Boom LOWER shown normally with the monitoring function?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-915
E-51 ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-51 ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION Details of failure
Arm OUT is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-916
Do a reconfirmation of the failure symptom.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the "Arm OUT is not shown normally with monitoring function" problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-52 ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-52 ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION Details of failure
Arm IN is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the "Arm IN is not shown normally with monitoring function" problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-917
E-53 BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-53 BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION Details of failure
Bucket DUMP is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-918
Do a reconfirmation of the failure symptom.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the "BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION" problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-54 BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-54 BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION Details of failure
Bucket CURL is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the "BUCKET CURL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION" problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-919
E-55 SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-55 SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION Details of failure
Swing is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-920
Do a reconfirmation of the failure symptom.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the "Swing is not shown normally with monitoring function" problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
E-56 TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-56 TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION Details of failure
TRAVEL is not shown normally with the monitoring function.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1
2
Reconfirmation 1. of failure symp2. tom
Do a reconfirmation of the failure symptom. Are other failures found by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Find the solution for other problems first. •
The machine monitor is defective.
•
Replace the machine monitor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the "TRAVEL is not shown normally with monitoring function" problem resolved?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-921
E-57 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
E-57 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION Details of failure
Service information is not displayed correctly by the monitoring function. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first. Monitoring code The service information can be monitored. (Code: 01901) Associated information
Associated information
No.
•
The connectors of electrical parts around the engine can be defective by heat and vibration. Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment.
•
For safety, use "short socket adapter" (799-601-7230) for 2-pin X connectors in the test of the service PPC oil pressure switch.
•
While the engine runs, do not check the connector of the oil pressure switch.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The service front PPC oil pressure switch is normal. Go to the next inspection item. The service front PPC oil pressure switch is defective.
YES
1
Service front PPC oil pressure switch
1.
Turn the starting switch to the OFF position.
•
2.
Disconnect connector P14. Connect the short socket adapter to the male side.
•
3.
Turn the starting switch to the ON position to troubleshoot.
4.
Is the phenomenon reproduced in the same way?
NO
•
Replace the service front PPC oil pressure switch.
•
Go to "Confirmation of repair". The service rear PPC oil pressure switch is normal.
• YES
2
Service rear PPC oil pressure switch
40-922
1.
Turn the starting switch to the OFF position.
•
2.
Disconnect connector P15. Connect the short socket adapter to the male side.
•
3.
Turn the starting switch to the ON position to troubleshoot.
4.
Is the phenomenon reproduced in the same way?
NO
Go to the next inspection item. The service rear PPC oil pressure switch is defective.
•
Replace the service rear PPC oil pressure switch.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
E-57 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION
40 TROUBLESHOOTING
No.
3
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01, P14 and P15. Con- YES • nect the T-adapter to each female side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Open circuit in wiring harness
Resistance
Measuring point and measurement condition
Standard value
Between CP01 (female) (35) and P14 (female) (1)
Max. 1 Ω
Between CP01 (female) (35) and P15 (female) (1)
Max. 1 Ω
NO
The wiring harness has no open circuits. Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no ground faults.
Between P14 (female) (2) and Max. 1 Ω ground (T06) Between P15 (female) (2) and Max. 1 Ω ground (T06)
4
Ground fault in wiring harness
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01, P14 and P15. Con- YES • nect the T-adapter to the female side of one of the connectors.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
5
Short circuit in wiring harness
Measuring point and measurement condition Between ground and one of CP01 (female) (35), P14 (female) (1), and P15 (female) (1)
Standard value
NO
•
The wiring harness has a ground fault.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no short circuits.
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connectors CP01, P14 and P15. Con- YES • nect the T-adapter to the female side of CP01.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value? Item
Resistance
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition Between CP01 (female) (35) and each pin other than pin (35)
Standard value Min. 1 MΩ
NO
Go to the next inspection item.
Go to the next inspection item.
•
The wiring harness has a short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
40-923
E-57 SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
6
7
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
Turn the starting switch to the ON position. Is the SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with service oil pressure switch
40-924
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-58 ATTACHMENT CIRCUIT CANNOT BE CHANGED
E-58 ATTACHMENT CIRCUIT CANNOT BE CHANGED Details of failure
The attachment hydraulic circuit cannot be changed. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first.
Associated information
No.
Associated information •
When working mode P or E is selected, the circuit is not changed to the crusher circuit (2-way circuit).
•
When working mode B is selected, the circuit is not changed to the breaker circuit (1way circuit).
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
1. 1
Wiring harness and connector 2.
2
Check the wiring harnesses and connectors. For details, see RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, Electrical equipment. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V07. Connect the T-adapter to the male side.
3.
Measure the resistance.
4.
Does the measurement result agree with the standard value?
Attachment return selector solenoid
Item
Resistance
3
Measuring point and measurement condition
20 to 60 Ω
Between V07 (male) (1) and ground
Min. 1 MΩ
1.
Turn the starting switch to the OFF position.
2.
Disconnect connector V07. Connect the T-adapter to the female side.
3.
Turn the starting switch to the ON position.
4. Hot short circuit 5. in wiring harness
•
A wiring harness or connector is defective.
•
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The attachment return selector solenoid is normal.
NO
• YES
Standard value
Between V07 (male) (1) and (2)
Go to the next inspection item.
NO
•
Go to the next inspection item.
•
The attachment return selector solenoid is defective.
•
Replace the attachment return selector solenoid.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
YES
Measure the voltage. Does the measurement result agree with the standard value? Item
Voltage
PC210-10M0, PC210LC-10M0
Measuring point and measurement condition
Standard value
Between V07 (female) (1) and Max 1V ground
NO
40-925
E-58 ATTACHMENT CIRCUIT CANNOT BE CHANGED
No.
4
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Diagnosis and treatment YES The repair is completed.
Turn the starting switch to the ON position. Is the ATTACHMENT CIRCUIT CANNOT BE CHANGED problem resolved?
NO
Return to the first inspection item.
Circuit diagram associated with attachment return selector solenoid
40-926
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY Details of failure
KOMTRAX system does not operate normally. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Associated information
Associated information
No.
1
•
Do the troubleshooting only if the administrator of the KOMTRAX system requests to check whether failure occurs in the system on the machine.
•
Even if the KOMTRAX system is defective, the nature of the problem is not shown on the machine.
•
All troubleshooting can be checked on the service menu of the machine monitor.
Cause
Procedures, Measurement, Values, Note
1.
Turn the starting switch to the ON position.
2.
Show the Terminal Status screen. For details, see TESTING AND ADJUSTING, KOMTRAX SETTINGS MENU (TERMINAL STATUS).
KOMTRAX Communication 3.
Is the monitoring display KOMTRAX Communication Inspection completed?
Diagnosis and treatment •
The transmission function of KOMTRAX is normal.
•
Go to the next inspection item. KOMTRAX communication is not open.
YES
• NO
•
Contact the KOMTRAX service hot line.
•
Go to "Confirmation of repair". The GPS Positioning function of KOMTRAX is normal.
•
2
GPS positioning
1.
Turn the starting switch to the ON position.
2.
Show the Terminal Status screen. For details, see TESTING AND ADJUSTING, KOMTRAX SETTINGS MENU (TERMINAL STATUS).
3.
Show the monitoring display of Positioning at a place under open sky.
4.
Are the latitude and longitude shown in 5 minutes?
YES • •
NO
•
Contact the KOMTRAX service hot line.
•
Go to "Confirmation of repair". The communication function of KOMTRAX is normal.
•
3
Communication function
1.
Turn the starting switch to the ON position.
2.
Show the GPS & Communication State screen. For details, see TESTING AND ADJUSTING, KOMTRAX SETTINGS MENU (GPS AND COMMUNICATION STATUS).
3.
Show the monitoring display of Communication .
4.
Is the communication reception level between 1 and 3 in a communication reception area of the mobile phone?
PC210-10M0, PC210LC-10M0
YES • •
NO
Go to the next inspection item. The GPS positioning function of KOMTRAX is defective.
Go to the next inspection item. The communication function of KOMTRAX is defective.
•
Contact the KOMTRAX service hot line.
•
Go to "Confirmation of repair".
40-927
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
No.
4
Cause
Transmission function
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the ON position.
2.
Show the GPS & Communication State screen. For details, see TESTING AND ADJUSTING, KOMTRAX SETTINGS MENU (GPS AND COMMUNICATION STATUS).
3.
Show the monitoring display of Number of Message(s) Not Yet Sent, and check the number of messages not sent.
4.
Does the measurement result agree with the standard value? Item
Measurement position and condition
Standard value
Diagnosis and treatment
5
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
40-928
The communication function of KOMTRAX is normal.
•
Go to the next inspection item.
•
The transmission function of KOMTRAX is defective.
•
Contact the KOMTRAX service hot line.
•
Go to "Confirmation of repair".
YES
NO
Number of mesMonitoring display: Number of 0 to 9 (norsage(s) mally 0) Message(s) Not Yet Sent not yet sent
1.
•
YES The repair is completed.
Turn the starting switch to the ON position. Is the KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY problem resolved?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-60 QUICK COUPLER DOES NOT WORK
E-60 QUICK COUPLER DOES NOT WORK Details of failure
The quick coupler does not work.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
1.
1
Wiring harness and connector 2.
2
L.H. knob switch
See RELATED INFORMATION TO TROUBLESHOOT, CHECKS BEFORE TROUBLESHOOTING, ELECTRICAL EQUIPMENT. Check according to the descriptions of wiring harnesses and connectors. Are the wiring harnesses and connectors normal?
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector M23. Connect the T-adapter to the male side.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Resistance
Measurement position and condition L.H. knob Between M23 switch: Push (male) (4) and L.H. knob (12) switch: Re-
Standard value Max. 1 Ω
Diagnosis and treatment •
The wiring harnesses and connectors are normal.
•
Go to the next inspection item. A wiring harness or connector is defective.
YES
• •
Repair or replace the defective wiring harness or connector.
•
Go to "Confirmation of repair". The L.H. knob switch is normal.
NO
• YES
NO
•
Go to the next inspection item.
•
The L.H. knob switch is defective.
•
Replace the L.H. knob switch.
•
Go to "Confirmation of repair".
Min. 1 MΩ
lease
PC210-10M0, PC210LC-10M0
40-929
E-60 QUICK COUPLER DOES NOT WORK
No.
3
Cause
Quick coupler switch
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect connector S42. Connect the T-adapter to the male side.
4.
Measure the resistance to troubleshoot.
5.
Does the troubleshooting result agree with the standard value? Item
Resistance
4
Quick coupler relay
Measurement position and condition
Standard value
Between S42 (male) (1) and Switch: ON (5)
Max. 1 Ω
Between S42 (male) (2) and Switch: ON (4)
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Insert the T-adapter into connector R40.
4.
Turn the battery disconnect switch to the ON position.
5.
Turn the starting switch to the ON position.
6.
Measure the resistance to troubleshoot.
7.
Does the troubleshooting result agree with the standard value? Item
Resistance
40-930
40 TROUBLESHOOTING
Measurement position and condition
Standard value
Diagnosis and treatment YES
NO
YES
NO
•
The quick coupler switch is normal.
•
Go to the next inspection item.
•
The quick coupler switch is defective.
•
Replace the quick coupler switch.
•
Go to "Confirmation of repair".
•
The quick coupler relay is normal.
•
Go to the next inspection item.
•
The quick coupler relay is defective.
•
Replace the quick coupler relay.
•
Go to "Confirmation of repair".
Quick coupler Between R40 switch: ON (male) (3) and Max. 1 Ω L.H. knob (5) switch ON
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
E-60 QUICK COUPLER DOES NOT WORK
Cause
Procedures, Measurement, Values, Note 1.
Turn the starting switch to the OFF position.
2.
Check that the system operating lamp is turned off. Turn the battery disconnect switch to the OFF position.
3.
Disconnect fuse box F01-9 and connectors CP01, M23, P50, R40, S42 and V40. Connect the T-adapter to each female side of CP01, P50, R40, S42 and V40.
4.
Measure the resistance to troubleshoot.
5.
Does the measurement result agree with the standard value? Item
5
Open circuit in wiring harness
Measurement position and condition Between CP01 (female) (54) and P50 (female) (2)
Resistance
YES
•
The wiring harness has no open circuits.
•
Go to the next inspection item.
•
The wiring harness has an open circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
•
The wiring harness has no hot short circuits.
•
Go to the next inspection item.
•
The wiring harness has a hot short circuit.
•
Repair or replace the wiring harness.
•
Go to "Confirmation of repair".
Standard value Max. 1 Ω
Between P50 (female) (1) and Max. 1 Ω ground Between F01-9 and S42 (female) (1)
Diagnosis and treatment
NO
Max. 1 Ω
Between S42 (female) (2) and Max. 1 Ω V40 (female) (2) Between S42 (female) (4) and Max. 1 Ω ground Between S42 (female) (5) and Max. 1 Ω R40 (female) (3) Between R40 (female) (5) and V40 (female) (1)
6
Max. 1 Ω
1.
Turn the starting switch to the OFF position.
2.
Insert the T-adapter into connector V40.
3.
Turn the starting switch to the ON position.
4.
Measure the voltage to troubleshoot.
Hot short circuit 5. in wiring harness
YES
Does the troubleshooting result agree with the standard value? Item
StandMeasurement position and condition ard value
Voltage Between V40 (1) and ground
PC210-10M0, PC210LC-10M0
Max. 1 V
NO
40-931
E-60 QUICK COUPLER DOES NOT WORK
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES The repair is completed.
7
8
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Have you identified the cause by reconfirmation? NO
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4.
Turn the starting switch to the ON position, and set the L.H. knob switch and quick coupler switch to ON. Is the QUICK COUPLER DOES NOT WORK problem resolved?
•
The pump controller can be defective.
•
Replace the pump controller.
•
Go to "Confirmation of repair".
YES The repair is completed.
NO
Return to the first inspection item.
Circuit diagram associated with quick coupler
40-932
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
E-60 QUICK COUPLER DOES NOT WORK
Circuit diagram associated with quick coupler pressure switch
PC210-10M0, PC210LC-10M0
40-933
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE)
40 TROUBLESHOOTING
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE) The information that follow are summarized in the troubleshooting table. Understand that information fully before troubleshooting. Failure
Failure symptom that occurs on the machine
Related information
Information about the occurred failure and its troubleshooting
No.
Check item
Troubleshooting procedure
1
2
It shows the check item to judge the cause of the failure. (Each number is serial number, not priority sequence.)
3 4
40-934
•
Troubleshooting of the check item or check method
•
Standard value to judge
•
Remarks for judgment criteria
Judgment and action YES
Action when YES
NO
Action when NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-1 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK
H-1 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK Details of failure
All work equipment, travel and swing do not move. Pre-troubleshooting
Associated informa- If a failure code is shown, do the troubleshooting for that code first. tion Reference information Do all the troubleshooting with work mode set to power mode (P). No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
YES
•
The PPC lock solenoid valve is normal.
•
Go to the next inspection item.
•
The PPC lock solenoid valve is defective.
•
Make a repair or replace the PPC lock solenoid valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Measuring point and measurement condition •
Fuel dial: Hi
•
PPC lock: LOCK
•
PPC lock solenoid valve Solenoid output pressure
Outlet hose of PPC lock solenoid valve
0 MPa {0 2 Hydraul- kg/cm }
ic oil temperature: 45 to 55°C •
Fuel dial: Hi
•
PPC lock: RELEASE 2.9 MPa {30
•
PC210-10M0, PC210LC-10M0
Standard value
NO
2 Hydraul- kg/cm } ic oil temperature: 45 to 55°C
40-935
H-1 ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition •
Self-pressure reducing valve Control circuit Oil pressure source pickup plug pressure
3
Piston pump
4
5
2.84 to 3.43
•
Fuel dial: MPa {29 to 35 Hi 2
•
Hydraulic oil temperature: 45 to 55°C
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Remove the pickup plug of main oil pressure.
4.
Turn the starting switch to the ON position.
5.
Do a test. For details, see TESTING AND ADJUSTING, METHOD FOR OPERATING NO INJECTION CRANKING.
The pump shaft possibly does not rotate due to a problem inside the damper. Check it.
2.
Does the pump shaft rotate?
1.
Stop the engine.
2.
Connect all the configuration equipment.
5.
Self pressure reducing is defective.
•
Make a repair or replace the self pressure reducing valve.
•
Go to "Confirmation of repair".
•
The piston pump is normal.
•
Go to the next inspection item.
•
The piston pump is defective.
•
Make a repair or replace the piston pump.
•
Go to "Confirmation of repair".
•
The damper is normal.
YES •
Go to the next inspection item. The damper is defective.
NO
YES
NO
Does oil flow out the pickup plug of main oil pressure?
1.
Confirmation of 3. repair 4.
Go to the next inspection item.
•
kg/cm }
Stop the engine.
Damper
40-936
Control lever: All levers in NEUTRAL
Self pressure reducing is normal.
Standard value
1.
6.
Diagnosis and treatment
• Do a test. For details, see TESTING AND ADJUSTING, TEST OIL PRESSURE OF CONTROL YES • CIRCUIT.
Item
2
40 TROUBLESHOOTING
• NO
•
Make a repair or replace the damper.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Do the work equipment, swing, and travel operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
40 TROUBLESHOOTING
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER Details of failure
All work equipment, swing, and travel lack speed or power. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
Associated information
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
Reference information For operations other than swing, check whether the speed is normal when the swing lock switch is in the ON position. If the speed is normal, check the swash plate sensors of the front and rear pumps for malfunction.
PC210-10M0, PC210LC-10M0
40-937
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PUMP SWASH PLATE SENSOR.
Measurement position and condition
Front pump swash plate sensor Monitoring Sensor code: 01138F output Pump swash voltage plate sensor voltage
40-938
Diagnosis and treatment YES
•
The front pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The front pump swash plate sensor is defective.
•
Make a repair or replace the front pump swash plate sensor.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
1
40 TROUBLESHOOTING
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in NEU0.72 to 1.98 V TRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Running with oneside spinning 2.72 to 3.98 V off the ground
•
Hydraulic oil temperature: 45 to 55°C
NO
PC210-10M0, PC210LC-10M0
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PUMP SWASH PLATE SENSOR.
YES
•
The rear pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The rear pump swash plate sensor is defective.
•
Make a repair or replace the rear pump swash plate sensor.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
2
Diagnosis and treatment
Measurement position and condition
Rear pump swash plate sensor Monitoring Sensor code: 01140R output Pump swash voltage plate sensor voltage
PC210-10M0, PC210LC-10M0
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in NEU0.72 to 1.98 V TRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Running with oneside spinning 2.72 to 3.98 V off the ground
•
Hydraulic oil temperature: 45 to 55°C
NO
40-939
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
•
Unload pressure
2.
Discharged pressure pickup port of front pump
The unload valve of the front pump is normal.
•
Go to the next inspection item.
•
Control lever: All levers in NEU2.5 to 4.5 TRAL
•
The unload valve of the front pump is defective.
NO
•
Make a repair or replace the unload valve of the front pump.
•
Go to "Confirmation of repair".
•
The unload valve of the rear pump is normal.
•
Go to the next inspection item.
•
The unload valve of the rear pump is defective.
•
Make a repair or replace the unload valve of the rear pump.
•
Go to "Confirmation of repair".
MPa {26 to 46
Hydraul- kg/cm2} ic oil temperature: 45 to 55°C
YES
Does the troubleshooting result agree with the standard value? Measurement position and condition
Unload valve of rear pump
•
Unload pressure
40-940
• YES
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Item
4
Measurement position and condition
Unload valve of front pump
1.
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
3
40 TROUBLESHOOTING
Discharged pressure pickup port of rear pump
•
Standard value
Control lever: All levers in NEU2.5 to 4.5 TRAL
NO
MPa {26 to 46
Hydraul- kg/cm2} ic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief valve of front pump
•
Main relief pressure
1.
2.
6
Main relief valve of rear pump
Measurement position and condition
Discharged pressure pickup port of front pump
•
Standard value
Control lever: Boom RAISE relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
NO
ic oil temperature: 45 to 55°C
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Measurement position and condition •
Main relief pressure
PC210-10M0, PC210LC-10M0
Discharged pressure pickup port of rear pump
•
Control lever: Arm IN relief
33.1 to 37.2
•
Go to the next inspection item.
•
The main relief valve of the front pump is defective.
•
Adjust the main relief valve of the front pump.
•
If the oil pressure is not normal after the main relief valve of the front pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
•
The main relief valve of the rear pump is normal.
•
Go to the next inspection item. The main relief valve of the rear pump is defective.
•
Standard value
Hydraul- MPa {338 to 380 kg/cm2} ic oil temperature: 45 to 55°C
The main relief valve of the front pump is normal.
YES
Does the troubleshooting result agree with the standard value? Item
• YES
Does the troubleshooting result agree with the standard value? Item
5
Diagnosis and treatment
NO
•
Adjust the main relief valve of the rear pump.
•
If the oil pressure is not normal after the main relief valve of the rear pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
40-941
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Does the troubleshooting result agree with the standard value? Measurement position and condition •
Self-pressure reducing valve Control circuit Oil pressure source pickup plug pressure
40-942
Diagnosis and treatment
• Do a test. For details, see TESTING AND ADJUSTING, TEST OIL PRESSURE OF CONTROL YES • CIRCUIT.
Item
7
40 TROUBLESHOOTING
Control lever: All levers in NEUTRAL
Self pressure reducing is normal. Go to the next inspection item.
Standard value
2.84 to 3.43
•
Fuel dial: MPa {29 to 35 Hi 2
•
Hydraulic oil temperature: 45 to 55°C
kg/cm }
•
Self pressure reducing is defective.
•
Repair or replace the self pressure reducing valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
Measurement position and condition
Front pump PC-EPC valve PCEPC valve output pressure
Pressure pickup port for front PC mode selector pressure
Control lever: All levers in NEUTRAL
•
Fuel dial: 2.9 MPa {30 Lo kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
• •
PC210-10M0, PC210LC-10M0
Control lever: All levers in NEUTRAL
The PC-EPC valve of the front pump is normal.
•
Go to the next inspection item.
•
The PC-EPC valve of the front pump is defective.
•
Adjust the PC-EPC valve of the front pump.
•
If the oil pressure is not normal after the PC-EPC valve of rhw front pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
Standard value
•
•
• YES
Does the troubleshooting result agree with the standard value? Item
8
Diagnosis and treatment
0.70 to 1.09 Fuel dial: MPa {7.1 to Hi 11.1 kg/cm2}
NO
Hydraulic oil temperature: 45 to 55°C
40-943
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
Measurement position and condition
Rear pump PCEPC valve PCEPC valve output pressure
1.
2.
40-944
Pressure pickup port for rear PC mode selector pressure
•
Control lever: All levers in NEUTRAL
•
Fuel dial: 2.9 MPa {30 Lo kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: All levers in NEUTRAL
Discharged pressure pickup port of front pump
•
Hydraulic oil temperature: 45 to 55°C
PC valve output pressure
Pressure pickup port for front pump control pressure
•
•
Control lever: Boom RAISE relief
Go to the next inspection item.
•
The PC-EPC valve of the rear pump is defective.
•
Adjust the PC-EPC valve of the rear pump.
•
Make a repair or replace the PC-EPC valve of the rear pump.
•
Go to "Confirmation of repair".
•
The PC valve of the front pump is normal.
•
Go to the next inspection item.
•
The PC valve of the front pump is defective.
•
Adjust the PC valve of the front pump.
•
If the oil pressure is not normal after the PC valve of the front pump is adjusted, make a repair or replace the servo piston assembly.
•
Go to "Confirmation of repair".
11.1 kg/cm }
YES
Standard value
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve disic oil charged prestempera- sure is 1:0.6 ture: 45 (approx. 3/5)
to 55°C
•
0.70 to 1.09
Fuel dial: MPa {7.1 to Hi 2
Does the troubleshooting result agree with the standard value?
Pump discharge pressure
The PC-EPC valve of the rear pump is normal.
YES
NO
•
Measurement position and condition
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
Item
PC valve of 10 front pump
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
9
40 TROUBLESHOOTING
NO
PC210-10M0, PC210LC-10M0
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
YES
Does the troubleshooting result agree with the standard value? Item
PC valve of 11 rear pump
Diagnosis and treatment
Measurement position and condition
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Pressure pickup port for rear pump control pressure
PC210-10M0, PC210LC-10M0
•
•
Control lever: Arm IN relief
The PC valve of the rear pump is normal.
•
Go to the next inspection item. The PC valve of the rear pump is defective.
•
Standard value
Oil pressure ratio between pump discharged presHydraul- sure and PC valve disic oil tempera- charged presture: 45 sure is 1:0.6 to 55°C (approx. 3/5)
•
•
Adjust the PC valve of the rear pump.
•
If the oil pressure is not normal after the PC valve of the rear pump is adjusted, make a repair or replace the servo piston assembly.
•
Go to "Confirmation of repair".
NO
40-945
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment YES
•
The LS-EPC valve is normal.
•
Go to the next inspection item.
•
The LS-EPC valve is defective.
•
Repair or replace the LS-EPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
Measurement position and condition
12 LS-EPC valve LSEPC valve output pressure
40-946
40 TROUBLESHOOTING
Pickup port for selecting pressure of LS setting
•
Control lever: All levers in NEUTRAL
•
Travel speed: Lo
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Travel lever fine control
•
Travel speed: Hi
•
Hydraulic oil temperature: 45 to 55°C
Standard value
Approximately 2.9 MPa {approximately 30 kg/cm2}
NO
0 MPa {0 kg/cm2}
PC210-10M0, PC210LC-10M0
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
YES
•
The front pump LS valve is normal.
•
Go to the next inspection item.
•
The LS valve of the front pump is defective.
•
Adjust the LS valve of the front pump.
•
If the oil pressure is not normal after adjusting the LS valve of the front pump, repair or replace it.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
LS valve of 13 front pump
Diagnosis and treatment
Measurement position and condition
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
PC210-10M0, PC210LC-10M0
•
•
•
•
Standard value
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
NO
to 55°C
40-947
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment YES
Measurement position and condition
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
•
•
•
•
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
NO
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
•
Go to the next inspection item.
•
The LS valve of the rear pump is defective.
•
Adjust the LS valve of the rear pump.
•
If the oil pressure is not normal after adjusting the LS valve of the rear pump, repair or replace it.
•
Go to "Confirmation of repair".
•
The servo piston is normal.
•
Go to the next inspection item. The servo piston is defective.
to 55°C
1.
Check inside the pump servo equipment.
2.
Are the orifice and filter free not clogged and clean?
• NO
40-948
The rear pump LS valve is normal.
Standard value
YES
15 Servo piston
•
Does the troubleshooting result agree with the standard value? Item
LS valve of 14 rear pump
40 TROUBLESHOOTING
•
Make a repair or replace the servo piston.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
H-2 All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER
40 TROUBLESHOOTING
No.
Cause
16 Piston pump
17
Procedures, Measurement, Values, Note 1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Remove the pickup plug of main oil pressure.
4.
Turn the starting switch to the ON position.
5.
Do a test. For details, see TESTING AND ADJUSTING, METHOD FOR OPERATING NO INJECTION CRANKING.
6.
Does oil flow out the pickup plug of main oil pressure?
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
Diagnosis and treatment YES
NO
•
The piston pump is normal.
•
Go to the next inspection item.
•
The piston pump is defective.
•
Repair or replace the piston pump.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Do the work equipment, swing, and travel operate normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-949
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR
40 TROUBLESHOOTING
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR Details of failure
The fine control performance or response is low. Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The F pump pressure can be monitored. (Code: 01100) • No.
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PUMP SWASH PLATE SENSOR.
Measuring point and measurement condition
The front pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The front pump swash plate sensor is defective.
Monitoring Sensor code: 01138F output Pump swash voltage plate sensor voltage
•
Make a repair or replace the front pump swash plate sensor.
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in NEU0.72 to 1.98V TRAL
•
Hydraulic oil temperature: 45 to 55°C
Front pump swash plate sensor
40-950
YES
•
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
•
Fuel dial: Hi
•
Control lever: Running with oneside spinning 2.72 to 3.98 V off the ground
•
Hydraulic oil temperature: 45 to 55°C
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PUMP SWASH PLATE SENSOR.
YES
•
The rear pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The rear pump swash plate sensor is defective.
•
Make a repair or replace the rear pump swash plate sensor.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
2
Diagnosis and treatment
Measuring point and measurement condition •
Fuel dial: Hi
•
Control lever: All levers in NEU0.72 to 1.98V TRAL
•
Hydraulic oil temperature: 45 to 55°C
Rear pump swash plate sensor Monitoring Sensor code: 01140R output Pump swash voltage plate sensor voltage
PC210-10M0, PC210LC-10M0
Standard value
•
Fuel dial: Hi
•
Control lever: Running with oneside spinning 2.72 to 3.98 V off the ground
•
Hydraulic oil temperature: 45 to 55°C
NO
40-951
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment YES
•
The LS-EPC valve is normal.
•
Go to the next inspection item.
•
The LS-EPC valve is defective.
•
Make a repair or replace the LS-EPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
3
40 TROUBLESHOOTING
Measuring point and measurement condition
LS-EPC valve LSEPC valve output pressure
Pickup port for selecting pressure of LS setting
•
Control lever: All levers in NEUTRAL
•
Travel speed: Lo
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Travel lever fine control
•
Travel speed: Hi
•
Hydraulic oil temperature: 45 to 55°C
Standard value
Approximately 2.9 MPa {approximately 30 kg/cm2}
NO
0 MPa {0 kg/cm2}
• YES • 4
LS circuit orifice
1.
Check the LS circuit orifice.
2.
Is the orifice free of clogging and clean?
•
Go to the next inspection item. The or is defective.
•
Make a repair or replace the orifice.
•
Go to "Confirmation of repair".
NO
40-952
The orifice is normal.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
5
YES
•
The front pump LS valve is normal.
•
Go to the next inspection item.
•
The LS valve of the front pump is defective.
•
Adjust the LS valve of the front pump.
•
If the oil pressure is not normal after the LS valve of the front pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
LS valve of front pump
Diagnosis and treatment
Measuring point and measurement condition
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
PC210-10M0, PC210LC-10M0
•
•
•
•
Standard value
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
NO
to 55°C
40-953
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
6
Diagnosis and treatment YES
Measuring point and measurement condition
Servo piston
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
•
•
•
•
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
NO
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
1.
Check inside the pump servo equipment.
2.
Are the orifice and filter free not clogged and clean?
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
40-954
•
Go to the next inspection item.
•
The LS valve of the rear pump is defective.
•
Adjust the LS valve of the rear pump.
•
If the oil pressure is not normal after the LS valve of the rear pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
•
The servo piston is normal.
•
Go to the next inspection item. The servo piston is defective.
to 55°C
• NO
8
The rear pump LS valve is normal.
Standard value
YES
7
•
Does the troubleshooting result agree with the standard value? Item
LS valve of rear pump
40 TROUBLESHOOTING
•
Make a repair or replace the servo piston.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Do the work equipment, swing, and travel operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP Details of failure
Unusual noise is heard from around the hydraulic pump.
Associated information No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
•
The pump shaft seal is normal.
•
Go to the next inspection item. There is a possibility that hydraulic oil flows into the flywheel chamber due to breakage of the pump shaft seal.
• 1
Hydraulic oil level
1.
Check the hydraulic oil level.
2.
Is there no signs of hydraulic oil leakage? Is the hydraulic oil level normal? NO •
Replace the pump shaft seal.
•
Go to "Confirmation of repair". The hydraulic oil is normal.
• YES
2
Hydraulic oil
1.
Check the hydraulic oil.
2.
Is the hydraulic oil free of bubbles, not cloudy and normal?
• •
NO
•
Change the hydraulic oil.
•
Go to "Confirmation of repair". The hydraulic tank cap is normal.
• YES
• •
3
Hydraulic tank cap
1.
Check the hydraulic tank cap.
2.
Is the hydraulic tank cap free of clogging and clean? NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The hydraulic oil is defective.
Go to the next inspection item. There is a possibility that the inside of the tank is negative pressure due to clogging of the hydraulic tank cap.
•
Clean the hydraulic tank cap.
•
Go to "Confirmation of repair".
40-955
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
•
The hydraulic tank strainer is normal.
•
Go to the next inspection item. There is a possibility that the inside of the tank is negative pressure due to clogging of the hydraulic tank strainer.
• 4
Hydraulic tank strainer
1.
Check the hydraulic tank strainer.
2.
Is the hydraulic tank strainer free of clogging and clean? NO •
Clean the hydraulic tank strainer.
•
Go to "Confirmation of repair". The hydraulic tank return filter is normal.
• YES
5
Return filter of hydraulic tank
1.
Check the return filter of hydraulic tank.
2.
Is the hydraulic tank return filter clean and free of clogging and metal particles?
•
NO
6
7
Piston pump
1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Remove the pickup plug of main oil pressure.
4.
Turn the starting switch to the ON position.
5.
Do a test. For details, see TESTING AND ADJUSTING, METHOD FOR OPERATING NO INJECTION CRANKING.
6.
Does oil flow out the pickup plug of main oil pressure?
1.
Stop the engine.
Confirmation of 2. repair 3. 4.
40-956
Connect all the configuration equipment.
YES
NO
Go to the next inspection item. The return filter of the hydraulic tank is defective.
•
Clean or replace the return filter of the hydraulic tank.
•
Go to "Confirmation of repair". The piston pump is normal.
• •
Go to the next inspection item.
•
The piston pump is defective.
•
Repair or replace the piston pump.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Is the sound around the oil pump normal?
•
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS Details of failure
The engine speed drops largely or the engine stops. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first. Monitoring code
Associated information
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
Reference information For operations other than swing, check whether the speed is normal when the swing lock switch is in the ON position. If the speed is normal, check the swash plate sensors of the front and rear pumps for malfunction.
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PUMP SWASH PLATE SENSOR.
YES
•
The front pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The front pump swash plate sensor is defective.
•
Make a repair or replace the front pump swash plate sensor.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Measuring point and measurement condition
Front pump swash plate sensor Monitoring Sensor code: 01138F output Pump swash voltage plate sensor voltage
PC210-10M0, PC210LC-10M0
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in NEU0.72 to 1.98 V TRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Running with oneside spinning 2.72 to 3.98 V off the ground
•
Hydraulic oil temperature: 45 to 55°C
NO
40-957
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PUMP SWASH PLATE SENSOR.
Measuring point and measurement condition
Rear pump swash plate sensor Monitoring Sensor code: 01140R output Pump swash voltage plate sensor voltage
1.
2.
3
Main relief valve of front pump
YES
•
The rear pump swash plate sensor is normal.
•
Go to the next inspection item.
•
The rear pump swash plate sensor is defective.
•
Make a repair or replace the rear pump swash plate sensor.
•
Go to "Confirmation of repair".
•
The main relief valve of ront pump is normal.
•
Go to the next inspection item. The main relief valve of front pump is defective.
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in NEU0.72 to 1.98 V TRAL
•
Hydraulic oil temperature: 45 to 55°C
NO
•
Fuel dial: Hi
•
Running with oneside spinning 2.72 to 3.98 V off the ground
•
Hydraulic oil temperature: 45 to 55°C
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
YES
•
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition •
Main relief pressure
40-958
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
2
40 TROUBLESHOOTING
Discharged pressure pickup port of front pump
•
Boom RAISE relief
Standard value
33.1 to 37.2 Hydraul- MPa {338 to ic oil 380 kg/cm2}
temperature: 45 to 55°C
NO
•
Adjust the main relief valve of the front pump.
•
If the oil pressure is not normal after the main relief valve of the front pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
4
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
Main relief valve of rear pump
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
2.
Discharged pressure pickup port of rear pump
•
Arm IN relief
•
Hydraul- 33.1 to 37.2 MPa {338 to ic oil 2 tempera- 380 kg/cm }
NO
PCEPC valve output pressure
Measuring point and measurement condition
Pressure pickup port for front PC mode selector pressure
Go to the next inspection item. The main relief valve of rear pump is defective.
•
Adjust the main relief valve of the rear pump.
•
If the oil pressure is not normal after the main relief valve of the rear pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair". The PC-EPC valve of the front pump is normal.
• YES
Control lever: All levers in NEUTRAL
•
Fuel dial: 2.9 MPa {30 Lo kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
•
Control lever: All levers in NEUTRAL
•
Go to the next inspection item.
•
The PC-EPC valve of the front pump is defective.
•
Adjust the PC-EPC valve of the front pump.
•
If the oil pressure is not normal after the PC-EPC valve of rhw front pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
Standard value
•
•
PC210-10M0, PC210LC-10M0
•
ture: 45 to 55°C
Does the troubleshooting result agree with the standard value?
Front pump PC-EPC valve
The main relief valve of rear pump is normal.
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
Item
5
Measuring point and measurement condition
• YES
Does the troubleshooting result agree with the standard value? Item
1.
Diagnosis and treatment
0.70 to 1.09 Fuel dial: MPa {7.1 to Hi 11.1 kg/cm2}
NO
Hydraulic oil temperature: 45 to 55°C
40-959
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
PCEPC valve output pressure
2.
PC valve of front pump
40-960
Pressure pickup port for rear PC mode selector pressure
•
Control lever: All levers in NEUTRAL
•
Fuel dial: 2.9 MPa {30 Lo kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: All levers in NEUTRAL
Discharged pressure pickup port of front pump
•
Hydraulic oil temperature: 45 to 55°C
PC valve output pressure
Pressure pickup port for front pump control pressure
•
•
Control lever: Boom RAISE relief
Go to the next inspection item.
•
The PC-EPC valve of the rear pump is defective.
•
Adjust the PC-EPC valve of the rear pump.
•
Make a repair or replace the PC-EPC valve of the rear pump.
•
Go to "Confirmation of repair".
•
The PC valve of the front pump is normal.
•
Go to the next inspection item.
•
The PC valve of the front pump is defective.
•
Adjust the PC valve of the front pump.
•
If the oil pressure is not normal after the PC valve of the front pump is adjusted, make a repair or replace the servo piston assembly.
•
Go to "Confirmation of repair".
11.1 kg/cm }
YES
Standard value
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve disic oil charged prestempera- sure is 1:0.6 ture: 45 (approx. 3/5)
to 55°C
•
0.70 to 1.09
Fuel dial: MPa {7.1 to Hi 2
Does the troubleshooting result agree with the standard value?
Pump discharge pressure
The PC-EPC valve of the rear pump is normal.
YES
NO
•
Measuring point and measurement condition
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
Item
7
Measuring point and measurement condition
Rear pump PCEPC valve
1.
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
6
40 TROUBLESHOOTING
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.
8
YES
Does the troubleshooting result agree with the standard value? Item
PC valve of rear pump
Diagnosis and treatment
Measuring point and measurement condition
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Pressure pickup port for rear pump control pressure
PC210-10M0, PC210LC-10M0
•
•
Control lever: Arm IN relief
The PC valve of the rear pump is normal.
•
Go to the next inspection item. The PC valve of the rear pump is defective.
•
Standard value
Oil pressure ratio between pump discharged presHydraul- sure and PC valve disic oil tempera- charged presture: 45 sure is 1:0.6 to 55°C (approx. 3/5)
•
•
Adjust the PC valve of the rear pump.
•
If the oil pressure is not normal after the PC valve of the rear pump is adjusted, make a repair or replace the servo piston assembly.
•
Go to "Confirmation of repair".
NO
40-961
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Measuring point and measurement condition
LS-EPC valve LSEPC valve output pressure
40-962
Diagnosis and treatment YES
•
The LS-EPC valve is normal.
•
Go to the next inspection item.
•
The LS-EPC valve is defective.
•
Make a repair or replace the LS-EPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
9
40 TROUBLESHOOTING
Pickup port for selecting pressure of LS setting
•
Control lever: All levers in NEUTRAL
•
Travel speed: Lo
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Travel lever fine control
•
Travel speed: Hi
•
Hydraulic oil temperature: 45 to 55°C
Standard value
Approximately 2.9 MPa {approximately 30 kg/cm2}
NO
0 MPa {0 kg/cm2}
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
YES
•
The front pump LS valve is normal.
•
Go to the next inspection item.
•
The LS valve of front pump is defective.
•
Adjust the LS valve of front pump.
•
If the oil pressure is not normal after the LS valve of the front pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
LS valve of 10 front pump
Diagnosis and treatment
Measuring point and measurement condition
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
PC210-10M0, PC210LC-10M0
•
•
•
•
Standard value
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
NO
to 55°C
40-963
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment YES
Measuring point and measurement condition
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
•
•
•
•
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
•
Go to the next inspection item.
•
The LS valve of rear pump is defective.
•
Adjust the LS valve of rear pump.
•
If the oil pressure is not normal after the LS valve of the rear pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
•
The servo piston is normal.
•
Go to the next inspection item. The servo piston is defective.
NO
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
to 55°C
1.
Check inside the pump servo equipment.
2.
Are the orifice and filter free not clogged and clean?
• NO
40-964
The rear pump LS valve is normal.
Standard value
YES
12 Servo piston
•
Does the troubleshooting result agree with the standard value? Item
LS valve of 11 rear pump
40 TROUBLESHOOTING
•
Make a repair or replace the servo piston.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
13 Piston pump
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS
Procedures, Measurement, Values, Note 1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Remove the pickup plug of main oil pressure.
4.
Turn the starting switch to the ON position.
5.
Do a test. For details, see TESTING AND ADJUSTING, METHOD FOR OPERATING NO INJECTION CRANKING.
6.
Does oil flow out the pickup plug of main oil pressure?
1.
Stop the engine.
Confirmation of 2. 14 repair 3. 4.
Connect all the configuration equipment.
Diagnosis and treatment YES
NO
PC210-10M0, PC210LC-10M0
The piston pump is normal.
•
Go to the next inspection item.
•
The piston pump is defective.
•
Repair or replace the piston pump.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Does the engine start normally?
•
NO
Return to the first inspection item.
40-965
H-6 BOOM SPEED OR POWER IS LOW
40 TROUBLESHOOTING
H-6 BOOM SPEED OR POWER IS LOW Details of failure
The boom speed or power is low. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
Associated information
No.
•
The boom RAISE PPC pressure can be monitored. (Code: 07400)
•
The boom LOWER PPC pressure can be monitored. (Code: 07401)
•
The merge-divider main solenoid current can be monitored. (Code: 08000)
•
The current of the merge-divider LS solenoid can be monitored.(Code: 08001)
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measurement position and condition
The R.H. PPC valve is normal.
•
Go to the next inspection item.
•
The R.H. PPC valve is defective.
PPC valve output pressure
•
Repair or replace the R.H. PPC valve.
Hydraulic hose of boom PPC circuit
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
R.H. PPC valve
•
Fuel dial: Hi
•
Control lever: Boom RAISE or boom LOWER
•
40-966
YES
•
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
H-6 BOOM SPEED OR POWER IS LOW
Cause
Merge-divider main EPC valve
Procedures, Measurement, Values, Note 1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL or in bucket CURL or arm IN until hydraulic relief to check.
5.
Does the troubleshooting result for output pressure of main EPC meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider Main Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to check.
9.
Does the troubleshooting result for the EPC current meet the standard value? Item
Measurement position and condition •
Main EPC output pressure
Mounting port (PP1S) for front pump oil pressure sensor
PC210-10M0, PC210LC-10M0
Control lever: All levers in NEU0 to 0.49 MPa TRAL {0 to 5 kg/
Hydraul- cm2} ic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief Hydraulic oil temperature: 45 to 55°C
•
The merge-divider main EPC valve is normal.
•
Go to the next inspection item.
•
The merge-divider main EPC valve is defective.
•
Repair or replace the merge-divider main EPC valve.
•
Go to "Confirmation of repair".
YES
Standard value
•
•
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
40-967
H-6 BOOM SPEED OR POWER IS LOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note Item
EPC current
Measurement position and condition
Monitoring code: 08000
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
3
Merge-divider LS-EPC valve
40-968
Diagnosis and treatment
Standard value
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL or in bucket CURL or arm IN until hydraulic relief to check.
5.
Does the diagnosis result for the LS-EPC output pressure meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider LS Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to check.
9.
Does the troubleshooting result for the EPC current meet the standard value?
YES
NO
•
The merge-divider LSEPC valve is normal.
•
Go to the next inspection item.
•
The merge-divider LSEPC valve is defective.
•
Repair or replace the merge-divider LS-EPC valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-6 BOOM SPEED OR POWER IS LOW
Procedures, Measurement, Values, Note Item
LSEPC output pressure
EPC current
Measurement position and condition
Mounting port (PP1S) for front pump oil pressure sensor
Monitoring code: 08001
PC210-10M0, PC210LC-10M0
Standard value
•
Control lever: All levers in NEU0 to 0.49 MPa TRAL
•
Hydraul- cm2} ic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
{0 to 5 kg/
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
Diagnosis and treatment
2.84 to 3.43 MPa {29 to 35 kg/cm2}
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
40-969
H-6 BOOM SPEED OR POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note
1.
4
Merge-divider main spool
40 TROUBLESHOOTING
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment •
The body and main spool of the merge-divider valve are normal.
•
Go to the next inspection item. The body and main spool of the merge-divider valve are defective.
YES
•
Are the merge-divider valve body and the main spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
•
Repair or replace the body and main spool of the merge-divider valve.
•
Go to "Confirmation of repair". The body and LS spool of the merge-divider valve are normal.
When the parts are restored, be careful not to let dirt to enter.
• 1.
5
Merge-divider LS spool
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES • •
Are the merge-divider valve body and the LS spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
•
Repair or replace the body and LS spool of the merge-divider valve.
•
Go to "Confirmation of repair". The body and spool of the boom control valve are normal.
When the parts are restored, be careful not to let dirt to enter.
1.
6
Boom control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
REMARK When the parts are restored, be careful not to let dirt to enter.
40-970
• YES • •
Are the control valve body and the boom spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) NO
Go to the next inspection item. The body and LS spool of the merge-divider valve are defective.
Go to the next inspection item. The body and spool of the boom control valve are defective.
•
Repair or replace the body and spool of the boom control valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
7
H-6 BOOM SPEED OR POWER IS LOW
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.
4.
Does the diagnosis result of hydraulic drift meet the standard value?
5.
Check by relieving the circuit of other work equipment.
6.
Is the boom stopped without moving?
7.
Check by interchanging the RAISE side and LOWER side compensation valves of the boom control valve.
Pressure com8. pensation valve on RAISE side of boom control valve
Diagnosis and treatment •
The pressure compensation valve on the RAISE side of the boom control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the RAISE side of the boom control valve is defective.
•
Repair or replace the pressure compensation valve on the RAISE side of the boom control valve.
•
Go to "Confirmation of repair".
YES
Is there no change in the nature of the problem? REMARK The RAISE side and LOWER side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
Main relief pressure
Discharged pressure pickup port of rear pump
Hydraulic drift
Boom cylinder
PC210-10M0, PC210LC-10M0
•
NO
Standard value
Control lever: Boom RAISE relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Max. 27 mm
40-971
H-6 BOOM SPEED OR POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note 1.
8
40 TROUBLESHOOTING
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.
4.
Does the diagnosis result of hydraulic drift meet the standard value?
5.
Check by relieving the circuit of other work equipment.
6.
Is the boom stopped without moving?
7.
Check by interchanging the RAISE side and LOWER side compensation valves of the boom control valve.
Pressure com8. pensation valve on LOWER side of boom control valve
•
The pressure compensation valve on the LOWER side of the boom control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the LOWER side of the boom control valve is defective.
•
Repair or replace the pressure compensation valve on the LOWER side of the boom control valve.
•
Go to "Confirmation of repair".
YES
Is there no change in the nature of the problem? REMARK The RAISE side and LOWER side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
40-972
Diagnosis and treatment
Main relief pressure
Discharged pressure pickup port of rear pump
Hydraulic drift
Boom cylinder
•
NO
Standard value
Control lever: Boom LOWER relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Max. 27 mm
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
9
H-6 BOOM SPEED OR POWER IS LOW
Energy recovery valve of boom control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Are the control valve body and the boom energyrecovery valve normal and free of twisting, sticking, scratches, dirt, fatigue of check valve spring and deformation? (The valve must move smoothly.)
Diagnosis and treatment •
The energy recovery valve of the boom control valve is normal.
•
Go to the next inspection item. The energy recovery valve of the boom control valve is defective.
YES
•
NO
•
Repair or replace the energy recovery valve of the boom control valve.
•
Go to "Confirmation of repair". The safety valve for the lock valve of the boom control valve is normal.
REMARK When the parts are restored, be careful not to let dirt to enter.
• 1.
Safety valve for lock valve of 10 boom control valve
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
YES •
Does the troubleshooting result agree with the standard value? Item
Main relief pressure
Measurement position and condition Discharged pressure pickup port of front pump
•
Standard value
Control lever: 33.1 to 37.2 Boom RAISE, MPa {338 to arm IN or 380 kg/cm2} DUMP relief
NO
•
Repair or replace the safety valve for the lock valve of the boom control valve.
•
Go to "Confirmation of repair". The lock valve of the boom control valve is normal.
• YES
Lock valve of 11 boom control valve
•
Are the lock valve body, pilot piston and poppet clean and free of twisting, sticking, scratches and dirt? REMARK When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
•
NO
Go to the next inspection item. The safety valve for the lock valve of the boom control valve is defective.
Go to the next inspection item. The lock valve of the boom control valve is defective.
•
Repair or replace the lock valve of the boom control valve.
•
Go to "Confirmation of repair".
40-973
H-6 BOOM SPEED OR POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
2.
Discharged pressure pickup port of rear pump
•
Control lever: Boom RAISE relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
NO
ic oil temperature: 45 to 55°C
Measurement position and condition •
Discharged pressure pickup port of rear pump
•
Control lever: Boom LOWER relief
Standard value
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
The suction valve on the RAISE side of the boom control valve is normal.
•
Go to the next inspection item.
•
The suction valve on the RAISE side of the boom control valve is defective.
•
Repair or replace the suction valve on the RAISE side of the boom control valve.
•
Go to "Confirmation of repair".
•
The suction safety valve on the LOWER side of the boom control valve is normal.
•
Go to the next inspection item.
•
The suction safety valve on the LOWER side of the boom control valve is defective.
•
Repair or replace the suction safety valve on the LOWER side of the boom control valve.
•
Go to "Confirmation of repair".
YES
Does the troubleshooting result agree with the standard value? Item
• YES
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
40-974
Measurement position and condition •
1.
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
Suction valve on RAISE side 12 of boom control valve
Suction safety valve on LOW13 ER side of boom control valve
40 TROUBLESHOOTING
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-6 BOOM SPEED OR POWER IS LOW
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment
LS shuttle 14 valve of boom control valve LS differential pressure
Measurement position and condition
Discharged pressure pickup port and load pressure pickup port of rear pump
The LS shuttle valve of the boom control valve is normal.
•
Go to the next inspection item.
•
The LS shuttle valve of the boom control valve is defective.
•
Clean the check valve seat of the LS shuttle valve of the boom control valve.
•
Go to "Confirmation of repair".
•
The LS shuttle valve of the L.H. travel control valve is normal.
•
Go to the next inspection item. The LS shuttle valve of the L.H. travel control valve is defective.
YES
Does the troubleshooting result agree with the standard value? Item
•
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 2.5 to 4.5 NEUMPa {26 to 46 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C
kg/cm }
•
Fuel dial: Hi
•
Control lever: Boom 1.70 to 1.85 RAISE fine con- MPa {17.0 to 18.5 kg/cm2} trol
•
Hydraulic oil temperature: 45 to 55°C
NO
YES
LS shuttle valve of L.H. 15 travel control valve
1.
Check the check valve seat in the shuttle valve of the L.H. travel control valve.
2.
Is the check valve seat clean and free of scratches and dirt?
•
•
Clean the check valve seat in the LS shuttle valve of the L.H. travel control valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40-975
H-6 BOOM SPEED OR POWER IS LOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment
LS shuttle 16 valve of bucket control valve LS differential pressure
Measurement position and condition
Discharged pressure pickup port and load pressure pickup port of rear pump
The LS shuttle valve of the bucket control valve is normal.
•
Go to the next inspection item.
•
The LS shuttle valve of the bucket control valve is defective.
•
Clean the check valve seat of the LS shuttle valve of the bucket control valve.
•
Go to "Confirmation of repair".
•
The LS shuttle valve of the service control valve is normal.
•
Go to the next inspection item. The LS shuttle valve of the service control valve is defective.
YES
Does the troubleshooting result agree with the standard value? Item
•
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 2.5 to 4.5 NEUMPa {26 to 46 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C
kg/cm }
•
Fuel dial: Hi
•
Control lever: Bucket CURL 1.70 to 1.85 and MPa {17.0 to DUMP fine con- 18.5 kg/cm2} trol
•
Hydraulic oil temperature: 45 to 55°C
NO
YES
1. LS shuttle 17 valve of service 2. control valve
Check the check valve seat in the shuttle valve of the service control valve.
•
Is the check valve seat clean and free of scratches and dirt?
•
Clean the check valve seat of the LS shuttle valve of the service control valve.
•
Go to "Confirmation of repair".
NO
40-976
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-6 BOOM SPEED OR POWER IS LOW
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST ENGINE OIL LEAKAGE.
2.
Does the troubleshooting result agree with the standard value? Item
Measurement position and condition
18 Boom cylinder Hose on head Oil side of boom leakage cylinder
19
•
Fuel dial: Hi
•
Control lever: Boom RAISE relief
•
Max. 20 cc/min
NO
Hydraulic oil temperature: 45 to 55°C
Stop the engine.
2.
Connect all the configuration equipment.
5.
YES
•
The boom cylinder is normal.
•
Go to the next inspection item.
•
The boom cylinder is defective.
•
Repair or replace the boom cylinder.
•
Go to "Confirmation of repair".
Standard value
1. Confirmation of 3. repair 4.
Diagnosis and treatment
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does the boom operate normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-977
H-7 Arm speed or power is low.
40 TROUBLESHOOTING
H-7 Arm speed or power is low. Details of failure
The arm speed or power is low. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
Associated information
No.
•
The arm IN PPC pressure can be monitored. (Code: 07200)
•
The arm OUT PPC pressure can be monitored. (Code: 07201)
•
The merge-divider main solenoid current can be monitored. (Code: 08000)
•
The current of the merge-divider LS solenoid can be monitored.(Code: 08001)
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measurement position and condition
L.H. PPC valve PPC valve output pressure
The L.H. PPC valve is normal.
•
Go to the next inspection item.
•
The L.H. PPC valve is defective.
•
Repair or replace the L.H. PPC valve.
Hydraulic hose of arm PPC circuit
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Arm IN or arm OUT
•
40-978
YES
•
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Hydraulic oil temperature: 45 to 55°C
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
H-7 Arm speed or power is low.
Cause
Merge-divider main EPC valve
Procedures, Measurement, Values, Note 1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL or in bucket CURL or arm IN until hydraulic relief to check.
5.
Does the troubleshooting result for output pressure of main EPC meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider Main Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to check.
9.
Does the troubleshooting result for the EPC current meet the standard value? Item
Measurement position and condition •
Main EPC output pressure
Mounting port (PP1S) for front pump oil pressure sensor
PC210-10M0, PC210LC-10M0
Control lever: All levers in NEU0 to 0.49 MPa TRAL {0 to 5 kg/
Hydraul- cm2} ic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief Hydraulic oil temperature: 45 to 55°C
•
The merge-divider main EPC valve is normal.
•
Go to the next inspection item.
•
The merge-divider main EPC valve is defective.
•
Repair or replace the merge-divider main EPC valve.
•
Go to "Confirmation of repair".
YES
Standard value
•
•
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
40-979
H-7 Arm speed or power is low.
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
EPC current
Monitoring code: 08000
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
3
Merge-divider LS-EPC valve
40-980
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL or in bucket CURL or arm IN until hydraulic relief to check.
5.
Does the diagnosis result for the LS-EPC output pressure meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider LS Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to check.
9.
Does the troubleshooting result for the EPC current meet the standard value? Item
Diagnosis and treatment
Measurement position and condition
YES
NO
•
The merge-divider LSEPC valve is normal.
•
Go to the next inspection item.
•
The merge-divider LSEPC valve is defective.
•
Repair or replace the merge-divider LS-EPC valve.
•
Go to "Confirmation of repair".
Standard value
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-7 Arm speed or power is low.
Procedures, Measurement, Values, Note
LSEPC output pressure
EPC current
Mounting port (PP1S) for front pump oil pressure sensor
Monitoring code: 08001
•
Control lever: All levers in NEU0 to 0.49 MPa TRAL
•
Hydraul- cm2} ic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
PC210-10M0, PC210LC-10M0
{0 to 5 kg/
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
Diagnosis and treatment
2.84 to 3.43 MPa {29 to 35 kg/cm2}
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
40-981
H-7 Arm speed or power is low.
No.
Cause
Procedures, Measurement, Values, Note
1.
4
Merge-divider main spool
40 TROUBLESHOOTING
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment •
The body and main spool of the merge-divider valve are normal.
•
Go to the next inspection item. The body and main spool of the mergedivider valve are defective.
YES
•
Are the merge-divider valve body and the main spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
•
Repair or replace the body and main spool of the merge-divider valve.
•
Go to "Confirmation of repair". The body and LS spool of the merge-divider valve are normal.
When the parts are restored, be careful not to let dirt to enter.
• 1.
5
Merge-divider LS spool
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES • •
Are the merge-divider valve body and the LS spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
•
Repair or replace the body and LS spool of the merge-divider valve.
•
Go to "Confirmation of repair". The body and spool of the arm control valve are normal.
When the parts are restored, be careful not to let dirt to enter.
1.
6
Arm control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
REMARK When the parts are restored, be careful not to let dirt to enter.
40-982
• YES • •
Are the control valve body and the arm spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) NO
Go to the next inspection item. The body and LS spool of the merge-divider valve are defective.
Go to the next inspection item. The body and spool of the arm control valve are defective.
•
Repair or replace the body and spool of the arm control valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
7
H-7 Arm speed or power is low.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.
4.
Does the diagnosis result of hydraulic drift meet the standard value?
5.
Check by relieving the circuit of other work equipment.
6.
Is the arm stopped?
7.
Check it by interchanging the pressure compensation valves on the IN side and OUT side of the arm control valve.
Pressure compensation valve 8. on IN side of arm control valve
Diagnosis and treatment •
The pressure compensation valve on the IN side of the arm control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the IN side of the arm control valve is defective.
•
Repair or replace the pressure compensation valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair".
YES
Is the phenomenon reproduced in the same way? REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
Main relief pressure
Discharged pressure pickup port of front pump
Hydraulic drift
Arm cylinder
PC210-10M0, PC210LC-10M0
•
NO
Standard value
Control lever: Arm IN relief
33.1 to 37.2 Hydraul- MPa {338 to 380 kg/cm2} ic oil
temperature: 45 to 55°C Max. 240 mm
40-983
H-7 Arm speed or power is low.
No.
Cause
Procedures, Measurement, Values, Note 1.
8
40 TROUBLESHOOTING
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.
4.
Does the diagnosis result of hydraulic drift meet the standard value?
5.
Check by relieving the circuit of other work equipment.
6.
Is the arm stopped?
7.
Check it by interchanging the pressure compensation valves on the IN side and OUT side of the arm control valve.
Pressure com8. pensation valve on OUT side of arm control valve
•
The pressure compensation valve on the OUT side of the arm control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the OUT side of the arm control valve is defective.
•
Repair or replace the pressure compensation valve on the OUT side of the arm control valve.
•
Go to "Confirmation of repair".
YES
Is the phenomenon reproduced in the same way? REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
40-984
Diagnosis and treatment
Main relief pressure
Discharged pressure pickup port of front pump
Hydraulic drift
Arm cylinder
•
NO
Standard value
Control lever: Arm OUT relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Max. 240 mm
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
9
H-7 Arm speed or power is low.
Energy recovery valve of arm control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Are the control valve body and the arm energyrecovery valve normal and free of twisting, sticking, scratches, dirt, fatigue of check valve spring and deformation? (The valve must move smoothly.)
Diagnosis and treatment •
The energy recovery valve of the arm control valve is normal.
•
Go to the next inspection item. The energy recovery valve of the arm control valve is defective.
YES
•
•
Make a repair or replace the energy recovery valve of the arm control valve.
•
Go to "Confirmation of repair". The quick return valve is normal.
NO
REMARK When the parts are restored, be careful not to let dirt to enter. 1.
Quick return 10 valve of arm control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Are the quick return valve body, pilot spool and check valve normal and free of twisting, sticking, scratches, dirt, fatigue of check valve spring and deformation? (The valve must move smoothly.)
• YES
When the parts are restored, be careful not to let dirt to enter.
Safety valve for lock valve of 11 arm control valve
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
PC210-10M0, PC210LC-10M0
Measurement position and condition Discharged pressure pickup port of front pump
•
The quick return valve is defective.
•
Make a repair or replace the quick return valve.
•
Go to "Confirmation of repair".
•
The safety valve for the lock valve of the arm control valve is normal.
•
Go to the next inspection item. The safety valve for the lock valve of the arm control valve is defective.
YES
Does the troubleshooting result agree with the standard value? Item
Go to the next inspection item.
NO
REMARK
1.
•
•
Standard value
Control lever: 33.1 to 37.2 Boom RAISE, MPa {338 to arm IN or 380 kg/cm2} DUMP relief
NO
•
Repair or replace the safety valve for the lock valve of the arm control valve.
•
Go to "Confirmation of repair".
40-985
H-7 Arm speed or power is low.
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The lock valve of the arm control valve is normal.
•
Go to the next inspection item. The lock valve of the arm control valve is defective.
YES Lock valve of arm control 12 valve (if equipped)
Are the lock valve body, pilot piston and poppet clean and free of twisting, sticking, scratches and dirt? REMARK When the parts are restored, be careful not to let dirt to enter.
1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
2.
Suction safety valve on IN 14 side of arm control valve
Discharged pressure pickup port of front pump
•
Control lever: Arm OUT relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
• Discharged pressure pickup port of front pump
•
Control lever: Arm IN relief
temperature: 45 to 55°C
Go to "Confirmation of repair". The suction valve on the OUT side of the arm control valve is normal.
•
Go to the next inspection item.
•
The suction valve on the OUT side of the arm control valve is defective.
•
Make a repair or replace the suction valve on the OUT side of the arm control valve.
•
Go to "Confirmation of repair".
•
The suction safety valve on the IN side of the arm control valve is normal.
•
Go to the next inspection item.
•
The suction safety valve on the IN side of the arm control valve is defective.
•
Repair or replace the suction safety valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair".
YES
Standard value
33.1 to 37.2 Hydraul- MPa {338 to 380 kg/cm2} ic oil
•
NO
ic oil temperature: 45 to 55°C
Measurement position and condition
Repair or replace the lock valve of the arm control valve.
YES
Does the troubleshooting result agree with the standard value? Item
•
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
40-986
Measurement position and condition •
1.
NO
Does the troubleshooting result agree with the standard value? Item
Suction valve on OUT side of 13 arm control valve
•
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-7 Arm speed or power is low.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment
LS shuttle 15 valve of arm control valve LS differential pressure
Measurement position and condition
Discharged pressure pickup port and load pressure pickup port of front pump
The LS shuttle valve of the arm control valve is normal.
•
Go to the next inspection item.
•
The LS shuttle valve of the arm control valve is defective.
•
Clean the check valve seat of the LS shuttle valve of the arm control valve.
•
Go to "Confirmation of repair".
•
The LS shuttle valve of the R.H. travel control valve is normal.
•
Go to the next inspection item. The LS shuttle valve of the R.H. travel control valve is defective.
YES
Does the troubleshooting result agree with the standard value? Item
•
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 2.5 to 4.5 NEUMPa {26 to 46 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C
kg/cm }
•
Fuel dial: Hi
•
Control lever: Arm IN and OUT 1.70 to 1.85 fine con- MPa {17.0 to 18.5 kg/cm2} trol
•
Hydraulic oil temperature: 45 to 55°C
NO
YES
LS shuttle valve of R.H. 16 travel control valve
1.
Check the check valve seat in the shuttle valve of the R.H. travel control valve.
2.
Is the check valve seat clean and free of scratches and dirt?
•
•
Clean the check valve seat in the LS shuttle valve of the R.H. travel control valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40-987
H-7 Arm speed or power is low.
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST ENGINE OIL LEAKAGE.
2.
Does the troubleshooting result agree with the standard value? Item
Measurement position and condition
17 Arm cylinder Hose on head Oil side of arm leakage cylinder
18
Fuel dial: Hi
•
Control lever: Arm IN relief
•
Hydraulic oil temperature: 45 to 55°C
Max. 20 cc/min
Stop the engine.
2.
Connect all the configuration equipment.
5.
YES
•
The arm cylinder is normal.
•
Go to the next inspection item.
•
The arm cylinder is defective.
•
Repair or replace the arm cylinder.
•
Go to "Confirmation of repair".
Standard value
1. Confirmation of 3. repair 4.
40-988
•
Diagnosis and treatment
NO
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does the arm move normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-8 BUCKET SPEED OR POWER IS LOW
H-8 BUCKET SPEED OR POWER IS LOW Details of failure
The bucket speed or power is low. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
Associated information
No.
•
The bucket CURL PPC pressure can be monitored. (Code: 07300)
•
The bucket DUMP PPC pressure can be monitored. (Code: 07301)
•
The current of the merge-divider main solenoid can be monitored. (Code: 08000)
•
The current of the merge-divider LS solenoid can be monitored. (Code: 08001)
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
YES
•
The R.H. PPC valve is normal.
•
Go to the next inspection item.
•
The R.H. PPC valve is defective.
•
Repair or replace the R.H. PPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Measurement position and condition •
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
R.H. PPC valve PPC valve output pressure
PC210-10M0, PC210LC-10M0
Hydraulic hose of bucket PPC circuit
Standard value
•
Fuel dial: Hi
•
Control lever: Bucket CURL or 2.84 to 3.43 MPa {29 to 35 bucket kg/cm2} DUMP
•
Hydraulic oil temperature: 45 to 55°C
NO
40-989
H-8 BUCKET SPEED OR POWER IS LOW
No.
2
Cause
Merge-divider main EPC valve
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL or in bucket CURL or arm IN until hydraulic relief to check.
5.
Does the troubleshooting result for output pressure of main EPC meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider Main Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to check.
9.
Does the troubleshooting result for the EPC current meet the standard value? Item
Measurement position and condition •
Main EPC output pressure
Mounting port (PP1S) for front pump oil pressure sensor
40-990
Control lever: All levers in NEU0 to 0.49 MPa TRAL {0 to 5 kg/
Hydraul- cm2} ic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief Hydraulic oil temperature: 45 to 55°C
•
The merge-divider main EPC valve is normal.
•
Go to the next inspection item.
•
The merge-divider main EPC valve is defective.
•
Repair or replace the merge-divider main EPC valve.
•
Go to "Confirmation of repair".
YES
Standard value
•
•
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-8 BUCKET SPEED OR POWER IS LOW
Cause
Procedures, Measurement, Values, Note
EPC current
Monitoring code: 08000
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
3
Merge-divider LS-EPC valve
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL or in bucket CURL or arm IN until hydraulic relief to check.
5.
Does the diagnosis result for the LS-EPC output pressure meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider LS Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to check.
9.
Does the troubleshooting result for the EPC current meet the standard value? Item
PC210-10M0, PC210LC-10M0
Diagnosis and treatment
Measurement position and condition
YES
NO
•
The merge-divider LSEPC valve is normal.
•
Go to the next inspection item.
•
The merge-divider LSEPC valve is defective.
•
Repair or replace the merge-divider LS-EPC valve.
•
Go to "Confirmation of repair".
Standard value
40-991
H-8 BUCKET SPEED OR POWER IS LOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
LSEPC output pressure
EPC current
Mounting port (PP1S) for front pump oil pressure sensor
Monitoring code: 08001
•
Control lever: All levers in NEU0 to 0.49 MPa TRAL
•
Hydraul- cm2} ic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
40-992
{0 to 5 kg/
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
Diagnosis and treatment
2.84 to 3.43 MPa {29 to 35 kg/cm2}
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
1.
4
Merge-divider main spool
H-8 BUCKET SPEED OR POWER IS LOW
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment •
The body and main spool of the merge-divider valve are normal.
•
Go to the next inspection item. The body and main spool of the mergedivider valve are defective.
YES
•
Are the merge-divider valve body and the main spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
•
Repair or replace the body and main spool of the merge-divider valve.
•
Go to "Confirmation of repair". The body and LS spool of the merge-divider valve are normal.
When the parts are restored, be careful not to let dirt to enter.
• 1.
5
Merge-divider LS spool
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES • •
Are the merge-divider valve body and the LS spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
•
Repair or replace the body and LS spool of the merge-divider valve.
•
Go to "Confirmation of repair". The body and spool of the bucket control valve are normal.
When the parts are restored, be careful not to let dirt to enter.
1.
6
Bucket control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
• YES • •
Are the control valve body and the boom spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
NO
Go to the next inspection item. The body and LS spool of the merge-divider valve are defective.
Go to the next inspection item. The body and spool of the bucket control valve are defective.
•
Repair or replace the body and spool of the bucket control valve.
•
Go to "Confirmation of repair".
40-993
H-8 BUCKET SPEED OR POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note 1.
7
40 TROUBLESHOOTING
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.
4.
Does the diagnosis result of hydraulic drift meet the standard value?
5.
Check by relieving the circuit of other work equipment.
6.
Is the bucket stopped?
7.
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve.
Pressure com8. pensation valve on CURL side of bucket control valve
•
The pressure compensation valve on the CURL side of the bucket control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the CURL side of the bucket control valve is defective.
•
Repair or replace the pressure compensation valve on the CURL side of the bucket control valve.
•
Go to "Confirmation of repair".
YES
Is the phenomenon reproduced in the same way? REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
40-994
Diagnosis and treatment
Main relief pressure
Discharged pressure pickup port of rear pump
Hydraulic drift
Bucket cylinder
•
NO
Standard value
Control lever: Bucket CURL relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Max. 58 mm
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
8
H-8 BUCKET SPEED OR POWER IS LOW
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.
4.
Does the diagnosis result of hydraulic drift meet the standard value?
5.
Check by relieving the circuit of other work equipment.
6.
Is the bucket stopped?
7.
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve.
Pressure com8. pensation valve on DUMP side of bucket control valve
Diagnosis and treatment •
The pressure compensation valve on the DUMP side of the bucket control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the DUMP side of the bucket control valve is defective.
•
Repair or replace the pressure compensation valve on the DUMP side of the bucket control valve.
•
Go to "Confirmation of repair".
YES
Is the phenomenon reproduced in the same way? REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
Main relief pressure
Discharged pressure pickup port of rear pump
Hydraulic drift
Bucket cylinder
PC210-10M0, PC210LC-10M0
•
NO
Standard value
Control lever: Bucket DUMP relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Max. 58 mm
40-995
H-8 BUCKET SPEED OR POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
9
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
2.
Discharged pressure pickup port of rear pump
•
Control lever: Bucket CURL relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Measurement position and condition •
Discharged pressure pickup port of rear pump
•
Control lever: Bucket DUMP relief
ic oil temperature: 45 to 55°C
•
Go to the next inspection item.
•
The suction safety valve on the CURL side of the bucket control valve is defective.
•
Repair or replace the suction safety valve on the CURL side of the bucket control valve.
•
Go to "Confirmation of repair".
•
The suction safety valve on the DUMP side of the bucket control valve is normal.
•
Go to the next inspection item.
•
The suction safety valve on the DUMP side of the bucket control valve is defective.
•
Repair or replace the suction safety valve on the DUMP side of the bucket control valve.
•
Go to "Confirmation of repair".
YES
Standard value
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
The suction safety valve on the CURL side of the bucket control valve is normal.
NO
Does the troubleshooting result agree with the standard value? Item
• YES
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
40-996
Measurement position and condition •
1.
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
Suction safety valve on CURL side of bucket control valve
Suction safety valve on DUMP 10 side of bucket control valve
40 TROUBLESHOOTING
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-8 BUCKET SPEED OR POWER IS LOW
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment
LS shuttle 11 valve of bucket control valve LS differential pressure
Measurement position and condition
Discharged pressure pickup port and load pressure pickup port of rear pump
The LS shuttle valve of the bucket control valve is normal.
•
Go to the next inspection item.
•
The LS shuttle valve of the bucket control valve is defective.
•
Clean the check valve seat in the LS shuttle valve of the bucket control valve.
•
Go to "Confirmation of repair".
•
The LS shuttle valve of the L.H. travel control valve is normal.
•
Go to the next inspection item. The LS shuttle valve of the L.H. travel control valve is defective.
YES
Does the troubleshooting result agree with the standard value? Item
•
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 2.5 to 4.5 NEUMPa {26 to 46 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C
kg/cm }
•
Fuel dial: Hi
•
Control lever: Bucket CURL 1.70 to 1.85 and MPa {17.0 to DUMP fine con- 18.5 kg/cm2} trol
•
Hydraulic oil temperature: 45 to 55°C
NO
YES
LS shuttle valve of L.H. 12 travel control valve
1.
Check the check valve seat in the shuttle valve of the L.H. travel control valve.
2.
Is the check valve seat clean and free of scratches and dirt?
•
•
Clean the check valve seat in the LS shuttle valve of the L.H. travel control valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40-997
H-8 BUCKET SPEED OR POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST ENGINE OIL LEAKAGE.
2.
Does the troubleshooting result agree with the standard value? Item
Measurement position and condition
13 Bucket cylinder Hose on head side of bucket cylinder
14
•
Fuel dial: Hi
•
Control lever: Bucket CURL relief
•
Max. 20 cc/min
YES
NO
Hydraulic oil temperature: 45 to 55°C
Stop the engine.
2.
Connect all the configuration equipment.
5.
Diagnosis and treatment •
The bucket cylinder is normal.
•
Go to the next inspection item.
•
The bucket cylinder is defective.
•
Repair or replace the bucket cylinder.
•
Go to "Confirmation of repair".
Standard value
1. Confirmation of 3. repair 4.
40-998
40 TROUBLESHOOTING
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does the bucket move normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION Details of failure
The work equipment do not move in single operation. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first. Monitoring code
Associated information
No.
•
The boom RAISE PPC pressure can be monitored. (Code: 07400)
•
The arm IN PPC pressure can be monitored. (Code: 07200)
•
The bucket CURL PPC pressure can be monitored. (Code: 07300)
•
The bucket DUMP PPC pressure can be monitored. (Code: 07301)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measuring point and measurement condition
L.H. PPC valve PPC valve output pressure
2
R.H. PPC valve
The L.H. PPC valve is normal.
•
Go to the next inspection item.
•
The L.H. PPC valve is defective.
•
Make a repair or replace the L.H. PPC valve.
Hydraulic hose of arm PPC circuit
•
Go to "Confirmation of repair".
•
The R.H. PPC valve is normal.
•
Go to the next inspection item.
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Arm IN or arm OUT
•
1.
YES
•
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Hydraulic oil temperature: 45 to 55°C
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
PC210-10M0, PC210LC-10M0
YES
40-999
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION
No.
Cause
Procedures, Measurement, Values, Note 2.
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
40-1000
40 TROUBLESHOOTING
Measuring point and measurement condition
Standard value
•
The R.H. PPC valve is defective.
•
Make a repair or replace the R.H. PPC valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION
Procedures, Measurement, Values, Note
Hydraulic hose of boom PPC circuit
PPC valve output pressure
Hydraulic hose of bucket PPC circuit
PC210-10M0, PC210LC-10M0
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Boom RAISE or boom LOWER
Diagnosis and treatment
2.84 to 3.43 MPa {29 to 35 kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Bucket CURL or 2.84 to 3.43 MPa {29 to 35 bucket kg/cm2} DUMP
•
Hydraulic oil temperature: 45 to 55°C
40-1001
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION
No.
Cause
Procedures, Measurement, Values, Note 1.
3
Boom control valve
40 TROUBLESHOOTING
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment The body and spool of the boom control valve are normal.
•
Go to the next inspection item. The body and spool of the boom control valve are defective.
YES
•
Are the control valve body and the boom spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
•
•
Make a repair or replace the body and spool of the boom control valve.
•
Go to "Confirmation of repair". The body and spool of the arm control valve are normal.
NO
When the parts are restored, be careful not to let dirt to enter.
• 1.
4
Arm control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES • •
Are the control valve body and the arm spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
•
Make a repair or replace the body and spool of the arm control valve.
•
Go to "Confirmation of repair". The body and spool of the bucket control valve are normal.
NO
When the parts are restored, be careful not to let dirt to enter.
• 1.
5
Bucket control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES • •
Are the control valve body and the boom spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
6
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
40-1002
Go to the next inspection item. The body and spool of the bucket control valve are defective.
•
Make a repair or replace the body and spool of the bucket control valve.
•
Go to "Confirmation of repair".
NO
When the parts are restored, be careful not to let dirt to enter.
Go to the next inspection item. The body and spool of the arm control valve are defective.
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does each work equipment operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE Details of failure
Hydraulic drift of boom is large.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note 1. 2.
Do a test. For details, see TESTING AND ADJUSTING, TEST ENGINE OIL LEAKAGE.
Measurement position and condition
Boom cylinder Hose on head Oil side of boom leakage cylinder
1.
2.
•
Fuel dial: Hi
•
Control lever: Boom RAISE relief
•
Max. 20 cc/min
NO
Measurement position and condition •
Main relief pressure
PC210-10M0, PC210LC-10M0
Discharged pressure pickup port of front pump
•
The boom cylinder is normal.
•
Go to the next inspection item.
•
The boom cylinder is defective.
•
Repair or replace the boom cylinder.
•
Go to "Confirmation of repair".
•
The safety valve for the lock valve of the boom control valve is normal.
•
Go to the next inspection item.
•
The safety valve for the lock valve of the boom control valve is defective.
•
Repair or replace the safety valve for the lock valve of the boom control valve.
•
Go to "Confirmation of repair".
Hydraulic oil temperature: 45 to 55°C
YES
Does the troubleshooting result agree with the standard value?
Safety valve for lock valve of boom control valve
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Item
2
YES
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Control lever: Boom RAISE, arm IN or DUMP relief Hydraulic oil temperature: 45 to 55°C
Standard value
33.1 to 37.2 MPa {338 to 380 kg/cm2}
NO
40-1003
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The lock valve of the boom control valve is normal.
•
Go to the next inspection item. The lock valve of the boom control valve is defective.
YES
3
4
Lock valve of boom control valve
Are the lock valve body, pilot piston and poppet clean and free of twisting, sticking, scratches and dirt? REMARK When the parts are restored, be careful not to let dirt to enter.
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
40-1004
•
NO
•
Repair or replace the lock valve of the boom control valve.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does the boom operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-11 HYDRAULIC DRIFT OF ARM IS LARGE
H-11 HYDRAULIC DRIFT OF ARM IS LARGE Details of failure
Hydraulic drift of the arm is large.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note 1. 2.
Do a test. For details, see TESTING AND ADJUSTING, TEST ENGINE OIL LEAKAGE.
Measurement position and condition •
Arm cylinder
• Hose on head Oil side of arm leakage cylinder
1.
2.
•
Fuel dial: Hi Control lever: Arm IN relief Hydraulic oil temperature: 45 to 55°C
Max. 20 cc/min
NO
•
Safety valve for lock valve of arm control valve Main relief pressure
PC210-10M0, PC210LC-10M0
Discharged pressure pickup port of front pump
•
Control lever: Boom RAISE, arm IN or DUMP relief Hydraulic oil temperature: 45 to 55°C
The arm cylinder is normal.
•
Go to the next inspection item.
•
The arm cylinder is defective.
•
Repair or replace the arm cylinder.
•
Go to "Confirmation of repair".
•
The safety valve for the lock valve of the arm control valve is normal.
•
Go to the next inspection item.
•
The safety valve for the lock valve of the arm control valve is defective.
•
Repair or replace the safety valve for the lock valve of the arm control valve.
•
Go to "Confirmation of repair".
YES
Does the troubleshooting result agree with the standard value? Measurement position and condition
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Item
2
YES
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Standard value
33.1 to 37.2 MPa {338 to 380 kg/cm2}
NO
40-1005
H-11 HYDRAULIC DRIFT OF ARM IS LARGE
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The lock valve of the arm control valve is normal.
•
Go to the next inspection item. The lock valve of the arm control valve is defective.
YES
3
Lock valve of arm control valve (if equipped)
Are the lock valve body, pilot piston and poppet clean and free of twisting, sticking, scratches and dirt? REMARK When the parts are restored, be careful not to let dirt to enter.
1.
2.
4
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
5
Arm control valve
Measurement position and condition •
1.
2.
Discharged pressure pickup port of front pump
•
Control lever: Arm IN relief
33.1 to 37.2 Hydraul- MPa {338 to 380 kg/cm2} ic oil
NO
•
Go to "Confirmation of repair". The suction safety valve on the IN side of the arm control valve is normal.
•
Go to the next inspection item.
•
The suction safety valve on the IN side of the arm control valve is defective.
•
Repair or replace the suction safety valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair".
•
The body and spool of the arm control valve are normal.
•
Go to the next inspection item. The body and spool of the arm control valve are defective.
YES
•
Are the control valve body and the arm spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) When the parts are restored, be careful not to let dirt to enter.
Repair or replace the lock valve of the arm control valve.
YES
temperature: 45 to 55°C
Release the remaining pressure from the hydraulic tank and piping to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
•
•
Standard value
REMARK
40-1006
NO
Does the troubleshooting result agree with the standard value? Item
Suction safety valve on IN side of arm control valve
•
NO
•
Repair or replace the body and spool of the arm control valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
6
H-11 HYDRAULIC DRIFT OF ARM IS LARGE
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Check by relieving the circuit of other work equipment.
4.
Is the arm stopped?
5.
Check it by interchanging the pressure compensation valves on the IN side and OUT side of the arm control valve.
Pressure com- 6. pensation valve on IN side of arm control valve
Diagnosis and treatment •
The pressure compensation valve on the IN side of the arm control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the IN side of the arm control valve is defective.
•
Repair or replace the pressure compensation valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair".
YES
Is the phenomenon reproduced in the same way? REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
Main relief pressure
PC210-10M0, PC210LC-10M0
Discharged pressure pickup port of front pump
•
Control lever: Arm IN relief
NO
Standard value
33.1 to 37.2 Hydraul- MPa {338 to 380 kg/cm2} ic oil
temperature: 45 to 55°C
40-1007
H-11 HYDRAULIC DRIFT OF ARM IS LARGE
No.
Cause
Procedures, Measurement, Values, Note 1.
7
Pressure compensation valve on OUT side of arm control valve
40 TROUBLESHOOTING
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Check by relieving the circuit of other work equipment.
4.
Is the arm stopped?
5.
Check it by interchanging the pressure compensation valves on the IN side and OUT side of the arm control valve.
6.
Is the phenomenon reproduced in the same way?
The pressure compensation valve on the OUT side of the arm control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the OUT side of the arm control valve is defective.
•
Repair or replace the pressure compensation valve on the OUT side of the arm control valve.
•
Go to "Confirmation of repair".
YES
The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Measurement position and condition •
Main relief pressure
Discharged pressure pickup port of front pump
•
Standard value
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Stop the engine.
2.
Connect all the configuration equipment.
5.
NO
Control lever: Arm OUT relief
1. Confirmation of 3. repair 4.
40-1008
•
REMARK
Item
8
Diagnosis and treatment
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does the arm move normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE Details of failure
Hydraulic drift of the bucket is large.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note 1. 2.
Do a test. For details, see TESTING AND ADJUSTING, TEST ENGINE OIL LEAKAGE.
Measurement position and condition
Bucket cylinder Hose on head Oil side of bucket leakage cylinder
1.
2.
2
Suction safety valve on DUMP side of bucket control valve
YES
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
•
Fuel dial: Hi
•
Control lever: Bucket CURL relief
•
Max. 20 cc/min
NO
Main relief pressure
Measurement position and condition
PC210-10M0, PC210LC-10M0
Discharged pressure pickup port of rear pump
•
•
Go to the next inspection item.
•
The bucket cylinder is defective.
•
Repair or replace the bucket cylinder.
•
Go to "Confirmation of repair".
•
The suction safety valve on the DUMP side of the bucket control valve is normal.
•
Go to the next inspection item.
•
The suction safety valve on the DUMP side of the bucket control valve is defective.
•
Repair or replace the suction safety valve on the DUMP side of the bucket control valve.
•
Go to "Confirmation of repair".
Hydraulic oil temperature: 45 to 55°C
YES
Does the troubleshooting result agree with the standard value?
•
The bucket cylinder is normal.
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Item
•
Control lever: Bucket DUMP relief
Standard value
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
NO
40-1009
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE
No.
Cause
Procedures, Measurement, Values, Note 1.
3
Bucket control valve
40 TROUBLESHOOTING
2.
Release the remaining pressure from the hydraulic tank and piping to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment
NO
4
Pressure compensation valve on CURL side of bucket control valve
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Check by relieving the circuit of other work equipment.
4.
Is the bucket stopped?
5.
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve.
6.
Is the phenomenon reproduced in the same way?
Go to the next inspection item. The body and spool of the bucket control valve are defective.
•
Repair or replace the body and spool of the bucket control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the CURL side of the bucket control valve is normal.
•
YES •
Go to the next inspection item.
•
The pressure compensation valve on the CURL side of the bucket control valve is defective.
•
Repair or replace the pressure compensation valve on the CURL side of the bucket control valve.
•
Go to "Confirmation of repair".
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
Main relief pressure
40-1010
• •
When the parts are restored, be careful not to let dirt to enter. 1.
The body and spool of the bucket control valve are normal.
YES
Are the control valve body and the boom spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
•
Discharged pressure pickup port of rear pump
•
Control lever: Bucket CURL relief
Standard value
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
NO
ic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
5
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE
Pressure compensation valve on DUMP side of bucket control valve
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result of main relief pressure meet the standard value?
3.
Check by relieving the circuit of other work equipment.
4.
Is the bucket stopped?
5.
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve.
6.
Is the phenomenon reproduced in the same way?
•
The pressure compensation valve on the DUMP side of the bucket control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the DUMP side of the bucket control valve is defective.
•
Repair or replace the pressure compensation valve on the DUMP side of the bucket control valve.
•
Go to "Confirmation of repair".
YES
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting. Item
Measurement position and condition •
Main relief pressure
6
Diagnosis and treatment
Discharged pressure pickup port of rear pump
•
Standard value
Control lever: Bucket DUMP relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
NO
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does the bucket move normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-1011
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES
40 TROUBLESHOOTING
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES Details of failure
When a work equipment is operated until hydraulically relieved, another work equipment moves.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
1
Cause
Procedures, Measurement, Values, Note 1.
Check by relieving the circuit of other work equipment.
2.
Is the boom stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve on RAISE side 5. of boom control valve 6.
Diagnosis and treatment The pressure compensation valve on the RAISE side of the boom control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the RAISE side of the boom control valve is defective.
YES
•
Check by interchanging the RAISE side and LOWER side compensation valves of the boom control valve. Is the phenomenon reproduced in the same way?
•
NO
•
Repair or replace the pressure compensation valve on the RAISE side of the boom control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the IN side of the arm control valve is normal.
REMARK The RAISE side and LOWER side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
2
•
1.
Check by relieving the circuit of other work equipment.
2.
Is the arm stopped?
3.
Stop the engine.
•
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Go to the next inspection item.
•
The pressure compensation valve on the IN side of the arm control valve is defective.
•
Repair or replace the pressure compensation valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair".
Pressure compensation valve on IN side of 5. arm control valve 6.
Check it by interchanging the pressure compensation valves on the IN side and OUT side of the arm control valve. Is the phenomenon reproduced in the same way?
YES
NO
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
40-1012
PC210-10M0, PC210LC-10M0
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES
40 TROUBLESHOOTING
No.
3
Cause
Procedures, Measurement, Values, Note 1.
Check by relieving the circuit of other work equipment.
2.
Is the bucket stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve on CURL side 5. of bucket control valve 6.
Diagnosis and treatment The pressure compensation valve on the CURL side of the bucket control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the CURL side of the bucket control valve is defective.
YES
•
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve. Is the phenomenon reproduced in the same way?
•
NO
•
Repair or replace the pressure compensation valve on the CURL side of the bucket control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the DUMP side of the bucket control valve is normal.
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
4
1.
Check by relieving the circuit of other work equipment.
2.
Is the bucket stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve on DUMP side 5. of bucket control valve 6.
•
YES • •
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve. Is the phenomenon reproduced in the same way?
NO
•
Repair or replace the pressure compensation valve on the DUMP side of the bucket control valve.
•
Go to "Confirmation of repair".
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
5
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
Go to the next inspection item. The pressure compensation valve on the DUMP side of the bucket control valve is defective.
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does each work equipment operate normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-1013
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE
40 TROUBLESHOOTING
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE Details of failure
Time lag of the work equipment is large. Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The F pump pressure can be monitored. (Code: 01100) • No.
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Measuring point and measurement condition
The LS-EPC valve is normal.
•
Go to the next inspection item.
•
The LS-EPC valve is defective.
LSEPC valve output pressure
•
Make a repair or replace the LS-EPC valve.
Pickup port for selecting pressure of LS setting
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Lo
•
Control lever: All levers in Approximately 2.9 MPa {apNEUproximately TRAL
•
LS-EPC valve
40-1014
YES
•
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
2 Hydraul- 30 kg/cm } ic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Travel lever fine 0 MPa {0 control kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE
Energy recovery valve of boom control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Are the control valve body and the boom energyrecovery valve clean and free of twisting, sticking, scratches and dirt? (The valve must move smoothly.)
Diagnosis and treatment •
The boom energy recovery valve is normal.
•
Go to the next inspection item. The boom energy recovery valve is defective.
YES
•
NO
•
Make a repair or replace the boom energy recovery valve.
•
Go to "Confirmation of repair". The arm energy recovery valve is normal.
REMARK When the parts are restored, be careful not to let dirt to enter. 1.
3
Energy recovery valve of arm control valve
2.
Release the remaining pressure from the hydraulic tank and piping, and troubleshoot it. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Are the control valve body and the arm energyrecovery valve clean and free of twisting, sticking, scratches and dirt? (The valve must move smoothly.)
• YES • •
NO
•
Make a repair or replace the arm energy recovery valve.
•
Go to "Confirmation of repair". The suction safety valve on the LOWER side of the boom control valve is normal.
REMARK When the parts are restored, be careful not to let dirt to enter. 1.
2.
4
Suction safety valve on LOWER side of boom control valve
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
• YES
Does the troubleshooting result agree with the standard value? Item
Measuring point and measurement condition •
Main relief pressure
PC210-10M0, PC210LC-10M0
Discharged pressure pickup port of rear pump
•
Control lever: Boom LOWER relief
Standard value
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
ic oil temperature: 45 to 55°C
Go to the next inspection item. The arm energy recovery valve is defective.
•
Go to the next inspection item.
•
The suction safety valve on the LOWER side of the boom control valve is defective.
•
Make a repair or replace the suction safety valve on the LOWER side of the boom control valve.
•
Go to "Confirmation of repair".
NO
40-1015
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
5
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
2.
6
Discharged pressure pickup port of front pump
•
Control lever: Arm IN relief
33.1 to 37.2
Hydraul- MPa {338 to 380 kg/cm2} ic oil temperature: 45 to 55°C
Measuring point and measurement condition •
Discharged pressure pickup port of rear pump
•
Control lever: Bucket CURL relief
ic oil temperature: 45 to 55°C
•
Go to the next inspection item.
•
The suction safety valve on the IN side of the arm control valve is defective.
•
Make a repair or replace the suction safety valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair".
•
The suction safety valve on the CURL side of the bucket control valve is normal.
•
Go to the next inspection item.
•
The suction safety valve on the CURL side of the bucket control valve is defective.
•
Make a repair or replace the suction safety valve on the CURL side of the bucket control valve.
•
Go to "Confirmation of repair".
YES
Standard value
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
The suction safety valve on the IN side of the arm control valve is normal.
NO
Does the troubleshooting result agree with the standard value? Item
• YES
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Main relief pressure
40-1016
Measuring point and measurement condition •
1.
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
Suction safety valve on IN side of arm control valve
Suction safety valve on CURL side of bucket control valve
40 TROUBLESHOOTING
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
7
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
•
Main relief pressure
8
Measuring point and measurement condition
Discharged pressure pickup port of rear pump
•
Standard value
Control lever: Bucket DUMP relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
Check by relieving the circuit of other work equipment.
2.
Is the boom stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve on RAISE side 5. of boom control valve 6.
•
Go to the next inspection item.
•
The suction safety valve on the DUMP side of the bucket control valve is defective.
•
Make a repair or replace the suction safety valve on the DUMP side of the bucket control valve.
•
Go to "Confirmation of repair".
•
The pressure compensation valve on the RAISE side of the boom control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the RAISE side of the boom control valve is defective.
YES
•
Check by interchanging the RAISE side and LOWER side compensation valves of the boom control valve. Is the phenomenon reproduced in the same way?
The suction safety valve on the DUMP side of the bucket control valve is normal.
NO
ic oil temperature: 45 to 55°C
1.
• YES
Does the troubleshooting result agree with the standard value? Item
Suction safety valve on DUMP side of bucket control valve
Diagnosis and treatment
•
Make a repair or replace the pressure compensation valve on the RAISE side of the boom control valve.
•
Go to "Confirmation of repair".
NO
REMARK The RAISE side and LOWER side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
PC210-10M0, PC210LC-10M0
40-1017
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE
No.
9
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Check by relieving the circuit of other work equipment.
2.
Is the boom stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve on LOWER 5. side of boom control valve 6.
Diagnosis and treatment The pressure compensation valve on the LOWER side of the boom control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the LOWER side of the boom control valve is defective.
YES
•
Check by interchanging the RAISE side and LOWER side compensation valves of the boom control valve. Is the phenomenon reproduced in the same way?
•
•
Make a repair or replace the pressure compensation valve on the LOWER side of the boom control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the IN side of the arm control valve is normal.
NO
REMARK The RAISE side and LOWER side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
•
1.
Check by relieving the circuit of other work equipment.
2.
Is the arm stopped?
3.
Stop the engine.
•
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Go to the next inspection item.
•
The pressure compensation valve on the IN side of the arm control valve is defective.
•
Make a repair or replace the pressure compensation valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair".
Pressure compensation valve 10 on IN side of 5. arm control valve 6.
Check it by interchanging the pressure compensation valves on the IN side and OUT side of the arm control valve. Is the phenomenon reproduced in the same way?
YES
NO
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
40-1018
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE
Procedures, Measurement, Values, Note 1.
Check by relieving the circuit of other work equipment.
2.
Is the arm stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve 11 on OUT side of 5. arm control valve 6.
Diagnosis and treatment The pressure compensation valve on the OUT side of the arm control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the OUT side of the arm control valve is defective.
YES
•
Check it by interchanging the pressure compensation valves on the IN side and OUT side of the arm control valve. Is the phenomenon reproduced in the same way?
•
NO
•
Make a repair or replace the pressure compensation valve on the OUT side of the arm control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the CURL side of the bucket control valve is normal.
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
• 1.
Check by relieving the circuit of other work equipment.
2.
Is the bucket stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve 12 on CURL side 5. of bucket control valve 6.
YES • •
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve. Is the phenomenon reproduced in the same way?
•
Make a repair or replace the pressure compensation valve on the CURL side of the bucket control valve.
•
Go to "Confirmation of repair".
NO
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The pressure compensation valve on the CURL side of the bucket control valve is defective.
40-1019
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Check by relieving the circuit of other work equipment.
2.
Is the bucket stopped?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Pressure compensation valve 13 on DUMP side 5. of bucket control valve 6.
Diagnosis and treatment The pressure compensation valve on the DUMP side of the bucket control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the DUMP side of the bucket control valve is defective.
YES
•
Check it by interchanging the pressure compensation valves on the CURL side and DUMP side of the bucket control valve. Is the phenomenon reproduced in the same way?
•
•
Make a repair or replace the pressure compensation valve on the DUMP side of the bucket control valve.
•
Go to "Confirmation of repair".
NO
REMARK The IN side and OUT side compensation valves have a different area ratio. Make sure to restore them after troubleshooting.
14
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
40-1020
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does each work equipment operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE
40 TROUBLESHOOTING
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE Details of failure
The one-touch power maximizing function does not operate.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
YES
•
The 2-stage relief solenoid valve is normal.
•
Go to the next inspection item.
•
The 2-stage relief solenoid valve is defective.
•
Repair or replace the 2-stage relief solenoid valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
Measurement position and condition •
Fuel dial: Hi
•
Swing lock switch: OFF
•
2-stage relief solenoid valve Solenoid output pressure
Outlet hose of 2-stage relief solenoid valve
•
Fuel dial: Hi
•
Swing lock switch: ON
•
PC210-10M0, PC210LC-10M0
Hydraulic oil temperature: 45 to 55°C
Hydraulic oil temperature: 45 to 55°C
Standard value
0 MPa {0 kg/cm2}
NO
2.9 MPa {30 kg/cm2}
40-1021
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measurement position and condition •
Fuel dial: Hi
•
Normal relief
•
Control lever: Bucket independent relief
•
2
40-1022
Diagnosis and treatment
Main relief pressure of front pump
Discharged pressure pickup port of front pump
Fuel dial: Hi
•
Onetouch power maximizing function relief
•
Control lever: Bucket independent relief
•
Hydraulic oil temperature: 45 to 55°C
The front main relief solenoid valve is normal.
•
Go to the next inspection item.
•
The front main relief solenoid valve is defective.
•
Repair or replace the main relief solenoid valve of the front pump.
•
Go to "Confirmation of repair".
Standard value
33.1 to 37.2 MPa {338 to 380 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
• YES
Does the troubleshooting result agree with the standard value? Item
Front main relief solenoid valve
40 TROUBLESHOOTING
NO
36.1 to 37.2 MPa {368 to 405kg/cm2}
PC210-10M0, PC210LC-10M0
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measurement position and condition •
Fuel dial: Hi
•
Normal relief
•
Control lever: Bucket independent relief
•
3
4
Main relief pressure of rear pump
Discharged pressure pickup port of rear pump
Fuel dial: Hi
•
Onetouch power maximizing function relief
•
Control lever: Bucket independent relief
•
Hydraulic oil temperature: 45 to 55°C
Go to the next inspection item.
•
The rear main relief solenoid valve is defective.
•
Repair or replace the main relief solenoid valve of the rear pump.
•
Go to "Confirmation of repair".
NO
36.1 to 37.2 MPa {368 to 405kg/cm2}
Stop the engine.
2.
Connect all the configuration equipment.
5.
•
33.1 to 37.2 MPa {338 to 380 kg/cm2}
1. Confirmation of 3. repair 4.
The rear pump main relief solenoid valve is normal.
Standard value
Hydraulic oil temperature: 45 to 55°C
•
• YES
Does the troubleshooting result agree with the standard value? Item
Rear main relief solenoid valve
Diagnosis and treatment
YES The repair is completed.
Start the engine. Push the L.H. knob switch to troubleshoot. Does the one-touch power maximizing function operate normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-1023
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED
40 TROUBLESHOOTING
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED Details of failure
When an attachment is installed, the attachment circuit cannot be changed over. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code •
The swing LEFT PPC pressure can be monitored. (Code: 09001)
•
The swing RIGHT PPC pressure can be monitored. (Code: 09002)
Associated informa- Reference information tion • In the ATT mode, the service circuit is changed over to the double-acting circuit. The safety valve becomes low-pressure setting.
No.
•
In the B mode, the service circuit is changed over to the single-acting circuit. The safety valve becomes high-pressure setting.
•
The setting of the safety valve is changed over only at the B port. The A port side is always at the low-pressure setting.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
Measurement position and condition
Attachment return selector solenoid valve Solenoid outlet pressure
40-1024
Outlet hose of attachment selector solenoid valve
The attachment return selector solenoid valve is normal.
•
Go to the next inspection item.
•
The attachment return selector solenoid valve is defective.
•
Repair or replace the attachment return selector solenoid valve.
•
Go to "Confirmation of repair".
Standard value
•
Work mode: ATT
•
Fuel dial: 0 MPa {0 Hi
•
• YES
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
2 Hydraul- kg/cm } ic oil temperature: 45 to 55°C
•
Work mode: B
•
Fuel dial: Hi
•
Hydraul- kg/cm2} ic oil temperature: 45 to 55°C
NO
2.9 MPa {30
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
1.
2
Attachment return selector valve
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED
2.
Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Is the attachment return selector valve clean and free of twisting, sticking, scratches and fatigue of the spring?
Diagnosis and treatment •
The attachment return selector valve is normal.
•
Go to the next inspection item. The attachment return selector valve is defective.
YES
•
NO
•
Repair or replace the attachment return selector valve.
•
Go to "Confirmation of repair". The safety valve of the service control valve is normal.
• YES •
3
Safety valve of service control valve
1.
Adjust the safety valve.
2.
Does oil pressure remain defective?
•
NO
1. 4
Confirmation of 2. repair 3. 4.
Stop the engine. Connect all the configuration equipment.
PC210-10M0, PC210LC-10M0
•
Repair or replace the safety valve of the service control valve.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Do the attachments change over normally?
Go to the next inspection item. The safety valve of the service control valve is defective.
NO
Return to the first inspection item.
40-1025
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED
40 TROUBLESHOOTING
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED Details of failure
The oil flow in the attachment circuit cannot be changed. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first.
Associated information
No.
1
Reference information •
For machines with an attachment installed, the flow rate of the service circuit changes according to the selected mode.
•
The flow adjustment procedure is different between ATT mode and B mode of work mode. For details, see the Operation and Maintenance Manual.
Cause
Attachment flow adjustment EPC valve
Procedures, Measurement, Values, Note 1.
Stop the engine.
2.
Run the engine at high idle. Troubleshoot the out- YES put pressure of the EPC valve.
3.
Does the measuring result of output pressure of EPC valve meet the standard value?
4.
Troubleshoot the current value with the monitoring function. (Code: 01700)
5.
Does the measuring result of current value meet the standard value? Item
Measurement position and condition •
EPC valve output pressure
Service pedal: NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Service pedal: Operated
•
Hydraulic oil temperature: 45 to 55°C
Current Monitoring function (Code: value 01700)
40-1026
Diagnosis and treatment
Standard value 0 MPa {0 kg/cm2}
Pressure corresponding to each flow setting
NO
•
The attachment flow adjustment EPC valve is normal.
•
Go to the next inspection item.
•
The EPC valve for attachment flow adjustment is defective.
•
Repair or replace the EPC valve for attachment flow adjustment.
•
Go to "Confirmation of repair".
0.3 to 0.91 A
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
PPC outlet pressure
3
Measurement position and condition
Service PPC valve
1. Confirmation of 2. repair 3. 4.
YES
•
The service PPC valve is normal.
•
Go to the next inspection item.
•
The service PPC valve is defective.
•
Repair or replace the service PPC valve.
•
Go to "Confirmation of repair".
Does the output pressure change according to the movement of the pedal? Item
2
Diagnosis and treatment
Outlet hose of service PPC valve
Standard value
•
NEUTRAL
•
Fuel dial: Hi
•
Hydraul- kg/cm2} ic oil temperature: 45 to 55°C
0 MPa {0
•
Operation
•
Fuel dial: Pressure corHi
•
Hydraul- each flow setic oil ting temperature: 45 to 55°C
NO
responding to
Stop the engine. Connect all the configuration equipment.
YES The repair is completed.
Start the engine to troubleshoot. Do the attachments change over normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-1027
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER
40 TROUBLESHOOTING
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER Details of failure
In a combined operation of work equipment, the equipment having heavier load moves slower.
Associated informa- Pre-troubleshooting tion If a failure code is displayed, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The pressure compensation valve on the IN side of the arm control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the IN side of the arm control valve is defective.
YES
1
Pressure com- 1. pensation valve 2. on IN side of arm control 3. valve
•
Start the engine. Operate the boom RAISE and arm IN at the same time, and troubleshoot. Is the movement of boom RAISE normal?
•
Repair or replace the pressure compensation valve on the IN side of the arm control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the RAISE side of the boom control valve is normal.
NO
•
YES •
2
Pressure com- 1. pensation valve 2. on RAISE side of boom control 3. valve
•
Start the engine. Operate boom RAISE and arm IN at the same time, and troubleshoot. Is the movement of Arm OUT normal? NO
40-1028
Go to the next inspection item. The pressure compensation valve on the RAISE side of the boom control valve is defective.
•
Repair or replace the pressure compensation valve on the RAISE side of the boom control valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The pressure compensation valve on the CURL side of the bucket control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the CURL side of the bucket control valve is defective.
YES
3
1. Pressure com- 2. pensation valve on CURL side of bucket con3. trol valve
Start the engine.
•
Operate boom RAISE and bucket CURL or arm OUT and bucket CURL at the same time, and troubleshoot. Is the movement of boom RAISE or arm OUT normal?
NO
•
Repair or replace the pressure compensation valve on the CURL side of the bucket control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the LOWER side of the boom control valve is normal.
•
YES •
4
Pressure com- 1. pensation valve 2. on LOWER side of boom 3. control valve
•
Start the engine. Operate boom LOWER and arm OUT at the same time, and troubleshoot. Is the movement of Arm OUT normal? NO
5
1.
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
Go to the next inspection item. The pressure compensation valve on the LOWER side of the boom control valve is defective.
•
Repair or replace the pressure compensation valve on the LOWER side of the boom control valve.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Operate the lever to troubleshoot. Does the work equipment operate normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-1029
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY
40 TROUBLESHOOTING
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY Details of failure
When swing is operated while traveling, the travel speed lowers largely.
Pre-troubleshooting Associated informaIf the travel speed is also slow when traveling without swing, troubleshoot TRAVEL tion SPEED IS SLOW in H mode first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The LS shuttle valve of the L.H. travel control valve is normal.
•
Go to the next inspection item. The LS shuttle valve of the L.H. travel control valve is defective.
YES
1
LS shuttle valve of L.H. travel control valve
1.
Check the check valve seat in the shuttle valve of the L.H. travel control valve.
2.
Is the check valve seat clean and free of scratches and dirt?
•
•
Clean or replace the check valve seat in the LS shuttle valve of the L.H. travel control valve.
•
Go to "Confirmation of repair". The LS shuttle valve of the swing control valve is normal.
NO
• YES •
2
LS shuttle valve of swing control valve
1.
Check the check valve seat in the shuttle valve of the swing control valve.
2.
Is the check valve seat clean and free of scratches and dirt?
•
•
Clean or replace the check valve seat in the LS shuttle valve of the swing control valve.
•
Go to "Confirmation of repair".
NO
1. 3
Confirmation of 2. repair 3. 4.
40-1030
Stop the engine. Connect all the configuration equipment.
YES The repair is completed.
Start the engine to troubleshoot. Does the work equipment operate normally?
Go to the next inspection item. The LS shuttle valve of the swing control valve is defective.
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW
40 TROUBLESHOOTING
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW Details of failure
In a combination operation of swing and boom RAISE, the boom rising speed is slow.
Pre-troubleshooting Associated informaIf boom RAISE is also slow when only the boom is operated, troubleshoot BOOM tion SPEED IS SLOW OR POWER IS LOW in H mode first. No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The LS select valve of the swing control valve is normal.
•
Go to the next inspection item. The LS select valve of the swing control valve is defective.
YES
1
LS select valve 1. of swing control valve 2.
• Check the LS select valve of the swing control valve. Are the valve operation and seal normal?
•
Clean or replace the check valve seat in the LS select valve of the swing control valve.
•
Go to "Confirmation of repair".
NO
1. 2
Confirmation of 2. repair 3. 4.
Stop the engine. Connect all the configuration equipment.
YES The repair is completed.
Start the engine to troubleshoot. Does the boom operate normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-1031
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
40 TROUBLESHOOTING
H-21 MACHINE DOES NOT TRAVEL STRAIGHT Details of failure
The machine does not travel straight. Pre-troubleshooting
Associated informa- If a failure code is shown, do the troubleshooting for that code first. tion Monitoring code The travel PPC pressure can be monitored. (Code: 01882)
40-1032
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
YES
•
The R.H. PPC valve is normal.
•
Go to the next inspection item.
•
The R.H. PPC valve is defective.
•
Make a repair or replace the R.H. PPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
Item
1
Diagnosis and treatment
PPC valve output presR.H. PPC valve sure
Hydraulic hose of boom PPC circuit
•
Fuel dial: Hi
•
R.H. travel lever in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
•
Difference between R.H. and L.H. of PPC valve outlet pressure
PC210-10M0, PC210LC-10M0
-
R.H. travel lever in FORWARD/ REVERSE
Standard value
0 MPa {0 kg/cm2}
NO 2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
Max. 0.4 MPa {max. 4 kg/ cm2}
40-1033
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
L.H. PPC valve
Measuring point and measurement condition
PPC valve output pressure
Hydraulic hose of arm PPC circuit
•
Fuel dial: Hi
•
L.H. travel lever in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
•
Difference between R.H. and L.H. of PPC valve outlet pressure
40-1034
Diagnosis and treatment YES
•
The L.H. PPC valve is normal.
•
Go to the next inspection item.
•
The L.H. PPC valve is defective.
•
Make a repair or replace the L.H. PPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
2
40 TROUBLESHOOTING
-
L.H. travel lever in FORWARD/ REVERSE
Standard value
0 MPa {0 kg/cm2}
NO 2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
Max. 0.4 MPa {max. 4 kg/ cm2}
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL PRESSURE OF CONTROL YES CIRCUIT.
2.
Does the troubleshooting result agree with the standard value? Item
3
Measuring point and measurement condition
Self-pressure reducing valve Control circuit Oil pressure source pickup plug pressure
1.
2.
4
•
Fuel dial: Hi
•
Control lever: All levers in 2.84 to 3.43 NEUMPa {29 to 35 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C
•
The self-pressure reducing valve is normal.
•
Go to the next inspection item.
•
The self-pressure reducing valve is defective.
•
Make a repair or replace the self-pressure reducing valve.
•
Go to "Confirmation of repair".
•
The front pump LS valve is normal.
•
Go to the next inspection item.
•
The LS valve of the front pump is defective.
•
Adjust the LS valve of the front pump.
•
If the oil pressure is not normal after the LS valve of the front pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
Standard value
NO
kg/cm }
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
YES
Does the troubleshooting result agree with the standard value? Item
LS valve of front pump
Diagnosis and treatment
Measuring point and measurement condition
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
Pump discharge pressure
Discharged pressure pickup port of front pump
PC valve output pressure
Load pressure pickup port of front pump
PC210-10M0, PC210LC-10M0
•
•
•
•
Standard value
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
NO
to 55°C
40-1035
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
5
40-1036
Diagnosis and treatment YES
•
The rear pump LS valve is normal.
•
Go to the next inspection item.
•
The LS valve of the rear pump is defective.
•
Adjust the LS valve of the rear pump.
•
If the oil pressure is not normal after the LS valve of the rear pump is adjusted, make a repair or replace it.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
LS valve of rear pump
40 TROUBLESHOOTING
Measuring point and measurement condition
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
Pump discharge pressure
Discharged pressure pickup port of rear pump
PC valve output pressure
Load pressure pickup port of rear pump
•
•
•
•
Standard value
Oil pressure ratio between pump discharged pressure and PC valve disHydraul- charged presic oil sure is 1:1 (altempera- most the ture: 45 same presto 55°C sure)
Control lever: All levers in NEUTRAL
Control lever: Travel lever in half stroke
Oil pressure ratio between pump discharged pressure and PC Hydraul- valve discharged presic oil tempera- sure is 1:0.6 ture: 45 (approx. 3/5)
NO
to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
YES
•
The travel junction solenoid valve is normal.
•
Go to the next inspection item.
•
The travel junction solenoid valve is defective.
•
Make a repair or replace the travel junction solenoid valve.
•
Go to "Confirmation of repair".
•
The travel junction valve is normal.
•
Go to the next inspection item. The travel junction valve is defective.
Does the troubleshooting result agree with the standard value? Item
6
Diagnosis and treatment
Measuring point and measurement condition
Travel junction solenoid valve
•
Fuel dial: Hi
•
Two in NEUTRAL
• Solenoid valve outlet pressure
Outlet hose of travel junction solenoid valve
Standard value
0 MPa {0 2 Hydraul- kg/cm }
ic oil temperature: 45 to 55°C •
Fuel dial: Hi
•
One operated
•
NO
Approximately 2.9 MPa {apHydraul- proximately ic oil 30 kg/cm2}
temperature: 45 to 55°C 1.
7
Travel junction valve
2.
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES
•
Is the junction valve spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK When the parts are restored, be careful not to let dirt to enter.
1.
8
R.H. travel con- 2. trol valve
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
Make a repair or replace the travel junction valve.
•
Go to "Confirmation of repair". The R.H. travel control valve is normal.
• YES
• •
Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
• NO
Go to the next inspection item. The R.H. travel control valve is defective.
•
Make a repair or replace the R.H. travel control valve.
•
Go to "Confirmation of repair".
NO
40-1037
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
No.
Cause
Procedures, Measurement, Values, Note 1.
9
40 TROUBLESHOOTING
L.H. travel con- 2. trol valve
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment YES
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
5.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the FORWARD right side and REVERSE right side of the R.H. travel control valve and troubleshoot again.
Pressure compensation valve on FORWARD 10 6. Is the phenomenon reproduced in the same way? right side of travel control Measuring point and meas- Standard valItem valve urement condition ue •
Fuel dial: Hi
•
R.H. travel FOR36.8 to 40.2 WARD hydraulic MPa {375 to 410 kg/cm2} relief
Discharged pressure pickup port of front pump •
40-1038
•
Go to the next inspection item. The L.H. travel control valve is defective.
•
Make a repair or replace the L.H. travel control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the FORWARD right side of the travel control valve is normal.
NO
When the parts are restored, be careful not to let dirt to enter.
Main relief pressure
The L.H. travel control valve is normal.
•
Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
1.
•
•
YES •
Go to the next inspection item.
•
The pressure compensation valve on the forward right side of the travel control valve is defective.
•
Make a repair or replace the pressure compensation valve on the FORWARD right side of the travel control valve.
•
Go to "Confirmation of repair".
NO
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
5.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the REVERSE right side and FORWARD right side of the R.H. travel control valve and troubleshoot again.
Pressure compensation valve on REVERSE 11 6. Is the phenomenon reproduced in the same way? right side of travel control Measuring point and meas- Standard valItem valve urement condition ue
Main relief pressure
•
Fuel dial: Hi
•
R.H. travel REVERSE 36.8 to 40.2 hydraulic MPa {375 to 410 kg/cm2} relief
Discharged pressure pickup port of front pump •
PC210-10M0, PC210LC-10M0
Diagnosis and treatment •
The pressure compensation valve on the REVERSE right side of the travel control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the reverse right side of the travel control valve is defective.
•
Make a repair or replace the pressure compensation valve on the REVERSE right side of the travel control valve.
•
Go to "Confirmation of repair".
YES
NO
Hydraulic oil temperature: 45 to 55°C
40-1039
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
5.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the FORWARD left side and REVERSE left side of the L.H. travel control valve and troubleshoot again.
Diagnosis and treatment
Main relief pressure
•
Fuel dial: Hi
•
L.H. travel FOR36.8 to 40.2 WARD hydraulic MPa {375 to 410 kg/cm2} relief
Discharged pressure pickup port of front pump •
40-1040
ue
The pressure compensation valve on the FORWARD left side of the travel control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the forward left side of the travel control valve is defective.
•
Make a repair or replace the pressure compensation valve on the FORWARD left side of the travel control valve.
•
Go to "Confirmation of repair".
YES
Pressure compensation valve 12 on FORWARD 6. Is the phenomenon reproduced in the same way? left side of travMeasuring point and meas- Standard valel control valve Item urement condition
•
NO
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
Stop the engine.
4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
5.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the REVERSE left side and FORWARD left side of the L.H. travel control valve and troubleshoot again.
Diagnosis and treatment
Main relief pressure
•
Fuel dial: Hi
•
L.H. travel REVERSE 36.8 to 40.2 hydraulic MPa {375 to 410 kg/cm2} relief
Discharged pressure pickup port of front pump •
1.
14
Center swivel joint
ue
•
Go to the next inspection item.
•
The pressure compensation valve on the reverse left side of the travel control valve is defective.
•
Make a repair or replace the pressure compensation valve on the REVERSE left side of the travel control valve.
•
Go to "Confirmation of repair".
•
The center swivel joint is normal.
•
Go to the next inspection item.
•
The center swivel joint is defective.
•
Make a repair or replace the center swivel joint.
•
Go to "Confirmation of repair".
NO
Hydraulic oil temperature: 45 to 55°C
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Do a test by interchanging the right and left hoses between the swivel joint and travel motor.
3.
Is the phenomenon reproduced in the same way? REMARK When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
The pressure compensation valve on the REVERSE left side of the travel control valve is normal.
YES
Pressure compensation valve 13 on REVERSE 6. Is the phenomenon reproduced in the same way? left side of travMeasuring point and meas- Standard valel control valve Item urement condition
•
YES
NO
40-1041
H-21 MACHINE DOES NOT TRAVEL STRAIGHT
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
2.
Does the troubleshooting result agree with the standard value? Item
15
Measuring point and measurement condition
R.H. travel motor Drain hose of Oil R.H. travel leakage motor
1. 2.
Diagnosis and treatment YES
•
Fuel dial: Hi
•
Travel relief
•
Hydraul- l/min ic oil temperature: 45 to 55°C
L.H. travel motor Drain hose of Oil L.H. travel leakage motor
Max. 27.2
YES
•
Fuel dial: Hi
•
Travel relief
•
Hydraul- l/min ic oil temperature: 45 to 55°C
Max. 27.2
4.
40-1042
Stop the engine. Connect all the configuration equipment.
The R.H. travel motor is defective.
•
Make a repair or replace the R.H. travel motor.
•
Go to "Confirmation of repair".
•
The L.H. travel motor is normal.
•
Go to the next inspection item.
•
The L.H. travel motor is defective.
•
Make a repair or replace the L.H. travel motor.
•
Go to "Confirmation of repair".
•
The final drive is normal.
•
Go to the next inspection item. The final drive is defective.
•
Make a repair or replace the final drive.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Does the machine travel normally?
•
• NO
Confirmation of 2. 18 repair 3.
Go to the next inspection item.
NO
Is the final drive clean and free of unusual noise, abnormal heat generation and metal powder in the drained oil?
1.
•
Standard value
YES
17 Final drive
The R.H. travel motor is normal.
NO
Does the troubleshooting result agree with the standard value? Measuring point and measurement condition
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
Item
16
40 TROUBLESHOOTING
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW Details of failure
The machine is not steered well or the steering power is low. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first.
Associated informa- Monitoring code tion • The travel PPC pressure can be monitored. (Code: 01882)
No.
•
The current of the merge-divider main solenoid can be monitored. (Code: 08000)
•
The current of the merge-divider LS solenoid can be monitored. (Code: 08001)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST TRAVEL PPC VALVE OUTLET PRESSURE.
YES
•
The R.H. travel PPC valve is normal.
•
Go to the next inspection item.
•
The R.H. travel PPC valve is defective.
•
Repair or replace the R.H. travel PPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel lever in NEUTRAL
•
1
Diagnosis and treatment
R.H. travel PPC valve Output pressure of travel PPC valve
Hydraulic hose of boom and travel PPC circuit
PC210-10M0, PC210LC-10M0
0 MPa {0 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever:
•
R.H. travel lever in FORWARD/ REVERSE
•
Standard value
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
40-1043
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST TRAVEL PPC VALVE OUTLET PRESSURE.
Measurement position and condition •
Fuel dial: Hi
•
Control lever: L.H. travel lever in NEUTRAL
•
L.H. travel PPC valve Output pressure of travel PPC valve
Hydraulic hose of arm and travel PPC circuit
YES
•
The L.H. travel PPC valve is normal.
•
Go to the next inspection item.
•
The L.H. travel PPC valve is defective.
•
Repair or replace the L.H. travel PPC valve.
•
Go to "Confirmation of repair".
Standard value
0 MPa {0 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: L.H. travel lever in FORWARD/ REVERSE
•
40-1044
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
2
40 TROUBLESHOOTING
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
Travel junction valve
2.
Fuel dial: Hi
•
Control lever: Right and left travel 0 MPa {0 levers in kg/cm2} NEUTRAL
Outlet hose of travel junction solenoid valve
Hydraulic oil temperature: 45 to 55°C
NO
•
Fuel dial: Hi
•
Control lever: One Approximately travel 2.9 MPa {aplever op- proximately erated 2
•
Hydraulic oil temperature: 45 to 55°C
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES
Is the junction valve spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) NO
When the parts are restored, be careful not to let dirt to enter. Merge-divider main EPC valve
1. 2.
•
Go to the next inspection item.
•
The travel junction solenoid valve is defective.
•
Repair or replace the travel junction solenoid valve.
•
Go to "Confirmation of repair".
•
The travel junction valve is normal.
•
Go to the next inspection item.
•
The travel junction valve is defective.
•
Repair or replace the travel junction valve.
•
Go to "Confirmation of repair".
•
The merge-divider main EPC valve is normal.
30 kg/cm }
REMARK
5
The travel junction solenoid valve is normal.
Standard value
•
• Solenoid valve outlet pressure
4
Measurement position and condition
Travel junction solenoid valve
1.
YES
•
Does the troubleshooting result agree with the standard value? Item
3
Diagnosis and treatment
Stop the engine. Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND
PC210-10M0, PC210LC-10M0
YES
40-1045
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment
ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. 3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL, or in bucket CURL or arm IN until hydraulic relief to troubleshoot.
5.
Does the troubleshooting result for output pressure of main EPC meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider Main Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to troubleshoot.
9.
Does the troubleshooting result for the EPC current meet the standard value? Item
Measurement position and condition •
•
Main EPC output pressure
Mounting port (PP1S) for front pump oil pressure sensor
Control lever: All levers in NEU0 to 0.49 MPa TRAL
{0 to 5 kg/ Hydraul- cm2}
NO
Go to the next inspection item.
•
The merge-divider main EPC valve is defective.
•
Repair or replace the merge-divider main EPC valve.
•
Go to "Confirmation of repair".
ic oil temperature: 45 to 55°C •
•
40-1046
Standard value
•
Control lever: Bucket CURL relief + Arm IN relief Hydraulic oil temperature: 45 to 55°C
2.84 to 3.43 MPa {29 to 35 kg/cm2}
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
EPC current
Monitoring code: 08000
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
6
Merge-divider LS-EPC valve
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
1.
Stop the engine.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
3.
Take out the mounting port (PP1S) for the front pump oil pressure sensor. Attach a hydraulic tester.
4.
Set the fuel control dial to Hi. Put the work equipment control lever in NEUTRAL, or in bucket CURL or arm IN until hydraulic relief to troubleshoot.
5.
Does the diagnosis result for the LS-EPC output pressure meet the standard value?
6.
After troubleshooting, restore to the original state.
7.
Show the Merge-divider LS Sol Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
8.
Operate the work equipment control lever to troubleshoot.
9.
Does the troubleshooting result for the EPC current meet the standard value? Item
PC210-10M0, PC210LC-10M0
Diagnosis and treatment
Measurement position and condition
YES
NO
•
The merge-divider LSEPC valve is normal.
•
Go to the next inspection item.
•
The merge-divider LSEPC valve is defective.
•
Repair or replace the merge-divider LS-EPC valve.
•
Go to "Confirmation of repair".
Standard value
40-1047
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note
LSEPC output pressure
EPC current
Mounting port (PP1S) for front pump oil pressure sensor
Monitoring code: 08001
•
Control lever: All levers in NEU0 to 0.49 MPa TRAL
•
Hydraul- cm2} ic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
40-1048
Diagnosis and treatment
{0 to 5 kg/
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: All levers in NEUTRAL
•
Hydraulic oil temperature: 45 to 55°C
•
Control lever: Bucket CURL relief + Arm IN relief
•
40 TROUBLESHOOTING
2.84 to 3.43 MPa {29 to 35 kg/cm2}
0mA
800 to 1000 mA
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
1.
7
Merge-divider main spool
2.
Release the remaining pressure in the hydraulic YES tank and piping to troubleshoot. For details, see • TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYS• TEM. Are the merge-divider valve body and the main spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
Repair or replace the body and main spool of the merge-divider valve.
•
Go to "Confirmation of repair". The body and LS spool of the merge-divider valve are normal.
•
8
Merge-divider LS spool
2.
Release the remaining pressure in the hydraulic YES tank and piping to troubleshoot. For details, see • TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYS• TEM. Are the merge-divider valve body and the LS spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
NO
9
R.H. travel con- 2. trol valve
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Repair or replace the body and LS spool of the merge-divider valve.
•
Go to "Confirmation of repair". The R.H. travel control valve is normal.
• YES
REMARK When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
• •
Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.)
Go to the next inspection item. The body and LS spool of the merge-divider valve are defective.
•
When the parts are restored, be careful not to let dirt to enter.
1.
Go to the next inspection item. The body and main spool of the mergedivider valve are defective.
•
When the parts are restored, be careful not to let dirt to enter.
1.
The body and main spool of the merge-divider valve are normal.
Go to the next inspection item. The R.H. travel control valve is defective.
•
Repair or replace the R.H. travel control valve.
•
Go to "Confirmation of repair".
NO
40-1049
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
L.H. travel con- 2. 10 trol valve
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment YES
When the parts are restored, be careful not to let dirt to enter. 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value? Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel FORWARD relief
•
Main relief pressure
Discharged pressure pickup port of front pump
Go to the next inspection item. The L.H. travel control valve is defective.
•
Repair or replace the L.H. travel control valve.
•
Go to "Confirmation of repair". The work equipment, swing, and travel circuits of the front pump are normal.
•
YES •
Go to the inspection items for the oil pressure in the work equipment, swing, and travel circuits of the rear pump.
•
The work equipment, swing, and travel circuits of the front pump is defective.
•
Go to the next inspection item.
Standard value
36.2 to 40.2 MPa {370 to 410 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: R.H. travel REVERSE relief
•
40-1050
•
NO
REMARK
Oil pressure in work equipment, swing, 11 and travel circuits of front pump
The L.H. travel control valve is normal.
•
Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.)
Item
•
NO
36.2 to 40.2 MPa {370 to 410 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The pressure compensation valve on the FORWARD right side of the travel control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the forward right side of the travel control valve is defective.
YES
Pressure compensation valve 1. on FORWARD 12 right side of travel control 2. valve
• Interchange the FORWARD right side and REVERSE right side pressure compensation valves on the R.H. travel control valve to troubleshoot. Is the phenomenon reproduced in the same way? •
Repair or replace the pressure compensation valve on the FORWARD right side of the travel control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the REVERSE right side of the travel control valve is normal.
NO
•
YES • Pressure compensation valve 1. on REVERSE 13 right side of travel control 2. valve
• Interchange the REVERSE right side and FORWARD right side pressure compensation valves on the R.H. travel control valve to troubleshoot. Is the phenomenon reproduced in the same way? •
Repair or replace the pressure compensation valve on the REVERSE right side of the travel control valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The pressure compensation valve on the reverse right side of the travel control valve is defective.
40-1051
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Diagnosis and treatment •
The main relief valve of the front pump is normal.
•
Go to the next inspection item.
•
The main relief valve of the front pump is defective.
•
Repair or replace the main relief valve of the front pump.
•
Go to "Confirmation of repair".
•
The safety valve of the R.H. travel motor is normal.
•
Go to the next inspection item. The safety valve of the R.H. travel motor is defective.
YES
Does the troubleshooting result agree with the standard value? Item
Main relief 14 valve of front pump
Measurement position and condition •
Main relief pressure
Discharged pressure pickup port of front pump
•
Standard value
Control lever: Boom RAISE relief
33.1 to 37.2 MPa {338 to Hydraul- 380 kg/cm2}
NO
ic oil temperature: 45 to 55°C
YES
Safety valve of 1. 15 R.H. travel motor 2.
Interchange the directional safety valves on the R.H. and L.H. travel motors to troubleshoot.
•
Is the phenomenon reproduced in the same way? NO
•
Repair or replace the safety valve of the R.H. travel motor
•
Go to "Confirmation of repair". The check valve of the R.H. travel motor is normal.
• YES • Check valve of 1. 16 R.H. travel motor 2.
Interchange the check valves on the FORWARD and REVERSE sides on the same travel motor.
•
Is the phenomenon reproduced in the same way? NO
40-1052
Go to the next inspection item. The check valve of the R.H. travel motor is defective.
•
Repair or replace the check valve of the R.H. travel motor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value? Item
Oil pressure in work equipment, swing, 17 and travel circuits of rear pump
Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel FORWARD relief
•
Main relief pressure
Discharged pressure pickup port of rear pump
Fuel dial: Hi
•
Control lever: R.H. travel REVERSE relief
•
PC210-10M0, PC210LC-10M0
YES
•
The work equipment, swing, and travel circuits of the rear pump is normal.
•
Go to the inspection items for the suction valve of the R.H. travel control valve.
•
The work equipment, swing, and travel circuits of the rear pump is defective.
•
Go to the next inspection item.
Standard value
36.1 to 38.8 MPa {368 to 395 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Diagnosis and treatment
NO
36.1 to 38.8 MPa {368 to 395 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
40-1053
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The pressure compensation valve on the FORWARD left side of the travel control valve is normal.
•
Go to the next inspection item. The pressure compensation valve on the forward left side of the travel control valve is defective.
YES
Pressure com- 1. pensation valve 18 on FORWARD left side of travel control valve 2.
•
Interchange the pressure compensation valves on the FORWARD left side and REVERSE left side of the L.H. travel control valve to troubleshoot. Is the phenomenon reproduced in the same way?
•
Repair or replace the pressure compensation valve on the FORWARD left side of the travel control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the REVERSE left side of the travel control valve is normal.
NO
•
YES • Pressure com- 1. pensation valve 19 on REVERSE left side of travel control valve 2.
Interchange the pressure compensation valves on the REVERSE left side and FORWARD left side of the L.H. travel control valve to troubleshoot.
•
Is the phenomenon reproduced in the same way? NO
40-1054
Go to the next inspection item. The pressure compensation valve on the reverse left side of the travel control valve is defective.
•
Repair or replace the pressure compensation valve on the REVERSE left side of the travel control valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
•
The main relief valve of the rear pump is normal.
•
Go to the next inspection item.
•
The main relief valve of the rear pump is defective.
•
Repair or replace the main relief valve of the rear pump.
•
Go to "Confirmation of repair".
•
The safety valve of the L.H. travel motor is normal.
•
Go to the next inspection item. The safety valve of the L.H. travel motor is defective.
YES
Does the troubleshooting result agree with the standard value? Item
Main relief 20 valve of rear pump
Diagnosis and treatment
Measurement position and condition •
Main relief pressure
Discharged pressure pickup port of rear pump
•
Control lever: Arm IN relief
Standard value
33.1 to 37.2
NO
Hydraul- MPa {338 to 380 kg/cm2} ic oil temperature: 45 to 55°C
YES
Safety valve of 21 L.H. travel motor
1.
Interchange the directional safety valves on the R.H. and L.H. travel motors to troubleshoot.
2.
Is the phenomenon reproduced in the same way?
•
NO
•
Repair or replace the safety valve of the L.H. travel motor
•
Go to "Confirmation of repair". The check valve of the L.H. travel motor is normal.
• YES • Check valve of 22 L.H. travel motor
1.
Interchange the check valves on the FORWARD and REVERSE sides on the same travel motor.
2.
Is the phenomenon reproduced in the same way?
•
NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The check valve of the L.H. travel motor is defective.
•
Repair or replace the check valve of the L.H. travel motor.
•
Go to "Confirmation of repair".
40-1055
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
No.
Cause
Procedures, Measurement, Values, Note 1.
Suction valve 23 of R.H. travel control valve
40 TROUBLESHOOTING
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Adjust the relief valve.
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
4.
Diagnosis and treatment •
The suction valve of the R.H. travel control valve is normal.
•
Go to the next inspection item. The suction valve of the R.H. travel control valve is defective.
YES
•
•
Repair or replace the suction valve of the R.H. travel control valve.
•
Go to "Confirmation of repair". The suction valve of the L.H. travel control valve is normal.
NO
Is the oil pressure equal between the front and rear ports?
• 1.
Suction valve 24 of L.H. travel control valve
2.
Adjust the relief valve.
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
4.
1.
25
Center swivel joint
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
• •
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Do a test by interchanging the right and left hoses between the swivel joint and travel motor.
3.
Is the phenomenon reproduced in the same way? When the parts are restored, be careful not to let dirt to enter.
Repair or replace the suction valve of the L.H. travel control valve.
•
Go to "Confirmation of repair". The center swivel joint is normal.
• YES
NO
Go to the next inspection item. The suction valve of the L.H. travel control valve is defective.
• NO
Is the oil pressure equal between the front and rear ports?
REMARK
40-1056
YES
•
Go to the next inspection item.
•
The center swivel joint is defective.
•
Repair or replace the center swivel joint.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
2.
Does the troubleshooting result agree with the standard value? Item
26
Measurement position and condition
R.H. travel motor Drain hose of Oil R.H. travel leakage motor
1. 2.
•
Fuel dial: Hi
•
Control lever: Travel relief
•
Measurement position and condition
L.H. travel motor
• Drain hose of Oil L.H. travel leakage motor
Confirmation of 2. 28 repair 3. 4.
Max. 27.2 l/min
NO
YES
Does the troubleshooting result agree with the standard value?
•
1.
YES
•
Hydraulic oil temperature: 45 to 55°C
Max. 27.2 l/min
Stop the engine. Connect all the configuration equipment.
NO
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item.
•
The R.H. travel motor is defective.
•
Repair or replace the R.H. travel motor.
•
Go to "Confirmation of repair".
•
The L.H. travel motor is normal.
•
Go to the next inspection item.
•
The L.H. travel motor is defective.
•
Repair or replace the L.H. travel motor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Does the machine travel normally?
The R.H. travel motor is normal.
Standard value
Fuel dial: Hi Control lever: Travel relief
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
Item
27
Hydraulic oil temperature: 45 to 55°C
Diagnosis and treatment
NO
Return to the first inspection item.
40-1057
H-23 TRAVEL SPEED IS SLOW
40 TROUBLESHOOTING
H-23 TRAVEL SPEED IS SLOW Details of failure
The travel speed is slow. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first. Monitoring code
Associated information
40-1058
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
•
The travel PPC pressure can be monitored. (Code: 01882)
•
The current of the LS-EPC solenoid can be monitored. (Code: 01500)
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-23 TRAVEL SPEED IS SLOW
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST TRAVEL PPC VALVE OUTLET PRESSURE.
YES
•
The R.H. travel PPC valve is normal.
•
Go to the next inspection item.
•
The R.H. travel PPC valve is defective.
•
Repair or replace the R.H. travel PPC valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel lever in NEUTRAL
•
1
Diagnosis and treatment
R.H. travel PPC valve Output pressure of travel PPC valve
Hydraulic hose of boom and travel PPC circuit
PC210-10M0, PC210LC-10M0
0 MPa {0 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: R.H. travel lever in FORWARD/ REVERSE
•
Standard value
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
40-1059
H-23 TRAVEL SPEED IS SLOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST TRAVEL PPC VALVE OUTLET PRESSURE.
Measurement position and condition •
Fuel dial: Hi
•
Control lever: L.H. travel lever in NEUTRAL
•
L.H. travel PPC valve Output pressure of travel PPC valve
Hydraulic hose of arm and travel PPC circuit
The L.H. travel PPC valve is normal.
•
Go to the next inspection item.
•
The L.H. travel PPC valve is defective.
•
Repair or replace the L.H. travel PPC valve.
•
Go to "Confirmation of repair".
Standard value
0 MPa {0 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: L.H. travel lever in FORWARD/ REVERSE
•
40-1060
YES
•
Does the troubleshooting result agree with the standard value? Item
2
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-23 TRAVEL SPEED IS SLOW
Cause
Procedures, Measurement, Values, Note 1.
2.
• Do a test. For details, see TESTING AND ADJUSTING, TEST OIL PRESSURE OF CONTROL YES • CIRCUIT. Does the troubleshooting result agree with the standard value? Item
Measurement position and condition •
3
Diagnosis and treatment
Self-pressure reducing valve Control circuit Oil pressure source pickup plug pressure
PC210-10M0, PC210LC-10M0
Control lever: All levers in NEUTRAL
Self pressure reducing is normal. Go to the next inspection item.
Standard value
2.84 to 3.43
•
Fuel dial: MPa {29 to 35 Hi 2
•
Hydraulic oil temperature: 45 to 55°C
kg/cm }
•
Self pressure reducing is defective.
•
Repair or replace the self pressure reducing valve.
•
Go to "Confirmation of repair".
NO
40-1061
H-23 TRAVEL SPEED IS SLOW
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
LSEPC valve output pressure
5
Measurement position and condition
LS-EPC valve
1.
R.H. travel con- 2. trol valve
YES
•
The LS-EPC valve is normal.
•
Go to the next inspection item.
Pickup port for selecting pressure of LS setting
•
Control lever: Travel lever in NEUTRAL
•
Travel speed: Lo
•
Hydraulic oil temperature: 45 to 55°C
•
The LS-EPC valve is defective.
•
Repair or replace the LS-EPC valve.
•
Go to "Confirmation of repair".
•
Control lever: Travel lever fine control
•
Travel speed: Hi
•
Hydraulic oil temperature: 45 to 55°C •
The R.H. travel control valve is normal.
•
Go to the next inspection item. The R.H. travel control valve is defective.
Standard value
Approximately 2.9 MPa {approximately 30 kg/cm2}
NO
0 MPa {0 kg/cm2}
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES
•
Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK When the parts are restored, be careful not to let dirt to enter.
40-1062
Diagnosis and treatment
Does the troubleshooting result agree with the standard value? Item
4
40 TROUBLESHOOTING
•
Repair or replace the R.H. travel control valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
6
H-23 TRAVEL SPEED IS SLOW
L.H. travel con- 2. trol valve
Release the remaining pressure in the hydraulic system to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Diagnosis and treatment YES
7
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the FORWARD right side and REVERSE right side of the R.H. travel control valve and troubleshoot again.
4.
Is the phenomenon reproduced in the same way? Item
Main relief pressure
Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel FORWARD relief
Discharged pressure pickup port of front pump •
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. The L.H. travel control valve is defective.
•
Repair or replace the L.H. travel control valve.
•
Go to "Confirmation of repair". The pressure compensation valve on the FORWARD right side of the travel control valve is normal.
NO
When the parts are restored, be careful not to let dirt to enter.
Pressure compensation valve on FORWARD right side of travel control valve
The L.H. travel control valve is normal.
•
Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) REMARK
1.
•
Hydraulic oil temperature: 45 to 55°C
•
YES •
Go to the next inspection item.
•
The pressure compensation valve on the forward right side of the travel control valve is defective.
•
Repair or replace the pressure compensation valve on the FORWARD right side of the travel control valve.
•
Go to "Confirmation of repair".
Standard value
NO
36.1 to 38.8 MPa {368 to 395 kg/cm2}
40-1063
H-23 TRAVEL SPEED IS SLOW
No.
Cause
Procedures, Measurement, Values, Note 1.
8
Pressure compensation valve on REVERSE right side of travel control valve
40 TROUBLESHOOTING
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the REVERSE right side and FORWARD right side of the R.H. travel control valve and troubleshoot again.
4.
Is the phenomenon reproduced in the same way? Item
Main relief pressure
Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel REVERSE relief
Discharged pressure pickup port of front pump •
40-1064
Hydraulic oil temperature: 45 to 55°C
Diagnosis and treatment •
The pressure compensation valve on the REVERSE right side of the travel control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the reverse right side of the travel control valve is defective.
•
Repair or replace the pressure compensation valve on the REVERSE right side of the travel control valve.
•
Go to "Confirmation of repair".
YES
Standard value
NO
36.1 to 38.8 MPa {368 to 395 kg/cm2}
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
9
H-23 TRAVEL SPEED IS SLOW
Pressure compensation valve on FORWARD left side of travel control valve
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the FORWARD left side and REVERSE left side of the L.H. travel control valve and troubleshoot again.
4.
Is the phenomenon reproduced in the same way? Item
Main relief pressure
Measurement position and condition •
Fuel dial: Hi
•
Control lever: L.H. travel FORWARD relief
Discharged pressure pickup port of front pump •
PC210-10M0, PC210LC-10M0
Diagnosis and treatment The pressure compensation valve on the FORWARD left side of the travel control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the forward left side of the travel control valve is defective.
•
Repair or replace the pressure compensation valve on the FORWARD left side of the travel control valve.
•
Go to "Confirmation of repair".
YES
Standard value
NO
36.1 to 38.8 MPa {368 to 395 kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
40-1065
H-23 TRAVEL SPEED IS SLOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
2.
Does the troubleshooting result agree with the standard value?
3.
If an abnormality is found in the troubleshooting result, interchange the pressure compensation valves on the REVERSE left side and FORWARD left side of the L.H. travel control valve and troubleshoot again.
4.
Is the phenomenon reproduced in the same way?
Pressure compensation valve 10 on REVERSE left side of travel control valve
Item
Main relief pressure
Measurement position and condition •
Fuel dial: Hi
•
Control lever: L.H. travel REVERSE relief
Discharged pressure pickup port of front pump •
1.
Suction valve 11 of R.H. travel control valve
40-1066
•
The pressure compensation valve on the REVERSE left side of the travel control valve is normal.
•
Go to the next inspection item.
•
The pressure compensation valve on the reverse left side of the travel control valve is defective.
•
Repair or replace the pressure compensation valve on the REVERSE left side of the travel control valve.
•
Go to "Confirmation of repair".
•
The suction valve of the R.H. travel control valve is normal.
•
Go to the next inspection item. The suction valve of the R.H. travel control valve is defective.
YES
Standard value
NO
36.1 to 38.8 MPa {368 to 395 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Adjust the relief valve.
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
4.
Diagnosis and treatment
Is the oil pressure equal between the front and rear ports?
YES
•
•
Repair or replace the suction valve of the R.H. travel control valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-23 TRAVEL SPEED IS SLOW
Cause
Procedures, Measurement, Values, Note 1.
Suction valve 12 of L.H. travel control valve
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Adjust the relief valve.
3.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
4.
1. 2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
•
R.H. travel motor
• Drain hose of Oil R.H. travel leakage motor
1. 2.
Hydraulic oil temperature: 45 to 55°C
L.H. travel motor Drain hose of Oil L.H. travel leakage motor
PC210-10M0, PC210LC-10M0
•
Fuel dial: Hi
•
Control lever: Travel relief
•
Hydraulic oil temperature: 45 to 55°C
•
Repair or replace the suction valve of the L.H. travel control valve.
•
Go to "Confirmation of repair". The R.H. travel motor is normal.
• YES
Max. 27.2 l/min
NO
YES
Does the troubleshooting result agree with the standard value? Measurement position and condition
Go to the next inspection item. The suction valve of the L.H. travel control valve is defective.
•
Go to the next inspection item.
•
The R.H. travel motor is defective.
•
Repair or replace the R.H. travel motor.
•
Go to "Confirmation of repair".
•
The L.H. travel motor is normal.
•
Go to the next inspection item.
•
The L.H. travel motor is defective.
•
Repair or replace the L.H. travel motor.
•
Go to "Confirmation of repair".
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
Item
14
•
•
NO
Fuel dial: Hi Control lever: Travel relief
The suction valve of the L.H. travel control valve is normal.
•
Does the troubleshooting result agree with the standard value? Measurement position and condition
• YES
Is the oil pressure equal between the front and rear ports?
Item
13
Diagnosis and treatment
Standard value
Max. 27.2 l/min
NO
40-1067
H-23 TRAVEL SPEED IS SLOW
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
15 Final drive
Is the final drive clean and free of unusual noise, abnormal heat generation and metal powder in the drained oil?
16
Stop the engine.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
40-1068
The final drive is normal.
•
Go to the next inspection item. The final drive is defective.
• NO
1.
•
•
Repair or replace the final drive.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Push the L.H. knob switch to troubleshoot. Does the one-touch power maximizing function operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-24 ONE OF TRACKS DOES NOT RUN
H-24 ONE OF TRACKS DOES NOT RUN Details of failure
One of the tracks does not run. Pre-troubleshooting If a failure code is displayed, do the troubleshooting for that code first.
Associated informa- Monitoring code tion • The travel PPC pressure can be monitored. (Code: 01882)
No.
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
YES
•
The R.H. travel PPC valve is normal.
•
Go to the next inspection item.
•
The R.H. travel PPC valve is defective.
•
Replace the R.H. travel PPC valve.
•
Go to "Confirmation of repair".
Does the measurement result agree with the standard value? Item
Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel lever in NEUTRAL
•
1
Diagnosis and treatment
R.H. travel PPC valve PPC valve output pressure
Hydraulic hose of boom PPC circuit
PC210-10M0, PC210LC-10M0
0 MPa {0 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: R.H. travel lever in FORWARD/ REVERSE
•
Standard value
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
40-1069
H-24 ONE OF TRACKS DOES NOT RUN
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measurement position and condition •
Fuel dial: Hi
•
Control lever: L.H. travel lever in NEUTRAL
•
L.H. travel PPC valve PPC valve output pressure
Hydraulic hose of arm PPC circuit
The L.H. travel PPC valve is normal.
•
Go to the next inspection item.
•
The L.H. travel PPC valve is defective.
•
Replace the L.H. travel PPC valve.
•
Go to "Confirmation of repair".
Standard value
0 MPa {0 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: L.H. travel lever in FORWARD/ REVERSE
•
40-1070
YES
•
Does the measurement result agree with the standard value? Item
2
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-24 ONE OF TRACKS DOES NOT RUN
Cause
Procedures, Measurement, Values, Note 1.
Go to the inspection items Show the PUMP PRESSURE screen. For details, YES of the R.H. travel control see TESTING AND ADJUSTING, SERVICE valve. MODE, MONITORING.
2.
Start the engine.
3.
Operate each travel lever to troubleshoot.
4.
Does the measurement result agree with the standard value?
•
When the front pump pressure is low, go to the inspection items for the suction valve of the R.H. travel control valve.
•
When the rear pump pressure is low, go to the inspection items for the suction valve of the L.H. travel control valve.
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK
The body and spool of the R.H. travel control valve are normal.
Item
3
Main pump pressure
Front pump pressure
Rear pump pressure
1.
4
R.H. travel con- 2. trol valve
Measurement position and condition •
Monitoring code: 01100
•
Control lever: Operate L.H. travel lever
•
Hydraulic oil temperature: 45 to 55°C
•
Monitoring code: 01101
•
Control lever: Operate R.H. travel lever
•
Hydraulic oil temperature: 45 to 55°C
Standard value Approximately 4 MPa {approximately 41 kg/cm2}
1.
L.H. travel con- 2. trol valve
NO
Approximately 4 MPa {approximately 41 kg/cm2}
When the parts are restored, be careful not to let dirt to enter.
5
Diagnosis and treatment
•
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the travel spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. The body and spool of the R.H. travel control valve are defective. Replace the body and spool of the R.H. travel control valve. Go to "Confirmation of repair". The body and spool of the L.H. travel control valve are normal. Go to the next inspection item. The body and spool of the L.H. travel control valve are defective. Replace the body and spool of the L.H. travel control valve. Go to "Confirmation of repair".
40-1071
H-24 ONE OF TRACKS DOES NOT RUN
No.
Cause
Procedures, Measurement, Values, Note
1.
6
Suction valve of R.H. travel control valve
40 TROUBLESHOOTING
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Check the suction valve of the R.H. travel control valve.
3.
Is the suction valve of the R.H. travel control valve normal?
Diagnosis and treatment •
The suction valve of the R.H. travel control valve is normal.
•
Go to the next inspection item. The suction valve of the R.H. travel control valve is defective.
YES
•
NO
•
Replace the suction valve of the R.H. travel control valve.
•
Go to "Confirmation of repair". The suction valve of the L.H. travel control valve is normal.
• 1.
7
Suction valve of L.H. travel control valve
40-1072
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Check the suction valve of the L.H. travel control valve.
3.
Is the suction valve of the L.H. travel control valve normal?
YES • •
NO
Go to the next inspection item. The suction valve of the L.H. travel control valve is defective.
•
Replace the suction valve of the L.H. travel control valve.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
H-24 ONE OF TRACKS DOES NOT RUN
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS. •
If an abnormality is found in the troubleshooting result, go to the next troubleshooting.
•
When you find no abnormalities in the troubleshooting result, go to the next inspection item.
2.
Interchange the safety valves of R.H. and L.H. travel motors.
3.
Is the phenomenon reproduced in the same way? Item
8
Measurement position and condition •
Fuel dial: Hi
•
Control lever: R.H. travel FORWARD relief
Safety valve of R.H. travel motor •
Main relief pressure
Discharged pressure pickup port of front pump
Fuel dial: Hi
•
Control lever: R.H. travel REVERSE relief
•
PC210-10M0, PC210LC-10M0
•
The safety valve of the R.H. travel motor is normal.
•
Go to the next inspection item.
•
The safety valve of the R.H. travel motor is defective.
•
Replace the safety valve of the R.H. travel motor.
•
Go to "Confirmation of repair".
YES
Standard value
36.1 to 38.8 MPa {368 to 395 kg/cm2}
NO
Hydraulic oil temperature: 45 to 55°C
•
Diagnosis and treatment
36.1 to 38.8 MPa {368 to 395 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
40-1073
H-24 ONE OF TRACKS DOES NOT RUN
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS. •
If an abnormality is found in the troubleshooting result, go to the next troubleshooting.
•
When you find no abnormalities in the troubleshooting result, go to the next inspection item.
2.
Interchange the safety valves of R.H. and L.H. travel motors.
3.
Is the phenomenon reproduced in the same way? Item
9
40 TROUBLESHOOTING
Measurement position and condition •
Fuel dial: Hi
•
Control lever: L.H. travel FORWARD relief
Safety valve of L.H. travel motor •
Main relief pressure
Discharged pressure pickup port of rear pump
Fuel dial: Hi
•
Control lever: L.H. travel REVERSE relief
•
40-1074
•
The safety valve of the L.H. travel motor is normal.
•
Go to the next inspection item.
•
The safety valve of the L.H. travel motor is defective.
•
Replace the safety valve of the L.H. travel motor.
•
Go to "Confirmation of repair".
YES
Standard value
36.1 to 38.8 MPa {368 to 395 kg/cm2}
NO
Hydraulic oil temperature: 45 to 55°C
•
Diagnosis and treatment
36.1 to 38.8 MPa {368 to 395 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-24 ONE OF TRACKS DOES NOT RUN
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The check valve of the R.H. travel motor is normal.
•
Go to the next inspection item. The check valve of the R.H. travel motor is defective.
YES
Check valve of 10 R.H. travel motor
1.
Interchange the check valves on the FORWARD side and REVERSE side on the same travel motor.
2.
Is the phenomenon reproduced in the same way?
•
NO
•
Replace the check valve of the R.H. travel motor.
•
Go to "Confirmation of repair". The check valve of the L.H. travel motor is normal.
• YES • Check valve of 11 L.H. travel motor
1.
Interchange the check valves on the FORWARD side and REVERSE side on the same travel motor.
2.
Is the phenomenon reproduced in the same way?
•
NO
•
Replace the check valve of the L.H. travel motor.
•
Go to "Confirmation of repair". The parking brake of the R.H. travel motor is normal.
• YES • Parking brake 12 of R.H. travel motor
1.
Run the R.H. travel motor off the ground with the brake applied to troubleshoot.
2.
Is Right Travel stopped?
•
NO
Replace the parking brake of the R.H. travel motor.
•
Go to "Confirmation of repair". The parking brake of the L.H. travel motor is normal.
YES • 1.
Run the L.H. travel motor off the ground with the brake applied to troubleshoot.
2.
Is Left Travel stopped?
•
NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The parking brake of the R.H. travel motor is defective.
•
•
Parking brake 13 of L.H. travel motor
Go to the next inspection item. The check valve of the L.H. travel motor is defective.
Go to the next inspection item. The parking brake of the L.H. travel motor is defective.
•
Replace the parking brake of the L.H. travel motor.
•
Go to "Confirmation of repair". 40-1075
H-24 ONE OF TRACKS DOES NOT RUN
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
2.
Does the measurement result agree with the standard value? Item
14
40 TROUBLESHOOTING
Measurement position and condition
R.H. travel motor Drain hose of Oil R.H. travel leakage motor
1. 2.
•
Fuel dial: Hi
•
Control lever: Travel relief
•
YES
Max. 27.2 l/min
NO
YES
Does the measurement result agree with the standard value? Measurement position and condition •
L.H. travel motor
• Drain hose of Oil L.H. travel leakage motor
•
Hydraulic oil temperature: 45 to 55°C
Max. 27.2 l/min
NO
YES
16 Final drive
Is the final drive clean and free of unusual noise, abnormal heat generation and metal powder in the drained oil?
•
Go to the next inspection item.
•
The R.H. travel motor is defective.
•
Replace the R.H. travel motor.
•
Go to "Confirmation of repair".
•
The L.H. travel motor is normal.
•
Go to the next inspection item.
•
The L.H. travel motor is defective.
•
Replace the L.H. travel motor.
•
Go to "Confirmation of repair".
•
The final drive is normal.
•
Go to the next inspection item. The final drive is defective.
• NO
40-1076
The R.H. travel motor is normal.
Standard value
Fuel dial: Hi Control lever: Travel relief
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
Item
15
Hydraulic oil temperature: 45 to 55°C
Diagnosis and treatment
•
Replace the final drive.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-24 ONE OF TRACKS DOES NOT RUN
Procedures, Measurement, Values, Note 1.
Confirmation of 2. 17 repair 3. 4.
Stop the engine. Connect all the configuration equipment.
Diagnosis and treatment YES The repair is completed.
Start the engine to troubleshoot. Does the machine travel normally?
PC210-10M0, PC210LC-10M0
NO
Return to the first inspection item.
40-1077
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST
40 TROUBLESHOOTING
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST Details of failure
The travel speed does not change, or the travel speed is too slow or fast. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first.
Associated informa- Monitoring code tion • The travel PPC pressure can be monitored. (Code: 01882)
No.
•
The F pump pressure can be monitored. (Code: 01100)
•
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
1
LS-EPC valve
Show the LS-EPC Solenoid Current screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
2.
Start the engine.
3.
Set the work mode to P.
4.
Operate the travel lever in a fine control to do troubleshooting.
5.
Does the measurement result of the LS-EPC current value agree with the standard value?
6.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
7.
Does the measuring result of the output pressure of the LS-EPC valve meet the standard value? Item
LSEPC current value
40-1078
Measuring point and measurement condition
Monitoring code: 01500
•
Fuel dial: Hi
•
Travel speed: Lo
•
Fuel dial: Hi
•
Travel speed: Mi
•
Fuel dial: Hi
•
Travel speed: Hi
Diagnosis and treatment YES
Standard value
NO Approximately 680 mA
•
The LS-EPC valve is normal.
•
Go to the next inspection item.
•
The LS-EPC valve is defective.
•
Clean or replace the LS-EPC valve.
•
Go to "Confirmation of repair".
Approximately 400 mA
0 mA
PC210-10M0, PC210LC-10M0
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
LSEPC valve output pressure
PC210-10M0, PC210LC-10M0
Pickup port for selecting pressure of LS setting
•
Fuel dial: Hi
•
Travel lever: NEUTRAL
•
Travel speed: Lo
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Travel lever: Fine control
•
Travel speed: Hi
•
Hydraulic oil temperature: 45 to 55°C
Diagnosis and treatment
Approximately 2.9 MPa {approximately 30 kg/cm2}
0 MPa {0 kg/cm2}
40-1079
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
Solenoid outlet pressure
3
Measuring point and measurement condition
Travel speed solenoid valve
1. Confirmation of 2. repair 3. 4.
40-1080
Diagnosis and treatment YES
•
The travel speed solenoid valve is normal.
•
Go to the next inspection item.
•
The travel speed solenoid valve is defective.
•
Replace the travel speed solenoid valve.
•
Go to "Confirmation of repair".
Does the measurement result agree with the standard value? Item
2
40 TROUBLESHOOTING
Outlet hose of travel speed increase solenoid valve
•
Fuel dial: Hi
•
Travel lever: NEUTRAL
•
Travel speed: Lo
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Travel lever: Fine control
•
Travel speed: Hi
•
Hydraulic oil temperature: 45 to 55°C
Standard value
0 MPa {0 kg/cm2}
NO
2.9 MPa {30 kg/cm2}
Stop the engine. Connect all the configuration equipment.
YES The repair is completed.
Start the engine to troubleshoot. Does the steering operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT
H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT Details of failure
The machine does not swing to the right or left. Pre-troubleshooting
If a failure code is displayed, do the troubleshooting for that code first. Associated informaMonitoring code tion • The F pump pressure can be monitored. (Code: 01100) • No.
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
YES
•
The swing PPC valve is normal.
•
Go to the next inspection item.
•
The swing PPC valve is defective.
•
Replace the swing PPC valve.
•
Go to "Confirmation of repair".
Does the measurement result agree with the standard value? Item
1
Diagnosis and treatment
Measurement position and condition
Swing PPC valve PPC outlet pressure
Outlet hose of swing PPC valve
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
PC210-10M0, PC210LC-10M0
Standard value
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
40-1081
H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
Diagnosis and treatment
Measurement position and condition
Swing parking brake solenoid valve Solenoid output pressure
Outlet hose of solenoid valve for swing parking brake
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
The swing parking brake solenoid valve is normal.
•
Go to the next inspection item.
•
The swing parking brake solenoid valve is defective.
•
Replace the swing parking brake solenoid valve.
•
Go to "Confirmation of repair".
•
The parking brake of the swing motor is normal.
•
Go to the next inspection item. The parking brake of the swing motor is defective.
Standard value
•
•
• YES
Does the measurement result agree with the standard value? Item
2
40 TROUBLESHOOTING
NO
2.9 MPa {30 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
YES
3
Parking brake of swing motor
1.
Release the brake of the swing motor. Do a swing operation to troubleshoot.
2.
Is the circuit relieved during swing operation?
•
NO
40-1082
•
Replace the parking brake of the swing motor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
4
H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT
Cause
Main pump pressure
Procedures, Measurement, Values, Note 1.
Open the Pump pressure screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
2.
Start the engine.
3.
Operate the work equipment control lever for swing to troubleshoot.
4.
Does the measurement result agree with the standard value? Item
Front pump pressure
1.
5
Swing control valve
2.
Measurement position and condition
Monitoring code: 01100
Standard value
Diagnosis and treatment YES
Go to the inspection item of "Swing control valve".
Go to the inspection item NO of "Safety valve of swing motor".
Approximately 4 MPa {approximately 41 kg/cm2}
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the swing spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
•
The body and spool of the swing control valve are normal. Go to the next inspection item. The body and spool of the swing control valve are defective. Replace the body and spool of the swing control valve. Go to "Confirmation of repair".
40-1083
H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Measurement position and condition
Safety valve of swing motor Relief pressure during swing
Discharged pressure pickup port of rear pump
•
Fuel dial: Hi
•
Control lever: Swing relief
•
•
1. 2.
Swing lock switch: ON
NO 27.4 to 40.2 MPa {280 to 320 kg/cm2}
The safety valve of the swing motor is normal.
•
Go to the next inspection item.
•
Adjust the oil pressure of the safety valve for the swing motor.
•
If it is not normal after adjustment, replace the safety valve.
•
Go to "Confirmation of repair".
•
The swing motor is normal.
•
Go to the next inspection item.
•
The swing motor is defective.
•
Replace the swing motor.
•
Go to "Confirmation of repair".
Hydraulic oil temperature: 45 to 55°C
YES
Does the measurement result agree with the standard value? Measurement position and condition •
Fuel dial: Hi
•
Control lever: Swing relief
Swing motor Oil Swing motor leakage drain hose
•
•
40-1084
YES
•
Standard value
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
Item
7
Diagnosis and treatment
Does the measurement result agree with the standard value? Item
6
40 TROUBLESHOOTING
Swing lock switch: ON
Standard value
NO Max. 10 l/min
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-26 MACHINE DOES NOT SWING TO RIGHT OR LEFT
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
8
Swing machinery
Is the swing machinery clean and free of unusual noise, abnormal heat generation and metal powder in the drained oil?
9
Confirmation of 2. repair 3. 4.
Stop the engine. Connect all the configuration equipment.
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. The swing machinery is defective.
•
Replace the swing machinery.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Does the machine swing normally?
The swing machinery is normal.
• NO
1.
•
NO
Return to the first inspection item.
40-1085
H-27 SWINGS ONLY IN ONE DIRECTION
40 TROUBLESHOOTING
H-27 SWINGS ONLY IN ONE DIRECTION Details of failure
The machine swings only to the right or left. Pre-troubleshooting
If a failure code is displayed, do the troubleshooting for that code first. Associated informaMonitoring code tion • The swing LEFT PPC pressure can be monitored. (Code: 09001) • No.
The swing RIGHT PPC pressure can be monitored. (Code: 09002)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measurement position and condition
Swing PPC valve PPC outlet pressure
The swing PPC valve is normal.
•
Go to the next inspection item.
•
The swing PPC valve is defective.
•
Replace the swing PPC valve.
Outlet hose of swing PPC valve
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
40-1086
YES
•
Does the measurement result agree with the standard value? Item
1
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
2
H-27 SWINGS ONLY IN ONE DIRECTION
Cause
Main pump pressure
Procedures, Measurement, Values, Note 1.
Open the Pump pressure screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
2.
Start the engine.
3.
Operate the work equipment control lever for swing to troubleshoot.
4.
Does the measurement result agree with the standard value? Item
Front pump pressure
1.
3
Swing control valve
2.
Measurement position and condition
Monitoring code: 01100
Standard value
Diagnosis and treatment YES
Go to the inspection item of "Swing control valve".
Go to the inspection item NO of "L.H. shuttle valve of swing motor".
Approximately 4 MPa {approximately 41 kg/cm2}
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the swing spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK When the parts are restored, be careful not to let dirt to enter.
• • YES
1.
4
L.H. shuttle valve of swing motor
2. 3.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Interchange the L.H. and R.H. shuttle valves of the swing motor. Is the phenomenon reproduced in the same way?
PC210-10M0, PC210LC-10M0
• •
NO
The body and spool of the swing control valve are normal. Go to the next inspection item. The body and spool of the swing control valve are defective. Replace the body and spool of the swing control valve. Go to "Confirmation of repair". The L.H. shuttle valve of the swing motor is normal. Go to the next inspection item. The L.H. shuttle valve of the swing motor is defective.
•
Replace the L.H. shuttle valve of the swing motor.
•
Go to "Confirmation of repair".
40-1087
H-27 SWINGS ONLY IN ONE DIRECTION
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The R.H. shuttle valve of the swing motor is normal.
•
Go to the next inspection item. The R.H. shuttle valve of the swing motor is defective.
YES 1.
5
R.H. shuttle valve of swing motor
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. shuttle valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
Replace the R.H. shuttle valve of the swing motor.
•
Go to "Confirmation of repair". The L.H. check valve of the swing motor is normal.
• YES 1.
6
L.H. check valve of swing motor
2. 3.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Interchange the L.H. and R.H. check valves of the swing motor. Is the phenomenon reproduced in the same way?
• •
NO
•
Replace the L.H. check valve of the swing motor.
•
Go to "Confirmation of repair". The R.H. check valve of the swing motor is normal.
• YES 1.
7
R.H. check valve of swing motor
2.
Interchange the L.H. and R.H. check valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
1. 8
Confirmation of 2. repair 3. 4.
40-1088
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
Stop the engine. Connect all the configuration equipment.
• •
NO
Go to the next inspection item. The R.H. check valve of the swing motor is defective.
•
Replace the R.H. check valve of the swing motor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Does the machine swing normally?
Go to the next inspection item. The L.H. check valve of the swing motor is defective.
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)
40 TROUBLESHOOTING
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) Details of failure
Swing acceleration or swing speed is low in right and left directions. Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The F pump pressure can be monitored. (Code: 01100) • No.
Cause
Procedures, Measurement, Values, Note 1.
1
Swing control valve
The R pump pressure can be monitored. (Code: 01101)
2.
Diagnosis and treatment
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the swing spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK When the parts are restored, be careful not to let dirt to enter.
• • YES •
2
LS shuttle valve of R.H. travel control valve
1.
Check the check valve seat in the shuttle valve of the R.H. travel control valve.
2.
Is the check valve seat clean and free of scratches and dirt?
•
Go to the next inspection item. The body and spool of the swing control valve are defective. Replace the body and spool of the swing control valve. Go to "Confirmation of repair". The LS shuttle valve of the R.H. travel control valve is normal. Go to the next inspection item. The LS shuttle valve of the R.H. travel control valve is defective.
•
Clean the check valve seat in the LS shuttle valve of the R.H. travel control valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
The body and spool of the swing control valve are normal.
40-1089
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The LS shuttle valve of the L.H. travel control valve is normal.
•
Go to the next inspection item. The LS shuttle valve of the L.H. travel control valve is defective.
YES
3
LS shuttle valve of L.H. travel control valve
1.
Check the check valve seat in the shuttle valve of the L.H. travel control valve.
2.
Is the check valve seat clean and free of scratches and dirt?
•
•
Clean the check valve seat in the LS shuttle valve of the L.H. travel control valve.
•
Go to "Confirmation of repair". The LS shuttle valve of the boom control valve is normal.
NO
1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
YES
Does the measurement result agree with the standard value? Item
4
•
LS shuttle valve of boom control valve LS differential pressure
Measuring point and measurement condition
Discharged pressure pickup port and load pressure pickup port of rear pump
Fuel dial: Hi
•
Control lever: All levers in 3.5 ± 1.0 MPa NEU{36 ± 10 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C Fuel dial: Hi
•
Control lever: Boom RAISE fine control
•
Go to the next inspection item.
•
The LS shuttle valve of the boom control valve is defective.
•
Clean the check valve seat in the LS shuttle valve of the boom control valve.
•
Go to "Confirmation of repair".
Standard value
•
•
•
kg/cm }
NO
1.8 (+0.05/-0.1) MPa {18 (+0.5/-1.0) 2 Hydraul- kg/cm }
ic oil temperature: 45 to 55°C
40-1090
PC210-10M0, PC210LC-10M0
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
LS shuttle valve of arm control valve LS differential pressure
Measuring point and measurement condition
Discharged pressure pickup port and load pressure pickup port of front pump
Fuel dial: Hi
•
Control lever: All levers in 3.5 ± 1.0 MPa NEU{36 ± 10 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C Fuel dial: Hi
•
Control lever: Arm IN and OUT fine control
•
The LS shuttle valve of the arm control valve is normal.
•
Go to the next inspection item.
•
The LS shuttle valve of the arm control valve is defective.
•
Clean the check valve seat in the LS shuttle valve of the arm control valve.
•
Go to "Confirmation of repair".
Standard value
•
•
• YES
Does the measurement result agree with the standard value? Item
5
Diagnosis and treatment
kg/cm }
NO
1.8 (+0.05/-0.1) MPa {18 (+0.5/-1.0) 2 Hydraul- kg/cm }
ic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40-1091
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.
Diagnosis and treatment
LS shuttle valve of bucket control valve LS differential pressure
Measuring point and measurement condition
Discharged pressure pickup port and load pressure pickup port of rear pump
Fuel dial: Hi
•
Control lever: All levers in 3.5 ± 1.0 MPa NEU{36 ± 10 TRAL 2
•
Hydraulic oil temperature: 45 to 55°C Fuel dial: Hi
•
Control lever: Bucket CURL and DUMP fine control
•
The LS shuttle valve of the bucket control valve is normal.
•
Go to the next inspection item.
•
The LS shuttle valve of the bucket control valve is defective.
•
Clean the check valve seat in the LS shuttle valve of the bucket control valve.
•
Go to "Confirmation of repair".
•
The LS shuttle valve of the service control valve is normal.
•
Go to the next inspection item. The LS shuttle valve of the service control valve is defective.
Standard value
•
•
• YES
Does the measurement result agree with the standard value? Item
6
40 TROUBLESHOOTING
kg/cm }
NO
1.8 (+0.05/-0.1) MPa {18 (+0.5/-1.0) kg/cm2}
Hydraulic oil temperature: 45 to 55°C
YES
7
1. LS shuttle valve of service 2. control valve
Check the check valve seat in the shuttle valve of the service control valve.
•
Is the check valve seat clean and free of scratches and dirt?
•
Clean the check valve seat in the LS shuttle valve of the service control valve.
•
Go to "Confirmation of repair".
NO
40-1092
PC210-10M0, PC210LC-10M0
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
Measuring point and measurement condition
Swing parking brake solenoid valve Solenoid output pressure
Outlet hose of solenoid valve for swing parking brake
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
The swing parking brake solenoid valve is normal.
•
Go to the next inspection item.
•
The swing parking brake solenoid valve is defective.
•
Replace the swing parking brake solenoid valve.
•
Go to "Confirmation of repair".
•
The parking brake of the swing motor is normal.
•
Go to the next inspection item. The parking brake of the swing motor is defective.
Standard value
•
•
• YES
Does the measurement result agree with the standard value? Item
8
Diagnosis and treatment
NO
2.9 MPa {30 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
YES
9
Parking brake of swing motor
1.
Release the swing parking brake. Swing the machine.
2.
Does the machine swing normally?
•
NO
PC210-10M0, PC210LC-10M0
•
Replace the parking brake of the swing motor.
•
Go to "Confirmation of repair".
40-1093
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Measuring point and measurement condition •
Safety valve of swing motor
• Swing relief pressure
Discharged pressure pickup port of rear pump
•
2.
The safety valve of the swing motor is normal.
•
Go to the next inspection item.
•
The safety valve of the swing motor is defective.
•
Replace the safety valve.
•
Go to "Confirmation of repair".
•
The swing motor is normal.
•
Go to the next inspection item.
•
The swing motor is defective.
•
Replace the swing motor.
•
Go to "Confirmation of repair".
Standard value
Swing lock switch: ON Control lever: Swing relief
NO
27.4 to 40.2 MPa {280 to 2 Fuel dial: 320 kg/cm }
Hydraulic oil temperature: 45 to 55°C
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
YES
Does the measurement result agree with the standard value? Item
Measuring point and measurement condition
11 Swing motor Oil Swing motor leakage drain hose
40-1094
YES
•
Hi •
1.
Diagnosis and treatment
Does the measurement result agree with the standard value? Item
10
40 TROUBLESHOOTING
•
Swing lock switch: ON
•
Control lever: Swing relief
•
Fuel dial: Hi
•
Hydraulic oil temperature: 45 to 55°C
Standard value
NO Max. 10 l/min
PC210-10M0, PC210LC-10M0
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment YES
12
Swing machinery
Is the swing machinery clean and free of unusual noise, abnormal heat generation and metal powder in the drained oil?
Confirmation of 2. 13 repair 3. 4.
Stop the engine. Connect all the configuration equipment.
PC210-10M0, PC210LC-10M0
•
Go to the next inspection item. The swing machinery is defective.
•
Replace the swing machinery.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine to troubleshoot. Does the machine swing normally?
The swing machinery is normal.
• NO
1.
•
NO
Return to the first inspection item.
40-1095
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION
40 TROUBLESHOOTING
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION Details of failure
The swing acceleration performance is low or the swing speed is slow in only one direction. Pre-troubleshooting
If a failure code is displayed, do the troubleshooting for that code first. Associated informaMonitoring code tion • The swing LEFT PPC pressure can be monitored. (Code: 09001) • No.
The swing RIGHT PPC pressure can be monitored. (Code: 09002)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measurement position and condition
Swing PPC valve PPC outlet pressure
The swing PPC valve is normal.
•
Go to the next inspection item.
•
The swing PPC valve is defective.
•
Replace the swing PPC valve.
Outlet hose of swing PPC valve
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
40-1096
YES
•
Does the measurement result agree with the standard value? Item
1
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION
40 TROUBLESHOOTING
No.
2
Cause
Main pump pressure
Procedures, Measurement, Values, Note 1.
Open the Pump pressure screen. For details, see TESTING AND ADJUSTING, SERVICE MODE, MONITORING.
2.
Start the engine.
3.
Operate the work equipment control lever for swing to troubleshoot.
4.
Does the measurement result agree with the standard value? Item
Front pump pressure
1.
3
Swing control valve
2.
Measurement position and condition
Monitoring code: 01100
Standard value
Diagnosis and treatment YES
Go to the inspection item of "Swing control valve".
Go to the inspection item of "Pressure compensation NO valve on swing RIGHT side of swing control valve".
Approximately 4 MPa {approximately 41 kg/cm2}
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the swing spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK When the parts are restored, be careful not to let dirt to enter.
• • YES
1.
4
Pressure compensation valve on swing RIGHT side of 2. swing control valve 3.
•
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
•
Interchange the R.H. and L.H. pressure compensation valves of the swing control valve. Is the phenomenon reproduced in the same way?
PC210-10M0, PC210LC-10M0
NO
The body and spool of the swing control valve are normal. Go to the next inspection item. The body and spool of the swing control valve are defective. Replace the body and spool of the swing control valve. Go to "Confirmation of repair". The L.H. pressure compensation valve of the swing control valve is normal. Go to the next inspection item. The L.H. pressure compensation valve of the swing control valve is defective.
•
Replace the L.H. pressure compensation valve of the swing control valve.
•
Go to "Confirmation of repair".
40-1097
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The R.H. pressure compensation valve of the swing control valve is normal.
•
Go to the next inspection item. The R.H. pressure compensation valve of the swing control valve is defective.
YES 1.
5
Pressure compensation valve on swing LEFT 2. side of swing control valve 3.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
•
Interchange the R.H. and L.H. pressure compensation valves of the swing control valve. Is the phenomenon reproduced in the same way?
NO
•
Replace the R.H. pressure compensation valve of the swing control valve.
•
Go to "Confirmation of repair". The L.H. suction valve of the swing motor is normal.
• YES 1.
6
L.H. suction valve of swing motor
2. 3.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Interchange the R.H. and L.H. suction valves of the swing motor. Is the phenomenon reproduced in the same way?
• •
NO
•
Replace the L.H. suction valve of the swing motor.
•
Go to "Confirmation of repair". The R.H. suction valve of the swing motor is normal.
• YES 1.
7
R.H. suction valve of swing motor
40-1098
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the R.H. and L.H. suction valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
• •
NO
Go to the next inspection item. The L.H. suction valve of the swing motor is defective.
Go to the next inspection item. The R.H. suction valve of the swing motor is defective.
•
Replace the R.H. suction valve of the swing motor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The L.H. check valve of the swing motor is normal.
•
Go to the next inspection item. The L.H. check valve of the swing motor is defective.
YES 1.
8
L.H. check valve of swing motor
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. check valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
Replace the L.H. check valve of the swing motor.
•
Go to "Confirmation of repair". The R.H. check valve of the swing motor is normal.
• YES 1.
9
R.H. check valve of swing motor
2. 3.
1. Confirmation of 2. 10 repair 3. 4.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Interchange the L.H. and R.H. check valves of the swing motor. Is the phenomenon reproduced in the same way?
Stop the engine. Connect all the configuration equipment.
• •
NO
PC210-10M0, PC210LC-10M0
•
Replace the R.H. check valve of the swing motor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Does the machine swing normally?
Go to the next inspection item. The R.H. check valve of the swing motor is defective.
NO
Return to the first inspection item.
40-1099
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)
40 TROUBLESHOOTING
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) Details of failure
The upper structure overruns too much when it stops swinging (in both right and left directions). Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The F pump pressure can be monitored. (Code: 01100) • No.
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Measuring point and measurement condition
Safety valve of swing motor Relief pressure during swing
Discharged pressure pickup port of rear pump
•
Fuel dial: Hi
•
Control lever: Swing relief
•
•
40-1100
YES
•
The safety valve of the swing motor is normal.
•
Go to the next inspection item.
•
Adjust the oil pressure of the safety valve for the swing motor.
•
If it is not normal after adjustment, replace the safety valve.
•
Go to "Confirmation of repair".
Does the measurement result agree with the standard value? Item
1
Diagnosis and treatment
Swing lock switch: ON
Standard value
NO 27.4 to 40.2 MPa {280 to 320 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
2.
Does the measurement result agree with the standard value? Item
2
Measuring point and measurement condition •
Fuel dial: Hi
•
Control lever: Swing relief
Swing motor Oil Swing motor leakage drain hose
•
•
1. 3
Confirmation of 2. repair 3. 4.
Swing lock switch: ON
Diagnosis and treatment YES
The swing motor is normal.
•
Go to the next inspection item.
•
The swing motor is defective.
•
Replace the swing motor.
•
Go to "Confirmation of repair".
Standard value
NO Max. 10 l/min
Hydraulic oil temperature: 45 to 55°C
Stop the engine. Connect all the configuration equipment.
YES The repair is completed.
Start the engine. Does the machine swing normally?
PC210-10M0, PC210LC-10M0
•
NO
Return to the first inspection item.
40-1101
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)
40 TROUBLESHOOTING
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) Details of failure
The upper structure overruns too much when it stops swinging (in both right and left directions). Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The F pump pressure can be monitored. (Code: 01100) • No.
The R pump pressure can be monitored. (Code: 01101)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measuring point and measurement condition
Swing PPC valve PPC outlet pressure
The swing PPC valve is normal.
•
Go to the next inspection item.
•
The swing PPC valve is defective.
•
Replace the swing PPC valve.
Outlet hose of swing PPC valve
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
40-1102
YES
•
Does the measurement result agree with the standard value? Item
1
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The slow return valve of the swing RIGHT PPC is normal.
•
Go to the next inspection item. Remove the slow return valve of the swing RIGHT PPC. Check its strainer for clogging.
YES
2
Slow return valve of swing RIGHT PPC
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. swing slow return valves.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
If the strainer is clogged, clean the strainer or replace the slow return valve of the swing RIGHT PPC.
•
Go to "Confirmation of repair". The slow return valve of the swing LEFT PPC is normal.
• YES •
3
Slow return valve of swing LEFT PPC
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. swing slow return valves.
3.
1.
4
Swing control valve
2.
Is the phenomenon reproduced in the same way?
•
•
If the strainer is clogged, clean the strainer or replace the slow return valve of the swing LEFT PPC.
•
Go to "Confirmation of repair". The body and spool of the swing control valve are normal.
NO
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the swing spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK When the parts are restored, be careful not to let dirt to enter.
PC210-10M0, PC210LC-10M0
Go to the next inspection item. Remove the slow return valve of the swing LEFT PPC. Check its strainer for clogging.
•
Go to the next inspection item. The body and spool of the swing control valve are defective. Replace the body and spool of the swing control valve. Go to "Confirmation of repair".
40-1103
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The L.H. suction valve of the swing motor is normal.
•
Go to the next inspection item. Remove the L.H. suction valve of the swing motor. Check the valve for seizure, scratches, etc.
YES
5
L.H. suction valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the R.H. and L.H. suction valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
If there is a seizure, scratch, etc. on the valve, replace the L.H. suction valve of the swing motor.
•
Go to "Confirmation of repair". The R.H. suction valve of the swing motor is normal.
• YES • •
6
R.H. suction valve of swing motor
1.
Interchange the R.H. and L.H. suction valves of the swing motor.
2.
Is the phenomenon reproduced in the same way? NO
•
If there is a seizure, scratch, etc. on the valve, replace the R.H. suction valve of the swing motor.
•
Go to "Confirmation of repair". The L.H. check valve of the swing motor is normal.
• YES •
7
L.H. check valve of swing motor
40-1104
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. check valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
Go to the next inspection item. Remove the R.H. suction valve of the swing motor. Check the valve for seizure, scratches, etc.
Go to the next inspection item. Remove the L.H. check valve of the swing motor. Check the valve for seizure and scratches, etc.
•
If there is a seizure, scratch, etc. on the valve, replace the L.H. check valve of the swing motor.
•
Go to "Confirmation of repair".
PC210-10M0, PC210LC-10M0
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The R.H. check valve of the swing motor is normal.
•
Go to the next inspection item. Remove the R.H. check valve of the swing motor. Check the valve for seizure and scratches, etc.
YES
8
R.H. check valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. check valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
1. 9
Confirmation of 2. repair 3. 4.
Stop the engine. Connect all the configuration equipment.
•
NO
PC210-10M0, PC210LC-10M0
If there is a seizure, scratch, etc. on the valve, replace the R.H. check valve of the swing motor.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Does the machine swing normally?
•
NO
Return to the first inspection item.
40-1105
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS
40 TROUBLESHOOTING
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS Details of failure
The shock is large when the upper structure stops swinging. Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The swing LEFT PPC pressure can be monitored. (Code: 09001) • No.
The swing RIGHT PPC pressure can be monitored. (Code: 09002)
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST PPC VALVE OUTLET PRESSURE.
Measuring point and measurement condition
Swing PPC valve PPC outlet pressure
The swing PPC valve is normal.
•
Go to the next inspection item.
•
The swing PPC valve is defective.
•
Replace the swing PPC valve.
Outlet hose of swing PPC valve
•
Go to "Confirmation of repair".
Standard value
•
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C
•
Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
40-1106
YES
•
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
No.
Cause
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The slow return valve of the swing RIGHT PPC is normal.
•
Go to the next inspection item. Remove the slow return valve of the swing RIGHT PPC. Check its strainer for clogging.
YES
2
Slow return valve of swing RIGHT PPC
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. swing slow return valves.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
If the strainer is clogged, clean the strainer or replace the slow return valve of the swing RIGHT PPC.
•
Go to "Confirmation of repair". The slow return valve of the swing LEFT PPC is normal.
• YES •
3
Slow return valve of swing LEFT PPC
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. swing slow return valves.
3.
Is the phenomenon reproduced in the same way?
•
•
If the strainer is clogged, clean the strainer or replace the slow return valve of the swing LEFT PPC.
•
Go to "Confirmation of repair". The swing motor reverse prevention valve is normal.
NO
• 1.
4
Swing motor reverse prevention valve
2.
1. 5
Confirmation of 2. repair 3. 4.
Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Is the spool in the travel motor reverse prevention valve clean and free of sticking, seizure or fatigue of the spring?
Stop the engine. Connect all the configuration equipment.
YES • •
NO
PC210-10M0, PC210LC-10M0
Go to the next inspection item. The swing motor reverse prevention valve is defective.
•
Replace the swing motor reverse prevention valve.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Does the machine swing normally?
Go to the next inspection item. Remove the slow return valve of the swing LEFT PPC. Check its strainer for clogging.
NO
Return to the first inspection item.
40-1107
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS
40 TROUBLESHOOTING
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS Details of failure
A large unusual noise is heard when the upper structure stops swinging.
Associated informa- Pre-troubleshooting tion If a failure code is shown, do the troubleshooting for that code first. No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
1
Solenoid outlet pressure
Measuring point and measurement condition
Outlet hose of solenoid valve of variable back pressure valve
Fuel dial: Hi
•
NEUTRAL
•
Hydraul- kg/cm2} ic oil temperature: 45 to 55°C Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
1.
2
Back pressure valve 2.
40-1108
The solenoid valve of the variable back pressure valve is normal.
•
Go to the next inspection item.
•
The solenoid valve of the variable back pressure valve is defective.
•
Replace the solenoid valve of the variable back pressure valve.
•
Go to "Confirmation of repair".
•
The back pressure valve is normal.
•
Go to the next inspection item. The back pressure valve is defective.
Standard value
•
•
• YES
Does the troubleshooting result agree with the standard value? Item
Solenoid valve of variable back pressure valve
Diagnosis and treatment
0 MPa {0
NO
2.84 to 3.43 MPa {29 to 35 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Is the spool in the back pressure valve clean and free of sticking, seizure and fatigue of the spring?
YES
• •
Make a repair or replace the back pressure valve.
•
Go to "Confirmation of repair".
NO
PC210-10M0, PC210LC-10M0
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
YES
•
The safety valve of the swing motor is normal.
•
Go to the next inspection item.
•
Adjust the oil pressure of the safety valve for the swing motor.
•
If it is not normal after adjustment, replace the safety valve.
•
Go to "Confirmation of repair".
•
The L.H. suction valve of the swing motor is normal.
•
Go to the next inspection item. Remove the L.H. suction valve of the swing motor. Check the valve for seizure, scratches, etc.
Does the troubleshooting result agree with the standard value? Item
3
Diagnosis and treatment
Measuring point and measurement condition
Safety valve of swing motor Relief pressure during swing
Discharged pressure pickup port of rear pump
•
Fuel dial: Hi
•
Control lever: Swing relief
•
•
Swing lock switch: ON
Standard value
NO 27.4 to 40.2 MPa {280 to 320 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
YES
4
L.H. suction valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the R.H. and L.H. suction valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
PC210-10M0, PC210LC-10M0
•
NO
•
If there is a seizure, scratch, etc. on the valve, replace the L.H. suction valve of the swing motor.
•
Go to "Confirmation of repair".
40-1109
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The R.H. suction valve of the swing motor is normal.
•
Go to the next inspection item. Remove the R.H. suction valve of the swing motor. Check the valve for seizure, scratches, etc.
YES
5
R.H. suction valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the R.H. and L.H. suction valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
If there is a seizure, scratch, etc. on the valve, replace the R.H. suction valve of the swing motor.
•
Go to "Confirmation of repair". The swing machinery is normal.
• YES
6
Swing machinery
Is the swing machinery clean and free of unusual noise, abnormal heat generation and metal powder in the drained oil?
• NO
1. 7
Confirmation of 2. repair 3. 4.
40-1110
Stop the engine. Connect all the configuration equipment.
Go to the next inspection item. The swing machinery is defective.
•
Replace the swing machinery.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Does the machine swing normally?
•
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)
40 TROUBLESHOOTING
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) Details of failure
While the swing parking brake is applied, the swing drift on a slope is large. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first.
Associated informa- Associated information tion When the swing lock switch is turned to the ON position, or when the cancel switch of the swing parking brake is turned to the NORMAL position, the swing brake is applied and swing is locked by a disc brake. No.
Cause
Procedures, Measurement, Values, Note 1.
2.
Do a test. For details, see TESTING AND ADJUSTING, TEST OUTLET PRESSURE OF SOLENOID VALVE.
Measuring point and measurement condition
Swing parking brake solenoid valve Solenoid output pressure
Outlet hose of solenoid valve for swing parking brake
Fuel dial: Hi
•
Control lever: All levers in 0 MPa {0 NEUTRAL kg/cm2}
•
Hydraulic oil temperature: 45 to 55°C Fuel dial: Hi
•
Control lever: Swing LEFT, swing RIGHT
•
PC210-10M0, PC210LC-10M0
The swing parking brake solenoid valve is normal.
•
Go to the next inspection item.
•
The swing parking brake solenoid valve is defective.
•
Replace the swing parking brake solenoid valve.
•
Go to "Confirmation of repair".
Standard value
•
•
• YES
Does the troubleshooting result agree with the standard value? Item
1
Diagnosis and treatment
NO
2.9 MPa {30 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
40-1111
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)
No.
Cause
Procedures, Measurement, Values, Note 1.
Do a test. For details, see TESTING AND ADJUSTING, TEST OIL LEAKAGE.
2.
Does the troubleshooting result agree with the standard value? Item
2
Measuring point and measurement condition •
Fuel dial: Hi
•
Control lever: Swing relief
Swing motor Oil Swing motor leakage drain hose
•
•
3
Swing lock switch: ON
YES
NO Max. 10 l/min
•
The swing motor is normal.
•
Go to the next inspection item.
•
The swing motor is defective.
•
Replace the swing motor.
•
Go to "Confirmation of repair".
Hydraulic oil temperature: 45 to 55°C
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
5.
Diagnosis and treatment
Standard value
1. Confirmation of 3. repair 4.
40-1112
40 TROUBLESHOOTING
YES
Return to the first inspection item.
Turn the starting switch to the ON position. Incline the machine. Apply the swing parking brake to troubleshoot.
NO The repair is completed.
Does the machine swing normally?
PC210-10M0, PC210LC-10M0
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40 TROUBLESHOOTING
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) Details of failure
While the swing parking brake is released, the swing drift on a slope is large. Pre-troubleshooting
If a failure code is shown, do the troubleshooting for that code first. Associated informaMonitoring code tion • The F pump pressure can be monitored. (Code: 01100) • No.
Cause
Procedures, Measurement, Values, Note 1.
1
Swing control valve
The R pump pressure can be monitored. (Code: 01101)
2.
Diagnosis and treatment
• Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see YES TESTING AND ADJUSTING, RELEASE RE• MAINING PRESSURE FROM HYDRAULIC SYSTEM. • Are the control valve body and the swing spool clean and free of twisting, sticking, scratches and dirt? (The spool must move smoothly.) • NO REMARK When the parts are restored, be careful not to let dirt to enter.
• • YES
2
1. Pressure compensation valve on swing RIGHT side of 2. swing control valve 3.
•
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
•
Interchange the R.H. and L.H. pressure compensation valves of the swing control valve. Is the phenomenon reproduced in the same way?
PC210-10M0, PC210LC-10M0
NO
The body and spool of the swing control valve are normal. Go to the next inspection item. The body and spool of the swing control valve are defective. Replace the body and spool of the swing control valve. Go to "Confirmation of repair". The L.H. pressure compensation valve of the swing control valve is normal. Go to the next inspection item. The L.H. pressure compensation valve of the swing control valve is defective.
•
Replace the L.H. pressure compensation valve of the swing control valve.
•
Go to "Confirmation of repair".
40-1113
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The R.H. pressure compensation valve of the swing control valve is normal.
•
Go to the next inspection item. The R.H. pressure compensation valve of the swing control valve is defective.
YES 1.
3
Pressure compensation valve on swing LEFT 2. side of swing control valve 3.
1.
2.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Interchange the R.H. and L.H. pressure compensation valves of the swing control valve. Is the phenomenon reproduced in the same way?
Do a test. For details, see TESTING AND ADJUSTING, TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS.
Measuring point and measurement condition
Safety valve of swing motor Relief pressure during swing
Discharged pressure pickup port of rear pump
•
Fuel dial: Hi
•
Control lever: Swing relief
•
•
40-1114
NO
•
Replace the R.H. pressure compensation valve of the swing control valve.
•
Go to "Confirmation of repair". The safety valve of the swing motor is normal.
• YES
•
Go to the next inspection item.
•
Adjust the oil pressure of the safety valve for the swing motor.
•
If it is not normal after adjustment, replace the safety valve.
•
Go to "Confirmation of repair".
Does the troubleshooting result agree with the standard value? Item
4
•
Swing lock switch: ON
Standard value
NO 27.4 to 40.2 MPa {280 to 320 kg/cm2}
Hydraulic oil temperature: 45 to 55°C
PC210-10M0, PC210LC-10M0
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
40 TROUBLESHOOTING
No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The L.H. suction valve of the swing motor is normal.
•
Go to the next inspection item. Remove the L.H. suction valve of the swing motor. Check the valve for seizure, scratches, etc.
YES
5
L.H. suction valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the R.H. and L.H. suction valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
If there is a seizure, scratch, etc. on the valve, replace the L.H. suction valve of the swing motor.
•
Go to "Confirmation of repair". The R.H. suction valve of the swing motor is normal.
• YES •
6
R.H. suction valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the R.H. and L.H. suction valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
If there is a seizure, scratch, etc. on the valve, replace the R.H. suction valve of the swing motor.
•
Go to "Confirmation of repair". The L.H. check valve of the swing motor is normal.
• YES •
7
L.H. check valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. check valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
PC210-10M0, PC210LC-10M0
•
NO
Go to the next inspection item. Remove the R.H. suction valve of the swing motor. Check the valve for seizure, scratches, etc.
Go to the next inspection item. Remove the L.H. check valve of the swing motor. Check the valve for seizure and scratches, etc.
•
If there is a seizure, scratch, etc. on the valve, replace the L.H. check valve of the swing motor.
•
Go to "Confirmation of repair".
40-1115
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
No.
Cause
40 TROUBLESHOOTING
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The R.H. check valve of the swing motor is normal.
•
Go to the next inspection item. Remove the R.H. check valve of the swing motor. Check the valve for seizure and scratches, etc.
YES
8
R.H. check valve of swing motor
1.
Release the remaining pressure in the hydraulic tank and piping. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
2.
Interchange the L.H. and R.H. check valves of the swing motor.
3.
Is the phenomenon reproduced in the same way?
•
NO
•
If there is a seizure, scratch, etc. on the valve, replace the R.H. check valve of the swing motor.
•
Go to "Confirmation of repair". The swing motor reverse prevention valve is normal.
• 1.
9
10
Swing motor reverse prevention valve
2.
Is the spool in the travel motor reverse prevention valve clean and free of sticking, seizure or fatigue of the spring?
1.
Turn the starting switch to the OFF position.
2.
Connect all the configuration equipment.
Confirmation of 3. repair 4. 5.
40-1116
Release the remaining pressure in the hydraulic tank and piping to troubleshoot. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM.
YES • •
NO
YES
Go to the next inspection item. The swing motor reverse prevention valve is defective.
•
Replace the swing motor reverse prevention valve.
•
Go to "Confirmation of repair".
Return to the first inspection item.
Turn the starting switch to the ON position. Incline the machine and apply the swing parking brake.
NO The repair is completed.
Does the machine swing normally?
PC210-10M0, PC210LC-10M0
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE)
40 TROUBLESHOOTING
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE) Details of failure
The fan speed is abnormal. Pre-troubleshooting If a failure code is shown, do the troubleshooting for that code first.
Associated informa- Monitoring code tion The fan speed can be monitored. (Code: 10007) Reference information Do all the troubleshooting with work mode set to P mode. No.
Cause
Procedures, Measurement, Values, Note 1.
2.
1
Do a test. For details, see TESTING AND ADJUSTING, "TEST ENGINE SPEED", "TEST ENGINE SPEED".
YES
Engine speed
Measuring point and measurement condition
Standard value
Engine at low idle
980 to 1120 rpm
Alternator belt
The engine speed is normal.
•
Go to the next inspection item.
•
The engine speed is defective.
•
Test the engine. For details, see ENGINE RUNS ROUGH OR IS UNSTABLE in S mode.
Engine speed at high idle (swing lock switch: ON)
1780 to 1920 rpm
•
Go to "Confirmation of repair".
•
The alternator belt is normal.
•
Go to the next inspection item. The alternator belt is defective.
NO
YES
2
•
Does the troubleshooting result agree with the standard value? Item
Engine speed
Diagnosis and treatment
1.
Check if the alternator belt is worn or damaged.
2.
Is the alternator belt normal?
• NO
•
Replace the alternator belt.
•
Go to "Confirmation of repair".
YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
Do the troubleshooting above again. Can you identify the cause by reconfirmation?
PC210-10M0, PC210LC-10M0
NO
•
The fan clutch can be defective.
•
Replace the fan clutch.
•
Go to "Confirmation of repair".
40-1117
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE)
No.
Cause
Procedures, Measurement, Values, Note 1.
4
Confirmation of 2. repair 3. 4.
40-1118
40 TROUBLESHOOTING
Turn the starting switch to the OFF position. Connect all the configuration equipment.
Diagnosis and treatment YES The repair is completed.
Start the engine. Does the fan operate normally?
NO
Return to the first inspection item.
PC210-10M0, PC210LC-10M0
40 TROUBLESHOOTING
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN Details of failure
Unusual noise is heard from around the fan.
Associated information No.
Cause
Procedures, Measurement, Values, Note
Diagnosis and treatment •
The installation condition of the fan and fan clutch is normal.
•
Go to the next inspection item. The installation condition of fan and fan clutch is defective.
YES 1.
1
Installation condition of fan and fan clutch 2.
Check the installation condition of the fan and fan clutch for looseness.
•
Is the installation condition of the fan and fan clutch normal? NO
•
Install the fan and fan clutch again.
•
Go to "Confirmation of repair". The installation condition of the shroud is normal.
• YES
2
Installation condition of shroud
1.
Check the installation condition of the shroud for interference between the fan and the shroud.
2.
Is the installation condition of the shroud normal?
• •
REMARK If the shroud interferes with the fan, the installation condition of the shroud is defective.
Go to the next inspection item. The installation condition of the shroud is defective.
•
Install the shroud again.
•
If a breakage is found, replace the shroud.
•
Go to "Confirmation of repair".
NO
YES The repair is completed.
3
Reconfirmation 1. of inspection 2. item
1. 4
Confirmation of 2. repair 3. 4.
Do the troubleshooting above again. Can you identify the cause by reconfirmation? NO
Turn the starting switch to the OFF position. Connect all the configuration equipment.
PC210-10M0, PC210LC-10M0
The fan clutch can be defective.
•
Replace the fan clutch.
•
Go to "Confirmation of repair".
YES The repair is completed.
Start the engine. Does the fan operate normally?
•
NO
Return to the first inspection item.
40-1119
50 DISASSEMBLY AND ASSEMBLY
PC210-10M0, PC210LC-10M0
50-1
CONTENTS
50 DISASSEMBLY AND ASSEMBLY
CONTENTS ABBREVIATION LIST .................................................................................................................................... 50-6 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ................................................................50-11 HOW TO READ THIS MANUAL.............................................................................................................50-11 COATING MATERIALS LIST................................................................................................................. 50-13 SPECIAL TOOLS LIST ......................................................................................................................... 50-17 SKETCHES OF SPECIAL TOOLS........................................................................................................ 50-26 PREPARATION............................................................................................................................................ 50-32 DRAIN AND ADD COOLANT................................................................................................................ 50-32 DRAIN COOLANT ......................................................................................................................... 50-32 ADD COOLANT ............................................................................................................................. 50-33 DRAIN AND AD HYDRAULIC OIL ........................................................................................................ 50-35 DRAIN HYDRAULIC OIL ............................................................................................................... 50-35 ADD HYDRAULIC OIL ................................................................................................................... 50-36 DRAIN AND ADD FUEL........................................................................................................................ 50-38 DRAIN FUEL.................................................................................................................................. 50-38 ADD FUEL ..................................................................................................................................... 50-39 COLLECT AND REFILL REFRIGERANT.............................................................................................. 50-42 COLLECT REFRIGERANT ............................................................................................................ 50-42 REFILL REFRIGERANT ................................................................................................................ 50-42 ENGINE AND COOLING SYSTEM.............................................................................................................. 50-43 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY ......................................................................... 50-43 REMOVE SUPPLY PUMP ASSEMBLY.......................................................................................... 50-44 INSTALL SUPPLY PUMP ASSEMBLY ........................................................................................... 50-48 REMOVE AND INSTALL INJECTOR ASSEMBLY ................................................................................ 50-52 REMOVE INJECTOR ASSEMBLY ................................................................................................. 50-53 INSTALL INJECTOR ASSEMBLY .................................................................................................. 50-56 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY ..................................................................... 50-63 REMOVE CYLINDER HEAD ASSEMBLY ...................................................................................... 50-64 INSTALL CYLINDER HEAD ASSEMBLY ....................................................................................... 50-75 REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .................................................................. 50-90 REMOVE STARTING MOTOR ASSEMBLY ................................................................................... 50-90 INSTALL STARTING MOTOR ASSEMBLY .................................................................................... 50-92 REMOVE AND INSTALL ALTERNATOR BELT ..................................................................................... 50-95 REMOVE ALTERNATOR BELT...................................................................................................... 50-95 INSTALL ALTERNATOR BELT....................................................................................................... 50-99 REMOVE AND INSTALL RADIATOR ASSEMBLY ...............................................................................50-102 REMOVE RADIATOR ASSEMBLY................................................................................................50-102 INSTALL RADIATOR ASSEMBLY.................................................................................................50-105 REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY.............................................................50-108 REMOVE HYDRAULIC COOLER ASSEMBLY .............................................................................50-109 INSTALL HYDRAULIC COOLER ASSEMBLY ..............................................................................50-112 REMOVE AND INSTALL AFTER COOLER ASSEMBLY......................................................................50-115 REMOVE AFTER COOLER ASSEMBLY ......................................................................................50-115 INSTALL AFTER COOLER ASSEMBLY .......................................................................................50-117 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY ...........................................................................50-121 REMOVE FAN CLUTCH ASSEMBLY ...........................................................................................50-122 INSTALL FAN CLUTCH ASSEMBLY.............................................................................................50-126 REMOVE AND INSTALL FAN ..............................................................................................................50-132 REMOVE FAN ..............................................................................................................................50-132 INSTALL FAN................................................................................................................................50-132 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ......................................................50-134 REMOVE ENGINE AND MAIN PUMP ASSEMBLY.......................................................................50-135 INSTALL ENGINE AND MAIN PUMP ASSEMBLY........................................................................50-151 REMOVE AND INSTALL ENGINE FRONT OIL SEAL .........................................................................50-168 REMOVE ENGINE FRONT OIL SEAL ..........................................................................................50-168 INSTALL ENGINE FRONT OIL SEAL ...........................................................................................50-171 50-2
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
CONTENTS
REMOVE AND INSTALL ENGINE REAR OIL SEAL............................................................................50-174 REMOVE ENGINE REAR OIL SEAL ............................................................................................50-174 INSTALL ENGINE REAR OIL SEAL .............................................................................................50-176 REMOVE AND INSTALL FUEL COOLER ASSEMBLY ........................................................................50-180 REMOVE FUEL COOLER ASSEMBLY.........................................................................................50-180 INSTALL FUEL COOLER ASSEMBLY..........................................................................................50-181 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY ........................................................................50-183 REMOVE ENGINE HOOD ASSEMBLY ........................................................................................50-183 INSTALL ENGINE HOOD ASSEMBLY..........................................................................................50-185 REMOVE AND INSTALL FUEL TANK ASSEMBLY ..............................................................................50-187 REMOVE FUEL TANK ASSEMBLY ..............................................................................................50-188 INSTALL FUEL TANK ASSEMBLY................................................................................................50-192 REMOVE AND INSTALL AIR CLEANER ASSEMBLY..........................................................................50-198 REMOVE AIR CLEANER ASSEMBLY ..........................................................................................50-198 INSTALL AIR CLEANER ASSEMBLY ...........................................................................................50-200 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .......................................50-202 REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY .......................................................50-202 INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................50-205 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ..........................................50-208 REMOVE AIR CONDITIONER CONDENSER ASSEMBLY ..........................................................50-208 INSTALL AIR CONDITIONER CONDENSER ASSEMBLY............................................................50-210 POWER TRAIN...........................................................................................................................................50-212 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ......................................50-212 REMOVE TRAVEL MOTOR AND FIANL DRIVE ASSEMBLY.......................................................50-213 INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ........................................................50-215 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY.............................................................50-217 DISASSEMBLE FINAL DRIVE ASSEMBLY ..................................................................................50-218 ASSEMBLE FINAL DRIVE ASSEMBLY ........................................................................................50-223 REMOVE AND INSTALL SWIVEL MOTOR AND SWING MACHINERY ASSEMBLY ..........................50-235 REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY ............................................50-236 INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .............................................50-238 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY ................................................50-242 DISASSEMBLE SWING MACHINERY ASSEMBLY......................................................................50-243 ASSEMBLE SWING MACHINERY ASSEMBLY............................................................................50-249 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY .......................................................................50-258 REMOVE SWING CIRCLE ASSEMBLY........................................................................................50-258 INSTALL SWING CIRCLE ASSEMBLY .........................................................................................50-259 UNDERCARRIAGE AND FRAME...............................................................................................................50-260 SEPARATION AND CONNECTION OF TRACK ASSEMBLY...............................................................50-260 SEPARATE TRACK ASSEMBLY...................................................................................................50-260 INSTALL TRACK ASSEMBLY.......................................................................................................50-263 REMOVE AND INSTALL SPROCKET .................................................................................................50-267 REMOVE SPROCKET..................................................................................................................50-267 INSTALL SPROCKET ...................................................................................................................50-268 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY..................................................50-269 REMOVE IDLER AND IDLER CUSHION ASSEMBLY ..................................................................50-269 INSTALL IDLER AND IDLER CUSHION ASSEMBLY ...................................................................50-270 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY ........................................................................50-272 DISASSEMBLE IDLER ASSEMBLY .............................................................................................50-272 ASSEMBLE IDLER ASSEMBLY ...................................................................................................50-274 DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY.......................................................50-281 DISASSEMBLE IDLER CUSHION ASSEMBLY ............................................................................50-282 ASSEMBLE IDLER CUSHION ASSEMBLY ..................................................................................50-283 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY .......................................................50-285 DISASSEMBLE TRACK ROLLER ASSEMBLY.............................................................................50-286 ASSEMBLE TRUCK ROLLER ASSEMBLY...................................................................................50-287 DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY ...................................................50-289 DISASSEMBLE CARRIER ROLLER ASSEMBLY .........................................................................50-289 PC210-10M0, PC210LC-10M0
50-3
CONTENTS
50 DISASSEMBLY AND ASSEMBLY
ASSEMBLE CARRIER ROLLER ASSEMBLY...............................................................................50-291 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ...............................................................50-294 REMOVE REVOLVING FRAME ASSEMBLY................................................................................50-295 INSTALL REVOLVING FRAME ASSEMBLY .................................................................................50-298 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY..................................................................50-301 REMOVE COUNTERWEIGHT ASSEMBLY ..................................................................................50-301 INSTALL COUNTERWEIGHT ASSEMBLY ...................................................................................50-302 HYDRAULIC SYSTEM................................................................................................................................50-304 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .........................................................50-304 REMOVE CENTER SWIVEL JOINT ASSEMBLY..........................................................................50-305 INSTALL CENTER SWIVEL JOINT ASSEMBLY...........................................................................50-308 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ..........................................50-312 DISASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ................................................................50-313 ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY......................................................................50-314 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...................................................................50-316 REMOVE HYDRAULIC TANK ASSEMBLY ...................................................................................50-317 INSTALL HYDRAULIC TANK ASSEMBLY ....................................................................................50-321 REMOVE AND INSTALL MAIN PUMP ASSEMBLY .............................................................................50-327 REMOVE MAIN PUMP ASSEMBLY..............................................................................................50-328 INSTALL MAIN PUMP ASSEMBLY...............................................................................................50-335 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY ....................................................................50-342 REMOVE CONTROL VALVE ASSEMBLY ....................................................................................50-343 INSTALL CONTROL VALVE ASSEMBLY......................................................................................50-355 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .....................................................50-368 REPLACE PRESSURE COMPENSATION VALVE SEAL RING....................................................50-369 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY .............................50-371 DISASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ...................................................50-372 ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY.........................................................50-372 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY .................................................50-374 DISASSEMBLE TRAVEL PPC VALVE ASSEMBLY ......................................................................50-374 ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ............................................................................50-375 WORK EQUIPMENT...................................................................................................................................50-377 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY ................................................................50-377 REMOVE WORK EQUIPMENT ASSEMBLY.................................................................................50-378 INSTALL WORK EQUIPMENT ASSEMBLY..................................................................................50-381 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...............................50-384 DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY ....................................................50-385 ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY ..........................................................50-390 CAB RELATED PARTS...............................................................................................................................50-399 REMOVE AND INSTALL OPERATOR CAB ASSEMBLY .....................................................................50-399 REMOVE OPERATOR CAB ASSEMBLY......................................................................................50-400 INSTALL OPERATOR CAB ASSEMBLY .......................................................................................50-410 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ...........................................50-420 REMOVE OPERATOR CAB GLASS (ADHERED GLASS) ...........................................................50-422 INSTALL OPERATOR CAB GLASS (ADHERED GLASS).............................................................50-422 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY ....................................................................50-433 REMOVE FRONT WINDOW ASSEMBLY .....................................................................................50-434 INSTALL FRONT WINDOW ASSEMBLY ......................................................................................50-437 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY........................................................................50-443 REMOVE FLOOR FRAME ASSEMBLY ........................................................................................50-444 INSTALL FLOOR FRAME ASSEMBLY .........................................................................................50-450 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY ........................................................50-458 REMOVE AIR CONDITIONER UNIT ASSEMBLY.........................................................................50-459 INSTALL AIR CONDITIONER UNIT ASSEMBLY ..........................................................................50-467 REMOVE AND INSTALL OPERATOR SEAT .......................................................................................50-475 REMOVE OPERATOR SEAT........................................................................................................50-475 INSTALL OPERATOR SEAT .........................................................................................................50-476 REMOVE AND INSTALL SEATBELT ...................................................................................................50-478 50-4
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
CONTENTS
REMOVE SEATBELT....................................................................................................................50-478 INSTALL SEATBELT .....................................................................................................................50-479 REMOVE AND INSTALL FRONT WIPER ASSEMBLY ........................................................................50-480 REMOVE FRONT WIPER ASSEMBLY.........................................................................................50-480 INSTALL FRONT WIPER ASSEMBLY ..........................................................................................50-486 ELECTRICAL SYSTEM ..............................................................................................................................50-494 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ..........................................................50-494 REMOVE ENGINE CONTROLLER ASSEMBLY ...........................................................................50-494 INSTALL ENGINE CONTROLLER ASSEMBLY ............................................................................50-496 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY..............................................................50-498 REMOVE PUMP CONTROLLER ASSEMBLY ..............................................................................50-498 INSTALL PUMP CONTROLLER ASSEMBLY ...............................................................................50-500 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ...............................................................50-504 REMOVE MACHINE MONITOR ASSEMBLY................................................................................50-504 INSTALL MACHINE MONITOR ASSEMBLY .................................................................................50-507 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR .................................................................50-511 REMOVE PUMP SWASH PLATE SENSOR .................................................................................50-511 INSTALL PUMP SWASH PLATE SENSOR...................................................................................50-513 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY.............................................................50-516 REMOVE KOMTRAX TERMINAL ASSEMBLY .............................................................................50-516 INSTALL KOMTRAX TERMINAL ASSEMBLY ..............................................................................50-519
PC210-10M0, PC210LC-10M0
50-5
50 DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
ABBREVIATION LIST •
This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.
•
Abbreviations that are used in general society may not be included.
•
Special abbreviations that appear infrequently are noted in the text.
•
This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ABS
Anti-skid Brake System
AISS
Automatic Idling Setting Engine System
AJSS
Advanced Joystick Steering System
Steering
ARAC
Automatic Retarder Accelerator Control
Travel and brake
ARSC
Automatic Retarder Speed Control
Travel and brake (HD, HM)
(WA)
(HD, HM)
Travel and brake (HD, HM)
Explanation A function that releases the brakes when the tires skid (wheels stop rotating), and applies the brakes again when the wheels start to rotate. A function that automatically sets the idle speed. A function that uses a lever to perform the steering operations instead of a steering wheel. Moreover, the lever is used to shifts gear and changes direction (FORWARD, REVERSE). A function that automatically applies the retarder with a constant braking force when the accelerator pedal is released while the machine is traveling downhill. A function that automatically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when the accelerator pedal is released while the machine is traveling downhill.
ASR
Automatic Spin Regula- Travel and brake tor (HD, HM)
A function that automatically uses the optimum braking force to drive both wheels when the tires spin on soft ground.
ATT
Attachment
A device that can be fixed onto the standard machine in order to enable it to do different jobs.
BCV
Brake cooling oil control Brake valve (HD)
CAN
Controller Area Network
Communication and electronic control
One of communication standards that are used in the network on the machine
CDR
Crankcase Depression Regulator
Engine
A regulator valve that is installed to KCCV ventilator. It is written as CDR valve and it is not used singly.
CLSS
Closed-center Load Sensing System
Hydraulic system
A system that simultaneously actuates multiple actuators regardless of the load (provides better combined operation than OLSS).
Engine
A function that maintains optimum fuel injection amount and fuel injection timing by engine controller electronically controlling supply pump, common rail, and injector.
CRI
50-6
Common Rail Injection
WORK EQUIPMENT
A valve that divides part of the brake cooling oil to reduce the load on the hydraulic pump when the retarder is not being used.
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system)
Abbreviation
Actual word spelled out
ECM
Electronic Control Module
ECMV
Electronic Control Modulation Valve
ECSS
Electronically Controlled Travel Suspension System (WA)
A system that ensures smooth high-speed travel by absorbing vibration of machine during travel with spring effect of accumulator.
ECU
Electronic Control Unit
An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECM)
EGR
Exhaust Gas RecirculaEngine tion
A function that recirculates part of exhaust gas to combustion chamber in order to reduce combustion temperature, controls emission of NOx.
Equipment ManageMACHINE MONITOR ment Monitoring System
A system which enables data (filter, oil replacement interval, malfunctions on machine, failure code, and failure history) from each sensor to be checked on the monitor.
EPC
Electromagnetic ProporHydraulic system tional Control
This mechanism allows actuators to be operated in proportion to the current supplied.
FOPS
Falling Object Protective Cab and canopy Structure
EMMS
F-N-R
GPS
GNSS
Forward-Neutral-Reverse Global Positioning System
Electronic control system
Transmission (D, HD, WA, etc)
Electronic control system
Operation Communication (KOMTRAX, KOMTRAX Plus)
Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)
Explanation An electronic control device that uses the signals from the sensors on the machine to command the optimum actuation to the actuators. (Same as ECU) A proportional electromagnetic valve that gradually increases oil pressure to engage clutch and reduces transmission shock.
A structure that protects the operator's head from falling objects. ISO 3449 compliant Forward - Neutral - Reverse A system that uses satellites to determine the current location on the earth 1. A system that uses satellites such as GPS, GALILEO, etc. to determine location on the earth. A function which uses a combination of hydraulic motor and bevel shaft to control difference in travel speed of right and left tracks. Accordingly, machine can turn without using steering clutch.
HSS
Hydrostatic Steering System
Steering
HST
Hydrostatic Transmission
Transmission
ICT
Information and Communication Technology
Communication and electronic control
A general term for the engineering and its socially applied technology of information processing and communication.
Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
IMA
Inlet Metering Actuator
PC210-10M0, PC210LC-10M0
(D Series)
(D, WA)
A hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor to shift gear steplessly without using gears.
50-7
50 DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
Abbreviation
IMU
Actual word spelled out
Inertial Measurement Unit
Purpose of use (major applicable machine (*1), or component/system)
Explanation
Engine
A device that detects the angle (or angular velocity) and acceleration of the 3 axes that control motions.
IMV (+)
Inlet Metering Valve
Engine
A valve which is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump. (Same as IMV)
KCCV
KOMATSU Closed Crankcase Ventilation
Engine
A mechanism that separates oil in blowby gas and send it back to the intake side for it to be burned again. It primarily consists of filters.
KCSF
Komatsu Catalyzed Soot Filter
Engine
KDOC
Komatsu Diesel Oxidation Catalyst
KDPF
A filter that captures soot in exhaust gas. It is built in to KDPF A catalyst that is used for purifying exhaust gas.
Engine
Komatsu Diesel ParticuEngine late Filter
It is built in to KDPF or used in combination with the muffler in some cases. A component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it. It is installed instead of the conventional muffler. A function that recovers the driving force of the wheels by braking automatically with the optimum force and at the same time activates the inter-axle differential lock when the wheels idle machine travels on the soft ground road.
Komatsu Traction Control System
Travel and brake
LCD
Liquid Crystal Display
MACHINE MONITOR
A display equipment such as a monitor which assembles in the liquid crystal element.
LED
Light Emitting Diode
Electronic parts
It refers to semiconductor element that emits light when the voltage is applied in forward direction.
LIN
Local Interconnect Network
Communication and electronic control
One of communication standards that are used in the network on the machine
LS
Load Sensing
Hydraulic system
Function that detects differential pressure of pump and controls discharged volume corresponding to load.
LVDS
Low Voltage Differential Signaling
Communication and electronic control
One of communication standards that are used in the network on the machine
MAF
Mass Air Flow
Engine
This indicates engine intake air flow. Mass air flow sensor is described as MAF sensor in some cases.
MMS
Multimedia Messaging Service
Communication
A service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
NC
Normally Closed
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally closed if it is not actuated (it opens when it is actuated).
NO
Normally Open
Electrical system, Hydraulic system
An electrical or a hydraulic circuits. Circuit is normally open if it is not actuated (it closes when it is actuated).
KTCS
50-8
(HM)
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
Abbreviation OLSS PC
PCCS
Actual word spelled out Open-center Load Sensing System
ABBREVIATION LIST
Purpose of use (major applicable machine (*1), or component/system) Hydraulic system
Pressure Compensation Hydraulic system Palm command control system
Steering (D Series)
Explanation A hydraulic system that can operate multiple actuators at the same time regardless of the load. A function used to correct oil pressure. A function that electronically controls the engine and transmission. It is done by a controller that instantly analyses data from each lever, pedal, and dial.
PCV
Pre-stroke Control Valve Engine
A valve that is installed at inlet port of pump and it adjusts fuel intake amount in order to control fuel discharged volume of supply pump.
PPC
Proportional Pressure Control
This system is used for controlling proportional pressure. It moves actuators in proportion to the oil pressure.
PPM
Piston Pump and Motor
PTO
Power Take Off
Power train system
PTP
Power Tilt and power Pitch dozer
WORK EQUIPMENT
ROPS
Roll-Over Protective Structure
Hydraulic system Hydraulic system (D, PC, etc)
(D Series)
Cab and canopy
A piston type hydraulic pump and motor A mechanism that takes out the force for the work equipment separately from the travel. A function that hydraulically performs tilt operation and pitch operation of the bulldozer blade. A protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. ISO 3471 compliant
SCR
Selective Catalytic Reduction
Urea SCR system
An exhaust gas purifier using urea water to convert nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It Done also be mentioned as exhaust gas purification catalyst , or part of the of related devices.
Le Système internationUnit al d'unités
A universal unit system and "a single unit for a single quantity" is the basic principle applied.
SOL
Solenoid
Electrical system
An actuator consisting of a solenoid and an iron core that is moved by the magnetic force when the solenoid is energized.
TWV
2-Way Valve
Hydraulic system
A solenoid valve that switches over direction of flow.
VGT
Variable Geometry Turbocharger
Engine
The turbocharger on which the cross-section area of the exhaust passage is made variable.
SI
*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader
PC210-10M0, PC210LC-10M0
50-9
50 DISASSEMBLY AND ASSEMBLY
ABBREVIATION LIST
List of abbreviations used in the circuit diagrams Abbreviation A/C
Air Conditioner
A/D
Analogue-to-Digital
A/M
Air Mix Damper
ACC
Accessory
ADD
Additional
AUX
Auxiliary
BR
Battery Relay
CW
Clockwise
CCW
Counter Clockwise
ECU
Electronic Control Unit
ECM
Electronic Control Module
ENG
Engine
EXGND
External Ground
F.G.
Frame Ground
GND
Ground
IMA
Inlet Metering Actuator
NC
No Connection
S/T STRG
Steering
SIG
Signal
SOL
Solenoid
STD
Standard
OPT OP PRESS SPEC SW TEMP
50-10
Actual word spelled out
Option Pressure Specification Switch Temperature
T/C
Torque Converter
T/M
Transmission
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
Reading the special tools list •
The special tools required for removal and installation work are described in the list as symbols such as A, ..., X. Part number, part name, necessity, and quantity are described.
•
Details of the special tools are on "SPECIAL TOOLS LIST". Details of sketches are on "SKETCHES OF SPECIAL TOOLS". Special tools required for a specified work is also described in each work procedures.
•
The symbols used in the table of special tools indicate the following meanings. ■: Not substitutable, and work cannot be performed without the tool. ●: Very useful tools which can be substituted with commercially available tools.
Reading the work procedures All the necessary information for the work procedure, the precautions and prior knowledge relating to the work procedures is described step by step.
Reading the symbols Important safety and quality portions are marked with the following symbols so that Shop Manual is used effectively. Symbol
Item
Summary
k
Danger
This symbol indicates extremely high possibility of serious harm which will result in death or serious injury if it is not avoided.
k
Warning
This symbol indicates serious harm a potentially hazardous situation which will result in death or serious injury if it is not avoided.
k
Caution
This symbol indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.
Weight
This symbol indicates the weight of parts and components. Be careful when selecting wires and working posture for slinging work.
Tightening torque
This symbol indicates the tightening torque for portions which requires special care in assembling work.
Coat
This symbol indicates a place to be coated with adhesive, grease, etc. in assembling work.
Oil and coolant
This symbol indicates a place to supply oil, coolant, etc. along with the quantity. (*1)
Draining
This symbol indicates a place to drain oil, coolant, etc. and the quantity.
*1: For details of a place to supply oil, coolant, etc. and the quantity, see SPECIFICATIONS, "TABLE OF FUEL, COOLANT, AND LUBRICANTS".
Reading the signal word Signal word for notice and remark describes the following. Symbol
Item
NOTICE
Notice
PC210-10M0, PC210LC-10M0
Summary If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.
50-11
HOW TO READ THIS MANUAL
Symbol
Item
REMARK
Remarks
50 DISASSEMBLY AND ASSEMBLY
Summary Information contained in this signal word is useful to know.
Reading the unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.
50-12
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
COATING MATERIALS LIST
COATING MATERIALS LIST Coating materials which are not listed below, use the equivalent of products shown in this manual. Liquid adhesive Komatsu code
Part No.
Volume
Container
LT-1A
790-129-9030
150 g
Tube
20 g (2 pieces)
Polyethylene container
LT-1B
LT-2
790-129-9050
790-129-9180
50 g
790-129-9060
Adhesive 1 kg
Polyethylene container
LT-3
Set of adhesive and hardener
Hardener 500 g
LT-4
790-129-9040
250 g
Polyethylene container
790-129-9120
75 g
Tube
50 g
Polyethylene container
Holtz MH705 ThreeBond 1735
Aron Alpha 201
Loctite 499
Loctite 648-50
790-129-9140
790-129-9130
428-99-80070
79A-129-9110
PC210-10M0, PC210LC-10M0
2 g
20 cc
50 cc
Container
Polyethylene container
Main features and applications •
Use to prevent rubber gaskets, rubber cushions, and cork plugs from falling off.
•
Use for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl chloride), rubber, metal, and non-metal parts which require immediate and strong adhesion.
•
Features: Resistance to heat and chemicals
•
Use to keep bolts and plugs from coming loose. It can also be used as a sealant.
•
Use to bond and seal metal, glass, and plastics etc.
•
Used as sealant for plugs for machined holes.
•
Heat-resistant seal used to repair engines
•
Instantaneous adhesive
•
Curing time: From 5 sec. to 3 min.
•
Use to bond mainly metals, rubbers, plastics, and woods.
•
Instantaneous adhesive
•
Quick-curing type (max. strength is obtained after 30 minutes)
•
Use to bond rubbers, plastics, and metals.
•
General-purpose instantaneous adhesive with excellent resistance to heat and impact
•
Use for the bushing mounting faces of axle supports.
•
Features: Resistance to heat and chemicals
•
Use to bond high-temperature fit parts.
Tube
Polyethylene container
50-13
50 DISASSEMBLY AND ASSEMBLY
COATING MATERIALS LIST
Liquid gasket Komatsu code
Part No.
Volume
Container
1 kg
Polyethylene container
Main features and applications •
Use to seal various threaded portions, pipe joints, and flanges.
•
Use to seal taper plugs, elbows, and nipples for hydraulic piping.
•
Features: Silicon-based heat and coldresistant
•
Use to seal flange surface and threaded portions
•
Use to seal the Oil pan, final drive case, etc.
•
Features: Silicon-based quick-curing sealant
•
Use to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
•
Features: Silicon-based heat, vibration, and shock-resistant
•
Use to seal transfer case, etc.
•
Use for coarse rough surfaces such as the upper seal of a circle gear that does not require fastening and waterproof for weld gaps etc.
•
Can be coated with paint.
•
Use as lubricant or sealant when inserting radiator hoses
1206E
•
Can be coated with paint.
LG-11
•
Feature: Can be used together with solid gaskets.
•
Use for covers of the transmission case and steering case etc.
•
Liquid gasket used to repair engine
LG-5
LG-6
LG-7
790-129-9080
790-129-9160
790-129-9170
200 g
1 kg
Tube
Tube
LG-8 ThreeBond
419-15-18131
100 g
Tube
1207B LG-9 ThreeBond
790-129-9310
200 g
Tube
1206D LG-10 ThreeBond
ThreeBond
790-129-9320
200 g
Tube
790-129-9330
200 g
Tube
790-129-9090
100 g
Tube
Volume
Container
1121 ThreeBond 1211
Molybdenum disulfide lubricant Komatsu code
LM-P
LM-S
50-14
Part No.
-
-
200 g
190 g
Main features and applications •
Use to prevent galling and seizure of press-fitting portions, shrink-fitted portions, and threaded portion.
•
Use to lubricate linkages, bearings, etc.
•
Spray type
•
Thin molybdenum disulfide films are made on metal surfaces to prevent the metals from galling.
•
Use for drive shaft splines, needle bearings, various link pins, bolts, etc.
Tube
Container
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
COATING MATERIALS LIST
Seizure prevention compound Komatsu code
LC-G NEVER-SEEZ
Part No.
Volume
Container
-
-
Container
Part No.
Volume
Container
Various
Various
Main features and applications •
Feature: Seizure and galling prevention compound with metallic super-fine-grain, etc.
•
Use for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Grease Komatsu code
Main features and applications
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI
SYG2-160LI
G0-LI (*)
SYGA-160CNLI
*: For cold regions
•
Lithium grease with extreme pressure lubrication performance, general purpose type.
•
Use for parts under heavy load.
•
Caution: DO NOT use this grease for roller bearings, such as swing circle bearings, etc. or splines.
•
Caution: Use this grease for work equipment pins only when installing them, but do not use it afterwards.
•
Higher seizure resistance, heat resistance, and waterproof than molybdenum disulfide grease
•
Not conspicuous on machine since color is white.
•
Reduces effect on microorganisms, animals, and plants. This is based on swift decomposition by natural bacteria.
•
Feature: Silicon-based grease with wider operating temperature range and superior thermal oxidative stability to prevent deterioration of rubber and plastic.
•
Use for oil seals of the transmission, etc.
SYG0-400LI-A (*) SYG0-16CNLI (*)
Grease that includes molyb- SYG2-400M denum disulSYG2-400M-A fide SYGA-16CNM LM-G (G2-M) Hyper white grease
SYG2-400T-A
G2-T G0-T (*)
SYG0-400T-A (*)
*: For cold regions
SYG0-16CNT (*)
Biogrease
SYG2-400B
G2-B
SYGA-16CNB
G2-BT (*)
SYG2-400BT (*)
400 g20
Bellowstype container
16 kg
Container
400 g
Bellowstype container
400 g10
SYG2-16CNT
*: For use at high tempera- SYture and under GA-16CNBT high load (*)
16 kg
Container
400 g 16 kg
Bellowstype container Container
G2-S ThreeBond
-
200 g
Tube
1855
PC210-10M0, PC210LC-10M0
50-15
50 DISASSEMBLY AND ASSEMBLY
COATING MATERIALS LIST
Komatsu code
G2-U-SENS Grease
Part No.
427-12-11871
Volume
2 kg
Container
Container
Main features and applications •
Feature: Urea (organic) grease with heat resistance and long service life, inclusion type.
•
Use for rubber, bearing and oil seal in damper.
•
Caution: Do not mix with lithium grease.
Primer
Loctite 712 Primer 435-98 for SUNSTAR Coating
Part No.
Volume
Container
428-99-80080
100 mℓ
Glass container
22M-54–27260
150 mℓ
Glass container
SUNSTAR Primer 435-41 for 22M-54-27240 glass
150 mℓ
Steel can
SUNSTAR sash primer GP-402
22M-54-27250
900 mℓ
Steel can
Part No.
Volume
Container
Japan Sikaflex 20Y-54-39850 256HV
310 mℓ
Polyethylene container
SUNSTAR Penguin Super 22M-54-27210 560
320 mℓ
Ecocart (special container)
SUNSTAR Penguin Seal #560
320 mℓ
Ecocart (special container)
Part No.
Volume
Container
SUNSTAR Penguin Seal No.2505
417-926-3920
320 mℓ
Polyethylene container
SEKISUI Silicone Sealant
20Y-54-55130
333 mℓ
Polyethylene container
GE TOSHIBA SILICONES TOSSEAL381
22M-54-27220
333 mℓ
Cartridge
Main features and applications •
For adhered window glass
Komatsu code
Use to accelerate hardening of instantaneous adhesive. •
Use as primer for cab side (Expiration date: 4 months after its production date)
•
Use as primer for black ceramic-coated glass surface and for hard polycarbonate-coated surface (expiration date: 6 months after its production date)
•
Use as primer for ceramic coated glass (expiration date: 6 months after its production date)
Adhesive
416-926-6950
Main features and applications For adhered window glass
Komatsu code
•
Use as adhesive for glass (Expiration date: 6 months after its production date)
•
Use as adhesive for glass (Expiration date: 6 months after its production date)
•
Use as adhesive for glass (Expiration date: 6 months after its production date)
Caulking material
50-16
Main features and applications For adhered window glass
Komatsu code
•
Use to seal for joint between glasses (Expiration date: 4 months after its production date)
•
Use to seal front window (Expiration date: 6 months after its production)
•
Translucent white seal used for joint between glasses (Expiration date: 12 months after its production date)
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
SPECIAL TOOLS LIST How to read the tool list •
Part No.: Tools with part number 79*T-***-**** are not supplied (to be locally manufactured).
•
Necessity: ■: Not substitutable, and work cannot be performed without the tool. ●: Tools extremely useful if available or tools that can be substituted with commercially available tool.
•
New/Redesign: N: Tools with new part numbers, newly developed for this model. R: Tools, with advanced part numbers, developed by improving existing tools for other models. Blank: Tools already available for other models that can be used without any modification.
•
Sketch: ○: Sketches are provided for the tool with this mark. Sketches are introduced in "Sketches of Special Tools". "Sketches of Special Tools" includes all sketches for part numbers that start with "79*T-***-***".
Tools to be used when you remove and install the supply pump assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Support
795-799-6130
1
B
Push puller
790-101-3000
1
Remarks
Tools to be used when you remove and install the injector assembly Symbol
Part name
Part No.
Specifications
Q'ty
Remarks
A
Puller
795-799-6700
1
Removal of injector assembly
B
Gear
795-799-1131
1
Adjustment of valve clearance
C
Remover
795-799-8150
1
Removal of inlet connector
Tools to be used when you remove and install the cylinder head assembly Symbol
Part name
Part No.
Specifications
Q'ty
Remarks
A
Puller
795-799-6700
1
Removal of injector assembly
B
Gear
795-799-1131
1
Adjustment of valve clearance
C
Remover
795-799-8150
1
Removal of inlet connector
D
Wrench
790-331-1120 Angle
1
Angle tightening of bolt
E
Gauge
795-790-4510
1
Measurement of bolt
PC210-10M0, PC210LC-10M0
50-17
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
Tools to be used when you remove and install the hydraulic oil cooler assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Oil stopper
796-460-1210
1
B
Adapter
796-770-1320
1
Remarks
Tools to be used when you remove and install the fan clutch assembly Symbol
Part name
Part No.
A
Nut
01580-11210
B
Bolt
01011-81210
Specifications
Q'ty
Remarks
1 M12 x 110 mm
1
Tools to be used when you remove and install the engine and main pump assembly Symbol A
B
C
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70210
Nominal 02
4
2 Cap
02789-00210
Nominal 02
4
1 Plug
07376-70422
Nominal 04
2
2 Cap
02789-00422
Nominal 04
2
1 Plug
07376-70628
Nominal 06
1
2 Cap
02789-00628
Nominal 06
1
Remarks
Tools to be used when you remove and install the engine front oil seal Symbol
Part name
Part No.
Specifications
Q'ty
A
Seal puller
795-799-6400
1
B
Wrench
790-331-1120 Angle
1
Remarks
Tools to be used when you remove and install the engine rear oil seal Symbol A
Part name Seal puller
Part No.
Specifications
795-799-6500
Q'ty
Remarks
1
Tools to be used when you remove and install the fuel cooler assembly Symbol A
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70315
Nominal 03
2
2 Cap
02789-00315
Nominal 03
2
Remarks
Tools to be used when you remove and install the fuel tank assembly Symbol A
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70315
Nominal 03
1
2 Cap
02789-00315
Nominal 03
1
50-18
Remarks
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
Tools to be used when you remove and install the travel motor and final drive assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Plug
21W-629-9895 #10
2
B
Cap
21W-629-9915 #10
2
C
Plug
07376-70210
#02
1
D
Cap
02789-00210
#02
1
E
Plug
07376-70422
#04
1
F
Cap
02789-00422
#04
1
Remarks
Removal and installation of travel motor and final drive assembly
Tools to be used when you disassemble and assemble the final drive assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Wrench assembly
796-427-1400
1
B
Installer
796-140-1000
1
Push tool
796T-427-1510
1
Block
790-101-2510
2
Leg
790-101-2610
1
Adapter
790-101-2730
2
Nut
790-101-2560
2
Plate
790-101-2570
4
Puller
790-101-2102 294 kN {30 t}
1
Pump
790-331-1102
1
D
Wrench
790-331-1110
1
E
Guide
796T-427-1710
1
Gear puller
790-101-3501
1
Plate
790-201-2660
1
G
Push tool
792T-423-1350
1
H
Push-pull scale
79A-264-0091
1
C
F
Remarks
Disassembly and assembly of final drive assembly
Tools to be used when you remove and install the swing motor and swing machinery assembly Symbol A
B
C
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70210
Nominal 02
2
2 Cap
02789-00210
Nominal 02
2
1 Plug
07376-70522
Nominal 05
1
2 Cap
02789-00522
Nominal 05
1
1 Plug
07376-70628
Nominal 06
1
2 Cap
02789-00628
Nominal 06
1
PC210-10M0, PC210LC-10M0
Remarks
50-19
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
Tools to be used when you disassemble and assemble the swing machinery assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Push tool
790-201-1410 #02
1
B
Push tool
796-426-1120 #02
1
Plate
796T-426-1130 #06
1
Grip
790-101-5421 #06
1
Bolt
01010-81240
#05
1
D
Spacer
790-201-2710 #05
1
E
Spacer
790-201-2840
1
F
Spacer
790-201-2470
1
G
Spacer
793T-615-1760
1
H
Plate
790-201-2660
1
C
Remarks
Disassembly and assembly of swing machinery assembly
Tools to be used when you separate and connect the track shoe assembly Symbol
A
Part name
Part No.
Specifications
Q'ty
Remover and installer
791-650-3000
1
Cylinder (980 kN {100 t})
790-101-1300
1
Pump
790-101-1102
1
Remarks Separation and connection of track assembly
Tools to be used when you disassemble and assemble the idler assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Installer
791-530-1510
1
B
Plate
790-101-5431
1
50-20
Remarks Disassembly and assembly of idler assembly
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
Tools to be used when you disassemble and assemble the idler cushion assembly Symbol
Part name Compressor (A) Compressor (B)
A
B
C
Part No.
Specifications
Q'ty
791-600-2001
Remarks
2
or
2
791-685-8006
Spacer
790-201-2780
1
Extension
791-635-3160
1
Cylinder (686 kN {70 t})
790-101-1600
1
Pump
791-101-1102
1
Guide bolt
790-640-2180
1
Push tool kit (B)
790-101-5201
1
•
Plate
790-101-5241
1
•
Grip
790-101-5221
1
•
Bolt
01010-51225
2
Push tool kit
790-201-1500
1
•
Plate
790-101-1620
1
•
Grip
790-101-5021
1
•
Bolt
01010-50816
2
Disassembly and assembly of idler cushion assembly
Tools to be used when you disassemble and assemble the track roller assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Installer
796-670-1020
1
B
Push tool
796T-667-1120
1
Remarks Disassembly and assembly of track roller assembly
Tools to be used when you disassemble and assemble the carrier roller assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Installer
790-434-1660
1
B
Spacer
793T-613-1380
1
C
Spacer
790-201-2820
1
D
Spacer
793T-417-1310
1
E
Push tool
796T-430-1310
1
Remarks
Disassembly and assembly of carrier roller assembly
Tools to be used when you remove and install the revolving frame assembly Symbol A
B
Part name
Part No.
Specifications
1 Plug
07376-70210
Nominal 02
2 Cap
02789-00210
Nominal 02
1 Plug
07376-70522
Nominal 05
2 Cap
02789-00522
Nominal 05
PC210-10M0, PC210LC-10M0
Q'ty
Remarks
50-21
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
Symbol C
Part name
Part No.
Specifications
1 Plug
07376-70628
Nominal 06
2 Cap
02789-00628
Nominal 06
Q'ty
Remarks
Q'ty
Remarks
Tools to be used when you remove and install the center swivel joint assembly Symbol A
B
C
D
Part name
Part No.
Specifications
1 Plug
07376-70210
Nominal 02
2
2 Cap
02789-00210
Nominal 02
2
1 Plug
07376-70422
Nominal 04
1
2 Cap
02789-00422
Nominal 04
1
1 Plug
07376-70522
Nominal 05
1
2 Cap
02789-00522
Nominal 05
1
1 Plug
07376-70628
Nominal 06
1
2 Cap
02789-00628
Nominal 06
1
Tools to be used when you disassemble and assemble the center swivel joint assembly Symbol
Part name Push puller
A
Part No.
Specifications
Q'ty
790-101-2501
1
•
Block
790-101-2510
1
•
Screw
790-101-2520
1
•
Nut
790-112-1180
1
•
Washer
790-101-2540
1
•
Leg
790-101-2630
2
•
Plate
790-101-2570
4
•
Nut
790-101-2560
2
•
Adapter
790-101-2560
2
•
Plate
790-201-1410
1
Remarks
Disassembly and assembly of center swivel joint assembly
Tools to be used when you remove and install the hydraulic tank assembly Symbol A
B
C
D
Part name
Part No.
Specifications
1 Plug
07376-70210
Nominal 02
2 Cap
02789-00210
Nominal 02
1 Plug
07376-70422
Nominal 04
2 Cap
02789-00422
Nominal 04
1 Plug
07376-70522
Nominal 05
2 Cap
02789-00522
Nominal 05
1 Plug
07376-70628
Nominal 06
2 Cap
02789-00628
Nominal 06
50-22
Q'ty
Remarks
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
Tools to be used when you remove and install the main pump assembly Symbol A
B
C
D
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70210
Nominal 02
3
2 Cap
02789-00210
Nominal 02
3
1 Plug
07376-70315
Nominal 03
1
2 Cap
02789-00315
Nominal 03
1
1 Plug
07376-70422
Nominal 04
2
2 Cap
02789-00422
Nominal 04
2
1 Plug
07376-70628
Nominal 06
1
2 Cap
02789-00628
Nominal 06
1
Remarks
Tools to be used when you remove and install the control valve assembly Symbol A
B
C
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70210
Nominal 02
17
2 Cap
02789-00210
Nominal 02
17
1 Plug
07376-70315
Nominal 03
1
2 Cap
02789-00315
Nominal 03
1
1 Plug
07376-70628
Nominal 06
1
2 Cap
02789-00628
Nominal 06
1
Remarks
Tools to be used when you disassemble and assemble the control valve assembly Symbol
Part name
Part No.
Specifications
Q'ty
Remarks
Guide diameter (21.8 mm)
796-946-1310
1
For 723-46-40100 and 723-46-40601
Guide diameter (21.4 mm)
796-946-1610
1
For 723-46-41100
Guide diameter (21.2 mm)
796-946-1810
1
For 723-46-43100 and 723-46-43400
Guide diameter (21.0 mm)
796-946-1910
1
For 723-46-46300 and 723-46-46101
Guide diameter (20.9 mm)
796-946-2110
1
For 723-46-44100
Guide diameter (20.6 mm)
796-946-2210
1
For 723-46-45100 and 723-46-45500
A
PC210-10M0, PC210LC-10M0
50-23
50 DISASSEMBLY AND ASSEMBLY
SPECIAL TOOLS LIST
Symbol
B
C
Part name
Part No.
Specifications
Q'ty
Remarks
Guide diameter (21.8 mm)
796-946-1320
1
For 723-46-40100 and 723-46-40601
Guide diameter (21.6 mm)
796-946-1420
1
For 723-46-42800
Guide diameter (21.4 mm)
796-946-1620
1
For 723-46-41100
Guide diameter (21.2 mm)
796-946-1820
1
For 723-46-43100 and 723-46-43400
Guide diameter (21.0 mm)
796-946-1920
1
For 723-46-46300 and 723-46-46101
Guide diameter (20.9 mm)
796-946-2120
1
For 723-46-44100
Guide diameter (20.6 mm)
796-946-2220
1
For 723-46-45100 and 723-46-45500
Sleeve
796-946-1330
1
For 723-46-40100 and 723-46-40601
Sleeve
796-946-1430
1
For 723-46-42800
Sleeve
796-946-1630
1
For 723-46-41100
Sleeve
796-946-1830
1
For 723-46-43100 and 723-46-43400
Sleeve
796-946-1930
1
For 723-46-46300 and 723-46-46101
Sleeve
796-946-2130
1
For 723-46-44100
Sleeve
796-946-2230
1
For 723-46-45100 and 723-46-45500
Tools to be used when you remove and install the work equipment assembly Symbol A
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70210
Nominal 02
1
2 Cap
02789-00210
Nominal 02
1
Remarks
Tools to be used when you disassemble and assemble the work equipment cylinder assembly Symbol
Q'ty
Remarks
790-502-1003
1
Disassembly and assembly of work equipment cylinder
1 Wrench
790-102-4300
1
2 Pin
790-102-4310
1
790-720-1000
1
1 Ring
796-720-1670
1
2 Clamp
07281-01279
1
A
B
Cylinder repair stand
C D
Part name
Expander
50-24
Part No.
Specifications
Removal and installation of piston pin Expansion of piston ring Expansion of piston ring
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
Symbol
Part name
- Push tool kit
E
Part No.
Specifications
Q'ty
790-201-1702
1
1
•
Grip
790-101-5021
1
2
•
Bolt
01010-50816
1
3
•
Push tool (for boom cylinder)
790-201-1871
1
4
•
Push tool (for arm cylinder)
790-201-1881
1
5
•
Push tool (for bucket cylinder)
790-445-4210
1
790-201-1500
1
- Push tool kit
F
SPECIAL TOOLS LIST
1
•
Grip
790-101-5021
1
2
•
Bolt
01010-50816
1
3
•
Plate (for boom cylinder)
790-201-1680
1
4
•
Plate (for arm cylinder)
790-201-1570
1
5
•
Plate (for bucket cylinder)
790-201-1690
1
Remarks
Press-fitting of cylinder head bushing
Press-fitting of dust seal
Tools to be used when you remove and install the operator's cab glass (adhered glass) Symbol
Part name
Part No.
Specifications
Q'ty
Remarks Removal and installation of operator cab glass (adhered glass)
A
Lifter (adhesive disc)
793-498-1210
1
B
Seat
20Y-54-13180
1
Tools to be used when you remove and install the front window assembly Symbol
Part name
Part No.
Specifications
Q'ty
A
Lifter (adhesive disc)
793-498-1210
1
B
Seat
20Y-54-13180
1
Remarks Removal and installation of front window assembly
Tools to be used when you remove and install the floor frame assembly Symbol A
B
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70210
Nominal 02
8
2 Cap
02789-00210
Nominal 02
8
1 Plug
07376-70315
Nominal 03
2
2 Cap
02789-00315
Nominal 03
2
PC210-10M0, PC210LC-10M0
Remarks
50-25
SKETCHES OF SPECIAL TOOLS
50 DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS Note: Komatsu does not take any responsibility for special tools manufactured in accordance with these sketches. Stopper
*
Plate
*
50-26
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Push tool
*
Guide
*
PC210-10M0, PC210LC-10M0
50-27
SKETCHES OF SPECIAL TOOLS
50 DISASSEMBLY AND ASSEMBLY
Push tool
*
Plate
*
50-28
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Spacer
*
Push tool
*
PC210-10M0, PC210LC-10M0
50-29
SKETCHES OF SPECIAL TOOLS
50 DISASSEMBLY AND ASSEMBLY
Spacer
*
Spacer
*
50-30
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
Push tool
*
PC210-10M0, PC210LC-10M0
50-31
50 DISASSEMBLY AND ASSEMBLY
DRAIN AND ADD COOLANT
PREPARATION DRAIN AND ADD COOLANT List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially available
2
Ratchet handle
Commercially available
1
3
Impact wrench
Commercially available
1
4
Torque wrench
Commercially available
5
Coolant container
Commercially available
k k k k k
19 mm
20 to 200 Nm
Remarks
1
1 As required
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".) If you drain the coolant or disconnect the heater hose when the radiator is still hot, you could be burned. Wait for the coolant temperature to cool down before you start the work.
DRAIN COOLANT Draining coolant 1. Open engine hood (1).
2.
Open the radiator cap (2), and release the remaining pressure.
50-32
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
3.
DRAIN AND ADD COOLANT
Remove the bolts (3) (7 pieces) and remove the cover (4). Tools: Impact wrench, socket Bolt (3): width across flats 19 mm, M12
4.
Loosen the drain valve (5) and drain the coolant. REMARK After you drain the coolant is complete, close the drain valve (5). Tool: Container to catch the coolant Coolant: 21.8 ℓ
ADD COOLANT Refilling with coolant 1. Refill the radiator (6) with coolant to the specified level through the coolant filler port. Run the engine to circulate the coolant. Then check the coolant level again. (For details, see OVERVIEW, "TABLE OF FUEL, COOLANT, AND LUBRICANTS".) REMARK Make sure the drain valve (5) of the coolant is closed before you refill with coolant. Coolant: 21.8 ℓ
PC210-10M0, PC210LC-10M0
50-33
DRAIN AND ADD COOLANT
2.
Install the radiator cap (2).
3.
Install the cover (4) with the bolts (3) (7 pieces).
50 DISASSEMBLY AND ASSEMBLY
Tools: Ratchet handle, socket, torque wrench Bolt (3): width across flats 19 mm, M12 Bolt (3): 98 to 123 Nm {10.0 to 12.5 kgm}
4.
Close the engine hood (1).
50-34
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
DRAIN AND AD HYDRAULIC OIL
DRAIN AND AD HYDRAULIC OIL Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially available
19 mm
1
2
Socket
Commercially available
24 mm
1
3
Ratchet handle
Commercially available
4
Box-end combination wrench
Commercially available
5
Impact wrench
Commercially available
6
Torque wrench
Commercially available
7
Oil container
Commercially available
k k k k
Remarks
1 24 mm
1 1
20 to 200 Nm
1 As required
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "HANDLE BATTERY DISCONNECT SWITCH".)
DRAIN HYDRAULIC OIL Cover 1. Open engine hood (1).
2.
Remove the bolts (2) (6 pieces) and remove the cover (3). Tools: Impact wrench, socket Bolt (2): width across flats 19 mm, M12
PC210-10M0, PC210LC-10M0
50-35
DRAIN AND AD HYDRAULIC OIL
50 DISASSEMBLY AND ASSEMBLY
Draining hydraulic oil 3. Loosen the drain plug (4) and drain hydraulic oil. REMARK After you drain the hydraulic oil is complete, tighten the drain plug (4). Tools: Ratchet handle, box-end wrench, socket, torque wrench, oil drain pan Drain plug (4): width across flats 5/8 inch (15.9 mm), M24 Hydraulic tank: 190 ℓ Drain plug (4): 58.8 to 78.5 Nm {6 to 8 kgm} 4.
Remove the bolts (5) (8 pieces), and remove the cover (6). Tools: Ratchet handle, box-end wrench, socket, torque wrench, oil drain pan Tools: Impact wrench, socket Bolt (2): width across flats 19 mm, M12
5.
Loosen the drain plug (7), and drain the hydraulic oil. REMARK Tighten the drain plug (7) after you drain the hydraulic oil. Tools: Ratchet handle, box-end wrench, socket, torque wrench, oil drain pan Drain plug (7): Width across flats 5/ 8 inch (15.9 mm), M24 Hydraulic tank: 30 ℓ Drain plug (7): 58.8 to 78.5 Nm {6 to 8 kgm}
ADD HYDRAULIC OIL Refilling with hydraulic oil 1. Remove oil fill caps (5).
50-36
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
2.
DRAIN AND AD HYDRAULIC OIL
Refill the hydraulic oil tank (6) to the specified level through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. (For details, see OVERVIEW, "TABLE OF FUEL, COOLANT, AND LUBRICANTS".) REMARK Before you fill with hydraulic oil, make sure the drain plug (4) is tightened. Hydraulic tank: 190 ℓ
3.
Install the oil fill caps (5).
Air bleeding 4. Bleeding air from the hydraulic circuit REMARK Make adjustments. See TESTING AND ADJUSTMENT "BLEED AIR FROM Hydraulic pressure CIRCUIT". Cover 5. Install the cover (3) with the bolts (2) (6 pieces). Tool: Socket, torque wrench Bolt (2): width across flats 19 mm, M12 Bolt (2): 98 to 123 Nm {10.0 to 12.5 kgm}
6.
Close the engine hood (1).
PC210-10M0, PC210LC-10M0
50-37
50 DISASSEMBLY AND ASSEMBLY
DRAIN AND ADD FUEL
DRAIN AND ADD FUEL List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially available
2
Ratchet handle
Commercially available
1
3
Impact wrench
Commercially available
1
4
Torque wrench
Commercially available
k k k k
19 mm
20 to 200 Nm
Remarks
1
1
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
DRAIN FUEL Cover 1. Open engine hood (1).
2.
Remove the bolts (2) (6 pieces) and remove the cover (3). Tools: Impact wrench, socket Bolt (2): width across flats 19 mm, M12
50-38
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
3.
DRAIN AND ADD FUEL
Remove the bolts (4) (8 pieces) and remove the cover (5). Tools: Impact wrench, socket Bolt (4): width across flats 19 mm, M12
Draining fuel 4. Open the drain valve (6) and drain the fuel. REMARK After fuel draining is complete, close the drain valve (6). Tool: Container to catch the fuel Fuel tank (when the tank is full): 400 ℓ
ADD FUEL Refilling with fuel 1. Remove the fuel filler pipe (7).
PC210-10M0, PC210LC-10M0
50-39
DRAIN AND ADD FUEL
2.
50 DISASSEMBLY AND ASSEMBLY
Fill the fuel tank (8) to the specified level with fuel. (For details see OUTLINE "TABLE OF FUEL, COOLANT, AND LUBRICANTS"). REMARK Prior to filling with fuel, make sure the drain valve (6) is tightened. Fuel tank (full): 400 ℓ
3.
Install the fuel filler pipe (7).
Cover 4. Install the cover (5) with the bolts (4) (8 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (4): width across flats 19 mm, M12 Bolt (4): 98 to 123 Nm {10.0 to 12.5 kgm}
5.
Install the cover (3) with the bolts (2) (6 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (2): width across flats 19 mm, M12 Bolt (2): 98 to 123 Nm {10.0 to 12.5 kgm}
6.
Close the engine hood (1).
50-40
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
DRAIN AND ADD FUEL
Air bleeding 7. Bleed air from fuel circuit. REMARK Make adjustments. See TESTING AND ADJUSTMENT "BLEED AIR FROM FUEL CIRCUIT".
PC210-10M0, PC210LC-10M0
50-41
COLLECT AND REFILL REFRIGERANT
50 DISASSEMBLY AND ASSEMBLY
COLLECT AND REFILL REFRIGERANT
k k k k k
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".) If refrigerant gas (R134a) gets in your eyes, you could lose your sight. If it touches your skins, you could suffer from frostbite. Therefore, use protective eyeglasses, gloves and working clothes with long sleeves while you collect or refill refrigerant.
NOTICE • Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. • For handling coolant, request services of a "Type 1 CFCs collection company" registered at the national level to the "CFC Recovery and Destruction Law". (Only to be performed by registered companies)
COLLECT REFRIGERANT Collecting refrigerant 1. Collect refrigerant (air conditioner gas: R134a) from the air conditioner circuit. Refrigerant to be collected: 780±50 g
REFILL REFRIGERANT Refilling with refrigerant 1. Refill the air conditioner circuit with the refrigerant (air conditioner gas: R134a). Refrigerant quantity: 780 ± 50 g
50-42
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
ENGINE AND COOLING SYSTEM REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY Swivel
- Engine hood
Fuel filter, A- bracket assembly
-
- Cover
Piping connector
-
- Fuel stop valve
Supply pump assembly
- Hose
-A
- Gear
List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially 12 mm available
1
2
Socket
Commercially 17 mm available
1
3
Socket
Commercially 19 mm available
1
4
Socket
Commercially available
1
5
Socket
Commercially available
1
6
Ratchet handle
Commercially available
1
7
Wrench
Commercially 13 mm available
1
8
Wrench
Commercially available
1
9
Box-end combination wrench
Commercially available
1
10
Impact wrench
Commercially available
1
11
Torque wrench
Commercially 5 to 50 Nm available
1
12
Torque wrench
Commercially 50 to 420 Nm available
1
13
Container to catch the fuel
Commercially available
1
14
1/2-inch spinner handle
Commercially available
1
15
Puller
Commercially available
1
Remarks
List of Special Tools Symbol A
Part name Support
PC210-10M0, PC210LC-10M0
Part number 795–799–6130
SPECIFICATION
Q'ty
Remarks
1
50-43
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
Symbol B k k k k k
Part name Push puller
Part number
SPECIFICATION
790-101-3000
Q'ty
Remarks
1
Place the machine on a level ground, and lower the work equipment to the ground in a stable attitude. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "HANDLE BATTERY DISCONNECT SWITCH".) When you remove and install the fuel piping, make sure no foreign matters enter the fuel piping. If dirt, etc. sticks to any part, wash that part completely with clean fuel.
NOTICE Check the connector numbers and installed positions before disconnecting wirings and hoses, and write them down.
REMOVE SUPPLY PUMP ASSEMBLY Swivel 1. Upper structure swivels 90°. Engine hood 2. Open engine hood (1). NOTICE Make sure the lock is engaged.
Cover 3. Remove the bolts (2) (6 pieces), and remove the fuel tank bottom cover (3). Tools: Impact wrench, socket Bolt (2): width across flats 19 mm, M12
4.
Remove the bolts (4a) (7 pieces), and remove the cover (4). Tools: Impact wrench, socket Bolt (4a): width across flats 19 mm, M12
50-44
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
Fuel stop valve 5. Remove the bolts (5a) (2 pieces), and remove the cover (5). Tools: Impact wrench, socket Bolt (5a): width across flats 19 mm, M12
6.
Tighten the fuel stop valve (5b).
Hose 7. Disconnect the fuel filter hoses (6) and (7). REMARK • Remove mud from the connector beforehand. This is to prevent the lock (a) from sticking. • Push on the locks (a) on both sides and pull out. • Fuel will be discharged when the hose is disconnected so be sure to prevent it from getting on anything. (Prepare a drain oil pan underneath) Tool: Drain oil pan 8.
Remove the cap (8a).
9.
Remove the joint bolt (8), and disconnect the fuel return hose (9). Tools: Impact wrench, socket Joint bolt (8): width across flats 17 mm
10. Disconnect the fuel return hose (10) with the joint (8b). Tools: Impact wrench, socket Joint (8b): Width across flats 19 mm
PC210-10M0, PC210LC-10M0
50-45
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Piping connector 11. Disconnect the connector C17 (12). 12. Remove the joint bolt (14), and disconnect the fuel supply hose (13). Tools: Impact wrench, socket Joint bolt (14): Width across flats 19 mm, M12
13. Remove the fuel spray prevention cap (15). 14. Loosen the sleeve nut, and disconnect the high-pressure pipe (16). Tool: Open-end wrench High-pressure pipe (16): Width across flats 19 mm
15. Remove the clamp (17). Tool: wrench Clamp (17) nut: width across flats 12 mm,
16. Remove the clamp (18a). REMARK Be careful not to lose the spacer when you remove the clamp (18a) bolt. Tool: wrench Nut for clamp (18a): Width across flats 15 mm 17. Remove the clamp (18b). Tools: Impact wrench, socket Clamp (18b) bolt: width across flats 12 mm, M8 18. Remove the joint bolt (18), and disconnect the fuel return tube (19). Tools: Impact wrench, socket Joint bolt (18): Width across flats 17 mm, M12 19. Remove the fuel spray prevention cap (20). 20. Loosen the sleeve nut, and remove the high-pressure pipe (16). Tool: Open-end wrench High-pressure pipe (16): Width across flats 19 mm 50-46
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
Supply pump assembly 21. Remove the nuts (21a) (3 pieces), and remove the supply pump assembly (21). NOTICE • The supply pump assembly (21) comes off together with the gear. • Detailed gear teeth processing (missing tooth etc.) to align with TOP is not provided. Tools: Ratchet handle, socket, box-end wrench Nut (21a): Width across flats 13 mm Gear 22. Fix the gear with the support (A) and 1/2 inch spinner handle (22), and loosen the nut (26).
$
NOTICE Do not remove the nut (26) from the shaft. Tool: Support (A), 1/2 inch spinner handle, socket Nut (26): Width across flats 27 mm
*
23. Install the puller (23) between the flange and gear (24). Tool: puller
*
24. Install push puller (B) on top of the puller (23) and shaft. Tool: Push puller (B)
25. Rotate the center bolt (25) until the gear separates from the shaft.
%
Tools: Ratchet handle, socket 26. Remove the puller (23) and push puller (B).
*
27. Remove the nut (26), lock washer (29), and gear (27) from the shaft (28). Tools: Ratchet handle, socket Nut (26): Width across flats 27 mm
PC210-10M0, PC210LC-10M0
50-47
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
INSTALL SUPPLY PUMP ASSEMBLY Gear 1. Install the gear (27) to the shaft (28). NOTICE Before installation, clean dusts and foreign materials on the mating faces of the shaft (28) and gear (27), and keep the mating faces dry. 2.
Install the lock washer (29) and the nut (26), and fingertighten them lightly.
3.
Fix the gear with the support (A) and 1/2 inch spinner handle (22), and tighten the nut (26).
$
Tool: Support (A), 1/2 inch spinner handle, socket, ratchet handle Nut (26): Width across flats 27 mm Nut (26): 105 ± 5 Nm {10.71 ± 0.51 kgm}
*
Supply pump assembly 4. Install the supply pump assembly (21) with the nuts (21a) (3 pieces). REMARK • If grease is applied too much to O-ring (21b), it will ooze out. Do not apply grease too much. (Apply it to the portion (c), groove of the O-ring). • When replacing the stud bolt (30) with a new one and when embedding it, apply Loctite to the stud bolt (30). • Use a new socket to install the nuts (21a) because it is difficult to install them on the cylinder block side. • If an old socket is used, the nut (21a) will fall off or be damaged because of the excess clearance between the socket and nut (21a). Tool: Ratchet handle, torque wrench, socket Nut (21a): Width across flats 13 mm O-ring (21b): Grease (rapeseed oil) Stud bolt (30): Loctite (190757) Nut (21a): 24 ± 4 Nm {2.45 ± 0.41 kgm} Stud bolt (30): 12 ± 2 Nm {1.22 ± 0.2 kgm}
50-48
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
Piping connector 5. Tighten the sleeve nut with your hands, and connect the high-pressure pipe (16). REMARK Connect the two sides. 6.
Tighten the sleeve nuts of the high-pressure pipe (16) on the pump side first, and then common rail side. Tool: Torque wrench, wrench High-pressure pipe (16): Width across flats 19 mm High-pressure pipe (16): 40 ± 4 Nm {4.08 ± 0.41 kgm}
7.
Install the clamp (17). Tool: Wrench, torque wrench Clamp (17) nut: 12-mm width across flats Clamp (17) nut: 24 ± 4 Nm {2.45 ± 0.41 kgm}
8.
Install the clamp (18b). Tool: Ratchet handle, torque wrench, socket Clamp (18b) bolt: 12-mm width across flats, M8 Clamp (18b) bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
9.
Install the clamp (18a). Tool: Wrench, torque wrench Nut for clamp (18a): Width across flats 15 mm
Clamp (18a) nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} 10. Install the fuel spray prevention caps (15) and (20). REMARK • Direct the slit of fuel spray prevention cap outward or downward when installing it. • The fuel spray prevention caps are installed so that the fuel will not spurt over the hot part of the engine and not catch fire when it leaks by any chance. 11. Connect the fuel return tube (19) with the joint bolt (18). Tool: Ratchet handle, torque wrench, socket Joint bolt (18): Width across flats 17 mm, M12 Joint bolt (18): 24 ± 4 Nm {2.45 ± 0.41 kgm} 12. Connect the fuel supply hose (13) with the joint bolt (14). Tool: Ratchet handle, torque wrench, socket Joint bolt (14): Width across flats 19 mm, M12 Joint bolt (14): 24±4 Nm {2.45±0.41 kgm} 13. Connect the connector C17 (12).
PC210-10M0, PC210LC-10M0
50-49
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Hose 14. Connect the fuel return hose (10) with the joint (8b). NOTICE • Do not reuse the removed hose as a rule because the internal part of the hose fitting can be damaged when you remove the hose. Replace the hose with a new one you reassemble it. • Before the engine cranking, put in 60 cc of fuel from the overflow outlet side. Tool: Ratchet handle, torque wrench, socket Joint (8b): Width across flats 19 mm, M12 Joint (8b): 24 ± 4 Nm {2.45 ± 0.41 kgm} 15. Connect the fuel return hose (9) with the joint bolt (8). NOTICE Do not reuse the removed hose as a rule because the internal part of the hose fitting can be damaged when you remove the hose. Replace the hose with a new one you reassemble it. Tool: Ratchet handle, torque wrench, socket Joint bolt (8): 17-mm width across flats Joint bolt (8): 19.6 to 29.4 Nm {2 to 3 kgm} 16. Install the cap (8a). 17. Connect the fuel filter hoses (6) and (7). NOTICE • Do not reuse the removed hose as a rule because the internal part of the hose fitting can be damaged when you remove the hose. Replace the hose with a new one you reassemble it. • Make sure the hose connecting portions have no dirt or dust. Fuel stop valve 18. Open the fuel stop valve (5b).
50-50
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
19. Install the cover (5) with the bolts (5a) (2 pieces). Tool: Ratchet handle, torque wrench, socket Bolt (5a): 19-mm width across flats, M12 Bolt (5a): 98 to 123 Nm {10 to 12.5 kgm}
Cover 20. Install the cover (4) with the bolts (4a) (7 pieces). Tool: Ratchet handle, torque wrench, socket Bolt (4a): 19-mm width across flats, M12 Bolt (4a): 98 to 123 Nm {10 to 12.5 kgm}
21. Install the fuel tank bottom cover (3) with the bolts (2) (6 pieces). Tool: Ratchet handle, torque wrench, socket Bolt (2): 19-mm width across flats, M12 Bolt (2): 98 to 123 Nm {10 to 12.5 kgm}
Engine hood 22. Close the engine hood (1).
Swing 23. Swing it, and put the upper part back to the original position. Air bleeding 24. Bleed air from the fuel circuit. REMARK For details, see TESTING AND ADJUSTING, "BLEED AIR FROM FUEL SYSTEM".
PC210-10M0, PC210LC-10M0
50-51
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
A-
Engine hood
- Clamp
- Head cover
Crosshead and Rocker Arm
- Inlet connector
-
Wiring harness - and gasket assembly
- Fuel piping
-A
Injector assembly
List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially available
1
2
Ratchet handle
Commercially available
1
3
Wrench
Commercially available
1
4
Box-end combination wrench
Commercially available
1
5
Hexagonal wrench
Commercially available
1
6
Impact wrench
Commercially available
1
7
Torque wrench
Commercially 0.5 to 3 Nm available
1
8
Torque wrench
Commercially 2 to 20 Nm available
1
9
Torque wrench
Commercially 5 to 50 Nm available
1
10
Torque wrench
Commercially 20 to 200 Nm available
1
11
Wire cutters
Commercially available
1
Remarks
List of Special Tools Symbol
Part name
Part number
SPECIFICATION
Q'ty
Remarks
A
Puller
795-799-6700
1
Removal of injector assembly
B
Gear
795-799-1131
1
Adjusting the valve clearance
C
Remover
795-799-8150
1
Removing the inlet connector
50-52
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
k k k k k
REMOVE AND INSTALL INJECTOR ASSEMBLY
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".) When you remove and install the fuel piping, be careful to prevent foreign material from entering. If dust, etc. adheres to some part, wash that part completely with clean fuel.
REMOVE INJECTOR ASSEMBLY Engine hood 1. Open engine hood (1). NOTICE Make sure the lock is engaged.
Clamp 2. Remove the clamp (7a) of the engine wiring harness (7), and cut the bands (7b) (2 pieces). Tools: Impact wrench, socket, wire cutters Bolt for clamp (7a): Width across flats 8 mm, M6
Head cover 3. Remove the bolts (8) (5 pieces), and remove the head cover (9). REMARK • After you loosen the bolt (8), hold the cover down to prevent mud etc. from entering and clean around the area by use of compressed air. • When you remove the head cover (9), do not allow it to come into contact with surrounding parts. Tools: Impact wrench, socket Bolt (8): Width across flats 13 mm, M8
PC210-10M0, PC210LC-10M0
50-53
REMOVE AND INSTALL INJECTOR ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Wiring harness and gasket assembly 4. Remove the wiring harness nuts (11) (2 pieces) from the injector (10). REMARK Do the same task on all cylinders in this same manner. Tools: Ratchet handle, socket Nut (11): Width across flats 8.7 mm
5.
Disconnect the connectors C9 (7d), C10 (7e), and C11 (7f) of the engine wiring harness (7). REMARK There are support tabs on the connectors. Push on these tabs and pull out the connector. When you remove the connectors, hold the gasket by hand so it does not move.
6.
Lift and remove the gasket assembly (13). REMARK • Be careful to prevent foreign material from entering the engine when you remove it. • When you remove the head cover (9), visually check the gasket assembly (13). If there are cracks, deterioration, or wear, use a new gasket assembly.
Fuel piping 7. Remove the fuel spray prevention caps (14) (12 pieces). 8.
Loosen the sleeve nut on the cylinder head side, and disconnect the high-pressure pipes (15), (15a), (15b), (15c), (15d), and (15e). REMARK • Loosen the sleeve nuts on the common rail side as well. • Do not remove the fuel pressure sensor (10a) or relief valve (10b) other than for replacement. Tool: Wrench High-pressure pipe (15), (15a), (15b), (15c), (15d), (15e): Width across flats 19 mm
Crosshead and Rocker Arm 9. Remove the rocker arms (16a) and (16b), and the crosshead (19) in this same manner by use of the procedure below.
50-54
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
1)
REMOVE AND INSTALL INJECTOR ASSEMBLY
Remove the bolts (16) (2 pieces), and remove the rocker arms (16a) and (16b). REMARK When you install the rocker arm, loosen the lock nut (17) and loosen the adjustment screw (18) 2 to 3 turns so that excessive force is not applied to the push rod. Tools: Ratchet handle, socket, box-end wrench, hexagonal wrench Bolt (16): width across flats 10 mm, M8 Lock nut (17): Width across flats 14.2 mm Adjustment screw (18): Width across flats 5.1 mm
2)
Remove the crossheads (19) (2 pieces). REMARK Record the location and direction of the crosshead (shapes of the holes (a) and (b)). (Install it in the noted direction when you reassemble it.)
Inlet connector 10. Remove the retainer (20), and remove the inlet connector (21). REMARK • Do the same task on all cylinders in this same manner. • Clean around the parts in advance to prevent mud, etc. from entering the connector hole. • Use the remover (C) when you remove the inlet connector (21). Tools: Impact wrench, socket, remover (C) Retainer (20): Width across flats 24 mm Injector assembly 11. Remove the injector assembly (22) in this same manner by use of the procedure below.
PC210-10M0, PC210LC-10M0
50-55
REMOVE AND INSTALL INJECTOR ASSEMBLY
1)
50 DISASSEMBLY AND ASSEMBLY
Remove the bolts (23) (2 pieces), and remove the injector assembly (22). Tools: Impact wrench, socket Bolt (23): width across flats 8 mm, M6
2)
Remove the injector assembly (22) with the puller (A).
k k
Do not pry the injector top to remove. Be careful not to allow debris or foreign material to enter the injector assembly (22) installation area.
$
Tool: Puller (A)
*
INSTALL INJECTOR ASSEMBLY Injector assembly 1. Install the injector assembly (22) on all cylinders in this same manner by use of the procedure below. NOTICE When you replace the injector assembly (22) with a new one, replace the inlet connector with a new one as well. REMARK Make sure the injector sleeve is free from scratches and dirt. 1) Install the o-ring (24) and gasket (25) on the injector assembly (22). NOTICE Use a new o-ring and gasket. 2)
Apply engine oil to the O-ring (24) and the mounting hole on the head for the injector assembly (22). O-ring (24) of injector assembly (22) and head: engine oil (EO15W-40)
3)
50-56
Align the concave part (b) of the holder (26) with the protruding part (a) of the injector assembly (22), and install the holder (26).
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
4)
Face the fuel inlet opening of the injector (22) towards the intake manifold and mount the injector to the cylinder head.
5)
Tighten the bolts (23) (2 pieces) 3 to 4 turns.
Inlet connector 2. Install the inlet connector (21) to each cylinder in this same manner by use of the procedure below. 1) Check the inlet connector (21) by use of the items below. If there are any issues, replace the connector. NOTICE • If there is a burr or wear found on the front tip (a) or rear tip (b) of the inlet connector • If there is foreign material on the edge filter of the rear tip (c) of the inlet connector • If a crack or deterioration is found on the oring for the upper part (d) of the inlet connector. • If wear or uneven contact is found on the seat surface (e) at the front end of the inlet connector. REMARK If high-pressure fuel leaks through the inlet connector, the seat surface has fine streaks or cracks.
2)
Apply engine oil to the head side mounting hole of the inlet connector (21). Head side mounting hole for the inlet connector (21): engine oil (EO15W-40)
3)
Apply engine oil to the o-ring (24) of the inlet connector (21). Align the positioning ball (21a) to the groove on the head. Fully insert the inlet connector (21). O-ring (24) for the inlet connector (21): engine oil (EO15W-40)
PC210-10M0, PC210LC-10M0
50-57
REMOVE AND INSTALL INJECTOR ASSEMBLY
4)
50 DISASSEMBLY AND ASSEMBLY
Tighten the bolt (23) in 2 increments. Tools: ratchet handle, socket, torque wrench Bolt (23): width across flats 8 mm, M6 Bolt (23) 1st time: 3.5 ± 0.35 Nm {0.36 ± 0.04 kgm} Bolt (23) 2nd time, additional degrees of tightening: 75 ± 5°
5)
Tighten the retainer (20). Tools: ratchet handle, socket, torque wrench Retainer (20): 50 ± 5 Nm {5.1 ± 0.51 kgm}
Crosshead and Rocker Arm 3. Install the crosshead (19), rocker arms (16a), and (16b) on all cylinders in this same manner by use of the procedure below. 1) Install crosshead (19). Install rocker arms (16a) and (16b) by use of bolts (16) (2 pieces). REMARK • Shape of holes at locations (a) and (b) of the crosshead are different. When you reuse the crosshead, use the same intake and exhaust valves and in the same direction. • Make sure the ball part on the adjustment screw (18) is securely inserted into the socket of the push rod, and then tighten the bolt (16). Bolt (16): width across flats 10 mm, M8 Bolt (16): 36 ± 5 Nm {3.67 ± 0.51 kgm}
50-58
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
2)
REMOVE AND INSTALL INJECTOR ASSEMBLY
Adjust the valve clearance. NOTICE • See Testing and Adjusting, "TEST AND ADJUST VALVE CLEARANCE" and then make adjustments. • Rotate the crankshaft with the gear (B), and adjust the valve clearance of each cylinder. Tool: gear (B)
3)
After you adjust the valve clearance, make sure the lock nut (17) is tightened to the specified torque. Tools: Box-end wrench, hexagonal wrench, torque wrench Lock nut (17): Width across flats 14.2 mm Adjustment screw (18): Width across flats 5 mm Lock nut (17): 24 ± 4 Nm {2.45 ± 0.41 kgm}
Fuel piping Do not reuse the high-pressure pipe by bending it.
k k
k
Be sure to use Komatsu genuine high-pressure pipe and fixing clamp, and observe the specified tightening torque. Install the high-pressure tubes and wiring harness 10 mm or more apart.
NOTICE • Check the items below before you install high-pressure pipe. If there is an issue, replace the high-pressure pipe with a new one since fuel will leak. • Visually check that the taper seal part of the connecting part (a) (2 mm area from the tip) is free from vertical slit scratches (b) and spotted dents (c). • Make sure the area (d) (2 mm from the tip) is free from variances in height (unevenness) that will catch your fingernail. 4. Lightly tighten sleeve nuts for the common rail (24) and high-pressure pipes (15), (15a), (15b), (15c), (15d), and (15e). Tools: wrench, torque wrench High-pressure pipe (15), (15a), (15b), (15c), (15d), (15e): Width across flats 19 mm High-pressure pipe (15), (15a), (15b), (15c), (15d), and (15e): 0.2 to 0.8 Nm {0.02 to 0.08 kgm} 5.
Fully tighten the high-pressure pipes (15), (15a), (15b), (15c), (15d), and (15e) by use of the procedure below. 1) High-pressure pipe ((15): Connector side) → ((15a): Connector side) → ((15b): Connector side) → ((15): Common rail side) → ((15a): Common rail side) → ((15b): Common rail side) 2) High-pressure pipe ((15c): Connector side) →((15d): Connector side) →((15e): Connector side) →((15c): Common rail side) →((15d): Common rail side) → ((15e): Common rail side)
PC210-10M0, PC210LC-10M0
50-59
REMOVE AND INSTALL INJECTOR ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Tools: wrench, torque wrench High-pressure pipe (15), (15a), (15b), (15c), (15d), (15e): Width across flats 19 mm High-pressure pipes (15), (15a), (15b), (15c), (15d), and (15e): 40 ± 4 Nm {4.08 ± 0.41 kgm} 6.
Install the fuel spray prevention caps (14) (12 pieces). REMARK • Direct the slits of the fuel spray prevention caps outward or downward to install them. • The fuel spray prevention caps are installed so that fuel will not spout over the hot part of the engine and catch fire when it leaks by any chance.
When you replace the fuel pressure sensor and relief valve 7. Use the procedure below when you replace the fuel pressure sensor (10a). NOTICE • Do not remove the fuel pressure sensor (10a) from the common rail (24) for a purpose other than replacement. • Be sure to replace fuel pressure sensors removed from the common rail with a new sensor. 1) Before you remove the fuel pressure sensor (10a), clean the area around it, and fully remove dirt, etc. 2) Disconnect the connector C8 (10c). 3)
Remove the fuel pressure sensor (10a). Tool: wrench Fuel pressure sensor (10a): Width across flats 27 mm
4)
Check the fuel pressure sensor connector for cracks, breakage, damage to the seal, foreign material on the pin as well as corrosion, bending and breakage of the pin.
5)
Install a new fuel pressure sensor (10a). Tools: wrench, torque wrench Fuel pressure sensor (10a): Width across flats 27 mm Fuel pressure sensor (10a) threads: gear oil (#90) Fuel pressure sensor (10a): 70 ± 5 Nm {7.1 ± 0.5 kgm}
6)
Connect the connector C8 (10c). REMARK Be careful not to connect backwards.
7)
Start the engine, and check for leakage. NOTICE See TESTING AND ADJUSTING, "TEST FUEL CIRCUIT FOR LEAKAGE".
50-60
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
8.
REMOVE AND INSTALL INJECTOR ASSEMBLY
Use the procedure below when you remove the relief valve (10b) 1) Before you remove the relief valve (10b), clean the area around it of mud etc. 2) Remove the relief valve (10b) NOTICE If the relief valve leakage is higher than specifications, do not reuse.
E *
Tools: ratchet handle, socket Relief valve (10b): Width across flats 18 mm 3)
Make sure there is no damage to the relief valve (10b) and high-pressure seal surfaces (a).
4)
Install the relief valve (10b)
k
D
Excessive tightening can cause leakage. Take care not to tighten excessively.
Tools: ratchet handle, socket, torque wrench Relief valve (10b): Width across flats 18 mm
*
Relief valve (10b) threads: gear oil (#90) Relief valve (10b): 100 ± 4 Nm {10.2 ± 0.4 kgm} 5)
Start the engine, and check for leakage. NOTICE See TESTING AND ADJUSTING, "TEST FUEL CIRCUIT FOR LEAKAGE".
Wiring harness and gasket assembly 9. Install the gasket assembly (13). 10. Connect the connectors C9 (7d), C10 (7e), and C11 (7f) of the engine wiring harness (7). k
Install the high-pressure tubes and wiring harness 10 mm or more apart.
11. Connect the harness to the injector (10) by use of nuts (11) (2 pieces). REMARK Do the same task on all cylinders in this same manner. Tools: ratchet handle, socket Nut (11): Width across flats 8.7 mm Nut (11): 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
PC210-10M0, PC210LC-10M0
50-61
REMOVE AND INSTALL INJECTOR ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Head cover 12. Install the head cover (9) with the bolts (8) (5 pieces). Tools: ratchet handle, socket, torque wrench Bolt (8): Width across flats 13 mm, M8 Bolt (8): 24 ± 4 Nm {2.45 ± 0.41 kgm}
Clamp 13. Install the bands (7b) (2 pieces) of the engine wiring harness (7), and install the clamp (7a). REMARK Use a new band (7b). Tools: ratchet handle, socket, torque wrench Bolt for clamp (7a): Width across flats 8 mm, M6 Clamp (7a) bolt: 10 ± 2 Nm {1.02 ± 0.2 kgm}
Engine hood 14. Close the engine hood (1).
50-62
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY Draining coolant ─
A ─ Hose
B─
Fan clutch assembly
Wiring Harness C─ and Gasket Assembly D-
Cover, wiring Engine hood as─ connector sembly
Muffler assembly
─A
─ Hose
─
Exhaust Manifold and Turbo─ ─B charger Assembly
─ Fan guard
─ Connector
High-pressure ─ Piping and Common Rail
Air conditioner ─ compressor assembly
─ Alternator
─
Wiring harness clamp, band
─ Head cover
-C
─ Inlet Connector
─
Injector assembly
─ Push rod
-D
─
Crosshead, rocker arm
Cylinder head assembly
Standard tool list The listed parts are for reference only. You can use the part that is not listed if it is applicable. No.
Part name
Part No.
Specifications
Q'ty
1
Socket
Commercially 8 mm available
1
2
Socket
Commercially 12 mm available
1
3
Socket
Commercially 14 mm available
1
4
Socket
Commercially 17 mm available
1
5
Socket
Commercially 22 mm available
1
6
Ratchet handle
Commercially available
1
7
Box-end combination wrench
Commercially 14 mm available
1
8
Impact wrench
Commercially available
1
9
Torque wrench
Commercially 0.5 to 3 Nm available
1
10
Torque wrench
Commercially 2 to 20 Nm available
1
11
Torque wrench
Commercially 5 to 50 Nm available
1
12
Torque wrench
Commercially 20 to 200 Nm available
1
13
Needle-nose pliers
Commercially available
1
PC210-10M0, PC210LC-10M0
Remarks
50-63
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
No.
Part name
14
Part No.
Specifications
Commercially available
Wire
Q'ty
Remarks
1
Special tool list Symbol
Part name
Part No.
Specifications
Q'ty
Remarks
A
Puller
795-799-6700
1
Removal of injector assembly
B
Gear
795-799-1131
1
Adjusting the valve clearance
C
Remover
795-799-8150
1
Removing the inlet connector
D
Wrench
790-331-1120 Angle
1
Bolt angle tightening
E
Gauge
795-790-4510
1
Bolt measurement
k k k k k
Place the machine on a level ground, and lower the work equipment to the ground in a stable attitude. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "HANDLE BATTERY DISCONNECT SWITCH".) When you remove and install the fuel piping, make sure no foreign matter enters the fuel piping. If dust, etc. sticks to any part, wash that part completely with clean fuel.
REMOVE CYLINDER HEAD ASSEMBLY Draining coolant 1. Drain the coolant. See "DRAIN AND ADD COOLANT". Engine hood assembly 2. Remove the engine hood assembly. See "REMOVE AND INSTALL ENGINE HOOD ASSEMBLY". Cover and Wiring Connector 3.
Remove parts indicated below. See " Remove ENGINE AND MAIN PUMP ASSEMBLY" •
Upper cover of control valve
•
Cover between oil pressure pump and engine
•
Frame between the control valve and the engine
•
Cover between the control valve and the engine
REMARK Temporarily remove the frame between the control valve and engine for a place to place your foot. Afterwards, replace the frame.
50-64
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Hose 4. Remove the cap (4c), remove the joint bolt (4d), and disconnect the fuel return hose (4). Tools: impact wrench, socket Joint bolt (4d): width across flats 17 mm, M12
5.
Remove the joint (4e), and disconnect the fuel return hose (4a). Tools: impact wrench, socket Joint (4e): Width across flats 19 mm, M12
Muffler assembly 6. Remove the bolts (6a) (2 pieces), and remove the cover (6). REMARK Caution: do not lose the spacer when you remove bolt (6a). Tools: impact wrench, socket Bolt (6a): width across flats 12 mm, M8
7.
Remove the clamp (7). Tools: impact wrench, socket Clamp (7) bolt: width across flats 17 mm, M12
8.
Remove the nuts (8c) (4 pieces), and remove the U-bolts (8b) (2 pieces). Tools: Impact wrench, socket Nut (8c): Width across flats 14 mm
9.
Lift the muffler assembly (8), and remove it. Tool: wire Muffler assembly (8): 18 kg
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Hose 10. Remove the hose (10) by use of the procedures below. 1)
Mark the hose (10) and tube. NOTICE Mark the end of the hose and the tube so that they can be reconnected correctly.
2)
Remove the clamps (10a) (4 pieces), and disconnect the hose (10). Tools: Ratchet handle, socket Clamp (10a): Width across flats 10 mm
11. If you disconnect at the air intake connector (10b), remove by use of the procedure below. 1) Remove the bolts (10c) (4 pieces), and remove the hose (10) and air intake connector (10b) together. Tools: Impact wrench, socket Bolt (10c): Width across flats 11 mm, M8 2)
Remove gasket (10d).
12. Remove the hose clamp (11b), and disconnect the radiator hose (11). Tools: ratchet handle, socket Hose clamp (11b): width across flats 8 mm 13. Remove the clamp (11c) and clip (11d), and disconnect the radiator hose (11a). Tools: ratchet handle, socket, needle-nose pliers Clamp (11c) bolt: width across flats 17 mm, M10 14. Remove clip (12a), and disconnect the heater hose (12). Tool: needle-nose pliers
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Fan guard 15. Remove the bolts (13b) (3 pieces), and remove the fan guard (13). Tools: impact wrench, socket Bolt (13b): Width across flats 17 mm, M10 16. Remove the bolts (13c) (2 pieces), and remove the fan guard (13a). Tools: Impact wrench, socket Bolt (13c): Width across flats 17 mm, M10 Connector 17. Disconnect the ambient pressure sensor connector C29 (14) and boost pressure sensor connector C4 (15), and move the wiring harness to the left side where it does not interfere with the work. REMARK For the ambient pressure sensor connector (14), move the lock to the right side (a). Press on the tab (t) and pull out the connector.
18. Disconnect the coolant temperature sensor connector C16 (17).
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
High-Pressure Piping and Common Rail 19. Disconnect the fuel pressure sensor connector C8 (18). 20. Remove the joint bolts (19a), (19b), and clamps (19c) (2 pieces), and remove the fuel return hose (19) from the rear surface of the common rail and cylinder head. Tools: ratchet handle, impact wrench, socket Joint bolt (19a): Width across flats 17 mm, M12 Joint bolt with check valve (19b): Width across flats 19 mm, M12 Clamp (19c) bolt: width across flats 12 mm, M8 21. Remove the clamps (21a) and (21b). REMARK Be careful not to drop the spacer when you remove the clamp (21a) nut. Tools: impact wrench, socket Clamp (21a) nut: width across flats 12 mm, Clamp (21b) bolt: width across flats 12 mm, M8 22. Remove the fuel spray prevention cap (22), loosen the sleeve nut, and remove the high-pressure pipe (21). Tool: Open-end wrench High-pressure pipe (21): Width across flats 19 mm 23. Remove the fuel spray prevention caps (23) (12 pieces) and loosen the sleeve nut. Next, remove the high-pressure pipes (24), (24a), (24b), (24c), (24d) and (24e). Tool: wrench High-pressure pipe (24), (24a), (24b), (24c), (24d), (24e): Width across flats 19 mm
24. Remove bolts (20a) 2,(20b) (2 pieces), then remove the common rail (20). REMARK Do not remove the fuel pressure sensor (25) or relief valve (25a) other than for replacement. Tools: impact wrench, socket Bolts (20a), (20b): Width across flats 10 mm, M8
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Exhaust manifold and turbocharger assembly 25. Remove the bolts (26a) (4 pieces), and remove the protection cover (26). Tools: impact wrench, socket Bolt (26a): width across flats 12 mm, M8 26. Loosen clamp (27) and disconnect tube (27a). Tools: ratchet handle, socket Clamp (27): Width across flats 10 mm 27. Remove the clamp (28), and disconnect the air hose (28a). REMARK Mark the end of the hose and the tube so that they can be reconnected correctly. Tools: ratchet handle, socket Clamp (28): Width across flats 13 mm 28. Loosen the sleeve nut, and disconnect the lubrication inlet hose (29). REMARK When you loosen the O-ring seal nut of the lubrication inlet hose (29), hold the connector (29a) on the turbocharger side with the wrench not to let it rotates together. Tool: Open-end wrench Lubrication inlet hose (29): Width across flats 20.6 mm, 13/16 inch Connector (29a): Width across flats 19mm 29. Remove the bolts (30a) (2 pieces), and disconnect the lubrication outlet hose (30). Tools: Impact wrench, socket Bolt (30a): Width across flats 10 mm, M8 30. Remove the bolts (31a) (12 pieces) but leave some pieces out of them. Tools: Impact wrench, socket Bolt (31a): Width across flats 10 mm, M8 31. Retain the exhaust manifold and turbocharger assembly (70) and remove the remaining bolts (31a). REMARK Caution: do not allow the spacer or gasket to fall when you remove the bolts (31a). Tools: impact wrench, socket, wire Bolt (31a): Width across flats 10 mm, M8 Exhaust manifold and turbocharger assembly (70): 25 kg 32. Lift and remove the exhaust manifold and turbocharger assembly (70).
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
Fan clutch assembly 33. Disconnect the connectors AC03 (36a) and M16 (32b) then remove them from the connector block. REMARK Mark the connection position to prevent connection mistakes. 34. Remove the clamps (32c) (2 pieces). REMARK Bend up and disengage the tabs on the clamp (a). Tools: impact wrench, socket Clamp (32c) bolt: width across flats 17 mm, M10 35. Remove the bolts (32a) (6 pieces), and remove the fan clutch assembly (32). REMARK After you remove the fan clutch assembly (32) allow it to drop downward. Tool: box-end wrench Bolt (32a): width across flats 14 mm, M10 Air conditioner compressor assembly 36. Loosen the bolts (33) and (34). REMARK Pushing in the air conditioner compressor will reduce the tension on the belt. Tools: ratchet handle, socket Bolt (33): width across flats 22 mm, M14 Bolt (34): Width across flats 22 mm, M14 37. Remove the air conditioner compressor belt (35). 38. Remove the bolts (36) (3 pieces), and remove the air conditioner compressor assembly (37). REMARK Remove air conditioner compressor assembly together with the bracket as a unit, and place on a counterweight. Tools: ratchet handle, socket Bolt (36): width across flats 17 mm, M10
50-70
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Alternator 39. Remove the alternator belt (38) by use of the procedure below. 1) Install the ratchet handle to the portion (p) (insertion angle: 12.7 mm) of the tensioner assembly (38a). Tool: ratchet handle 2) k
k
k
Rotate the ratchet handle in the direction (r) opposite the wind-up direction to loosen the tension of the alternator belt (38). Then remove the alternator belt. Make sure that the ratchet handle is securely mounted to the (p) part of the tensioner assembly (38a) before you rotate it. After you remove the alternator belt (38), allow the tensioner assembly (38a) to return slowly and carefully. Be careful not to get your fingers caught between the pulley and alternator belt (38) during work.
40. Remove the cap, remove the nut (40a), and disconnect the connector AB (40). Tools: ratchet handle, socket Nut (40a): Width across flats 8 mm 41. Disconnect the connector E12 (41).
42. Remove the bolts (39a) and (39b), and remove the alternator (39). Tools: impact wrench, socket Bolt (39a): Width across flats 17 mm, M10 Bolt (39b): width across flats 10 mm, M8
Wiring Harness Clamp and Band 43. Remove the clamp (43) of the wiring harness (42), and cut the bands (44) (2 pieces). Tools: impact wrench, socket, wire cutters Bolt for clamp (43): Width across flats 8 mm, M6
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
Head cover 44. Remove the bolts (45) (5 pieces), and remove the head cover (46) and blowby duct (47) together. REMARK • After you loosen the bolt (45), hold the cover down to prevent mud etc. from entering and clean around the area by use of an compressed air. • When you remove the head cover (46), do not allow it to come into contact with surrounding parts. Tools: impact wrench, socket Bolt (45): Width across flats 13 mm, M8 45. Remove the hexagonal head bolts (47a) (2 pieces) from the head cover (46), and remove the blowby duct (47). Tool: hexagonal wrench Hexagonal socket head bolt (47a): Width across flats 3 mm, M5 Wiring harness and gasket assembly 46. Remove the wiring harness nuts (49) (2 pieces) from the injector assembly (48). REMARK Do the same task on all cylinders in this same manner. Tools: ratchet handle, socket Nut (49): Width across flats 8.7 mm
47. Disconnect the connectors C9 (50a), C10 (50b), and C11 (50c) of the engine wiring harness (50). REMARK There are support tabs on the connectors. Push on these tabs and pull out the connector. When you remove the connector, hold the gasket by hand so it does not move. 48. Lift and remove the gasket assembly (51). REMARK • Be careful to prevent foreign material from entering the engine when you remove it. • When you remove the head cover (46), visually check the gasket assembly (51). If there are one cracks, deterioration, or wear, use a new gasket assembly (51). Crosshead and Rocker Arm 49. Remove the rocker arms (52a) and (52b), and the crosshead (55) in this same manner by use of the procedure below.
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
1)
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Remove the bolts (52) (2 pieces), and remove the rocker arms (52a) and (52b). REMARK When you install the rocker arm, loosen the lock nut (53) and loosen the adjustment screw (54) 2 to 3 turns so that excessive force is not applied to the push rod. Tools: Ratchet handle, socket, box-end combination wrench, hexagonal wrench Bolt (52): width across flats 10 mm, M8 Lock nut (53): Width across flats 14.2 mm Adjustment screw (54): Width across flats 5.1 mm
2)
Remove the crossheads (55) (2 pieces). REMARK Record the location and direction of the crosshead (shapes of the holes (a) and (b)). (Install it in the noted direction when you reassemble them.)
Inlet Connector 50. Remove the retainer (56), and remove the inlet connector (57). REMARK • Do the same task on all cylinders in this same manner. • Clean around the parts in advance to prevent mud, etc. from entering the connector hole. • Use the remover (C) to remove the inlet connector (57). Tools: impact wrench, socket, remover (C) Retainer (56): Width across flats 24 mm Injector assembly 51. Remove the injector assembly (58) from all cylinders in this same manner by use of the procedure below.
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
1)
Remove the bolts (59) (2 pieces), and remove the injector assembly (58). Tools: impact wrench, socket Bolt (59): width across flats 8 mm, M6
2)
Use a puller (A) to remove the injector assembly (48).
k k
Do not pry the injector top to remove.
$
Be careful not to allow debris or foreign material to enter the injector assembly (48) installation area.
Tool: puller (A)
*
Push rod 52. Remove the push rods (61) (2 pieces). REMARK Do the same task on all cylinders in this same manner.
Cylinder head assembly 53. Remove the bolts (62) (26 pieces), lift the cylinder head assembly (63), and remove it. Tools: impact wrench, socket, wire Bolt (62): Width across flats 18 mm, M12
Cylinder head assembly (63): 75 kg 54. Remove the cylinder head gasket (64). *
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
INSTALL CYLINDER HEAD ASSEMBLY Cylinder head assembly 1. Measure the stem length (a) of all the cylinder head bolts (62), and check that it is within the using limit. NOTICE • Allowable limit of bolt length: less than QQ 132.1 mm. • Use a new bolt if the bolt is longer than the allowable limit. • Use a gauge (E) to measure the stem length. Tool: gauge (E) 2.
Align the cylinder head gasket (64) with the installation position of the cylinder block.
NOTICE • Make sure there is no dirt or other debris on cylinder head installation surface or inside the cylinder.
• Check that the holes in the cylinder head gasket (64) are aligned with the holes in the cylinder head. 3.
Install the cylinder head assembly (63) on the cylinder block. Also, tighten the bolts (62) (26 pieces) by hand 2 to 3 turns or more.
*
Tool: wire Cylinder head assembly (63): 75 kg 4.
Tighten the bolts (62) in the numerical order shown in the figure. NOTICE Apply engine oil the engine bolt mounting location and on the seat surface of the bolt head. Threaded part of the bolt and seat surface of the bolt head: engine oil (EO15W-40) 1) When you perform angular tightening by use of a wrench (angle) (D) Tools: ratchet handle, socket, torque wrench, wrench (angle) (D) Bolt (106): Width across flats 18 mm, M12 1st time: 70 ± 6 Nm {7.14 ± 0.61 kgm} 2nd time: Rotate back all bolts by 360 ± 5° 3rd time: 105 ± 3 Nm {10.71 ± 0.31 kgm} 4th time: 90 ± 5° 2)
If the wrench (angle) (D) is not used, place marks on the cylinder head and bolt, and then tighten the bolt 90 ± 5°.
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Push rod 5. Install the push rods (61) (2 pieces). REMARK Do the same task on all cylinders in this same manner.
Injector assembly 6. Install the injector assembly (58) to each cylinder in this same manner by use of the procedure below. NOTICE When you replace the injector assembly (58) with a new one, replace the inlet connector with a new one as well. REMARK Make sure there are no scratches, debris, etc. on the injector sleeve. 1) Install the O-ring (58a) and gasket (58b) on the injector assembly (58). NOTICE Use a new O-ring and gasket. 2)
Apply engine oil to O-ring (58a) and installation-hole of the injector assembly (58) on the head. O-ring (58a) of injector assembly (58) and head: engine oil (EO15W-40)
3)
Align the concave part (a) with the convex part (b), and install the holder (58c) to the injector assembly (58).
4)
Face the fuel inlet opening of the injector assembly (58) towards the intake manifold and mount the assembly to the cylinder head.
5)
Tighten the bolts (59) (2 pieces) 3 to 4 turns. Tools: ratchet handle, socket Bolt (59): width across flats 8 mm, M6
Inlet connector 7. Install the inlet connector (21) to each cylinder in this same manner by use of the procedure below.
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
1)
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Check the inlet connector (57) by use of the items below. If there are any issues, replace the connector. NOTICE • Burr or wear found on the front tip (a) or rear tip (b) of the inlet connector • If foreign material is attached to the edge filter at the rear tip (c) of the inlet connector • A crack or deterioration is found on the O-ring of the inlet connector upper part (d). • Wear or uneven contact is found on the seat surface (e) at the front end of the inlet connector. REMARK If high-pressure fuel leaks through the inlet connector, the seat surface has fine streaks or cracks.
2)
Apply engine oil to the mounting hole for the inlet connector (57) on the head. Mounting hole for the inlet connector (57) on the head: engine oil (EO15W-40)
3)
Apply engine oil to the O-ring (57a) of the inlet connector (57). Align the positioning ball (57b) to the groove on the head. Fully insert the inlet connector (57). O-ring (57a) for the inlet connector (57): engine oil (EO15W-40)
4)
Tighten the bolts (59) (2 pieces) to the specified torque in 2 operations. Tools: ratchet handle, socket, torque wrench, wrench (angle) (D) Bolt (59): width across flats 8 mm, M6 Bolt (59) 1st time: 3.5 ± 0.35 Nm {0.36 ± 0.04 kgm} Bolt (59) 2nd time, additional degrees of tightening: 75± 5°
5)
Tighten the retainer (56). Tool: Ratchet handle, socket, torque wrench Retainer (56): Width across flats 24 mm Retainer (56): 50 ± 5 Nm {5.1 ± 0.51 kgm}
Crosshead and Rocker Arm 8. Install the crosshead (19), rocker arms (16a), and (16b) on all cylinders at the same time by use of the procedures below.
PC210-10M0, PC210LC-10M0
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1)
50 DISASSEMBLY AND ASSEMBLY
Install the crosshead (55), and install the rocker arms (52a) and (52b) with the bolts (52) (2 pieces). REMARK • Shape of holes at locations (a) and (b) of the crosshead are different. When you reuse the crosshead, use the same intake and exhaust valves and in the same direction. • Make sure the ball part on the adjustment screw (54) is securely inserted into the socket of the push rod, and then tighten the bolt (52). Tools: ratchet handle, socket, torque wrench Bolt (52): width across flats 10 mm, M8 Bolt (52): 36 ± 5 Nm {3.67 ± 0.51 kgm}
2)
Adjust the valve clearance. NOTICE • Refer to TESTING AND ADJUSTING, "TEST AND ADJUST VALVE CLEARANCE" and then make adjustments. • Rotate the crankshaft to adjust the valve clearance of each cylinder by using the gear (B). Tool: gear (B)
3)
After you adjust the valve clearance, make sure the lock nut (53) is tightened to the specified torque. Tools: Box-end wrench, hexagonal wrench, torque wrench Lock nut (53): Width across flats 14.2 mm Adjustment screw (54): Width across flats 5.1 mm Lock nut (53): 24 ± 4 Nm {2.45 ± 0.41 kgm}
50-78
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Wiring harness and gasket assembly 9. Install the gasket assembly (51). 10. Connect the connectors C9 (50a), C10 (50b), and C11 (50c) of the engine wiring harness (50). k
Install the high-pressure tubes and wiring harness 10 mm or more apart.
11. Install the wiring harness to the injector assembly (48) with the nuts (49) (2 pieces). REMARK • Do the same task on all cylinders in this same manner. • Check that the wiring harness does not interfere with the rocker arm. Tools: ratchet handle, socket, torque wrench Nut (49): Width across flats 8.7 mm Nut (49): 1.5 ± 0.25 Nm {0.15 ± 0.03 kgm} Head cover 12. Install the head cover (46) with the bolts (45) (5 pieces). REMARK When you install the head cover (46), do not allow it to come into contact with surrounding parts. Tools: ratchet handle, socket, torque wrench Bolt (45): Width across flats 13 mm, M8 Bolt (45): 24 ± 4 Nm {2.45 ± 0.41 kgm} 13. Install the blow-by duct (47) by use of hexagonal socket bolts (47a) (2 pieces). Tools: hexagonal wrench, torque wrench Hexagonal socket head bolt (47a): Width across flats 3 mm, M5 Hexagonal socket bolt (47a): 7 ± 2 Nm {0.71 ± 0.2 kgm} Wiring Harness Clamp and Band 14. Install the bands (44) (2 pieces) of the wiring harness (42), and install the clamp (43). REMARK Use a new band (44). Tools: ratchet handle, socket, torque wrench Bolt for clamp (43): Width across flats 8 mm, M6 Clamp (43) bolt: 10 ± 2 Nm {1.02 ± 0.2 kgm}
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Alternator 15. Install the alternator (39) with the bolts (39a) and (39b). Tools: ratchet handle, socket, torque wrench Bolt (39a): Width across flats 17 mm, M10 Bolt (39b): width across flats 10 mm, M8 Bolt (39a): 43±6 Nm {4.38±0.61 kgm} Bolt (39b): 24 ± 4 Nm {2.45 ± 0.41 kgm}
16. Connect the connector E12 (41). 17. Connect the connector AB (40) with the nut (40a), and install the cap. Tools: ratchet handle, socket, torque wrench Nut (40a): Width across flats 8 mm Nut (40a): 5.9 to 9.8 Nm {0.6 to 1.0 kgm}
18. Install alternator belt (38) by use of the procedures below. 1) Install the ratchet handle to the portion (p) (insertion angle: 12.7 mm) of the tensioner assembly (38a). 2) Install the alternator belt (38) when the ratchet handle is being rotated in the direction (r) opposite the windup direction. k
k k k
Make sure that the ratchet handle is securely mounted to the (p) part of the tensioner assembly (38a) before you rotate it. After you install the fan belt (38), allow the tensioner assembly (38a) to return slowly and carefully. Be careful not to get your fingers caught between the pulley and alternator belt (38) during work. Make sure that the belt groove and pulley groove are aligned.
Air conditioner compressor assembly 19. Install the air conditioner compressor assembly (37) with the bolts (36) (3 pieces). Tools: ratchet handle, socket, torque wrench Bolt (36): width across flats 17 mm, M10 Bolt (36): 59 to 74 Nm {6 to 7.5 kgm}
50-80
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
20. Install the air conditioner compressor belt (35). REMARK See TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION".
Fan clutch assembly 21. Install the fan clutch assembly (32) with the bolts (32a) (6 pieces). Tool: Box-end wrench, Torque wrench Bolt (32a): width across flats 14 mm, M10 Bolt (32a): 59 to 74 Nm {6 to 7.5 kgm} 22. Install the clamps (32c) (2 pieces). REMARK Connect the clamp (a) by bending up the tabs. Tools: ratchet handle, socket, torque wrench Clamp (32c) bolt: width across flats 17 mm, M10 Clamp (32c) bolt: 59 to 74 Nm {6 to 7.5 kgm} 23. Connect the connectors AC03 (36a) and M16 (32b). Exhaust manifold and turbocharger assembly 24. Lift the exhaust manifold and turbocharger assembly (70) and align them in the installation position. Tool: wire Exhaust manifold and turbocharger assembly (70): 25 kg 25. Install a new gasket, and tighten the exhaust manifold and turbocharger assembly (70) lightly with the bolts (31a) (12 pieces). NOTICE Adjust the exhaust manifold and turbocharger assembly (70) by loosening and tightening the bolts so that there is no offset or play. Tools: ratchet handle, socket Bolt (31a): Width across flats 10 mm, M8 26. Install bolts (31a) (12 pieces) by use of the procedure below. Tools: ratchet handle, socket, torque wrench Bolt (31a): Width across flats 10 mm, M8 1) Tighten the bolts in the order shown in the figure. Bolt (31a): 24 ± 4 Nm {2.45 ± 0.41 kgm} 2)
Fully tighten the bolts in the order shown in the figure. Bolt (31a): 53 ± 5 Nm {5.4 ± 0.51 kgm}
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
3)
50 DISASSEMBLY AND ASSEMBLY
Tighten only bolts (1), (2), (3), and (4) in the order shown in the figure.
Bolt (31a): 53 ± 5 Nm {5.4 ± 0.51 kgm} 27. Connect the lubrication outlet hose (30) with the bolts (30a) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (30a): Width across flats 10 mm, M8 Bolt (30a): 24 ± 4 Nm {2.45 ± 0.41 kgm} 28. Connect the lubrication hose (29) by use of a sleeve nut. REMARK • When you tighten the O-ring seal nut of the lubrication inlet hose (29), hold the connector (29a) on the turbocharger side with the wrench not to let it rotates together. • Make sure that the lubrication inlet hose (29) does not interfere with the turbo flange portion and lubrication outlet hose (30). Tool: Open-end wrench, torque wrench Lubrication inlet hose (29): Width across flats 20.6 mm Connector (29a): Width across flats 19 mm Lubrication inlet hose (29): 35±5 Nm {3.57±0.5 kgm} 29. Tighten the torque below in case you loosened the connector (29a). Tool: Open-end wrench, torque wrench Connector (29a): Width across flats 19 mm Connector (29a): 36±5 Nm {3.67±0.5 kgm} 30. Connect the air hose (28a) with the clamp (28). NOTICE • Use a new clamp (28). • Do not use an impact wrench. REMARK Air hose insertion depth: 40 mm Tools: ratchet handle, socket, torque wrench Clamp (28): Width across flats 13 mm Clamp (28) threaded part of bolt (d): lubricating oil (ThreeBond PANDO18B) 1)
Connect the air hose (28a) to the marked position.
2)
Set bridge (a) of the clamp (28) under the bolt (d). Then, tighten the bolt so that the overlap dimension (c) between the bridge (a) and band (b) is 5 mm or more.
REMARK • When reusing hose 50-82
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Align the clamp (28) with the mark of the clamp on the hose. Clamp (28): 6 Nm {0.6 kgm} or more • When using a new hose Tighten until the distance (e) of the clamp (28) is 7 to 10 mm. 31. Connect the air tube (27a) by use of the clamp (27). Tools: ratchet handle, socket, torque wrench Clamp (27): Width across flats 10 mm Clamp (27): 10.0 to 11.0 Nm {1.02 to 1.12 kgm} 32. Install the protection cover (26) with the bolts (26a) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (26a): width across flats 12 mm, M8 Bolt (26a): 27 to 34 Nm {2.8 to 3.5 kgm} High-pressure piping and common rail Do not reuse the high-pressure pipe by bending it.
k k
k
Be sure to use Komatsu genuine high-pressure pipe and fixing clamp, and observe the specified tightening torque. Install the high-pressure tubes and wiring harness 10 mm or more apart.
NOTICE • Check the items below before you install high-pressure pipe. If there is even one defect, replace the high-pressure pipe with a new one since fuel will leak. • Visually check that the taper seal part of the connecting part (a) (2 mm area from the tip) is free from vertical slit scratches (b) and spotted dents (c). • Make sure the area (d) (2 mm from the tip) is free from variances in height (unevenness) that will catch your fingernail. 33. Tighten the common rail (20) lightly by use of bolts (20a) (2 pieces) and (20b) (2 pieces). Tools: ratchet handle, socket Bolts (20a), (20b): Width across flats 10 mm, M8 Bolt (20a): Liquid gasket (Loctite 516 sealant) or (LG-7) REMARK Apply the liquid gasket but not to the first and second external threads.
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
34. By use of sleeve nuts, lightly tighten the high-pressure pipes (24), (24a), (24b), (24c), (24d), and (24e). Tools: wrench, torque wrench High-pressure pipe (24), (24a), (24b), (24c), (24d), (24e): Width across flats 19 mm High-pressure pipe (24), (24a), (24b), (24c), (24d), and (24e): 0.2 to 0.8 Nm {0.02 to 0.08 kgm} 35. Tighten the high-pressure pipes (24), (24a), (24b), (24c), (24d), and (24e) by use of the procedure below. 1) High-pressure pipe ((24): Connector side) → ((24a): Connector side) → ((24b): Connector side) → ((24): Common rail side) → ((24a): Common rail side) → ((24b): Common rail side) 2) High-pressure pipe ((24c): Connector side) →((24d): Connector side) →((24e): Connector side) →((24c): Common rail side) →((24d): Common rail side) → ((24e): Common rail side) Tools: wrench, torque wrench High-pressure pipe (24), (24a), (24b), (24c), (24d), (24e): Width across flats 19 mm High-pressure pipes (24), (24a), (24b), (24c), (24d), and (24e): 40 ± 4 Nm {4.08 ± 0.41 kgm} 36. Tighten the high-pressure pipe (21) lightly with the sleeve nut. Tool: wrench High-pressure pipe (21): Width across flats 19 mm 37. Tighten the clamps (21a) and (21b) lightly. Tools: ratchet handle, socket Clamp (21a) nut: width across flats 12 mm, Clamp (21b) bolt: width across flats 12 mm, M8 38. For the high-pressure pipe (21), fully tighten the supply pump assembly (60) side and then fully tighten the common rail (20) side. Tools: wrench, torque wrench High-pressure pipe (21): Width across flats 19 mm High-pressure pipe (21): 40 ± 4 Nm {4.08 ± 0.41 kgm} 39. Tighten bolts (20a) (2 pieces) and (20b) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolts (20a), (20b): Width across flats 10 mm, M8 Bolts (20a) and (20b): 24 ± 4 Nm {2.45 ± 0.41 kgm} 40. Tighten clamps (21a) and (21b). Tools: ratchet handle, socket, torque wrench Nut for clamp (21a): Width across flats 15 mm Clamp (21b) bolt: width across flats 12 mm, M8 Clamp (21a) nut: 24 ± 4 Nm {2.45 ± 0.41 kgm} Clamp (21b) bolt: 27 to 34 Nm {2.8 to 3.5 kgm} 50-84
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
41. Install the fuel spray prevention caps (22) (2 pieces), and (23) (12 pieces). REMARK • Direct the slits of the fuel spray prevention caps outward or downward to install them. • The fuel spray prevention caps are installed so that fuel will not spout over the hot part of the engine and catch fire when it leaks by any chance. 42. Install the fuel return hose (19) by use of joint bolts (19a) and (19b), and clamps (19c) (2 pieces). Tools: ratchet handle, socket, torque wrench Joint bolt (19a): Width across flats 17 mm, M12 Joint bolt with check valve (19b): Width across flats 19 mm, M12 Clamp (19c) bolt: width across flats 12 mm, M8 Joint bolts (19a) and (19b): 24 ± 4 Nm {2.45 ± 0.41 kgm} Clamp (19c) bolt: 27 to 34 Nm {2.8 to 3.5 kgm} 43. Connect the fuel pressure sensor connector C8 (18). When you replace the fuel pressure sensor and relief valve 44. For details, please see "REMOVE AND INSTALL INJECTOR ASSEMBLY". Connector 45. Connect the coolant temperature sensor connector C16 (17).
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
46. Connect the ambient pressure sensor connector C29 (14) and boost pressure sensor connector C4 (15). REMARK After you connect the ambient pressure sensor connector (14), move the lock to the left side (b).
Fan guard 47. Install the fan guard (13a) with the bolts (13c) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (13c): Width across flats 17 mm, M10 Bolt (13c): 59 to 74 Nm {6 to 7.5 kgm} 48. Install the fan guard (13) with the bolts (13b) (3 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (13b): Width across flats 17 mm, M10 Bolt (13b): 59 to 74 Nm {6 to 7.5 kgm} 49. Connect the heater hose (12) by use of clip (12a). Tool: needle-nose pliers 50. Connect the radiator hose (11a) with the clip (11d), and install the clamp (11c). Tool: Ratchet handle, socket, torque wrench, needle-nose pliers Bolt for clamp (11c): Width across flats 17 mm, M10 Bolt for clamp (11c): 59 to 74 Nm {6 to 7.5 kgm} 51. Connect the radiator hose (11) with the hose clamp (11b). REMARK Radiator hose insertion depth: 40 mm Tools: ratchet handle, socket, torque wrench Hose clamp (11b): width across flats 8 mm Hose clamp (11b): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
50-86
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
Hose 52. Install the hose (10) by use of the procedure below. NOTICE • Use a new clamp (10a). • Install clamps (10a) (2 pieces) at installation angle (f). Installation angle (f): 15° Tools: ratchet handle, socket, torque wrench Clamp (10a): Width across flats 8 mm Clamp bolt threaded part (d): lubricating oil (ThreeBond PANDO18B) 1) Connect the hose (10) to the marked position, and install the clamp (10a). NOTICE • Apply sealant to the (10) entire circumference of the hose equally. • Hose (10): inner seal material (ThreeBond 2720C or equivalent) 2)
Set bridge (a) of the clamp (10a) under the bolt (d). Tighten the bolt so that the overlap distance (c) of the bridge (a) and band (b) is 5 mm or more.
I
I
*
REMARK • When reusing hose Align the clamp (10a) with the mark of the clamp on the hose. Clamp (10a): 6 Nm {0.6 kgm} or more • When using a new hose Tighten until the distance (e) of the clamp (10a) is 7 to 10 mm. 53. If you connect at the air intake connector (10b), use the procedure below. PC210-10M0, PC210LC-10M0
50-87
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
1)
50 DISASSEMBLY AND ASSEMBLY
Install gasket (10d). REMARK Use a new gasket (10d).
2)
Install the hose (10) and air intake connector (10b) together with the bolts (10c) (4 pieces).
Tool: Ratchet handle, socket, torque wrench Bolt (10c): Width across flats 11 mm, M8 Bolt (10c): Liquid gasket (Loctite 516 sealant) or (LG-7) REMARK Apply the liquid gasket but not to the first and second external threads. Bolt (10c): 24 ± 4 Nm {2.4 ± 0.4 kgm} Muffler assembly 54. Lift the muffler assembly (8) and align it with the installation position. Tool: wire Muffler assembly (8): 18 kg Exhaust pipe (8a) full circumference of part (e): thermosetting seal agent (Musashi Holts Fire Gum or equivalent product) 55. Temporarily install muffler assembly (8) and exhaust pipe (8a). 56. Loosen the clamp (8e), and position the muffler assembly. Tools: ratchet handle, socket
H
D
Clamp (8e): Width across flats 11 mm 57. Install the U-bolt (8b) with the nut (8c). Nut (8c): Width across flats 14 mm Nut (8c): 9.8 to 14.7 Nm {1.0 to 1.5 kgm} 58. Tighten clamp (8e). Tools: ratchet handle, socket, torque wrench
*
Clamp (8e): Width across flats 11 mm Clamp (8e): 6.9 to 8.8 Nm {0.7 to 0.9 kgm} 59. Install the clamp (7). NOTICE Use a new clamp. Tools: ratchet handle, socket, torque wrench Clamp (7) bolt: width across flats 17 mm, M12 Clamp (7) bolt (1st time): 39.2 to 49 Nm {4 to 5 kgm} Clamp (7) bolt (2nd time): 68.6 to 122.5 Nm {7.0 to 12.5 kgm}
50-88
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
60. Install the cover (6) with the bolts (6a) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (6a): width across flats 12 mm, M8 Bolt (6a): 27 to 34 Nm {2.8 to 3.5 kgm}
Hose 61. Connect the fuel return hose (4a) with the joint (4e). NOTICE As a general rule, do not reuse the hose as internal components of the hose fittings are likely to be damaged during removal. Use a new part when you reassemble them. Tools: ratchet handle, socket, torque wrench Joint (4e): Width across flats 19 mm, M12 Joint (4e): 24 ± 4 Nm {2.45 ± 0.41 kgm} 62. Connect the fuel return hose (4) with the joint bolt (4d), and install the cap (4c). NOTICE As a general rule, do not reuse the hose as internal components of the hose fittings are likely to be damaged during removal. Use a new part when you reassemble. Tools: ratchet handle, socket, torque wrench Joint bolt (4d): Width across flats 17 mm, M12 Joint bolt (4d): 19.6 to 29.4 Nm {2.0 to 3.0 kgm} Cover and Wiring Connector 63. Install the parts below. See REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY. •
Upper cover of control valve
•
Cover between oil pressure pump and engine
•
Frame between the control valve and the engine
•
Cover between the control valve and the engine
Engine hood assembly 64. Install the engine hood assembly. See REMOVE AND INSTALL ENGINE HOOD ASSEMBLY. Refilling with coolant 65. Add coolant. See "DRAIN AND ADD COOLANT".
PC210-10M0, PC210LC-10M0
50-89
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially 19 mm available
1
2
Socket
Commercially available
1
3
Ratchet handle
Commercially available
1
4
Impact wrench
Commercially available
1
5
Torque wrench
Commercially 2 to 12 Nm available
1
6
Torque wrench
Commercially 20 to 200 Nm available
1
7
Phillips screwdriver
Commercially available
1
k k k k
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
REMOVE STARTING MOTOR ASSEMBLY Engine hood 1. Open engine hood (1). NOTICE Make sure the lock is engaged.
Cover 2. Remove the bolts (3) (3 pieces), and remove the cover (2). Tools: Impact wrench, socket Bolt (3): width across flats 19 mm, M12
50-90
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
3.
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
Remove the bolts (4) (6 pieces), and remove the cover (5). Tools: Impact wrench, socket Bolt (4): width across flats 19 mm, M12
4.
Remove the bolts (6a) (3 pieces), and remove the cover (6). Tools: Impact wrench, socket Bolt (6a): width across flats 19 mm, M12
Starting motor assembly 5. Remove the bolts (7a) (7 pieces), and remove the undercover (7). Tools: Impact wrench, socket Bolt (7a): width across flats 19 mm, M12
6.
Remove the cap (117).
7.
Remove the lock nut (8a), and disconnect the starting motor terminal B (8). Tools: Impact wrench, socket Lock nut (8a): Width across flats 17 mm
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
8.
50 DISASSEMBLY AND ASSEMBLY
Remove the screw (9a) and disconnect the starting motor C terminal (9). Tool: Phillips screwdriver
9.
Remove the bolt (10). Tools: Impact wrench, socket Bolt (10): width across flats 14 mm, M10
10. Remove the bolt (11), and remove the starting motor assembly (12) and gasket. Tools: Impact wrench, socket Bolt (11): width across flats 14 mm, M10
INSTALL STARTING MOTOR ASSEMBLY Starting motor assembly 1. Install the gasket. NOTICE Be sure to use a new gasket. 2.
Install the starting motor assembly (12) by use of bolt (11). Tools: Ratchet handle, socket, torque wrench Bolt (11): width across flats 14 mm, M10 Bolt (11): 59 to 74 Nm {6 to 7.5 kgm}
3.
Install the bolt (10). Tools: Ratchet handle, socket, torque wrench Bolt (10): width across flats 14 mm, M10 Bolt (10): 59 to 74 Nm {6 to 7.5 kgm}
4.
Connect the starter C terminal (9) by use of the screw (9a). Tools: Ratchet handle, socket, torque wrench, Phillips screwdriver Screw (9a): 2.6 to 4.6 Nm {0.27 to 0.47 kgm}
50-92
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
5.
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
Connect the starting motor terminal B (8) with the lock nut (8a). Tools: Ratchet handle, socket, torque wrench Lock nut (8a): Width across flats 17 mm Lock nut (8a): 17.7 to 24.5 Nm {1.8 to 2.5 kgm}
6.
Install the cap (117).
7.
Install the undercover (7) by use of bolts (7a) (7 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (7a): width across flats 19 mm, M12 Bolt (7a): 98 to 123 Nm {10 to 12.5 kgm}
Cover 8. Install the cover (6) by use of bolts (6a) (3 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (6a): width across flats 19 mm, M12 Bolt (6a): 98 to 123 Nm {10 to 12.5 kgm}
9.
Install the cover (5) with the bolts (4) (6 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (4): width across flats 19 mm, M12 Bolt (4): 98 to 123 Nm {10 to 12.5 kgm}
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
10. Install the cover (2) with the bolts (3) (3 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (3): width across flats 19 mm, M12 Bolt (3): 98 to 123 Nm {10 to 12.5 kgm}
Engine hood 11. Close the engine hood (1).
50-94
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
REMOVE AND INSTALL ALTERNATOR BELT Engine hood
- Cover
- Fan guard
-
Air conditioner compressor belt
- Fan clutch
-A
A- Alternator belt
List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially 17 mm available
1
2
Socket
Commercially 22 mm available
1
3
Socket
Commercially available
1
4
Ratchet handle
Commercially available
1
5
Ratchet handle
12.5 angle, number of teeth Commercially 20 or more, length approxiavailable mately 450 mm
1
6
Wrench
Commercially 55 mm available
1
7
Box-end combination wrench
Commercially 14 mm available
1
8
Impact wrench
Commercially available
1
9
Torque wrench
Commercially 20 to 200 Nm available
1
k k k k
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
REMOVE ALTERNATOR BELT Engine hood 1. Open engine hood (1). NOTICE Make sure the lock is engaged.
PC210-10M0, PC210LC-10M0
50-95
REMOVE AND INSTALL ALTERNATOR BELT
50 DISASSEMBLY AND ASSEMBLY
Cover 2. Open the radiator cap (2), and release the remaining pressure. REMARK Install the radiator cap after you release the remaining pressure.
3.
Remove the clamp (2a) and clip (2b), and disconnect the hose (2c). Tools: Impact wrench, socket, needle-nose pliers Clamp (2a) bolt: width across flats 17 mm, M10
4.
Remove the bolts (3a) (3 pieces), and remove the cover (3). Tools: Impact wrench, socket Bolt (3a): width across flats 17 mm, M10
5.
Remove the bolts (4) (2 pieces), and remove the cover (5). Tools: Impact wrench, socket Bolt (4): width across flats 17 mm, M10
6.
Remove the bolts (6) (2 pieces), and remove the cover (7). Tools: Impact wrench, socket Bolt (6): width across flats 17 mm, M10
50-96
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
Fan guard 7. Remove the bolts (8) (3 pieces), and remove the fan guard (9). Tools: Impact wrench, socket Bolt (8): Width across flats 17 mm, M10
8.
Remove the bolts (10) (2 pieces), and remove the fan guard (11). Tools: Impact wrench, socket Bolt (10): Width across flats 17 mm, M10
Air conditioner compressor belt 9. Remove the clamp (12), and disconnect the wiring harness (13). NOTICE Be careful not to damage the wiring harness (13). REMARK Move the wiring harness (13) aside to a safe area so that it does not hinder work. Tools: Impact wrench, socket Clamp (12) bolt: width across flats 17 mm, M10 10. Loosen the bolts (14a) and (14b), and remove the air conditioner compressor belt (14) from the air conditioner compressor. REMARK Pushing in the air conditioner compressor will reduce the tension on the belt. Tools: Ratchet handle, socket, wrench Bolt (14a): width across flats 22 mm, M14 Bolt (14b): Width across flats 22 mm, M14
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL ALTERNATOR BELT
50 DISASSEMBLY AND ASSEMBLY
Fan clutch assembly 11. Apply cushion material to the cleaning core (15).
12. Secure the shaft, remove the bolts (16) (6 pieces), and remove the fan clutch assembly (17) to the cooling core side. And then remove the air conditioner compressor belt (14). Tools: Box-end wrench, wrench Bolt (16): width across flats 14 mm, M10
Alternator belt 13. Install the ratchet handle to the portion (p) (insertion angle: 12.7 mm) of the tensioner assembly (18). Tool: Ratchet handle 14. Rotate the ratchet handle in the direction (r) opposite to the wind-up direction to loosen the tension of the alternator belt (19). Remove the alternator belt (19) as you take care of the wiring harness for the fan clutch. k k k k
k
50-98
Firmly set the wrench to the part (p) of the tensioner assembly (18), and rotate it. After removing the alternator belt (19), return the tensioner assembly (18) slowly and carefully. Be careful not to get your fingers caught between the pulley and alternator belt (19) during work. Pass the wiring harness of the fan clutch through the alternator belt (19) before you remove the alternator belt (19) to prevent damage to the wiring harness of the fan clutch. Make sure that the belt groove and pulley groove are aligned.
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
INSTALL ALTERNATOR BELT Alternator belt 1. Install the alternator belt (19), air conditioner compressor belt (14) to the fan pulley, secure the shaft, and install the bolts (16) (6 pieces). Tools: Ratchet handle, socket, torque wrench, wrench Bolt (16): width across flats 14 mm, M10 Bolt (16): 59 to 74 Nm {6 to 7.5 kgm}
2.
Remove the cushion material from the cooling core (15).
3.
Install the ratchet to the portion (p) (insertion angle: 12.7 mm) of the tensioner assembly (18). k
k k k k
Install the alternator belt (19) when the ratchet is being rotated in the direction (r) opposite the windup direction. Firmly engage the wrench into the part (p) of the tensioner assembly (18) to perform the rotation. Slowly and carefully allow the tensioner assembly (18) to return. Be careful not to get your fingers caught between the pulley and alternator belt (19) during work. Make sure that the belt groove and pulley groove are aligned.
Tool: Ratchet handle
PC210-10M0, PC210LC-10M0
50-99
REMOVE AND INSTALL ALTERNATOR BELT
50 DISASSEMBLY AND ASSEMBLY
Air conditioner compressor belt 4. Install the air conditioner compressor belt (14). 5.
Install the bolts (14a), (14b). REMARK see TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION" to adjust the tension of the belt for the air conditioner compressor. (For details, see TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION".) Tools: Ratchet handle, socket, torque wrench Bolt (14a): width across flats 22 mm, M14 Bolt (14b): Width across flats 22 mm, M14 Bolt (14a): 153 to 190 Nm {15.5 to 19.5 kgm} Bolt (14b): 153 to 190 Nm {15.5 to 19.5 kgm}
6.
Install clamps (12) and connect the wiring harness (13). Tools: Ratchet handle, socket, torque wrench Clamp (12) bolt: width across flats 17 mm, M10 Clamp (12) bolt: 59 to 74 Nm {6 to 7.5 kgm}
Fan guard 7. Install the fan guard (11) by use of bolts (10) (2 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (10): width across flats 17 mm, M10 Bolt (10): 59 to 74 Nm {6 to 7.5 kgm}
8.
Install the fan guard (9) by use of bolts (8) (3 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (8): width across flats 17 mm, M10 Bolt (8): 59 to 74 Nm {6 to 7.5 kgm}
50-100
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
Cover 9. Install the cover (7) with the bolts (6) (2 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (6): width across flats 17 mm, M10 Bolt (6): 59 to 74 Nm {6 to 7.5 kgm}
10. Install the cover (5) with the bolts (4) (2 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (4): width across flats 17 mm, M10 Bolt (4): 59 to 74 Nm {6 to 7.5 kgm}
11. Install the cover (3) by use of bolts (3a) (3 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (3a): width across flats 17 mm, M10 Bolt (3a): 59 to 74 Nm {6 to 7.5 kgm}
12. Install clamp (2a) and clip (2b) and then connect hose (2c). Tools: Ratchet handle, socket, needle-nose pliers, torque wrench Clamp (2a) bolt: width across flats 17 mm, M10 Clamp (2a) bolt: 59 to 74 Nm {6 to 7.5 kgm}
Engine hood 13. Close the engine hood (1).
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL RADIATOR ASSEMBLY Standard tool list The listed parts are for reference only. You can use the part that is not listed if it is applicable. No.
Part name
Part No.
Specifications
Q'ty
1
Socket
Commercially available
8 mm
1
2
Socket
Commercially available
17 mm
1
3
Socket
Commercially available
19 mm
1
4
Box-end combination wrench
Commercially available
17 mm
1
5
Impact wrench
Commercially available
6
Torque wrench
Commercially available
5 to 50 Nm
1
7
Torque wrench
Commercially available
20 to 100 Nm
1
8
Needle-nose pliers
Commercially available
1
9
Ratchet handle
Commercially available
1
10
Wire
Commercially available
1
k k k k
Remarks
1
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
NOTICE • Check installed positions before you disconnect hoses, and write them down. • Install a plug or flange in the place where a hydraulic hose is disconnected to prevent oil from flowing out.
REMOVE RADIATOR ASSEMBLY Draining coolant 1. Drain the coolant. See "DRAIN AND ADD COOLANT".
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL RADIATOR ASSEMBLY
Hose, cover 2. Remove the hose clamp (1) and disconnect the hose (2). Tools: Ratchet handle, socket Hose clamp (1): width across flats 8 mm
3.
Remove clip (3) and disconnect the hose (4). REMARK Mark the connection position to prevent connection mistakes. Tool: needle-nose pliers
4.
Remove clip (5) and disconnect the hose (6). REMARK Mark the connection position to prevent connection mistakes.
5.
Remove the bolts (7) (3 pieces) and remove the cover (8). Tools: Impact wrench, socket Bolt (7): width across flats 17 mm, M10
6.
Remove the bolts (9) (2 pieces), and remove the cover (10). Tools: Impact wrench, socket Bolt (9): width across flats 17 mm, M10
7.
Remove the hose clamp (11) and disconnect the hose (12). Tools: Ratchet handle, socket Hose clamp (11): width across flats 8 mm
PC210-10M0, PC210LC-10M0
50-103
REMOVE AND INSTALL RADIATOR ASSEMBLY
8.
50 DISASSEMBLY AND ASSEMBLY
Remove the bolts (13) (3 pieces) and remove the cover (14). Tools: Ratchet handle, box-end wrench, socket Bolt (13): width across flats 17 mm, M10
Radiator assembly 9. Lift the radiator assembly (15) to the suspension position (a). Tool: wire Radiator assembly (15): 14 kg
10. Remove the bolts (16) (2 pieces) and then remove the radiator assembly (15). NOTICE Be careful not to catch the bottom of the radiator assembly (15) when you lift it. Tools: Impact wrench, socket Bolt (16): width across flats 19 mm, M12
50-104
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL RADIATOR ASSEMBLY
INSTALL RADIATOR ASSEMBLY Radiator assembly 1. Sling the radiator assembly (15) at the slinging position (a), and align it with the installation position. NOTICE • Check that the heat insulation sealant (sponge) on the periphery of the radiator assembly (15) is not damaged. • If the heat insulation sealant (sponge) is damaged, replace it. • When you install the radiator assembly (15), be careful not to damage the heat insulation sealant (sponge) on the periphery. • Check from the under side that the convex portion (b) of the radiator assembly (15) is correctly aligned with the concave portion (c) on the machine side. Tool: Wire Radiator assembly (15): 14 kg
2.
Install the radiator assembly (15) with the bolts (16) (2 pieces). Tool: Ratchet handle, torque wrench, socket Bolt (16): 19-mm width across flats, M12 Bolt (16): 98 to 123 Nm {10.0 to 12.5 kgm}
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL RADIATOR ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Hose, cover 3. Install the cover (14) with the bolts (13) (3 pieces). Tool: Ratchet handle, torque wrench, socket Bolt (13): 17-mm width across flats, M10 Bolt (13): 59 to 74 Nm {6.0 to 7.5 kgm}
4.
Connect the hose (12) with the hose clamp (11). Tool: Ratchet handle, torque wrench, socket Hose clamp (11): 8-mm width across flats Hose clamp (11): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
5.
Install the cover (10) with the bolts (9) (2 pieces). Tool: Ratchet handle, torque wrench, socket Bolt (9): 17-mm width across flats, M10 Bolt (9): 59 to 74 Nm {6.0 to 7.5 kgm}
6.
Install the cover (8) with the bolts (7) (3 pieces). Tool: Ratchet handle, torque wrench, socket Bolt (7): 17-mm width across flats, M10 Bolt (7): 59 to 74 Nm {6.0 to 7.5 kgm}
7.
Connect the hose (6) with the clip (5).
8.
Connect the hose (4) with the clip (3). Tool: Needle-nose pliers
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50 DISASSEMBLY AND ASSEMBLY
9.
REMOVE AND INSTALL RADIATOR ASSEMBLY
Connect the hose (2) with the hose clamp (1). Tool: Ratchet handle, torque wrench, socket Hose clamp (1): 8-mm width across flats Hose clamp (1): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
Refilling with coolant 10. See "DRAIN AND ADD COOLANT", and refill the coolant.
PC210-10M0, PC210LC-10M0
50-107
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY
REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY Draining hydraulic oil
- Cover
-
Draining hydraulic oil
- Hose, cover
-
Hydraulic oil cooler assembly
List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially available
17 mm
1
2
Socket
Commercially available
19 mm
1
3
Extension bar
Commercially available
150 mm
1
4
Ratchet handle
Commercially available
5
Box-end combination wrench
Commercially available
6
Impact wrench
Commercially available
7
Torque wrench
Commercially available
8
Wire
Commercially available
1
Oil container
Commercially available
As require d
9
Remarks
1 17 mm
1 1
20 to 200 Nm
1
List of Special Tools Symbol
Part name
Part number
SPECIFICATION
Q'ty
A
Oil stopper
796-460-1210
1
B
Adapter
796-770-1320
1
k k k k
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
NOTICE • Check the connector numbers and installed positions before disconnecting wirings and hoses, and write them down. • Install a plug or flange in the place where a hydraulic hose is disconnected to prevent oil from flowing out.
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY
REMOVE HYDRAULIC COOLER ASSEMBLY Draining hydraulic oil 1. Drain the hydraulic oil. See "DRAIN AND ADD HYDRAULIC OIL" Cover 2. Remove the bolts (1) (7 pieces) and remove the cover (2). Tools: Impact wrench, socket Bolt (1): width across flats 19 mm, M12
Draining hydraulic oil 3. Remove the valve (3) and drain the hydraulic oil. REMARK • After draining is completed, install the valve (3). • When by use of an oil stopper (A) and adapter (B), remove the hydraulic tank strainer and use the oil stopper (A) and adapter (B) to stop the oil. • Loosen the filler cap on the hydraulic oil tank to reduce drain time. Tools: Oil stopper (A), adapter (B), ratchet handle, socket, torque wrench, oil drain pan Valve (3): width across flats 22 mm Oil cooler: 6 ℓ Valve (3): 19.6 ± 24.5 Nm {2.0 ± 2.5 kgm}
*
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY
4.
50 DISASSEMBLY AND ASSEMBLY
Open the cover (4).
Hose, cover 5. Remove the flange (5) and then disconnect the hose (6). Tools: Impact wrench, socket Flange (5) bolt: width across flats 19 mm, M12
6.
Remove flange (7) and then disconnect the hose (8). Tools: Impact wrench, socket, extension bar (150 mm) Flange (7) bolt: width across flats 19 mm, M12
7.
Remove the bolts (9) (3 pieces) and remove the cover (10). Tools: Ratchet handle, box-end wrench, socket Bolt (9): width across flats 17 mm, M10
8.
Remove the bolts (11) (2 pieces) and remove the cover (12). Tools: Ratchet handle, socket Bolt (11): width across flats 17 mm, M10
50-110
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
9.
REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY
Remove the bolts (13) (3 pieces) and remove the cover (14). Tools: Impact wrench, socket Bolt (13): width across flats 17 mm, M10
10. Remove the bolts (15) (2 pieces) and remove the cover (16). Tools: Impact wrench, socket Bolt (15): width across flats 17 mm, M10
Hydraulic oil cooler assembly 11. Lift and hold the hydraulic oil cooler assembly (17) to the suspension position (a). Tool: Wire lifting tool Hydraulic oil cooler assembly (17): 16 kg
12. Remove the bolts (18) (4 pieces) and then remove the hydraulic oil cooler assembly (17). NOTICE Be careful not to allow the bottom of the hydraulic oil cooler assembly (17) get caught on anything. Tools: Impact wrench, socket Bolt (18): width across flats 17 mm, M10
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
INSTALL HYDRAULIC COOLER ASSEMBLY Hydraulic oil cooler assembly 1. Lift the hydraulic oil cooler assembly (17) to the suspension position (a) and align with the install position. NOTICE • Make sure that the heat insulator sealant (sponge) on the periphery of the hydraulic oil cooler assembly (17) is not damaged. • If the heat insulator sealant (sponge) is damaged, replace it. • When you install the hydraulic oil cooler assembly (17), be careful not to damage the heat insulator sealant (sponge) on the periphery. • Check from below the machine that the protruding part (b) of the bottom of the hydraulic oil cooler assembly (17) is correctly aligned with the concave part (c) on the machine side. Tool: wire Hydraulic oil cooler assembly (17): 16 kg
2.
Install the hydraulic oil cooler assembly (17) by use of bolts (18) (4 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (18): width across flats 17 mm, M10 Bolt (18): 59 to 74 Nm {6.0 to 7.5 kgm}
50-112
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY
Hose, cover 3. Install the cover (16) with the bolts (15) (2 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (15): width across flats 17 mm, M10 Bolt (15): 59 to 74 Nm {6.0 to 7.5 kgm}
4.
Install the cover (14) with the bolts (13) (3 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (13): width across flats 17 mm, M10 Bolt (13): 59 to 74 Nm {6.0 to 7.5 kgm}
5.
Install the cover (12) with the bolts (11) (2 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (11): width across flats 17 mm, M10 Bolt (11): 59 to 74 Nm {6.0 to 7.5 kgm}
6.
Install the cover (10) with the bolts (9) (3 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (9): width across flats 17 mm, M10 Bolt (9): 59 to 74 Nm {6.0 to 7.5 kgm}
7.
Connect the hose (8) by use of the flange (7). Tools: Ratchet handle, torque wrench, socket, extension bar (150 mm) Flange (7) bolt: width across flats 19 mm, M12 Flange (7) bolt: 53.9 to 83.3 Nm {5.5 to 8.5 kgm}
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL HYDRAULIC COOLER ASSEMBLY
8.
50 DISASSEMBLY AND ASSEMBLY
Connect the hose (6) by use of the flange (5). Tools: Ratchet handle, torque wrench, socket Flange (5) bolt: width across flats 19 mm, M12 Flange (5) bolt: 53.9 to 83.3 Nm {5.5 to 8.5 kgm}
9.
Close the cover (4).
10. Install the cover (2) with the bolts (1) (7 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (1): width across flats 19 mm, M12 Bolt (1): 98 to 123 Nm {10.0 to 12.5 kgm}
Refilling with hydraulic oil 11. Add hydraulic oil. See "DRAIN AND ADD HYDRAULIC OIL".
50-114
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AFTER COOLER ASSEMBLY
REMOVE AND INSTALL AFTER COOLER ASSEMBLY Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same. No.
Part name
Part number
Specification
Q'ty
1
Socket wrench
Commercially available
13 mm
1
2
Socket wrench
Commercially available
17 mm
1
3
Socket wrench
Commercially available
19 mm
1
4
Box-end combination wrench
Commercially available
17 mm
1
5
Ratchet handle
Commercially available
1
6
Impact wrench
Commercially available
1
7
Torque wrench
Commercially available
8
Wire
Commercially available
k k k k
20 to 200 Nm
Remarks
1 1
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
NOTICE • Before you disconnect the wirings and hoses, check the connector numbers and installed positions and write them down. • Install a plug or a flange to parts where a hydraulic hose is disconnected to prevent oil from flowing out.
REMOVE AFTER COOLER ASSEMBLY Engine hood 1. Open engine hood (1).
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL AFTER COOLER ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Cover, hose, tube 2. Remove the bolts (2) (3 pieces) and remove the cover (3). Tools: Impact wrench, socket Bolt (2): width across flats 17 mm, M10
3.
Remove the bolts (4) (2 pieces) and remove the cover (5). Tools: Impact wrench, socket Bolt (4): width across flats 17 mm, M10
4.
Remove clamps (7) (2 pieces) and then disconnect the hose (6). REMARK Mark the end of the hose and the tube so that they can be reconnected correctly. Tools: Ratchet handle, socket Clamp (7): width across flats 13 mm M8
5.
Remove the bolts (8) (7 pieces) and remove the cover (9). Tools: Impact wrench, socket Bolt (8): width across flats 19 mm, M12
6.
Remove the bolts (10) (3 pieces) and remove the cover (11). Tools: Ratchet handle, box-end wrench, socket Bolt (10): width across flats 17 mm, M10
50-116
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
7.
REMOVE AND INSTALL AFTER COOLER ASSEMBLY
Remove flange (12) and then disconnect the tube (13). Tools: Ratchet handle, box-end wrench, socket Flange (12) bolt: width across flats 17 mm, M10
Aftercooler assembly 8. Remove the bolts (15) (2 pieces). Tools: Ratchet handle, box-end wrench, socket Bolt (15): Width across flats 19 mm, M12
9.
Lift and remove the aftercooler assembly (14) at the suspension position (a). Tool: Wire lifting tool Aftercooler assembly (14): 10 kg
INSTALL AFTER COOLER ASSEMBLY Aftercooler assembly 1. Lift the aftercooler assembly (14) to the suspension position (a) and align it with the installation position. Tool: Wire lifting tool Aftercooler assembly (14): 10 kg
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL AFTER COOLER ASSEMBLY
2.
50 DISASSEMBLY AND ASSEMBLY
Install the bolts (15) (2 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (15): Width across flats 19 mm, M12 Bolt (15): 34 to 74 Nm {3.5 to 7.5 kgm}
Cover, hose, tube 3. Connect the tube (13) by use of the flange (12). Tools: Ratchet handle, socket, torque wrench, box-end wrench Flange (12) bolt: width across flats 17 mm, M10 Flange (12) bolt: 34.2 to 53.8 Nm {3.5 to 5.5 kgm}
4.
Install the cover (11) with the bolts (10) (3 pieces). Tools: Ratchet handle, socket, torque wrench, box-end wrench Bolt (10): width across flats 17 mm, M10 Bolt (10): 59 to 74 Nm {6.0 to 7.5 kgm}
5.
Install the cover (9) with the bolts (8) (7 pieces). Tools: socket, torque wrench, ratchet handle Bolt (8): width across flats 19 mm, M12 Bolt (8): 98 to 123 Nm {10.0 to 12.5 kgm}
50-118
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50 DISASSEMBLY AND ASSEMBLY
6.
REMOVE AND INSTALL AFTER COOLER ASSEMBLY
Use the procedure below to connect the hose (6) by use of clamps (7) (2 pieces). NOTICE • Use a new clamp. • Do not use an impact wrench. • Install clamps (7) (2 pieces) at the clamp installation angle (f). Installation angle (f): 15° Tools: socket, torque wrench, ratchet handle Clamp (7): width across flats 13 mm, M8 Clamp (7): 6 Nm {0.6 kgm} or more 1)
Connect the hose (6) to the marked position. NOTICE Apply sealant to the entire circumference of the hose evenly. Hose (6) internal: sealing material (ThreeBond 2720C or equivalent)
2)
Set clamp (7) bridge (a) under the bolt (d). Tighten the bolt so that the overlap dimension (c) between the bridge (a) and band (b) is 5 mm or more. Bolt (d) threaded part: lubricating oil (ThreeBond PANDO 18B)
When reusing hose Align the clamp (7) with the mark of the clamp on the hose (6).
When using a new hose Tighten until the clamp dimension (e) is 7 to 10 mm. 7.
I
I
*
Install the cover (5) with the bolts (4) (2 pieces). Tools: socket, torque wrench, ratchet handle Bolt (4): width across flats 17 mm, M10 Bolt (4): 59 to 74 Nm {6.0 to 7.5 kgm}
8.
Install the cover (3) with the bolts (2) (3 pieces). Tools: socket, torque wrench, ratchet handle Bolt (2): width across flats 17 mm, M10 Bolt (2): 59 to 74 Nm {6.0 to 7.5 kgm}
PC210-10M0, PC210LC-10M0
50-119
REMOVE AND INSTALL AFTER COOLER ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Engine hood 9. Close the engine hood (1).
50-120
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY Draining coolant ─ Hose
Air conditioner ─ compressor assembly
─ Cover
─
Fan clutch assembly
Standard tool list The listed parts are for reference only. You can use the part that is not listed if it is applicable. No.
Part name
Part No.
Specifications
Q'ty
1
Socket
Commercially available
8 mm
1
2
Socket
Commercially available
13 mm
1
3
Socket
Commercially available
17 mm
1
4
Socket
Commercially available
22 mm
1
5
Ratchet handle
Commercially available
12.5 angle, number of teeth 20 or more, length approximately 450 mm
1
6
Ratchet handle
Commercially available
7
Open-end wrench
Commercially available
22 mm
1
8
Open-end wrench
Commercially available
55 mm
1
9
Box-end combination wrench
Commercially available
14 mm
1
10
Torque wrench
Commercially available
20 to 200 Nm
1
11
Guide bolt
Commercially available
Remarks
1
2
Special tool list Symbol
Part name
Part No.
A
Nut
01580-11210
B
Bolt
01011-81210
k k k k
Specifications
Q'ty
Remarks
1 M12×110 mm
1
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
PC210-10M0, PC210LC-10M0
50-121
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
NOTICE • Install a plug or flange in the place where a hydraulic hose is disconnected to prevent oil from flowing out. • Check the connector numbers and installed positions before disconnecting wirings and hoses, and write them down.
REMOVE FAN CLUTCH ASSEMBLY Draining coolant 1. Drain the coolant. See "DRAIN AND ADD COOLANT". Hose 2. Remove the hose clamp (1), and disconnect the hose (2). Tool: Ratchet handle, socket Hose clamp (1): 8-mm width across flats
3.
Remove the clip (3) and clamp (4), and disconnect the hose (5). Tool: Impact wrench, socket, needle-nose pliers Clamp (4) bolt: 17-mm width across flats, M10
4.
Remove the clamps (9) (4 pieces), and disconnect the hose (10). REMARK Put a matchmark on the hose end and tube so that they can be reconnected correctly. Tool: Socket, ratchet handle Clamp (9): 13-mm width across flats, M8
Cover 5. Remove the bolts (11) (3 pieces) and remove the cover (12). Tool: Impact wrench, socket Bolt (11): 17-mm width across flats, M10
50-122
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50 DISASSEMBLY AND ASSEMBLY
6.
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY
Remove the bolts (13) (2 pieces) and remove the cover (14). Tool: Impact wrench, socket Bolt (13): 17-mm width across flats, M10
7.
Remove the bolts (15) (2 pieces) and remove the cover (16). Tool: Impact wrench, socket Bolt (15): 17-mm width across flats, M10
8.
Remove the bolts (17) (3 pieces), and remove the fan guard (18). Tool: Impact wrench, socket Bolt (17): 17-mm width across flats, M10
9.
Remove the bolts (19) (2 pieces), and remove the fan guard (20). Tool: Impact wrench, socket Bolt (19): 17-mm width across flats, M10
10. Place cushion material on the cooling core (21). REMARK Place a cardboard not to damage the cooling core.
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
11. Remove the clamps (22) (3 pieces), and disconnect the connector M16 (23). Tool: Impact wrench, socket Clamp (22) bolt: 17-mm width across flats, M10
12. Remove the bolts (24) (6 pieces), and remove the fan clutch (25) to the cooling core side. Tool: Box-end combination wrench Bolt (24): 14-mm width across flats, M10
13. Remove the bolts (26) (6 pieces) and remove the cover (27). Tool: Impact wrench, socket Bolt (26): 17-mm width across flats
Air conditioner compressor assembly 14. Loosen the bolts (28) and (28a), and remove the air conditioner compressor belt (29). REMARK When you push in the air conditioner compressor, the belt tension is loosened. Tool: Impact wrench, socket Bolts (28) and (28a): 22-mm width across flats, M14
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY
15. Remove the bolts (30a) (4 pieces). Tool: Impact wrench, socket Bolt (30a): 13-mm width across flats, M8
16. Move the air conditioner compressor assembly (30) to the right side of the machine where it does not interfere with the work.
Fan clutch assembly 17. Install the ratchet handle to the part (p) of the tensioner assembly (31) (insertion angle: 12.7 mm). Tool: Ratchet handle 18. Rotate the ratchet handle in the direction (r) opposite to the winding-up direction to loosen the tension of the alternator belt (32), and remove the alternator belt (32) as you pay attention to the wiring harness of the fan clutch. k k k
Firmly install the ratchet handle to the part (p) of the tensioner assembly (31), and then rotate it. After removing the alternator belt (32), return the tensioner assembly (31) slowly and carefully. Be careful not to get your fingers caught between the pulley and alternator belt (32) during work.
19. Fix the fan pulley (34), and remove the bolts (33) (2 pieces). REMARK Before you remove the bolts (33), put a matchmark (s) on the fan pulley (34). Tool: Impact wrench, socket, wrench Bolt (33): 13-mm width across flats, M8 Fan pulley (34): 22-mm width across flats 20. Remove the fan pulley (34).
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
21. Remove the fan clutch assembly (35).
INSTALL FAN CLUTCH ASSEMBLY Fan clutch assembly 1. Align the fan clutch assembly (35) with the mount position REMARK Use cardboard, etc. to prevent the cooling core from being damaged.
2.
Install the guide bolts (36) (2 pieces) to the hub. Tools: Guide bolt, socket, ratchet handle
3.
Install the fan pulley (34) by use of bolts (33) (2 pieces). REMARK • Align it to the marks (s) placed before removal for installing. • Tighten as you target a median torque value of 54 Nm {5.5 kgm}. Tools: Socket, torque wrench, wrench Bolt (33): width across flats 13 mm, M8 Fan pulley (34): width across flats 22 mm Bolt (33): 34 to 74 Nm {3.5 to 7.5 kgm}
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50 DISASSEMBLY AND ASSEMBLY
4.
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY
Install the ratchet to the portion (p) (insertion angle: 12.7 mm) of the tensioner assembly (31). Tool: Ratchet handle
5.
Install the alternator belt (32) when the ratchet is being rotated in the direction (r) opposite the wind-up direction. k k k
Firmly engage the wrench into the part (p) of the tensioner assembly (31) to perform the rotation. Slowly and carefully allow the tensioner assembly (31) to return. Be careful not to get your fingers caught between the pulley and alternator belt (32) during work.
Tool: Ratchet handle
Air conditioner compressor assembly 6. Align the air conditioner compressor assembly (30) with the installation position.
7.
Install the bolts (30a) (4 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (30a): width across flats 13 mm, M8 Bolt (30a): 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL FAN CLUTCH ASSEMBLY
8.
50 DISASSEMBLY AND ASSEMBLY
Install the air conditioner compressor belt (29) by use of bolts (28), (28a). REMARK Adjust the tension of the belt for the air conditioner compressor. For details, see TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION". (For details, see TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TESION".) Tools: Socket, torque wrench, ratchet handle Bolt (28), bolt (28a): width across flats 22 mm, M14 Bolts (28), (28a): 153 to 190 Nm {15.5 to 19.5 kgm}
Cover 9. Install the cover (27) with the bolts (26) (6 pieces). Tools: Socket, torque wrench, ratchet handle Bolt (26): width across flats 17 mm, M10 Bolt (26): 59 to 74 Nm {6.0 to 7.5 kgm}
10. Secure the shaft and install the bolts (24) (6 pieces). Tools: Socket, torque wrench, wrench Bolt (24): width across flats 14 mm, M10 Bolt (24): 34 to 74 Nm {3.5 to 7.5 kgm}
11. Connect the connector M16 (23) and install the 3 clamps (22). Tools: Socket, torque wrench, ratchet handle Clamp (22) bolt: width across flats 17 mm, M10 Clamp (22) bolt: 59 to 74 Nm {6.0 to 7.5 kgm}
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY
12. Remove the cushion material from the cooling core (21).
13. Install the fan guard (20) by use of bolts (19) (2 pieces). Tools: Socket, torque wrench, ratchet handle Bolt (19): width across flats 17 mm, M10 Bolt (19): 59 to 74 Nm {6.0 to 7.5 kgm}
14. Install the fan guard (18) by use of bolts (17) (3 pieces). Tools: Socket, torque wrench, ratchet handle Bolt (17): width across flats 17 mm, M10 Bolt (17): 59 to 74 Nm {6.0 to 7.5 kgm}
15. Install the cover (16) with the bolts (15) (2 pieces). Tools: Socket, torque wrench, ratchet handle Bolt (15): width across flats 17 mm, M10 Bolt (15): 59 to 74 Nm {6.0 to 7.5 kgm}
16. Install the cover (14) with the bolts (13) (2 pieces). Tools: Socket, torque wrench, ratchet handle Bolt (13): width across flats 17 mm, M10 Bolt (13): 59 to 74 Nm {6.0 to 7.5 kgm}
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17. Install the cover (12) with the bolts (11) (3 pieces). Tools: Socket, torque wrench, ratchet handle Bolt (11): width across flats 17 mm, M10 Bolt (11): 59 to 74 Nm {6.0 to 7.5 kgm}
Hose 18. Connect the hose (10) with the clamps (9) (4 pieces) by use of the procedure below. NOTICE • Use a new clamp. • Do not use an impact wrench. • Install clamps (9) (2 pieces) at the clamp installation angle (f). Installation angle (f): 15° Tools: Socket, torque wrench, ratchet handle Clamp (9): width across flats 13 mm, M8 Clamp (9): 6 Nm (0.6 kgm) or more 1)
Connect the hose (10) to the marked position. NOTICE Apply sealant to the entire circumference of the hose evenly. Hose (10) internal: sealing material (ThreeBond 2720C or equivalent)
2)
Position the bridge (a) of clamp (9) under the bolt (d). Tighten the bolt so that the overlap dimension (c) between the bridge (a) and band (b) is 5 mm or more. Bolt (d) threaded part: lubricating oil (ThreeBond PANDO 18B)
When reusing hose Align the clamp (9) with the mark of the clamp on the hose (10).
When using a new hose Tighten until the clamp dimension (e) is 7 to 10 mm.
I
I
*
19. Connect the hose (5) by use of the clip (3), and install a clamp (4). Tools: Socket, torque wrench, needle-nose pliers, ratchet handle Clamp (4) bolt: width across flats 17 mm, M10 Clamp (4) bolt: 59 to 74 Nm {6.0 to 7.5 kgm}
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20. Connect the hose (2) by use of a hose clamp (1). Tools: Ratchet handle, socket, torque wrench Hose clamp (1): width across flats 8 mm Hose clamp (1): 10.8 to 11.8 Nm {1.1 to1.2 kgm}
Refilling with coolant 21. Add coolant. See "DRAIN AND ADD COOLANT".
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REMOVE AND INSTALL FAN Standard tool list No.
Part name
Part No.
Specifications
Q'ty
1
Impact wrench
Commercially available
1
2
Ratchet handle
Commercially available
1
3
Socket
Commercially available
14 mm
1
4
Torque wrench
Commercially available
10 to 50 Nm
1
k k k k
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
REMOVE FAN Fan clutch assembly 1. Remove the fan clutch assembly. REMARK For details, see "REMOVE AND INSTALL FAN CLUTCH ASSEMBLY". Fan 2. Remove the bolts (1) (6 pieces), and remove the fan (2). Tool: Impact wrench, socket Bolt (1): 14-mm width across flats, M10
INSTALL FAN Fan 1. Install the fan (2) by use of bolts (1) (6 pieces). Tool: Impact wrench, socket Bolt (1): Width across flats 14 mm, M10 Bolt (1): 20 to 24 Nm {2.04 to 2.45 kgm}
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Fan clutch assembly 2. Install the fan clutch assembly. REMARK For removal See "REMOVE AND INSTALL FAN CLUTCH ASSEMBLY".
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REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY Draining coolant ─
A ─ Hose
B─
─
Air cleaner asCover, hose, Engine hood as─ ─ sembly wiring connector sembly
Draining hydraulic oil
─
Fan clutch assembly
Air conditioner ─ compressor assembly
─ Connector
─
Engine controller
─A
─B
Engine and Hose, clamp, ─ main pump aswiring connector sembly
Standard tool list The listed parts are for reference only. You can use the part that is not listed if it is applicable. No.
Part name
Part No.
Specifications
Q'ty
1
Socket
Commercially available
8 mm
1
2
Socket
Commercially available
10 mm
1
3
Socket
Commercially available
11 mm
1
4
Socket
Commercially available
13 mm
1
5
Socket
Commercially available
17 mm
1
6
Socket
Commercially available
19 mm
1
7
Socket
Commercially available
22 mm
1
8
Socket
Commercially available
24 mm
1
9
Ratchet handle
Commercially available
10
Open-end wrench
Commercially available
19 mm
1
11
Open-end wrench
Commercially available
27 mm
1
12
Open-end wrench
Commercially available
36 mm
1
13
Box-end combination wrench
Commercially available
14 mm
1
14
Impact wrench
Commercially available
15
Torque wrench
Commercially available
5 to 50 Nm
1
16
Torque wrench
Commercially available
20 to 200 Nm
1
17
Needle-nose pliers
Commercially available
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Remarks
1
1
1
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50 DISASSEMBLY AND ASSEMBLY
No. 18
Part name
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
Part No.
Specifications
Commercially available
Wire
Q'ty
Remarks
1
Special tool list Symbol A
B
C k k k k
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70210
Nominal 02
4
2 Cap
02789-00210
Nominal 02
4
1 Plug
07376-70422
Nominal 04
2
2 Cap
02789-00422
Nominal 04
2
1 Plug
07376-70628
Nominal 06
1
2 Cap
02789-00628
Nominal 06
1
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
NOTICE • Install a plug or flange in the place where a hydraulic hose is disconnected to prevent oil from flowing out. • Check the connector numbers and installed positions before disconnecting wirings and hoses, and write them down.
REMOVE ENGINE AND MAIN PUMP ASSEMBLY Draining coolant 1. Drain the coolant. See "DRAIN AND ADD COOLANT". Draining hydraulic oil 2. Drain the hydraulic oil. See "DRAIN AND ADD HYDRAULIC OIL". Engine hood assembly 3. Remove the engine hood assembly. See "REMOVE AND INSTALL ENGINE HOOD ASSEMBLY". Cover, Hose, and Wiring Connector 4.
Remove the bolts (1) (7 pieces) and remove the cover (2). Tools: impact wrench, socket Bolt (1): width across flats 19 mm, M12
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5.
50 DISASSEMBLY AND ASSEMBLY
Remove the bolts (3) (4 pieces) and remove the cover (4). Tools: impact wrench, socket Bolt (3): width across flats 19 mm, M12
6.
Remove the bolts (5) (3 pieces) and remove the cover (6). Tools: impact wrench, socket Bolt (5): width across flats 19 mm, M12
7.
Remove the bolts (7) (4 pieces) and remove the cover (8). Tools: impact wrench, socket Bolt (7): width across flats 19 mm, M12
8.
Remove the bolts (9) (6 pieces) and remove the cover (10). Tools: impact wrench, socket Bolt (9): width across flats 19 mm, M12
9.
Open the cover (11).
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10. Remove clamps (12) (2 pieces) and then remove the hose (13). REMARK Move the removed hose to a safe place so that it does not interfere with the work. Tools: impact wrench, socket Clamp (12) bolt: width across flats 19 mm, M12
11. Remove the bolts (14) (7 pieces) and remove the cover (15). Tools: impact wrench, socket Bolt (14): width across flats 19 mm, M12
12. Remove clamps (16) (2 pieces) and disconnect the connector P67 (17). Tools: impact wrench, socket Clamp (16) bolt: width across flats 19 mm, M12
13. Remove the bolts (18) (4 pieces) and remove the cover (19). Tools: impact wrench, socket Bolt (18): width across flats 19 mm, M12
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14. Remove bolts (20) (3 pieces) and then remove the frame (21). Tools: impact wrench, socket Bolt (20): width across flats 19 mm, M12
15. Remove the bolts (22) (5 pieces) and remove the cover (23). Tools: impact wrench, socket Bolt (22): width across flats 19 mm, M12
16. Remove the cover (24).
17. Remove the bolt (25) and remove the cover (26). Tools: impact wrench, socket Bolt (25): width across flats 19 mm, M12
18. Remove the bolts (27) (3 pieces) and remove the cover (28). Tools: impact wrench, socket Bolt (27): width across flats 19 mm, M12
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19. Remove the bolts (29) (2 pieces) and remove the cover (30). Tools: impact wrench, socket Bolt (29): width across flats 19 mm, M12
20. Remove the bolts (31) (6 pieces) and remove the cover (32). Tools: impact wrench, socket Bolt (31): width across flats 19 mm, M12
21. Remove the bolts (33) (4 pieces) and remove the cover (34). Tools: impact wrench, socket Bolt (33): width across flats 19 mm, M12
22. Remove the bolts (35) (2 pieces) and remove the cover (36). Tools: impact wrench, socket Bolt (35): width across flats 19 mm, M12
23. Remove clamp (37). Tools: impact wrench, socket Clamp (37) bolt: width across flats 19 mm, M12
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24. Remove the bolts (38) (11 pieces) and remove the cover (39). Tools: impact wrench, socket Bolt (38): width across flats 19 mm, M12
25. Remove the bolts (40) (2 pieces) and remove the cover (41). Tools: impact wrench, socket Bolt (40): width across flats 19 mm, M12
Air cleaner assembly 26. Remove the air cleaner assembly. See "REMOVE AND INSTALL AIR CLEANER ASSEMBLY". Hose 27. Remove the hose clamp (42). Tools: socket, ratchet handle Hose clamp (42): width across flats 11 mm 28. Remove clamp (43) and then remove hose (44). REMARK Mark the end of the hose and the tube so that they can be reconnected correctly. Tools: socket, ratchet handle Clamp (43): width across flats 13 mm
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29. Remove the hose clamp (45) and disconnect the hose (46). Tools: ratchet handle, socket Hose clamp (45): width across flats 8 mm
30. Remove the clip (47) and clamp (48), and then disconnect the hose (49). Tools: impact wrench, socket, needle-nose pliers Clamp (48) bolt: width across flats 17 mm, M10
31. Remove the clamps (53) (2 pieces), and disconnect the hose (54). REMARK Mark the end of the hose and the tube so that they can be reconnected correctly. Tools: socket, ratchet handle Clamp (53): width across flats 13 mm, M8
Fan clutch assembly 32. Remove the bolts (55) (3 pieces) and remove the cover (56). Tools: impact wrench, socket Bolt (55): width across flats 17 mm, M10
33. Remove the bolts (57) (2 pieces) and remove the cover (58). Tools: impact wrench, socket Bolt (57): width across flats 17 mm, M10
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34. Remove the bolts (59) (2 pieces) and remove the cover (60). Tools: impact wrench, socket Bolt (59): width across flats 17 mm, M10
35. Remove bolts (61) (3 pieces) and then remove the fan guard (62). Tools: impact wrench, socket Bolt (61): width across flats 17 mm, M10
36. Remove bolts (63) (2 pieces) and then remove the fan guard (64). Tools: impact wrench, socket Bolt (63): width across flats 17 mm, M10
37. Apply cushion material to the cleaning core (65).
38. Remove clamps (66) (3 pieces) and disconnect the connector M16 (67). Tool: Socket Clamp (66) bolt: width across flats 17 mm, M10
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REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
39. Remove bolts (68) (6 pieces), and then remove the fan clutch assembly (69) from the cooling core side. Tool: Box-end wrench Bolt (68): width across flats 14 mm, M10
40. Remove the bolts (70) (6 pieces) and remove the cover (71). Tools: impact wrench, socket Bolt (70): width across flats 17 mm, M10
Air conditioner compressor assembly 41. Loosen the bolts (72) and (72a), and remove the air conditioner compressor belt (73). REMARK Pushing in the air conditioner compressor will reduce the tension on the belt. Tools: impact wrench, socket Bolts (72), (72a): width across flats 22 mm, M14
42. Remove the clamp (74). Tools: impact wrench, socket Clamp (74) bolt: width across flats 19 mm, M12
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43. Remove the bolts (75a) (4 pieces). Tools: impact wrench, socket Bolt (75a): width across flats 13 mm, M8
44. Move the air conditioner compressor assembly (75) to the counterweight side so that it does not interfere with the work.
Connector 45. Remove the cap (76).
46. Remove lock nut (76a) and disconnect the air intake heater E01 (76b). Tools: impact wrench, socket Lock nut (76a): width across flats 10 mm
Engine Controller 47. Disconnect the connector CE02 (77) and connector CE03 (78). REMARK Mark the connection position to make sure no mistake is made when reconnecting.
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48. Remove the connector E06 (79) from the connector block. REMARK Mark the connection position to make sure no mistake is made when reconnecting.
49. Remove the clips (80) (2 pieces).
50. Remove bolt (81) and then disconnect the ground cable T12 (81a). Tool: Socket Bolt (81): width across flats 19 mm, M12
51. Remove the clips (82) (2 pieces), and disconnect the connectors M37 (83) and D04 (84). REMARK Mark the connection position to make sure no mistake is made when reconnecting.
Hose, Clamp, and Wiring Connector 52. Remove the caps (85).
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53. Remove the joint bolt (86) and then disconnect the hose (87). Tools: impact wrench, socket Joint bolt (86): width across flats 17 mm, M10
54. Remove the clamp (88). Tools: impact wrench, socket Clamp (88) bolt: width across flats 19 mm, M12
55. Remove the joint bolt (89) and then disconnect the hose (90). Tools: impact wrench, socket Joint bolt (89): width across flats 17 mm, M10
56. Remove clip (91) and disconnect the hose (92). Tool: needle-nose pliers
57. Remove the clamp (93). Tools: impact wrench, socket Clamp (93) bolt: width across flats 19 mm, M12
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REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
58. Remove the clips (94) (2 pieces), and disconnect the connectors P27 (95) and P28 (96). REMARK Mark the connection position to make sure no mistake is made when reconnecting.
59. Remove clip (97) and disconnect connectors V11 (98), V19 (99), P22 (100), and V12 (101). REMARK Mark the connection position to make sure no mistake is made when reconnecting.
60. Remove clip (102) and disconnect connector P22 (103) from the connector block.
61. Remove bolts (104) (2 pieces). Tools: impact wrench, socket Bolt (104): width across flats 19 mm, M12 62. Remove clamp (105) and remove the dipstick pipe (106). Tool: needle-nose pliers
63. Remove bolts (107) (4 pieces) and disconnect the tube (108). Tools: impact wrench, socket Bolt (107): width across flats 19 mm, M12
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64. Loosen the sleeve nuts and disconnect the hoses (109) (2 pieces). REMARK Install the plug to the hose and fitting to prevent oil from flowing out. Tools: Wrench, plug (B) Hose (109): width across flats 27 mm, nominal 04
65. Remove the flange (110) and disconnect the hoses (111) (2 pieces). Tools: impact wrench, socket Flange (110) bolt: width across flats 17 mm, M10
66. Loosen the sleeve nuts and disconnect the hoses (112) (2 pieces). REMARK Install the plug to the hose and fitting to prevent oil from flowing out. Tools: wrench, plug (A) Hose (112): width across flats 19 mm, nominal 02
67. Loosen the sleeve nut, and disconnect the hose (113). REMARK Install the plug to the hose and fitting to prevent oil from flowing out. Tools: wrench, plug (C) Hose (113): width across flats 36 mm, nominal 06 68. Loosen the sleeve nuts, and disconnect the hoses (114) and (115). REMARK Install the plug to the hose and fitting to prevent oil from flowing out. Tools: wrench, plug (A) Hoses (114) and (115): width across flats 19 mm, nominal 02
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69. Remove the clamp (116). Tools: impact wrench, socket Clamp (116) bolt: width across flats 19 mm, M12
70. Remove the cap (117).
71. Remove the lock nut (118) and then disconnect the starter cable (118). Tools: torque wrench, socket, impact wrench Lock nut (118a): width across flats 17 mm
72. Remove clip (119) and then disconnect the connectors E08 (120), T10 (121), and P44 (122). REMARK Mark the connection position to prevent connection.
73. Remove bolt (123) and then disconnect the ground cable (124). Tools: impact wrench, socket Bolt (123): width across flats 17 mm, M10
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74. Remove the hose clamp (125) and disconnect the hose (126). Tools: socket, ratchet handle Hose clamp (125): width across flats 8 mm
75. Remove clip (127a) and then disconnect hose (127). Tool: needle-nose pliers
Engine and main pump assembly 76. By use of a sling, hold the engine and main pump assembly (128) in hoist position (a). Tool: wire Engine and main pump assembly (128): 755 kg
77. Remove bolts (129) (4 pieces), lift the engine and main pump assembly (128), and remove it. REMARK • Lift the assembly at 3 points (2 points on the engine and 1 point on the main pump), and remove it. • Check that all the wiring harnesses and pipes are disconnected before removing. Tools: impact wrench, socket Bolt (129): width across flats 24 mm, M16
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INSTALL ENGINE AND MAIN PUMP ASSEMBLY Engine and main pump assembly 1. Sling the Engine and Main Pump assembly (128). Align it in the installation position. REMARK Sling the assembly at 3 points (2 points on the engine and 1 point on the main pump), and install it. Tool: wire Engine and main pump assembly (128): 755 kg 2.
Install the engine and main pump assembly (128) with the bolts (129) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (129): width across flats 24 mm, M16 Bolt (129): 235 to 285 Nm {23.5 to 29.5 kgm}
Hose, Clamp, and Wiring Connector 3. Connect the hose (127) by use of the clip (127a). Tool: needle-nose pliers
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4.
50 DISASSEMBLY AND ASSEMBLY
Connect the hose (126) with the hose clamp (125). Tools: ratchet handle, socket, torque wrench Hose clamp (125): width across flats 8 mm Hose clamp (125): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
5.
Connect the ground cable (124) by use of a bolt (123). Tools: ratchet handle, socket, torque wrench Bolt (123): width across flats 17 mm, M10 Bolt (123): 59 to 74 Nm {6.0 to 7.5 kgm}
6.
Connect the connectors E08 (120), E10 (121), and P44 (122), and install the clip (119).
7.
Connect the starter cable (118) by use of a lock nut (118a). Tools: ratchet handle, torque wrench, socket Lock nut (118a): width across flats 17 mm Lock nut (118a): 17.7 to 24.5 Nm {1.8 to 2.5 kgm}
8.
Install the caps (117).
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9.
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
Attach the clamp (116). Tools: ratchet handle, socket, torque wrench Clamp (116) bolt: width across flats 19 mm, M12 Clamp (116) bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
10. Connect hoses (114) and (115) by use of a sleeve nut. Tools: wrench, torque wrench Hoses (114) and (115): width across flats 19 mm, nominal 02 Hoses (114) and (115): 34 to 54 Nm {3.5 to 5.5 kgm} 11. Connect hose (113) by use of a sleeve nut. Tools: wrench, torque wrench Hose (113): width across flats 36 mm, nominal 06 Hose (113): 177 to 245 Nm {18.0 to 25.0 kgm} 12. Connect hoses (112) (2 pieces) by use of a sleeve nut. Tools: wrench, torque wrench Hose (112): width across flats 19 mm, nominal 02 Hose (112): 34 to 54 Nm {3.5 to 5.5 kgm}
13. Connect hoses (111) (2 pieces) by use of a flange (110). Tools: ratchet handle, socket, torque wrench Flange (110) bolt: width across flats 17 mm, M10 Flange (110) bolt: 59 to 74 Nm {6.0 to 7.5 kgm}
14. Connect hoses (109) (2 pieces) by use of a sleeve nut. Tools: wrench, torque wrench Hose (109): width across flats 27 mm, nominal 04 Hose (109): 84 to 132 Nm {8.5 to 13.5 kgm}
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15. Connect the tube (108) by use of bolts (107) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (107): width across flats 19 mm, M12 Bolt (107): 98 to 123 Nm {10.0 to 12.5 kgm}
16. Install the dipstick pipe (106) by use of the clip (105). Tool: needle-nose pliers 17. Install bolts (104) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (104): width across flats 19 mm, M12 Bolt (104): 98 to 123 Nm {10.0 to 12.5 kgm}
18. Connect the connector P22 (103) to the connector block, and install the clip (102).
19. Connect the connector V11 (98), connector V19 (99), connector P22 (100), and connector V12 (101), and install the clip (97).
20. Connect the connectors P27 (95) and P28 (96), and install the clips (94) (2 pieces).
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21. Attach the clamp (93). Tools: ratchet handle, socket, torque wrench Clamp (93) bolt: width across flats 19 mm, M12 Clamp (93) bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
22. Connect the clip (91) by use of the hose (92). Tool: needle-nose pliers
23. Connect the hose (90) with the joint bolt (89). Tools: ratchet handle, socket, torque wrench Joint bolt (89): Width across flats 17 mm, M10 Joint bolt (89): 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
24. Attach the clamp (88). Tools: ratchet handle, socket, torque wrench Clamp (88) bolt: width across flats 19 mm, M12 Clamp (88) bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
25. Connect the hose (87) with the joint bolt (86). Tools: ratchet handle, socket, torque wrench Joint bolt (86): Width across flats 17 mm, M10 Joint bolt (86): 19.6 to 29.4 Nm {2.0 to 3.0 kgm}
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26. Install the caps (85).
Engine controller 27. Connect the connectors M37 (83) and D04 (84), and install the clips (82) (2 pieces).
28. Connect the ground T12 (81a) by use of the bolt (81). Tools: ratchet handle, socket, torque wrench Bolt (81): width across flats 19 mm, M12 Bolt (81): 98 to 123 Nm {10.0 to 12.5 kgm}
29. Install the clips (80) (2 pieces).
30. Install the connector E06 (79) to the connector block.
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31. Connect the connector CE02 (77) and connector CE03 (78).
Connector 32. Connect the intake air heater E01 (76b) by use of the lock nut (76a). Tools: ratchet handle, socket, torque wrench Lock nut (76a): width across flats 10 mm Lock nut (76a): 3.4 to 4.6 Nm {0.35 to 0.47 kgm}
33. Install the caps (76).
Air conditioner compressor assembly 34. Align the air conditioner compressor assembly (75) with the installation position.
35. Install the bolts (75a) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (75a): width across flats 13 mm, M8 Bolt (75a): 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
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50 DISASSEMBLY AND ASSEMBLY
36. Attach the clamp (74). Tools: ratchet handle, socket, torque wrench Clamp (74) bolt: width across flats 19 mm, M12 Clamp (74) bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
37. Install the air conditioner compressor belt (73) by use of bolts (72), (72a). REMARK Adjust the tension of the belt for the air conditioner compressor. For details, see TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION". (For details, see TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TESION".) Tools: ratchet handle, socket, torque wrench Bolts (72), (72a): width across flats 22 mm, M14 Bolts (72), (72a): 153 to 190 Nm {15.5 to 19.5 kgm}
Fan clutch assembly 38. Install the cover (71) with the bolts (70) (6 pieces). Tools: ratchet handle, socket, torque wrench Bolt (70): width across flats 17 mm, M10 Bolt (70): 59 to 74 Nm {6.0 to 7.5 kgm}
39. Install the fan clutch assembly (69) with the bolts (68) (6 pieces). Tools: ratchet handle, socket, torque wrench Bolt (68): width across flats 14 mm, M10 Bolt (68): 34 to 74 Nm {3.5 to 7.5 kgm}
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40. Connect the connector M16 (67), and install the clamps (66) (3 pieces). Tools: ratchet handle, socket, torque wrench Clamp (66) bolt: width across flats 17 mm, M10 Clamp (66) bolt: 59 to 74 Nm {6.0 to 7.5 kgm}
41. Remove the cushion material from the cooling core (65).
42. Install the fan guard (64) by use of bolts (63) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (63): width across flats 17 mm, M10 Bolt (63): 59 to 74 Nm {6.0 to 7.5 kgm}
43. Install the fan guard (62) by use of bolts (61) (3 pieces). Tools: ratchet handle, socket, torque wrench Bolt (61): width across flats 17 mm, M10 Bolt (61): 59 to 74 Nm {6.0 to 7.5 kgm}
44. Install the cover (60) with the bolts (59) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (59): width across flats 17 mm, M10 Bolt (59): 59 to 74 Nm {6.0 to 7.5 kgm}
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45. Install the cover (58) with the bolts (57) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (57): width across flats 17 mm, M10 Bolt (57): 59 to 74 Nm {6.0 to 7.5 kgm}
46. Install the cover (56) with the bolts (55) (3 pieces). Tools: ratchet handle, socket, torque wrench Bolt (55): width across flats 17 mm, M10 Bolt (55): 59 to 74 Nm {6.0 to 7.5 kgm}
Hose 47. Connect hose (54) by use of clamps (53) (2 pieces). NOTICE • Use a new clamp. • Do not use an impact wrench. • Install clamps (53) (2 pieces) at the clamp installation angle (f). Installation angle (f): 15° Tools: socket, torque wrench, ratchet handle Clamp (53): width across flats 13 mm, M8 Clamp (53): 6 Nm (0.6 kgm) or more 1)
Connect the hose to the marked position. NOTICE Apply sealant to the entire circumference of the hose evenly. Hose (54) internal: sealing material (ThreeBond 2720C or equivalent)
2)
Set clamp (53) bridge (a) under the bolt (d). Tighten the bolt so that the overlap dimension (c) between the bridge (a) and band (b) is 5 mm or more. Bolt (d) threaded part: lubricating oil (ThreeBond PANDO 18B)
When reusing hose Align the clamp (53) with the mark of the clamp on the hose (54).
When using a new hose Tighten until the clamp dimension (e) is 7 to 10 mm.
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I
*
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REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
48. Connect the hose (49) by use of the clip (47), and install the clamp (48). Tools: ratchet handle, socket, torque wrench, needle-nose pliers Clamp (48) bolt: width across flats 17 mm, M10 Clamp (48) bolt: 59 to 74 Nm {6.0 to 7.5 kgm}
49. Connect the hose (46) with the hose clamp (45). Tools: ratchet handle, socket, torque wrench Hose clamp (45): width across flats 8 mm Hose clamp (45): 10.8 to 11.8 Nm {1.1 to 1.2 kgm}
50. Connect the hose (44) with the clamp (43) use the procedure below. NOTICE • Use a new clamp. • Do not use an impact wrench. Tools: socket, torque wrench, ratchet handle Clamp (43): Width across flats 13 mm, M8 Clamp (43): 6 Nm (0.6 kgm) or more 1)
Connect the hose to the marked position. NOTICE Apply sealant to the entire circumference of the hose evenly. Hose (44) internal: sealing material (ThreeBond 2720C or equivalent)
2)
Set clamp (43) bridge (a) under the bolt (d). Tighten the bolt so that the overlap dimension (c) between the bridge (a) and band (b) is 5 mm or more. Bolt (d) threaded part: sealing material (ThreeBond 2720C or equivalent)
When reusing hose Align the clamp (43) with the mark of the clamp on the hose.
When using a new hose Tighten until the clamp dimension (e) is 7 to 10 mm. 51. Install the hose clamp (42). Tools: socket, torque wrench, ratchet handle Hose clamp (42): width across flats 11 mm Hose clamp (42): 5.9 to 8.1 Nm {0.59 to 0.81 kgm}
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50 DISASSEMBLY AND ASSEMBLY
Air cleaner assembly 52. Install the air cleaner assembly. See REMOVE AND INSTALL AIR CLEANER ASSEMBLY. Cover, Hose, and Wiring Connector 53. Install the cover (41) with the bolts (40) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (40): width across flats 19 mm, M12 Bolt (40): 98 to 123 Nm {10.0 to 12.5 kgm}
54. Install the cover (39) with the bolts (38) (11 pieces). Tools: ratchet handle, socket, torque wrench Bolt (38): width across flats 19 mm, M12 Bolt (38): 98 to 123 Nm {10.0 to 12.5 kgm}
55. Attach the clamp (37). Tools: ratchet handle, socket, torque wrench Clamp (37): width across flats 19 mm, M12 Clamp (37) bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
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56. Install the cover (36) with the bolts (35) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (35): width across flats 19 mm, M12 Bolt (35): 98 to 123 Nm {10.0 to 12.5 kgm}
57. Install the cover (34) with the bolts (33) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (33): width across flats 19 mm, M12 Bolt (33): 98 to 123 Nm {10.0 to 12.5 kgm}
58. Install the cover (32) with the bolts (31) (6 pieces). Tools: ratchet handle, socket, torque wrench Bolt (31): width across flats 19 mm, M12 Bolt (31): 98 to 123 Nm {10.0 to 12.5 kgm}
59. Install the cover (30) with the bolts (29) (2 pieces). Tools: ratchet handle, socket, torque wrench Bolt (29): width across flats 19 mm, M12 Bolt (29): 98 to 123 Nm {10.0 to 12.5 kgm}
60. Install the cover (28) with the bolts (27) (3 pieces). Tools: ratchet handle, socket, torque wrench Bolt (27): width across flats 19 mm, M12 Bolt (27): 98 to 123 Nm {10.0 to 12.5 kgm}
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61. Install the cover (26) with the bolt (25). Tools: ratchet handle, socket, torque wrench Bolt (25): width across flats 19 mm, M12 Bolt (25): 98 to 123 Nm {10.0 to 12.5 kgm}
62. Install the cover (24).
63. Install the cover (23) with the bolts (22) (5 pieces). Tools: ratchet handle, socket, torque wrench Bolt (22): width across flats 19 mm, M12 Bolt (22): 98 to 123 Nm {10.0 to 12.5 kgm}
64. Install frame (21) with bolts (20) (3 pieces). Tools: ratchet handle, socket, torque wrench Bolt (20): width across flats 19 mm, M12 Bolt (20): 98 to 123 Nm {10.0 to 12.5 kgm}
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65. Install the cover (19) with the bolts (18) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (18): width across flats 19 mm, M12 Bolt (18): 98 to 123 Nm {10.0 to 12.5 kgm}
66. Connect the connector P67 (17) with clamps (16) (2 pieces). Tools: ratchet handle, socket, torque wrench Clamp (16) bolt: width across flats 19 mm, M12 Clamp (16) bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
67. Install the cover (15) with the bolts (14) (7 pieces). Tools: ratchet handle, socket, torque wrench Bolt (14): width across flats 19 mm, M12 Bolt (14): 98 to 123 Nm {10.0 to 12.5 kgm}
68. Install hose (13) with clamps (12) (2 pieces). Tools: ratchet handle, socket, torque wrench Clamp (12) bolt: width across flats 19 mm, M12 Clamp (12) bolt: 98 to 123 Nm {10.0 to 12.5 kgm}
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69. Close the cover (11).
70. Install the cover (10) with the bolts (9) (6 pieces). Tools: ratchet handle, socket, torque wrench Bolt (9): width across flats 19 mm, M12 Bolt (9): 98 to 123 Nm {10.0 to 12.5 kgm}
71. Install the cover (8) with the bolts (7) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (7): width across flats 19 mm, M12 Bolt (7): 98 to 123 Nm {10.0 to 12.5 kgm}
72. Install the cover (6) with the bolts (5) (3 pieces). Tools: ratchet handle, socket, torque wrench Bolt (5): width across flats 19 mm, M12 Bolt (5): 98 to 123 Nm {10.0 to 12.5 kgm}
73. Install the cover (4) with the bolts (3) (4 pieces). Tools: ratchet handle, socket, torque wrench Bolt (3): width across flats 19 mm, M12 Bolt (3): 98 to 123 Nm {10.0 to 12.5 kgm}
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74. Install the cover (2) with the bolts (1) (7 pieces). Tools: ratchet handle, socket, torque wrench Bolt (1): width across flats 19 mm, M12 Bolt (1): 98 to 123 Nm {10.0 to 12.5 kgm}
Engine hood assembly 75. Install the engine hood assembly. See REMOVE AND INSTALL ENGINE HOOD ASSEMBLY. Refilling with hydraulic oil 76. Add hydraulic oil. See "DRAIN AND ADD HYDRAULIC OIL". Refilling with coolant 77. Add coolant. See. "DRAIN AND ADD COOLANT".
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REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
A─
Radiator assembly
─
Aftercooler asHydraulic oil ─ sembly cooler assembly
Fan clutch assembly
─
Engine front oil Vibration damp─ seal er
─
Fuel cooler assembly
Air conditioner ─ condenser assembly
─A
Standard tool list The listed parts are for reference only. You can use the part that is not listed if it is applicable. No.
Part name
Part No.
Specifications
Q'ty
1
Socket
Commercially 17 mm available
1
2
Socket
Commercially 19 mm available
1
3
Ratchet handle
Commercially available
1
4
Impact wrench
Commercially available
1
5
Torque wrench
Commercially 5 to 50 Nm available
1
6
Torque wrench
Commercially 20 to 200 Nm available
1
7
Tapping screw
Commercially available
1
Remarks
Special tool list Symbol
Part name
Part No.
Specifications
Q'ty
A
Seal puller
795-799-6400
1
B
Wrench
790-331-1120 Angle
1
k k k k
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable attitude. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "HANDLE BATTERY DISCONNECT SWITCH".)
REMOVE ENGINE FRONT OIL SEAL Radiator assembly 1. Remove the radiator assembly. See "REMOVE AND INSTALL RADIATOR ASSEMBLY". Hydraulic oil cooler assembly 2. Remove the hydraulic oil cooler assembly. See "REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY". Aftercooler assembly 3. Remove the aftercooler assembly. See "REMOVE AND INSTALL AFTERCOOLER ASSEMBLY".
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Fuel cooler assembly 4. Remove the fuel cooler assembly. See "REMOVE AND INSTALL FUEL COOLER ASSEMBLY". Air conditioner condenser assembly 5. Remove the bolts (1a) (2 pieces), and move the air conditioner condenser assembly (1) aside. REMARK Fix the air conditioner condenser assembly (1) with string, etc. so it does not close. Tool: Impact wrench, socket Bolt (1a): 17-mm width across flats, M10
6.
Remove the bolts (2) (6 pieces), and remove the cover (3). Tool: Impact wrench, socket Bolt (2): 19-mm width across flats, M12
7.
Remove the wing nuts (4) (3 pieces), and remove the nets (5) and (6).
Fan clutch assembly 8. Remove the fan clutch assembly. See "REMOVE AND INSTALL FAN CLUTCH ASSEMBLY". Vibration damper 9. Remove the bolts (7) (6 pieces), and remove the vibration damper (8). Tool: Impact wrench, socket Bolt (7): Width across flats 15 mm, M12
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Engine front oil seal 10. Remove the dust seal (9).
11. Install the seal puller (A) to the crankshaft. Tool: Seal puller (A) 12. Screw in the tapping screw (10) of the seal puller (A) to the seal carrier part of the engine front oil seal (11).
Tool: Tapping screw 13. Turn the handle clockwise, and remove the engine front oil seal (11). REMARK
$
*
Be careful not to damage the crankshaft while removing it.
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INSTALL ENGINE FRONT OIL SEAL Engine front oil seal 1. Install front oil seal (11) by use of the tool seal puller (A). REMARK • Before installing the seal, check that the end surface corner and the lip sliding surface of the crankshaft, and the housing are free from flaws, burrs, sharp edges, and rusts, etc. • When you assemble the seal, do not apply oil or grease to the shaft or seal lip. Also, fully wipe off oil or grease from the shaft. • Check values below for the cover (12) of the front oil seal (11). Protrusion (a): 0.5 mm or less Facial runout (b): 0.25 mm or less
$
*
Tools: Seal puller (A), dial gauge
E D
2.
*
Install the dust seal (9). REMARK Check dimension (c). Dimension (c): 12 + 0.1/0 mm Tool: Dial gauge
Vibration damper 3. Align the dowel pin hole with the dowel pin portion (d), and install the vibration damper (8). Tool: Dowel pin
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4.
50 DISASSEMBLY AND ASSEMBLY
Remove the bolts (7) (6 pieces) by use of the procedure below. 1) Tighten the bolts (7) (6 pieces) in diagonal order. Tools: Ratchet handle, torque wrench, socket Bolt (7): Width across flats 15 mm, M12 Bolt (7): 55 ± 5 Nm {5.61 ± 0.51 kgm} 2)
Loosen the bolts (7) (6 pieces) 180°. Tools: Ratchet handle, socket
3)
Tighten the bolts (7) (6 pieces) in diagonal order. Tools: Ratchet handle, torque wrench, socket Bolt (7): Width across flats 15 mm, M12 Bolt (7): 55 ± 5 Nm {5.61 ± 0.51 kgm}
4)
Tighten the bolts (7) (6 pieces) an additional 90 ± 5° by use of a wrench (angle). REMARK If an angle tightening wrench (B) is not used, place a mark on the vibration damper (8) or bolt (7) and then tighten the bolt 90 ± 5°. Tool: Wrench (angle) (B)
Fan clutch assembly 5. Install the fan clutch assembly. See "REMOVE AND INSTALL FAN CLUTCH ASSEMBLY". Air conditioner condenser assembly 6. Install the nets (5) and (6) with the wing nuts (4) (3 pieces).
7.
Install the cover (3) with the bolts (2) (6 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (2): width across flats 19 mm, M12 Bolt (2): 98 to 123 Nm {10 to 12.5 kgm}
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8.
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
Install the air conditioner condenser assembly (1) with the bolts (1a) (2 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (1a): width across flats 17 mm, M10 Bolt (1a): 59 to 74 Nm {6 to 7.5 kgm}
Fuel cooler assembly 9. Install the fuel assembly. See "REMOVE AND INSTALL FUEL ASSEMBLY". Aftercooler assembly 10. Install the aftercooler assembly. See "REMOVE AND INSTALL AFTERCOOLER ASSEMBLY". Hydraulic oil cooler assembly 11. Install the hydraulic oil cooler assembly. See "REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY". Radiator assembly 12. Install the radiator assembly. See "REMOVE AND INSTALL RADIATOR ASSEMBLY".
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REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially 17 mm available
1
2
Socket
Commercially available
1
3
Ratchet handle
Commercially available
1
4
Impact wrench
Commercially available
1
5
Torque wrench
Commercially 20 to 200 Nm available
1
6
Dial gauge
Commercially available
1
7
Wire
Commercially available
1
8
Eyebolt
Commercially M10 available
1
9
Guide bolt
Commercially M10 available
1
10
Guide bolt
Commercially M12 available
2
11
Tapping screw
Commercially available
1
12
Pilot
Commercially available
1
13
Plate
Commercially available
1
14
Stand
Commercially available
1
Remarks
List of Special Tools Symbol A k k k k
Part name Seal puller
Part number
SPECIFICATION
795-799-6500
Q'ty
Remarks
1
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
REMOVE ENGINE REAR OIL SEAL Main pump assembly 1. Remove the main pump assembly. See "REMOVE AND INSTALL MAIN PUMP ASSEMBLY". 50-174
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Damper assembly 2. Remove the bolt (1), and install the guide bolt (1a). Tools: Impact wrench, socket, ratchet handle, guide bolt (M10) Bolt (1): width across flats 17 mm, M10 3.
Remove the bolts (2a) (7 pieces), and remove the damper assembly (2). Tools: Impact wrench, socket Bolt (2a): width across flats 17 mm, M10
Flywheel assembly 4. Remove the bolts (3) (2 pieces), and insert the guide bolt (3a). Tools: Impact wrench, socket, ratchet handle, guide bolt (M12) Bolt (3): Width across flats 18 mm, M12
5.
Install the eyebolt to the point (b), lift the flywheel assembly (4), and hold it. Tools: Eyebolt (M10), wire Flywheel assembly (4): 30.5 kg
6.
Remove the bolts (3b) (6 pieces), and pull out the flywheel assembly (4). REMARK Be careful not to remove the guide bolt. Tools: Impact wrench, socket, guide bolt (M12) Bolt (3b): Width across flats 18 mm, M12
7.
Lift and remove the flywheel assembly (4).
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REMOVE AND INSTALL ENGINE REAR OIL SEAL
Engine rear oil seal 8. Install the seal puller (A) to the crankshaft. Tool: Seal puller (A) 9.
Install the tapping screw (5a) of the seal puller (A) to the seal carrier of the rear oil seal.
$
Tool: Tapping screw 10. Turn the handle clockwise, and remove the rear oil seal (5). REMARK
D *
Be careful not to damage the crankshaft when you remove it. Tool: Ratchet handle
INSTALL ENGINE REAR OIL SEAL Engine rear oil seal 1. Degrease, clean, and dry the sealing contact surface of the crankshaft (6), and the seal lip contact surface to prevent oil leakage. 2. Insert the pilot (6a) to the crankshaft (6), and insert the rear oil seal (5) into the flywheel housing.
D
NOTICE Do not remove the pilot (6a) installed to the engine rear oil seal (5) until you insert the crankshaft.
*
Tool: Pilot (6a) 3.
Insert the pilot (6a) to the crankshaft (6), and insert the rear oil seal (5) into the flywheel housing (7).
Tool: Pilot (6a)
D
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4.
REMOVE AND INSTALL ENGINE REAR OIL SEAL
Push in the rear oil seal (5) further, and remove pilot (6a).
D *
5.
Install the rear oil seal (5) to the flywheel housing (7) at correct depth with the seal puller (A). REMARK • When you push in the rear oil seal (5), make sure that the seal is not bent. • Measure the protrusion (x) of the rear oil seal (5) from the flywheel housing (7). The protrusion (x) must be in the range below. (x): 0.38 mm or below Tool: Seal puller (A), ratchet handle [
*
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Flywheel assembly 6. Install the eyebolt to the slinging position (b). Tool: Eyebolt (M10) 7.
With the guide bolt, sling and set the flywheel assembly (4) to the installation position. Tool: Guide bolt (M12), ratchet handle, socket, wire Flywheel assembly (4): 30.5 kg
8.
Tighten the bolts (3) (2 pieces) and (3b) (6 pieces) in the order shown in the figure. NOTICE Tighten the bolts with the plate (4a) so the flywheel assembly (4) does not rotate. REMARK Install the bolts (3b) (6 pieces), and then remove the guide bolts (3a). Tool: Ratchet handle, torque wrench, socket, plate Bolts (3), (3b): Width across flats 18 mm, M12 Bolts (3) and (3b): 137 ± 7 Nm {13.97 ± 0.71 kgm}
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Measuring the radial runout 9. Install the dial gauge (7a) to the stand, and install it to the flywheel housing (7).
Tool: Stand, digal gauge 10. Set the probe of the dial gauge (7a) to the spigot joint portion (c) or outside perimeter of the flywheel at a right angle. 11. Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values that the pointer of the dial gauge points.
F
D
G D
NOTICE
*
After you rotated the flywheel by 1 turn, check that the pointer of the dial gauge (7a) indicates the start position. Radial runout: 0.15 mm or less Measuring the facial runout 12. Similarly to the measurement of the radial runout, set the probe of the dial gauge (7a) to the end face (b) near the outside perimeter of the flywheel at a right angle. NOTICE When you measure the facial runout, move the crankshaft either to the front or the rear and eliminate the error caused by the backlash. 13. Rotate the flywheel by 1 turn, and measure the difference between the lowest and the highest values that the pointer of the dial gauge (7a) points. NOTICE Facial runout: 0.20 mm or less Damper assembly 14. Install the damper assembly (2) with the seal puller (A) and the guide bolt (1a). Tool: Seal puller (A), guide bolt (M10) 15. Remove the guide bolt (1a), and install the bolts (1) and (2a) (7 pieces). Tool: Ratchet handle, torque wrench, socket Bolts (1) and (2a): 17-mm width across flats, M10 Bolts (1) and (2a): 59 to 74 Nm {6 to 7.5 kgm}
Main pump assembly 16. Install the main pump assembly. See "REMOVE AND INSTALL MAIN PUMP ASSEMBLY".
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REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVE AND INSTALL FUEL COOLER ASSEMBLY Standard tool list The listed parts are for reference only. You can use the part that is not listed if it is applicable. No.
Part name
Part No.
Specifications
Q'ty
1
Socket
Commercially available
13 mm
1
2
Socket
Commercially available
17 mm
1
3
Ratchet handle
Commercially available
4
Open-end wrench
Commercially available
5
Impact wrench
Commercially available
6
Torque wrench
Commercially available
Remarks
1 22 mm
2 1
20 to 200 Nm
1
Special tool list Symbol A k k k k
Part name
Part No.
Specifications
Q'ty
1 Plug
07376-70315
Nominal 03
2
2 Cap
02789-00315
Nominal 03
2
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
NOTICE Check the connector numbers and installed positions before disconnecting wirings and hoses, and write them down. REMARK Drain fuel since fuel does not stop flowing through the fuel tank return hose when the fuel level is high.
REMOVE FUEL COOLER ASSEMBLY Fuel cooler assembly 1. Open the cover (1).
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50 DISASSEMBLY AND ASSEMBLY
2.
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
Remove the bolts (2) (2 pieces), and remove the cover (3). Tool: Impact wrench, socket Bolt (2): 13-mm width across flats, M8
3.
Loosen the sleeve nuts, and disconnect the hoses (4) (2 pieces). NOTICE • Be sure to fix the elbow (a) on the fuel cooler side with a different wrench, and disconnect the hoses without applying force to the cooler main unit. • If a wrench is not used, the force will be applied to the cooler main unit and the weld part (b) will come off. REMARK Plug the hoses to prevent dust and water from entering. Tool: Wrench, plug (A) Hose (4): 22-mm width across flats, nominal 03 Elbow (a): 22-mm width across flats
4.
Remove the bolts (5) (4 pieces), and remove the fuel cooler assembly (6). Tool: Impact wrench, socket Bolt (5): 13-mm width across flats, M8
INSTALL FUEL COOLER ASSEMBLY Fuel cooler assembly 1. Install the fuel cooler assembly (6) by use of bolts (5) (4 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (5): Width across flats 13 mm, M8 Bolt (5): 27 to 34 Nm {2.8 to 3.5 kgm}
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL FUEL COOLER ASSEMBLY
2.
50 DISASSEMBLY AND ASSEMBLY
Connect hoses (4) (2 pieces) by use of sleeve nuts. NOTICE • When you connect them, be sure to hold the elbow (a) on the fuel cooler side in place by use of another wrench so that the force is not applied to the cooler main unit. • If the wrench is not used, the force may be applied to the cooler main unit and the weld part (b) may crack. Tool: Open-end wrench, torque wrench Hose (4): Width across flats 22 mm, nominal 03 Elbow (a): Width across flats 22 mm Hose (4): 54 to 93 Nm {5.5 to 9.5 kgm}
3.
Install the cover (3) with the bolts (2) (2 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (2): Width across flats 17 mm, M10 Bolt (2): 59 to 74 Nm {6.0 to 7.5 kgm}
4.
Close the cover (1).
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same. No.
Part name
Part number
Specification
Q'ty
1
Socket
Commercially available
2
Ratchet handle
Commercially available
1
3
Impact wrench
Commercially available
1
4
Torque wrench
Commercially available
5
Needle-nose pliers
Commercially available
1
6
Webbing sling
Commercially available
2
k k k k
19 mm
20 to 200 Nm
Remarks
1
1
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
REMOVE ENGINE HOOD ASSEMBLY Engine hood assembly 1. Open engine hood (1).
2.
Lift and hold the engine hood (1). Tool: Webbing sling Engine hood assembly (1): 45 kg
PC210-10M0, PC210LC-10M0
50-183
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
3.
50 DISASSEMBLY AND ASSEMBLY
Remove the clips (2) (2 pieces) and then remove the dampers (3) (2 pieces). REMARK Secure the damper (3) to the engine hood. Tool: Needle-nose pliers
4.
Remove the bolts (4) and then remove the stay (5). Tools: Impact wrench, socket Bolt (4): width across flats 19 mm, M12
5.
Close the engine hood (1). REMARK Close the engine hood assembly (1) in suspended state.
6.
Remove the bolts (6) (4 pieces) and then remove the engine hood (1). NOTICE Be careful not to forget to disconnect the catch when lifting. Tools: Impact wrench, socket Bolt (6): width across flats 19 mm, M12
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
INSTALL ENGINE HOOD ASSEMBLY Engine hood assembly 1. Lift the engine hood (1) and align it with the install position. Tool: Webbing sling Engine hood assembly (1): 45 kg 2.
Install the engine hood (1) by use of bolts (6) (4 pieces). Tools: Ratchet handle, socket, torque wrench Bolt (6): width across flats 19 mm, M12 Bolt (6): 98 to 123 Nm {10.0 to 12.5 kgm}
3.
Open the engine hood (1), lift and hold. REMARK Open the engine hood assembly (1) while suspended.
4.
Install the stay (5) with the bolt (4). Tools: Ratchet handle, socket, torque wrench Bolt (4): width across flats 19 mm, M12 Bolt (4): 98 to 123 Nm {10.0 to 12.5 kgm}
5.
Install the dampers (3) (2 pieces) by use of clips (2) (2 pieces).
PC210-10M0, PC210LC-10M0
50-185
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
6.
50 DISASSEMBLY AND ASSEMBLY
Close the engine hood (1).
50-186
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY Draining fuel
- Engine hood
- Cover, handrail
-
Wiring connector
-
Fuel tank assembly
List of standard tools The tools noted are for reference and other tools can be used if that is what the tool is meant to be used for. No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially available
19 mm
1
2
Socket
Commercially available
24 mm
1
3
Ratchet handle
4
Wrench
Commercially available
5
Impact wrench
Commercially available
6
Torque wrench
Commercially available
7
Needle-nose pliers
Commercially available
8
Webbing sling
Commercially available
9
Wire
Commercially available
1
Fuel container
Commercially available
As require d
10
Commercially available
Remarks
1
22 mm
1 1
20 to 200 Nm
1 1
Width 25 mm × length 3 m
1
For 0.8 t
List of Special Tools Symbol A k k k k
Part name
Part number
SPECIFICATION
Q'ty
1 Plug
07376-70315
Nominal 03
1
2 Cap
02789-00315
Nominal 03
1
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "".)
NOTICE • Install a plug or flange in the place where a fuel hose is disconnected to prevent oil from flowing out. • Write down the connector numbers and installed positions before disconnecting electric wirings and hoses.
PC210-10M0, PC210LC-10M0
50-187
REMOVE AND INSTALL FUEL TANK ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
REMOVE FUEL TANK ASSEMBLY Draining fuel 1. Drain the fuel. See "DRAIN AND ADD FUEL" Engine hood 2. Open engine hood (1).
Cover, handrail 3.
Remove the bolts (2) (3 pieces) and remove the cover (3). Tools: Impact wrench, socket Bolt (2): width across flats 19 mm, M12
4.
Lift and hold the handrail (4). Tool: Webbing sling Handrail (4): 25 kg
5.
Open the cover (5).
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
6.
REMOVE AND INSTALL FUEL TANK ASSEMBLY
Remove the bolts (6) (8 pieces) and then remove the handrail (4). Tools: Impact wrench, socket Bolt (6): width across flats 19 mm, M12
Wiring connector 7. Disconnect connector L02 (7).
8.
Remove the bolts (8) (2 pieces), and remove the light (9). Tools: Impact wrench, socket Bolt (8): width across flats 19 mm, M12
9.
Remove clip (10). Tool: Needle-nose pliers
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL FUEL TANK ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
10. Remove the bolts (11) (4 pieces) and then lift and remove the cover (12). Tools: Impact wrench, socket, wire Bolt (11): width across flats 19 mm, M12 Cover (12): 30 kg
11. Remove the bolts (13) (4 pieces) and remove the cover (14). Tools: Impact wrench, socket Bolt (13): width across flats 19 mm, M12
12. Remove the clip (15) and disconnect the connector P21 (16).
Fuel tank assembly 13. Open the cover (17).
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
14. Remove the bolts (18) (4 pieces) and remove the cover (19). Tools: Impact wrench, socket Bolt (18): width across flats 19 mm, M12
15. Lift and hold the fuel tank assembly (20). REMARK Install a wire at the suspension position (a). Tool: wire Fuel tank assembly (20): 145 kg
16. Close the fuel valve (21).
17. Remove clip (22a) and then disconnect hose (22). Tool: Needle-nose pliers 18. Loosen the sleeve nuts and disconnect the hoses (23) (2 pieces). REMARK Install a plug to prevent fuel from flowing out. Tools: Wrench, plug (A) Hose (23): width across flats 22 mm, nominal 03
PC210-10M0, PC210LC-10M0
50-191
REMOVE AND INSTALL FUEL TANK ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
19. Remove bolts (24) (6 pieces) and then remove the fuel tank assembly (20). Tools: Impact wrench, socket Bolt (24): width across flats 24 mm, M16
INSTALL FUEL TANK ASSEMBLY Fuel tank assembly 1. Lift the fuel tank assembly (20) and align it with the install position. REMARK Install a wire at the suspension position (a). Tool: wire Fuel tank assembly (20): 145 kg
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
2.
REMOVE AND INSTALL FUEL TANK ASSEMBLY
Install the fuel tank assembly (20) by use of bolts (24) (6 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (24): width across flats 24 mm, M16 Bolt (24): 98 to 123 Nm {10.0 to 12.5 kgm}
3.
Connect the hose (22) by use of a clip (22a). Tool: Needle-nose pliers
4.
Connect hoses (23) (2 pieces) by use of sleeve nuts. Tools: Torque wrench, wrench Hose (23): width across flats 22 mm, nominal 03 Hose (23): 54 to 93 Nm {5.5 to 9.5 kgm}
5.
Open the fuel valve (21).
PC210-10M0, PC210LC-10M0
50-193
REMOVE AND INSTALL FUEL TANK ASSEMBLY
6.
50 DISASSEMBLY AND ASSEMBLY
Install the cover (19) with the bolts (18) (4 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (18): width across flats 19 mm, M12 Bolt (18): 98 to 123 Nm {10.0 to 12.5 kgm}
7.
Close the cover (17).
Wiring connector 8. Connect the connector P21 (16) and install the clip (15).
9.
Install the cover (14) with the bolts (13) (4 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (13): width across flats 19 mm, M12 Bolt (13): 98 to 123 Nm {10.0 to 12.5 kgm}
50-194
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
10. Lift the cover (12) and align it with the install position. Tool: wire Cover (12): 30 kg 11. Install the cover (12) with the bolts (11) (4 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (11): width across flats 19 mm, M12 Bolt (11): 98 to 123 Nm {10.0 to 12.5 kgm} 12. Install the clip (10). Tool: Needle-nose pliers
13. Install the light (9) with the bolts (8) (2 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (8): width across flats 19 mm, M12 Bolt (8): 98 to 123 Nm {10.0 to 12.5 kgm}
14. Connect the connector L02 (7).
Cover, handrail 15. Lift and hold the handrail (4). Tool: Webbing sling Handrail (4): 25 kg
PC210-10M0, PC210LC-10M0
50-195
REMOVE AND INSTALL FUEL TANK ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
16. Install the handrail (4) with the bolts (6) (8 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (6): width across flats 19 mm, M12 Bolt (6): 98 to 123 Nm {10.0 to 12.5 kgm}
17. Close the cover (5).
18. Install the cover (3) with the bolts (2) (3 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (2): width across flats 19 mm, M12 Bolt (2): 98 to 123 Nm {10.0 to 12.5 kgm}
Engine hood 19. Close the engine hood (1).
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
Refilling with fuel 20. Fill with fuel. See "DRAIN AND ADD FUEL"
PC210-10M0, PC210LC-10M0
50-197
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CLEANER ASSEMBLY Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same. No.
Part name
Part number
Specification
Q'ty
1
Socket
Commercially available
9.5 mm
1
2
Socket
Commercially available
19 mm
1
3
Ratchet handle
Commercially available
4
Torque wrench
Commercially available
5
Impact wrench
Commercially available
k k k k
Remarks
1 20 to 200 Nm
1 1
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".)
NOTICE Before you disconnect the wirings and hoses, check the connector numbers and installed positions and write them down.
REMOVE AIR CLEANER ASSEMBLY Engine Hood 1. Open the engine hood (1).
Cover 2. Remove the bolts (2) (4 pieces), and remove the cover (3). Tool: Impact wrench, socket Bolt (2): Width across flats 19 mm, M12
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50 DISASSEMBLY AND ASSEMBLY
3.
Open the cover (4).
4.
Open the cover (5).
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
Air cleaner assembly 5. Remove the clip (6), and disconnect the connector P23 (7).
6.
Remove the hose clamp (8), and disconnect the hose (9). Tool: Socket Hose clamp (8): Width across flats 9.5 mm
7.
Remove the bolts (10) (4 pieces), and remove the air cleaner assembly (11). Tool: Impact wrench, socket Bolt (10): Width across flats 19 mm, M12
PC210-10M0, PC210LC-10M0
50-199
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
INSTALL AIR CLEANER ASSEMBLY Air cleaner assembly 1. Install the air cleaner assembly (11) by use of bolts (10) (4 pieces). Tools: Ratchet handle, torque wrench, socket Bolt (10): width across flats 19 mm, M12 Bolt (10): 98 to 123 Nm {15.5 to 19.5 kgm}
2.
Connect the hose (9) by use of a hose clamp (8). Tools: Ratchet handle, torque wrench, socket Hose clamp (8): width across flats 9.5 mm Hose clamp (8): 10.0 to 11.0 Nm {1.02 to 1.12 kgm}
3.
Connect the connector P23 (7) and install the clip (6).
Cover 4. Close the cover (5).
50-200
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
5.
Close the cover (4).
6.
Install the cover (3) with the bolts (2) (4 pieces).
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
Tools: Ratchet handle, torque wrench, socket Bolt (2): width across flats 19 mm, M12 Bolt (2): 98 to 123 Nm {10.0 to 12.5 kgm}
Engine hood 7. Close the engine hood (1).
PC210-10M0, PC210LC-10M0
50-201
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY Collecting refrig─ Cover erant
─ Connector
─
Air conditioner ─ Hose compressor belt
─A
Air conditioner A ─ compressor assembly
Standard tool list The listed tools are for reference, and other tools that are not on the list can also be used if the function is the same. No.
Part name
Part number
Specification
Q'ty
1
Socket
Commercially available
10 mm
1
2
Socket
Commercially available
13 mm
1
3
Socket
Commercially available
17 mm
1
4
Socket
Commercially available
22 mm
1
5
Ratchet handle
Commercially available
1
6
Impact wrench
Commercially available
1
7
Torque wrench
Commercially available
5 to 50 Nm
1
8
Torque wrench
Commercially available
20 to 200 Nm
1
k k k k k
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".) If refrigerant gas (R134a) gets in your eyes, you could lose your sight. If it touches your skins, you could suffer from frostbite. Therefore, use protective eyeglasses, gloves and working clothes with long sleeves when you collect or refill refrigerant.
NOTICE • Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a). • Before you disconnect the wirings and hoses, check the connector numbers and installed positions and write them down.
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY Collecting refrigerant 1. Collect refrigerant. See "COLLECT AND REFILL REFRIGERANT" to refill refrigerant.
50-202
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
Cover 2. Open the engine hood (1).
3.
Remove the clamp (2). Tool: Impact wrench, socket Bolt for clamp (2): Width across flats 17 mm, M10
4.
Remove the bolts (3) (3 pieces), and remove the cover (4). Tool: Impact wrench, socket Bolt (3): Width across flats 17 mm, M10
5.
Remove the bolts (5) (2 pieces), and remove the cover (6). Tool: Impact wrench, socket Bolt (5): Width across flats 17 mm, M10
Connector 6. Remove the clips (7) (2 pieces), and disconnect the connectors AC03 (8) and M16 (9). REMARK Mark the connection position to prevent connection mistakes.
PC210-10M0, PC210LC-10M0
50-203
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
7.
50 DISASSEMBLY AND ASSEMBLY
Remove the clamp (10). REMARK The connector block is also tightened. Tool: Impact wrench, socket Bolt for clamp (10): Width across flats 17 mm, M10
Air conditioner compressor belt 8. Loosen the bolts (11) and (11a). REMARK Pushing in the air conditioner compressor will reduce the tension on the belt. Tool: Ratchet handle, socket Bolt (11), (11a): Width across flats 22 mm, M14
9.
Remove the air conditioner compressor belt (12).
Hose 10. Remove the bolts (13) (2 pieces), and disconnect the hoses (14) (2 pieces). REMARK • Plug the hose to prevent dust and water from entering. • Be careful not to damage or lose the O-ring. Tool: Ratchet handle, socket Bolt (13): Width across flats 10 mm, M6
50-204
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
Air conditioner compressor assembly 11. Remove the bolts (15) (4 pieces), and remove the air conditioner compressor assembly (16). Tool: Ratchet handle, socket Bolt (15): Width across flats 13 mm, M8
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY Air conditioner compressor assembly 1. Install the air conditioner compressor assembly (16) by use of bolts (15) (4 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (15): Width across flats 13 mm, M8 Bolt (15): 24.5 to 29.4 Nm {2.5 to 3.0 kgm}
Hose 2. Connect the hoses (14) (2 pieces) by use of bolts (13) (2 pieces). REMARK • When connecting the air conditioner piping, be careful to prevent any dirt, dust and water from entering the hoses. • Check that O-ring is installed to the connecting part of the air conditioning piping before connecting. • Do not reuse O-ring because it is deformed and deteriorated if it is used once. • When removing O-ring, use a cloth, etc. so that the piping is not damaged.
2ULQJ
• Check that a new O-ring is not damaged or deteriorated. • Apply compressor oil (DENSO: ND-OIL8) for refrigerant (R134a) on the o-ring. Tools: Ratchet handle, impact wrench, torque wrench (socket) Bolt (13): Width across flats 10 mm, M6
*
Bolt (13): 8 to 12 Nm {0.82 to 1.22 kgm}
PC210-10M0, PC210LC-10M0
50-205
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
Air conditioner compressor belt 3. Install the air conditioner compressor belt (12). REMARK For installation, see TESTING AND ADJUSTING, "TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION".
4.
Tighten the bolts (11) and (11a). Tool: Ratchet handle, socket, torque wrench Bolt (11), (11a): Width across flats 22 mm, M14 Bolt (11), (11a): 153 to 190 Nm {15.5 to 19.5 kgm}
Connector 5. Install the clamp (10). REMARK This also tightens the connector block. Tool: Ratchet handle, socket, torque wrench Bolt for clamp (10): Width across flats 17 mm, M10 Clamp (10) bolt: 59 to 74 Nm {6.0 to 7.5 kgm}
6.
Connect the connector AC03 (8) and connector M16 (9), and install the clips (7) (2 pieces).
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PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
Cover 7. Install the cover (6) with the bolts (5) (2 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (5): Width across flats 17 mm, M10 Bolt (5): 59 to 74 Nm {6.0 to 7.5 kgm}
8.
Install the cover (4) with the bolts (3) (3 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (3): Width across flats 17 mm, M10 Bolt (3): 59 to 74 Nm {6.0 to 7.5 kgm}
9.
Install the clamp (2). Tool: Ratchet handle, socket, torque wrench Bolt for clamp (2): Width across flats 17 mm, M10 Clamp (2) bolt: 59 to 74 Nm {6.0 to 7.5 kgm}
10. Close the engine hood (1).
Refilling with refrigerant 11. See "COLLECT AND REFILL REFRIGERANT" to fill refrigerant. Refilling with air conditioner compressor oil 12. Refill the air conditioner compressor oil. REMARK See APPENDIX, "REFILLING WITH COMPRESSOR OIL" for how to complete the work.
PC210-10M0, PC210LC-10M0
50-207
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY Standard tool list The listed parts are for reference only. You can use the part that is not listed if it is applicable. No.
Part name
Part No.
Specifications
Q'ty
1
Socket
Commercially available
10 mm
1
2
Socket
Commercially available
13 mm
1
3
Socket
Commercially available
17 mm
1
4
Ratchet handle
Commercially available
1
5
Impact wrench
Commercially available
1
6
Torque wrench
Commercially available
5 to 50 Nm
1
7
Torque wrench
Commercially available
20 to 200 Nm
1
k k k k k
Remarks
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".) If refrigerant gas (R134a) gets in your eyes, you could lose your sight. If it touches your skins, you could suffer from frostbite. Therefore, use protective eyeglasses, gloves and working clothes with long sleeves when you collect or refill refrigerant.
NOTICE • Never release the refrigerant (air conditioner gas: R134a) to the atmosphere. • For handling coolant, request services of a "Type 1 CFCs collection company" registered at the national level to the "CFC Recovery and Destruction Law". (Only to be performed by registered companies) • Check the connector numbers and installed positions before disconnecting wirings and hoses, and write them down.
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY Collecting refrigerant 1. Collect refrigerant. See "COLLECT AND REFILL REFRIGERANT" to refill refrigerant.
50-208
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
Air conditioner condenser assembly 2. Open the cover (1).
3.
Remove the bolt (2), and disconnect the hose (3). REMARK • Plug the hose to prevent dust and water from entering. • Be careful not to damage or lose the o-ring. Tool: Ratchet handle, socket Bolt (2): Width across flats 10 mm, M6
4.
Remove the bolt (4), and disconnect the hose (5). REMARK • Plug the hose to prevent dust and water from entering. • Be careful not to damage or lose the o-ring. Tool: Ratchet handle, socket Bolt (4): Width across flats 10 mm, M6
5.
Remove the bolts (6) (2 pieces) and remove the air conditioner condenser assembly (7). Tool: Impact wrench, socket Bolt (6): Width across flats 17 mm, M10
6.
Remove the bolts (8) (4 pieces) and remove the air conditioner condenser assembly (7). REMARK When you remove it, take care not to damage the core. Tool: Impact wrench, socket Bolt (8): Width across flats 13 mm, M8
PC210-10M0, PC210LC-10M0
50-209
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY Air conditioner condenser assembly 1. Install the air conditioner condenser assembly (7) with the bolts (8) (4 pieces). REMARK When you install the assembly, take care not to damage the core. Tool: Ratchet handle, socket, torque wrench Bolt (8): 13-mm width across flats, M8 Bolt (8) thread portion: adhesive (LT-2) Bolt (8): 10 to 15 Nm {1.2 to 1.5 kgm} 2.
Install the air conditioner condenser assembly (7) with the bolts (6) (2 pieces). Tool: Ratchet handle, socket, torque wrench Bolt (6): 17-mm width across flats, M10 Bolt (6): 59 to 74 Nm {6.0 to 7.5 kgm}
3.
Connect the hose (5) with the bolt (4). REMARK • When you connect the air conditioner piping, make sure no dirt, dust and water enters the hoses. • Before you connect the air conditioner piping, check that the O-ring is installed to the connecting part of the piping. • The used O-ring cannot be used again because it is deformed and deteriorated. • When you remove the O-ring, use a cloth, etc. so that the piping will not be damaged.
2ULQJ
• Check that the new O-ring is not damaged or deteriorated. • Apply the compressor oil (DENSO: ND-OIL8) for refrigerant (R134a) to the O-ring. Tool: Ratchet handle, socket, torque wrench Bolt (4): 10-mm width across flats, M6 Bolt (4): 8 to 12 Nm {0.82 to 1.22 kgm}
50-210
*
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
4.
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
Connect the hose (3) with the bolt (2). REMARK • When you connect the air conditioner piping, make sure no dirt, dust and water enters the hoses. • Before you connect the air conditioner piping, check that the O-ring is installed to the connecting part of the piping. • The used O-ring cannot be used again because it is deformed and deteriorated. • When you remove the O-ring, use a cloth, etc. so that the piping will not be damaged.
2ULQJ
• Check that the new O-ring is not damaged or deteriorated. • Apply the compressor oil (DENSO: ND-OIL8) for refrigerant (R134a) to the O-ring. Tool: Ratchet handle, socket, torque wrench Bolt (2): 10-mm width across flats, M6 Bolt (2): 8 to 12 Nm {0.82 to 1.22 kgm} 5.
*
Close the cover (1).
Refilling with refrigerant 6. Refill the refrigerant. See "COLLECT AND REFILL REFRIGERANT". Refilling with air conditioner compressor oil 7. Refill the air conditioner compressor oil. REMARK For details, see APPENDIX, "REFILL COMPRESSOR OIL".
PC210-10M0, PC210LC-10M0
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REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
POWER TRAIN REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY Standard tool list No.
Part name
Part No.
Specifications
Q'ty
1
Impact wrench
Commercially available
1
2
Ratchet handle
Commercially available
1
3
Socket
Commercially available
19 mm
1
4
Socket
Commercially available
24 mm
1
5
Open-end wrench
Commercially available
17 mm
1
6
Open-end wrench
Commercially available
27 mm
1
7
Open-end wrench
Commercially available
41 mm
1
8
Torque wrench
Commercially available
3 to 15 Nm
1
9
Torque wrench
Commercially available
10 to 50 Nm
1
10
Torque wrench
Commercially available
40 to 280 Nm
1
11
Torque wrench
Commercially available
100 to 1000 Nm
1
Remarks
Special tool list Symbol
Part name
Part No.
Specifications
Q'ty
A
Plug
21W-629-9895 #10
2
B
Cap
21W-629-9915 #10
2
C
Plug
07376-70210
#02
1
D
Cap
02789-00210
#02
1
E
Plug
07376-70422
#04
1
F
Cap
02789-00422
#04
1
50-212
Remarks
Removal and installation of travel motor and final drive assembly
PC210-10M0, PC210LC-10M0
50 DISASSEMBLY AND ASSEMBLY
k k k k k k k
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
Place the machine on a level ground, and lower the work equipment to the ground in a stable posture. Set the work equipment lock lever to LOCK position. Turn the starting switch to OFF position to stop the engine. Turn the battery disconnect switch to OFF position, and remove the key. (For details, see TESTING AND ADJUSTING, "BATTERY DISCONNECT SWITCH".) Loosen the hydraulic tank cap slowly, and release the pressure inside the hydraulic tank. Release the remaining pressure in the hydraulic circuit. For details, see TESTING AND ADJUSTING, RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM. Install a plug or flange in the place where a hydraulic hose is disconnected to prevent oil from flowing out.
REMOVE TRAVEL MOTOR AND FIANL DRIVE ASSEMBLY Sprocket 1. Remove the sprocket. REMARK For details, see "REMOVE AND INSTALL SPROCKET". Travel motor and final drive assembly 2. Remove the bolts (1a) (4 pieces), and remove the cover (1). Tool: Impact wrench, socket Bolt (1a): 19-mm width across flats, M12 Cover weight: 12.3 kg
3.
Loosen the sleeve nuts, and disconnect the hoses (2) (2 pieces). Tool: Wrench, plug (A), cap (B) Hose (2): 41-mm width across flats
4.
Loosen the sleeve nut, and disconnect the hose (3). Tool: Wrench, plug (C), cap (D) Hose (3): 19-mm width across flats
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REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
5.
50 DISASSEMBLY AND ASSEMBLY
Loosen the sleeve nut, and disconnect the hose (4). Tool: Wrench, plug (E), cap (F) Hose (4): 27-mm width across flats
6.
Sling the travel motor and the final drive assembly (6), and hold them. REMARK Be careful not to damage the hose mounting part. Tool: Webbing sling Travel motor and final drive assembly (6): 350 kg
7.
Remove the bolts (5) (18 pieces), the travel motor, and the final drive assembly (6). Tool: Impact wrench, extension bar (150 mm), socket Bolt (5): 24-mm width across flats, M16
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50 DISASSEMBLY AND ASSEMBLY
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY Travel motor and final drive assembly 1.
Lift the travel motor and final drive assembly (6), and hold it. REMARK Be careful not to damage the hose mounting part. Tool: Sling belt Travel motor and final drive assembly (6): 350 kg
2.
Install the travel motor and final drive assembly (6) with the bolts (5) (18 pieces). Tools: Impact wrench, extension bar (150 mm), socket, torque wrench Bolt (5): width across flats 24 mm, M16 Bolt (5): 265 to 309 Nm {27 to 31.5 kgm}
Hose 3. Connect the hose (4) with the sleeve nut. Tool: Open-end wrench, torque wrench Hose (4): Width across flats 27 mm Hose (4): 84 to 132 Nm {8.5 to 13.5 kgm}
4.
Connect the hose (3) with the sleeve nut. Tool: Open-end wrench, torque wrench Hose (3): Width across flats 19 mm Hose (3): 34 to 63 Nm {3.5 to 6.5 kgm}
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REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
5.
50 DISASSEMBLY AND ASSEMBLY
Connect hoses (2) (2 pieces) by use of sleeve nuts. Tool: Open-end wrench, torque wrench Hose (2): Width across flats 41 mm Hose (2): 177 to 245 Nm {18 to 25 kgm}
Cover 6. Install the cover (1) with the bolts (1a) (4 pieces). Tool: Impact wrench, socket, torque wrench Bolt (1a): Width across flats 19 mm, M12 Cover weight: 12.3 kg Bolt (1a): 98 to 123 Nm {10 to 12.5 kgm}
Sprocket 7. Install the sprocket. REMARK For mounting, see "REMOVE AND INSTALL SPROCKET". Refilling with hydraulic oil 8. Fill the final drive case with Komatsu genuine oil through the oil filler port. Start the engine to circulate the oil through the piping, and check the oil level again. REMARK For details, see STRUCTURE AND FUNCTION, "TABLE OF FUEL, COOLANT, AND LUBRICANTS". Air bleeding 9. Bleed air from the travel motor. REMARK Make adjustments. See TESTING AND ADJUSTMENT "AIR BLEEDING".
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50 DISASSEMBLY AND ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY Draining oil from No.1 planetary the final drive - carrier assemcase bly A- Ring nut
-
No.1 sun gear shaft
- No.2 sun gear
No.2 planetary - carrier assembly
-A
- Hub assembly
List of standard tools No.
Part name
Part number
SPECIFICATION
Q'ty
1
Socket
Commercially available
17 mm
1
2
Socket
Commercially available
24 mm
1
3
Ratchet handle
Commercially available
4
Square wrench
5
Impact wrench
Commercially available
6
Torque wrench
Commercially available
7
Scale (150 mm)
Commercially available
1
8
Eyebolt (M16)
Commercially available
2
9
Pin punch
Commercially available
1
10
Hammer
Commercially available
1
11
Wire
Commercially available
1
12
Chain
Commercially available
1
Commercially available
Applicable number
13
Drain oil pan
PC210-10M0, PC210LC-10M0
Remarks
1
Commercially available
1
1 40 to 280 Nm
Final drive case: 5.4 ℓ
1
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DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
50 DISASSEMBLY AND ASSEMBLY
List of Special Tools Symbol
Part name
Part number
SPECIFICATION
Q'ty
A
Wrench assembly
796-427-1400
1
B
Installer
796-140-1000
1
Push tool
796T-427-1510
1
Block
790-101-2510
2
Leg
790-101-2610
1
Adapter
790-101-2730
2
Nut
790-101-2560
2
Plate
790-101-2570
4
Puller
790-101-2102 294 kN{30 t}
1
Pump
790-331-1102
1
D
Wrench
790-331-1110
1
E
Guide
796T-427-1710
1
Gear puller
790-101-3501
1
Plate
790-201-2660
1
G
Push tool
792T-423-1350
1
H
Push-pull scale
79A-264-0091
1
C
F
k
Remarks
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
Clean all parts and make sure they are free from dirt or damage. Then apply powertrain oil (TO30 or equivalent) to the sliding surfaces. Assemble the parts.
DISASSEMBLE FINAL DRIVE ASSEMBLY Draining oil from the final drive case 1. Remove the drain plug (1a) and drain oil from the final drive case. Tools: Square wrench, drain oil pan Drain plug (1a): Width across flats 12.7 mm Final drive case: 3.5 ℓ
2.
Remove the bolts (1b) (20 pieces). Tools: Impact wrench, socket Bolt (1b): width across flats 24 mm, M16
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50 DISASSEMBLY AND ASSEMBLY
3.
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
Lift and remove the cover (1) by use of an eyebolt (J). REMARK If the ring gear (12) is lifted as well, tap the ring gear lightly with a plastic hammer to separate it. Tools: Plastic hammer, eyebolt (M16), chain Cover (1): 14 kg
No.1 planetary carrier assembly 4. Remove the washer (2).
5.
Remove the No.1 planetary carrier assembly (3).
6.
Drive the pin (4) into the shaft (5) and remove the shaft (5) from the No.1 planetary carrier (6). Tools: Pin punch, hammer
7.
After you remove the shaft (5) remove the pin (4) from the shaft (5).
PC210-10M0, PC210LC-10M0
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DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
8.
50 DISASSEMBLY AND ASSEMBLY
Remove the thrust washers (7), (10), No.1 planetary gear (8), and needle bearing (9).
No.1 sun gear shaft 9. Remove the No.1 sun gear shaft (11).
No.2 sun gear 10. Remove the ring gear (12). Tools: Eyebolt (M16), wire Ring gear (12): 34 kg
11. Remove the o-ring (12a) from the hub (28). NOTICE Do not reuse the o-ring (12a) that was removed.
12. Remove the thrust washer (13).
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50 DISASSEMBLY AND ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
13. Remove the No.2 sun gear (14).
No.2 planetary carrier assembly 14. Remove the thrust washer (15).
15. Lift and remove No.2 planetary carrier assembly (16). Tool: Webbing sling No.2 planetary carrier assembly (16): 30 kg
16. Drive the pin (17) into the shaft (18) and remove the shaft (18) from the No.2 planetary carrier (19). Tools: Pin punch, hammer
17. After you remove the shaft (18), remove the pin (17) from the shaft (18).
PC210-10M0, PC210LC-10M0
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50 DISASSEMBLY AND ASSEMBLY
18. Remove the thrust washers (20), (23), No.2 planetary gear (21), and needle bearing (22).
Ring nut 19. Remove the bolts (24a) (2 pieces) and remove the lock plate (24). Tools: Impact wrench, socket Bolt (24a): width across flats 17 mm, M10
20. Remove the ring nut (25) by use of the wrench assembly (A). Tool: Wrench assembly (A)
Hub assembly 21. Lift and remove the hub assembly (26) by use of the eyebolt (K). Tools: Chain, eyebolt (M16) Hub assembly (26): 75 kg
22. Remove the bearing (27).
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50 DISASSEMBLY AND ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
23. Remove the floating seal (32) from the hub (28).
24. Remove the bearing outer races (29) and (30) from the hub (28).
25. Remove the floating seal (33) from the travel motor (31).
26. Remove the bearing (34) by use of the gear puller and plate (F). REMARK The bearing may be removed without using the puller. Tools: Gear puller, plate (F)
ASSEMBLE FINAL DRIVE ASSEMBLY NOTICE Clean the parts and make sure they are free from dirt or damage. Apply power train oil (TO30) to the sliding surfaces. Assemble the parts together.
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50 DISASSEMBLY AND ASSEMBLY
Hub assembly 1. Press fit the bearing outer races (29) and (30) into the hub (28) by use of the push tool (G). Tool: Push tool
2.
Install the floating seal (32) to the hub assembly (26) with the installer (B).
NOTICE • Fully degrease and dry the O-ring and O-ring contact surface and then install the floating seal. • Insert the floating seal until the installer (B) comes into contact with the end surface of the hub (28).
%
Tool: Installer (B) *
3.
After you install the floating seal, measure the protrusions (Ba to Bd) of the floating seal from the housing at the measurement positions shown in the figure below. NOTICE • Make sure the difference in values from Ba to Bd between the maximum value (B-max) and minimum value (B-min) is 1 or less. B-max-B-min
