The Komatsu PC210I-10, PC210LCI-10 Crawler Excavator Shop Manual (SEN06499-11) is meant for people tearing into these machines, not just running them. This kind of excavator is doing trenching, bulk earthmoving, and finish grade work where downtime gets expensive fast. The people who usually need this manual are field techs, shop mechanics, and anyone responsible for getting a dead machine back online. They’re usually trying to track down faults, strip and rebuild components, and confirm they’re putting everything back to factory spec.
What this manual helps you do
- Trace electrical and sensor faults on the PC210I-10 and PC210LCI-10, using wiring information and expected signal paths.
- Diagnose hydraulic issues in the multi-pump system, from weak functions to overheating, with step-by-step test routines.
- Follow teardown and reassembly sequences for major components like the swing system, travel gear, cylinders, and main control valve.
- Check and adjust engine, fuel, and emission-related systems on the medium-horsepower diesel to match workshop repair standards.
- Verify calibration and setup items specific to the intelligent/LCI variants after component replacement or control system work.
Who this is for
This is a shop/service manual, so it’s aimed at field techs, shop mechanics, and fleet maintenance leads who already turn wrenches. Operators or trainees just looking for controls and daily checks will be happier with the Operation & Maintenance Manual instead.
FAQ
Q: Is this a PDF I can search and print?
A: Yes, this is a PDF shop manual you can search by keyword and print specific sections for use at the machine.
Q: Does it go deep enough for full overhauls?
A: These shop manuals usually walk you through diagnostic logic, disassembly/assembly, and adjustment procedures used for workshop-level repairs.
Q: How do I know if it matches my serial number or variant?
A: The title and code SEN06499-11 are for PC210I-10 and PC210LCI-10; if your ID plate matches those models, this is the right shop manual family, but always confirm against your dealer’s serial number guidance.
Bottom line: if you’re the one actually fixing or rebuilding a PC210I-10 or PC210LCI-10, this is the manual you want; if you just need operating instructions or basic maintenance intervals, you should look for the O&M manual instead.
📘 Show Index
Table of Contents:
- 00 Index and foreword
- Index
- Foreword, safety and general information
- Important safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling equipment of fuel system devices
- Handling of intake system parts
- Handling of hydraulic equipment
- Method of disconnecting and connecting of push-pull type coupler
- Handling of electrical equipment
- How to read electric wire code
- Precautions when performing operation
- Practical use of KOMTRAX
- Standard tightening torque table
- List of abbreviation
- Conversion table
- 01 Specification
- Table of contents
- Specifications
- Specification drawing
- Working range drawings
- Specifications
- Weight table
- Table of fuel, coolant, and lubricants
- 10 Structure and function
- Table of contents
- Engine and cooling system
- Engine related parts
- VGT
- EGR system piping drawing
- EGR system circuit diagram
- EGR valve
- EGR cooler
- KCCV layout drawing
- KCCV ventilator
- KDPF
- Cooling system
- Power train
- Power train system
- Swing circle
- Swing machinery
- Final drive
- Undercarriage and frame
- Track frame and idler cushion
- Hydraulic system
- Hydraulic component layout
- Valve control
- Hydraulic tank
- CLSS
- Main pump
- Control valve
- Swing motor
- Travel motor
- PPC valve
- Solenoid valve
- Attachment circuit selector valve (for high pressure circuit)
- Attachment circuit selector valve (for low pressure circuit)
- Anti-drop valve
- Center swivel joint
- Accumulator
- ATT EPC valve assembly
- Return oil filter
- Quick coupler control valve
- EPC valve for intelligent Machine Control
- Work equipment
- Work equipment
- Work equipment shim
- Bucket play adjustment shim
- Cab and its attachments
- Cab mount and cab tipping stopper
- ROPS cab
- Electrical system
- Electrical control system
- Machine monitor system
- KOMTRAX system
- Sensor
- Auto grease system
- 20 Standard value tables
- Table of contents
- Standard service value table
- Standard value table for engine
- Standard value table for machine
- Standard value table for electrical system
- 30 Testing and adjusting
- Table of contents
- Related information on testing and adjusting
- Tools for testing and adjusting
- Sketch of tools for testing and adjusting
- Engine and cooling system
- Testing engine speed
- Testing boost pressure
- Testing exhaust gas color
- Testing mass air flow and temperature sensor
- Testing and adjusting valve clearance
- Testing compression pressure
- Testing blowby pressure
- Testing engine oil pressure
- Testing EGR valve and VGT oil pressures
- Measuring fuel pressure
- Measuring fuel delivery, return and leakage
- Bleeding air from fuel system
- Testing fuel circuit for leakage
- Handling cylinder cutout mode operation
- Handling no-injection cranking operation
- Testing and adjusting air conditioner compressor belt tension
- Replacing fan belt
- Power train
- Testing swing circle bearing clearance
- Undercarriage and frame
- Testing and adjusting track tension
- Hydraulic system
- Releasing remaining pressure from hydraulic circuit
- Testing and adjusting oil pressure in work equipment, swing, and travel circuits
- Testing oil pressure of control circuit
- Testing and adjusting oil pressure in pump PC control circuit
- Testing and adjusting oil pressure in pump LS control circuit
- Testing output pressure of solenoid valve
- Testing PPC valve output pressure
- Adjusting play of work equipment and swing PPC valves
- Testing pump swash plate sensor
- Isolating the parts causing hydraulic drift in work equipment
- Testing oil leakage
- Bleeding air from hydraulic circuit
- Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side)
- Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side)
- Replacing accumulator bladder on high pressure side for accumulator piping
- Cab and its attachments
- Testing cab tipping stopper
- Adjusting mirrors
- Electrical system
- Special functions of machine monitor
- Special function of control box
- KOMTRAX terminal start-up procedure
- Adjusting rearview camera angle
- Handling voltage circuit of engine controller
- Handling battery disconnect switch
- Testing diodes
- Pm clinic
- 40 Troubleshooting
- Table of contents
- Related information on troubleshooting
- Troubleshooting points
- Sequence of events in troubleshooting
- Testing before troubleshooting
- Inspection procedure before troubleshooting
- Preparation for troubleshooting of electrical system
- Classification and procedure for troubleshooting
- Symptom and troubleshooting numbers
- Information in troubleshooting table
- Diagnostic procedure for wiring harness open curcuit of pressure sensor system
- Connector list and layout
- Connector contact identification
- T-branch box and T-branch adapter table
- Fuse location table
- Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
- Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
- Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135])
- Failure codes table
- Troubleshooting by failure code (Display of code)
- Failure code [879AKA] A/C Inner Sensor Open Circuit
- Failure code [879AKB] A/C Inner Sensor Short Circuit
- Failure code [879BKA] A/C Outer Sensor Open Circuit
- Failure code [879BKB] A/C Outer Sensor Short Circuit
- Failure code [879CKA] Ventilating Sensor Open Circuit
- Failure code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
- Failure code [879EMC] Ventilation Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [879GKX] Refrigerant Abnormality
- Failure code [989L00] Engine Controller Lock Caution1
- Failure code [989M00] Engine Controller Lock Caution2
- Failure code [989N00] Engine Controller Lock Caution3
- Failure code [A1U0N3] HC Desorb Request 1
- Failure code [A1U0N4] HC Desorb Request 2
- Failure code [AA10NX] Air Cleaner Clogging
- Failure code [AB00KE] Charge Voltage Low
- Failure code [B@BAZG] Engine Oil Pressure Low
- Failure code [B@BAZK] Eng Oil Level Low
- Failure code [B@BCNS] Engine Coolant Overheat
- Failure code [B@BCZK] Radiator Coolant Level Low
- Failure code [B@HANS] Hyd Oil Overheat
- Failure code [CA115] Eng Ne and Bkup Speed Sens Error
- Failure code [CA122] Chg Air Press Sensor High Error
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sensor 2 Supply Volt Low Error
- Failure code [CA221] Ambient Press Sensor High Error
- Failure code [CA222] Ambient Press Sensor Low Error
- Failure code [CA227] Sensor 2 Supply Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sensor Supply Volt Error
- Failure code [CA239] Ne Speed Sens Supply Volt High Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA295] Ambient Press Sens In Range Error
- Failure code [CA322] Inj #1(L#1) Open/Short Error
- Failure code [CA323] Inj #5(L#5) Open/Short Error
- Failure code [CA324] Inj #3(L#3) Open/Short Error
- Failure code [CA325] Inj #6(L#6) Open/Short Error
- Failure code [CA331] Inj #2(L#2) Open/Short Error
- Failure code [CA332] Inj #4(L#4) Open/Short Error
- Failure code [CA343] ECM Critical Internal Failure
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sensor 1 Supply Volt Low Error
- Failure code [CA356] Mass Air Flow Sensor High Error
- Failure code [CA357] Mass Air Flow Sensor Low Error
- Failure code [CA386] Sensor 1 Supply Volt High Error
- Failure code [CA428] Water in Fuel Sensor High Error
- Failure code [CA429] Water in Fuel Sensor Low Error
- Failure code [CA435] Eng Oil Press Sw Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA488] Chg Air Temp High Torque Derate
- Failure code [CA515] Rail Press Sens Sup Volt High Error
- Failure code [CA516] Rail Press Sens Sup Volt Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA555] Crankcase Press High Error 1
- Failure code [CA556] Crankcase Press High Error 2
- Failure code [CA559] Rail Press Low Error
- Failure code [CA595] Turbo Speed High Error 2
- Failure code [CA687] Turbo Speed Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA691] Intake Air Temp Sens High Error
- Failure code [CA692] Intake Air Temp Sens Low Error
- Failure code [CA697] ECM Int Temp Sensor High Error
- Failure code [CA698] ECM Int Temp Sensor Low Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1117] Persistent Data Lost Error
- Failure code [CA1664] KDOC Malfunction
- Failure code [CA1691] Regeneration Ineffective
- Failure code [CA1695] Sensor 5 Supply Volt High Error
- Failure code [CA1696] Sensor 5 Supply Volt Low Error
- Failure code [CA1843] Crankcase Press Sens High Error
- Failure code [CA1844] Crankcase Press Sens Low Error
- Failure code [CA1879] KDPF Delta P Sensor High Error
- Failure code [CA1881] KDPF Delta P Sensor Low Error
- Failure code [CA1883] KDPF Delta P Sens In Range Error
- Failure code [CA1921] KDPF Soot Load High Error 1
- Failure code [CA1922] KDPF Soot Load High Error 2
- Failure code [CA1942] Crankcase Press Sens In Range Error
- Failure code [CA1993] KDPF Delta Pressure Low Error
- Failure code [CA2185] Throt Sensor Sup Volt High Error
- Failure code [CA2186] Throt Sensor Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [CA2271] EGR Valve Pos Sens High Error
- Failure code [CA2272] EGR Valve Pos Sens Low Error
- Failure code [CA2288] Turbo Speed High Error 1
- Failure code [CA2311] IMV Solenoid Error
- Failure code [CA2349] EGR Valve Solenoid Open Error
- Failure code [CA2353] EGR Valve Solenoid Short Error
- Failure code [CA2357] EGR Valve Servo Error
- Failure code [CA2373] Exhaust Manifold Press Sens High error
- Failure code [CA2374] Exhaust Manifold Press Sens Low error
- Failure code [CA2375] EGR Orifice Temp Sens High Error
- Failure code [CA2376] EGR Orifice Temp Sens Low Error
- Failure code [CA2381] VGT Pos Sens High Error
- Failure code [CA2382] VGT Pos Sens Low Error
- Failure code [CA2383] VGT Solenoid Open Error
- Failure code [CA2386] VGT Solenoid Short Error
- Failure code [CA2387] VGT Servo Error
- Failure code [CA2554] Exh Manifold Press Sens In Range Error
- Failure code [CA2555] Grid Htr Relay Volt Low Error
- Failure code [CA2556] Grid Htr Relay Volt High Error
- Failure code [CA2637] KDOC Face Plugging
- Failure code [CA2639] Manual Stationary Regeneration Request
- Failure code [CA2961] EGR Orifice Temp High Error 1
- Failure code [CA2973] Chg Air Press Sensor In Range Error
- Failure code [CA3133] KDPF Outlet Press Sens High Error
- Failure code [CA3134] KDPF Outlet Press Sens Low Error
- Failure code [CA3135] KDPF Outlet Press Sens In Range Error
- Failure code [CA3251] KDOC Inlet Temp High Error
- Failure code [CA3253] KDOC Temp Error – Non Regeneration
- Failure code [CA3254] KDOC Outlet Temp High Error 1
- Failure code [CA3255] KDPF Temp Error – Non Regeneration
- Failure code [CA3256] KDPF Outlet Temp High Error 1
- Failure code [CA3311] KDOC Outlet Temp High Error 2
- Failure code [CA3312] KDPF Outlet Temp High Error 2
- Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
- Failure code [CA3314] KDOC Inlet Temp Sens High Error
- Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
- Failure code [CA3316] KDOC Outlet Temp Sens Low Error
- Failure code [CA3317] KDOC Outlet Temp Sens High Error
- Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
- Failure code [CA3319] KDPF Outlet Temp Sens High Error
- Failure code [CA3321] KDPF Outlet Temp Sens Low Error
- Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
- Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
- Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
- Failure code [CA3741] Rail Press Valve Trip Error
- Failure code [D110KB] Battery Relay Output Voltage
- Failure code [D19JKZ] Personal Code Relay Abnormality
- Failure code [D811MC] KOMTRAX Error
- Failure code [D862KA] GPS Antenna Open Circuit
- Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
- Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
- Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
- Failure code [DA20MC] Pump Controller
- Failure code [DA22KK] Pump Solenoid Power Low Error
- Failure code [DA25KP] 5V Sensor 1 Power Abnormality
- Failure code [DA29KQ] Model Selection Abnormality
- Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
- Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
- Failure code [DA2QKR] CAN2 Discon (Pump Con)
- Failure code [DA2RKR] CAN1 Discon (Pump Con)
- Failure code [DAF0MB] Monitor ROM Abnormality
- Failure code [DAF0MC] Monitor Error
- Failure code [DAF8KB] Camera Power Supply Short Circuit
- Failure code [DAF9KQ] Model Selection Abnormality
- Failure code [DAFGMC] GPS Module Error
- Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
- Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
- Failure code [DAFQKR] CAN2 Discon (Monitor)
- Failure code [DAZ9KQ] A/C Model Selection Abnormality
- Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
- Failure code [DB2QKR] CAN2 Discon (Engine Con)
- Failure code [DB2RKR] CAN1 Discon (Engine Con)
- Failure code [DB90KT] W/E Controller Internal Failure
- Failure code [DB90MC] W/E Controller Reset
- Failure code [DB92KK] W/E CON Solenoid Power Voltage Low Error
- Failure code [DB95KP] W/E CON 5V Sensor 0 Power Volt Low Error
- Failure code [DB96KP] W/E CON 5V Sensor 1 Power Volt Low Error
- Failure code [DB99KQ] Model Selection Signal Mismatch (W/E Con)
- Failure code [DB9LKA] Operating Lamp Open Circuit (W/E CON)
- Failure code [DB9LKB] Operating Lamp Hot Short Circuit (W/E CON)
- Failure code [DB9QKR] CAN2 Defective Communication (W/E CON)
- Failure code [DB9RKR] CAN1 Defective Communication (W/E CON)
- Failure code [DBR0KT] ICT Sensor Controller Internal Failure
- Failure code [DBR0MC] ICT Sensor Controller Reset
- Failure code [DBR2KK] ICT/S CON Solenoid Power Low Error
- Failure code [DBR5KP] ICT/S CON 5V Sensor 0 Power Abnormality
- Failure code [DBR6KP] ICT/S CON 5V Sensor 1 Power Abnormality
- Failure code [DBR9KQ] Model Selection Signal Mismatch (ICT Sens)
- Failure code [DBRLKA] Operating Lamp Open Circuit (ICT/S CON)
- Failure code [DBRLKB] Operating Lamp Short Circuit (ICT/S CON)
- Failure code [DBRQKR] CAN2 Discon (ICT/S CON)
- Failure code [DBRRKR] CAN 1 Discon (ICT/S CON)
- Failure code [DBRSKB] ICT/S Con Battery Relay Drive Short Cir.
- Failure code [DBRTKB] Control Box Activation Output Short Circuit (ICT Sensor Controller)
- Failure code [DBUSKR] Ethernet 0 Discon (GNSS Receiver)
- Failure code [DD20MA] Auto/Manual Selector Switch Error
- Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
- Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
- Failure code [DHPAMA] F Pump Press Sensor Abnormality
- Failure code [DHPBMA] R Pump Press Sensor Abnormality
- Failure code [DHS3MA] Arm IN PPC Press Sens Defective Function
- Failure code [DHS4MA] Bucket CURL PPC Press Sensor Def Function
- Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function
- Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function
- Failure code [DHSAMA] Swing RH PPC Press Sens Def Function
- Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
- Failure code [DHSCMA] Arm Dump PPC Press Sens Def Function
- Failure code [DHSDMA] Bucket Dump PPC Press Sens Def Function
- Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality
- Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality
- Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality
- Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality
- Failure code [DK80KM] IMU Calibration Not Complete
- Failure code [DK80KR] IMU Defective Communication
- Failure code [DK80KT] IMU Error
- Failure code [DKG1KM] Bucket Cylinder Calibration Not Complete
- Failure code [DKG1L8] Bucket Cyl Stroke Sensor Inrange Error
- Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality
- Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality
- Failure code [DKT0KM] Boom Cylinder Calibration Not Complete
- Failure code [DKT0L8] Boom Cyl Stroke Sensor Inrange Error
- Failure code [DKT1KA] Boom Cyl Stroke Sensor A Open Circuit
- Failure code [DKT1KB] Boom Cyl Stroke Sensor A Short Circuit
- Failure code [DKT2KA] Boom Cyl Stroke Sensor B Open Circuit
- Failure code [DKT2KB] Boom Cyl Stroke Sensor B Short Circuit
- Failure code [DKT4KM] Arm Cylinder Calibration Not Complete
- Failure code [DKT4L8] Arm Cylinder Stroke Sensor Inrange Error
- Failure code [DKT5KA] Arm Cyl Stroke Sensor A Open Circuit
- Failure code [DKT5KB] Arm Cyl Stroke Sensor A Short Circuit
- Failure code [DKT6KA] Arm Cyl Stroke Sensor B Open Circuit
- Failure code [DKT6KB] Arm Cyl Stroke Sensor B Short Circuit
- Failure code [DKT8KA] Bucket Cyl Stroke Sensor A Open Circuit
- Failure code [DKT8KB] Bucket Cyl Stroke Sensor A Short Circuit
- Failure code [DKT9KA] Bucket Cyl Stroke Sensor B Open Circuit
- Failure code [DKT9KB] Bucket Cyl Stroke Sensor B Short Circuit
- Failure code [DKTAKA] Bucket Cyl Stroke Reset Sens Open Circuit
- Failure code [DKTAKB] Bucket Cyl Stroke Reset Sens Short Circuit
- Failure code [DKTAMB] Bucket Cyl Stroke Reset Sens Inrange Error
- Failure code [DKTBKX] Boom Cyl Stroke Reset Enc A,B Abnormality
- Failure code [DKTBMC] Boom Cylinder Stroke Reset Encoder Error
- Failure code [DKTEMB] Boom Cyl Stroke Reset Enc Z Abnormality
- Failure code [DKTFKX] Boom Cyl Stroke Reset Enc A,B Abnormality
- Failure code [DKTFMC] Arm Cyl Stroke Reset Enc Error
- Failure code [DKTJMB] Arm Cyl Stroke Reset Enc Z Abnormality
- Failure code [DKU1MA] Boom Spool Stroke Sensor In Range Error
- Failure code [DKU2MA] Arm Spool Storke Sensor In Range Error
- Failure code [DKUGKA] Arm IN PPC Reduce Press EPC Open Circuit
- Failure code [DKUGKB] Arm IN PPC Reduce Press EPC Ground Fault
- Failure code [DKUGKY] Arm IN PPC Reduce Pressure EPC Hot Short
- Failure code [DKUHKA] Arm OUT PPC Reduce Press EPC Open Circuit
- Failure code [DKUHKB] Arm OUT PPC Reduce Press EPC Ground Fault
- Failure code [DKUHKY] Arm OUT PPC Reduce Pressure EPC Hot Short
- Failure code [DKV0KA] Boom Spool Stroke Sensor 1 Open Circuit
- Failure code [DKV0KY] Boom Spool Stroke Sensor 1 Hot Short Cir
- Failure code [DKV1KA] Arm Spool Stroke Sensor 1 Open Circuit
- Failure code [DKV1KY] Arm Spool Stroke Sensor 1 Hot Short Cir
- Failure code [DKV2KA] Boom Spool Stroke Sensor 2 Open Circuit
- Failure code [DKV2KY] Boom Spool Stroke Sensor 2 Hot Short Cir
- Failure code [DKV3KA] Arm Spool Stroke Sensor 2 Open Circuit
- Failure code [DKV3KY] Arm Spool Stroke Sensor 2 Hot Short Cir
- Failure code [DKV4MA] Boom RAISE PPC Press Sensor 2 Def Function
- Failure code [DKV5MA] Boom LOWER PPC Press Sensor 2 Def Function
- Failure code [DKV6MA] Arm OUT PPC Press Sensor 2 Def Function
- Failure code [DKV7MA] Arm IN PPC Press Sens 2 Defective Function
- Failure code [DKV8MA] Bucket DUMP PPC Press Sens 2 Def Function
- Failure code [DKV9MA] Bucket CURL PPC Press Sens 2 Def Function
- Failure code [DKVAMA] PPC Source Press Sensor Error
- Failure code [DKVBKA] Bucket CURL PPC Reduce Press EPC Open Cir
- Failure code [DKVBKB] Bucket CURL PPC Reduce Press EPC Grd Fault
- Failure code [DKVBKY] Bucket CURL PPC Reduce Press EPC Hot Short
- Failure code [DKVCKA] Boom RAISE PPC Intervention EPC Open Cir
- Failure code [DKVCKB] Boom RAISE PPC Intervention EPC Grnd Fault
- Failure code [DKVCKY] Boom RAISE PPC Intervention EPC Hot Short
- Failure code [DKVDKA] Boom RAISE EPC Cut Relay Open Circuit
- Failure code [DKVDKB] Boom RAISE EPC Cut Relay Ground Fault
- Failure code [DKVDKY] Boom RAISE EPC Cut Relay Hot Short Circuit
- Failure code [DKVDMA] Boom RAISE EPC Cut Relay Error
- Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
- Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
- Failure code [DV20KB] Travel Alarm Short Circuit
- Failure code [DW43KA] Travel Speed Sol Open Circuit
- Failure code [DW43KB] Travel Speed Sol Short Circuit
- Failure code [DW45KA] Swing holding brake Sol Open Circuit
- Failure code [DW45KB] Swing holding brake Sol Short Circuit
- Failure code [DW4FKA] Boom LOWER PPC Reduce Press EPC Open Cir
- Failure code [DW4FKB] Boom LOWER PPC Reduce Press EPC Grnd Fault
- Failure code [DW4FKY] Boom LOWER PPC Reduce Press EPC Hot Short
- Failure code [DW4GKA] Boom RAISE PPC Reduce Press EPC Open Cir.
- Failure code [DW4GKB] Boom RAISE PPC Reduce Press EPC Grnd Fault
- Failure code [DW4GKY] Boom RAISE PPC Reduce Press EPC Hot Short
- Failure code [DW4SKA] Bucket DUMP PPC Reduce Press EPC Open Cir
- Failure code [DW4SKB] Bucket DUMP PPC Reduce Press EPC Grd Fault
- Failure code [DW4SKY] Bucket DUMP PPC Reduce Press EPC Hot Short
- Failure code [DW91KA] Travel Junction Sol Open Circuit
- Failure code [DW91KB] Travel Junction Sol Short Circuit
- Failure code [DWA2KA] Attachment Sol Open Circuit
- Failure code [DWA2KB] Attachment Sol Short Circuit
- Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit
- Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
- Failure code [DWK2KA] Variable Back Press Sol Open Circuit
- Failure code [DWK2KB] Variable Back Press Sol Short Circuit
- Failure code [DWK8KA] Swing Press C/O Sol Open Circuit
- Failure code [DWK8KB] Swing Press C/O Sol Short Circuit
- Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
- Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
- Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
- Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
- Failure code [DXE0KA] LS-EPC Sol Open Circuit
- Failure code [DXE0KB] LS-EPC Sol Short Circuit
- Failure code [DXE4KA] Attachment Flow EPC Open Circuit
- Failure code [DXE4KB] Attachment Flow EPC Short Circuit
- Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
- Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
- Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
- Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
- Failure code [DY20KA] Wiper Working Abnormality
- Failure code [DY20MA] Wiper Parking Abnormality
- Failure code [DY2CKB] Washer Drive Short Circuit
- Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
- Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
- Troubleshooting of electrical system (E-mode)
- E-1 Engine does not start (Engine does not crank)
- E-2 Manual preheating system does not work
- E-3 Automatic preheating system does not work
- E-4 Preheating monitor does not light up when preheater is operated
- E-5 When starting switch is turned to ON position, machine monitor displays nothing
- E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow
- E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow
- E-8 Coolant temperature monitor lights up in white while engine is running
- E-9 Hydraulic oil temperature monitor lights up in white while engine is running
- E-10 Charge level monitor lights up while engine is running
- E-11 Fuel level monitor lights up in red while engine is running
- E-12 Air cleaner clogging monitor lights up in yellow while engine is running
- E-13 Water separator monitor lights up while engine is running
- E-14 Coolant temperature monitor lights up in red while engine is running
- E-15 Hydraulic oil temperature monitor lights up in red while engine is running
- E-16 Engine oil pressure monitor lights up in red while engine is running
- E-17 Fuel gauge indicates either full or empty and does not move
- E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)
- E-19 Coolant temperature gauge indicates either Min. or Max. and does not move
- E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.)
- E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not move
- E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.)
- E-23 Content of display on machine monitor is different from that of actual machine
- E-24 Machine monitor does not display some items
- E-25 Function switch does not work
- E-26 Automatic preheating system does not work (In cold season)
- E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated
- E-28 Auto-deceleration is not actuated or canceled when lever is operated
- E-29 Working mode selection screen is not diplayed when working mode switch is operated
- E-30 Engine or hydraulic pump setting does not change when working mode is changed
- E-31 Travel speed monitor does not change when travel speed switch is operated
- E-32 Travel speed does not change while travel speed selection is changed
- E-33 Alarm buzzer does not stop sounding
- E-34 When starting switch is turned to OFF position, service meter is not displayed
- E-35 Service mode cannot be selected
- E-36 Any of work equipment, swing and travel does not work
- E-37 Any of work equipment, swing and travel cannot be locked
- E-38 Machine cannot swing while swing brake cancel switch is canceled
- E-39 Swing brake does not operate while swing brake cancel switch is locked
- E-40 One-touch power maximizing function does not work or monitor is not displayed
- E-41 One-touch power maximizing function cannot be canceled
- E-42 Travel alarm does not sound when machine travels
- E-43 Alarm does not stop sounding while machine is stopped
- E-44 Horn does not sound
- E-45 Horn does not stop sounding
- E-46 Wiper monitor does not light up or go out when wiper switch is operated
- E-47 Wiper does not operate when wiper switch is operated
- E-48 Window washer does not operate when window washer switch is operated
- E-49 BOOM LOWER indication is not displayed properly with monitoring function
- E-50 ARM DUMP indication is not displayed properly with monitoring function
- E-51 ARM IN indication is not displayed properly with monitoring function
- E-52 BOOM RAISE indication is not displayed properly with monitoring function
- E-53 BUCKET CURL indication is not displayed properly with monitoring function
- E-54 BUCKET DUMP indication is not displayed properly with monitoring function
- E-55 SWING indication is not displayed properly with monitoring function
- E-56 TRAVEL indication is not displayed properly with monitoring function
- E-57 Service is not displayed properly with monitoring function
- E-58 Attachment hydraulic circuit cannot be changed
- E-59 KOMTRAX system does not operate normally
- E-60 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!]
- E-61 Control box displays the message [GPS receiver not connected!]
- E-62 Control box displays the message [Waiting for radio link…]
- E-63 Control box displays the message [Tilt Bucket Sensor Offline!]
- E-64 Control box displays the message [Waiting for satellites…]
- E-65 Control box displays the message [Komatsu controller not connected!]
- E-66 Control box displays the message [Sensors are invalid]
- E-67 Control box displays the message [Waiting to initialize…]
- E-68 Control box displays the message [Initializing…]
- E-69 Control box displays the message [No GPS Localization…]
- E-70 Control box displays the message [Low precisions…]
- E-71 Control box displays [Out of design area…]
- E-72 Control box displays [Avoidance Area Breach]
- E-73 Control box can not be turned on
- E-74 Control box does not display intelligent Machine Control screen
- E-75 Control box does not display hydraulic excavator image
- E-76 Control box does not display design surface
- E-77 Control box touch panel does not respond
- E-78 Control box touch panel is inaccurate
- E-79 When checking and adjusting the bucket edge position, the value is different from actual machine
- E-80 When pressing auto/manual switch, Semi-auto limited digging mode is not displayed.
- E-81 Automatic leveling assist function does not work while Semi-auto limited digging mode is displayed
- E-82 Automatic stop control function does not work while Semi-auto limited digging mode is displayed
- E-83 Blade edge position on design surface is not accurate when automatic leveling assist function is on.
- E-84 Blade edge stop position is not accurate for design surface when automatic stop control function is on
- E-85 Opposite direction compass does not show the opposite direction
- E-86 NG occurs very often in IMU calibration diagnosis
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Information described in troubleshooting table (H-mode)
- System chart for hydraulic system
- Failure mode and cause table
- H-1 All of work equipment, swing and travel operation lacks speed or power
- H-2 Engine speed drops significantly or engine stalls
- H-3 All work equipment, swing and travel does not work
- H-4 Unusual sound is heard from around hydraulic pump
- H-5 Fine control performance or response is poor
- H-6 Boom speed or power is low
- H-7 Arm speed or power is low
- H-8 Bucket speed or power is low
- H-9 Work equipment does not move in single operation
- H-10 Hydraulic drift of boom is large
- H-11 Hydraulic drift of arm is large
- H-12 Hydraulic drift of bucket is large
- H-13 Time lag of work equipment is large
- H-14 When part of work equipment is relieved singly, other parts of work equipment move
- H-15 One-touch power maximizing function does not operate
- H-16 In combined operation of work equipment, equipment having heavier load moves slower
- H-17 In combined operations of swing and boom RAISE, boom rising speed is low
- H-18 In combined operations of swing and travel, travel speed drops largely
- H-19 Machine does not travel straight
- H-20 Travel speed is slow
- H-21 Machine is hard to steer or travel power is low
- H-22 Travel speed does not change, or travel speed is too slow or fast
- H-23 One of tracks does not run
- H-24 Upper structure does not swing to the right or left
- H-25 Upper structure swing only to the right or left
- H-26 Swing acceleration or swing speed is low in both directions (right and left)
- H-27 Swing acceleration performance is poor or swing speed is slow in only one direction
- H-28 Upper structure overruns excessively when it stops swinging (both right and left)
- H-29 Upper structure overruns excessively when it stops swinging (either right or left)
- H-30 Shock is large when upper structure stops swinging
- H-31 Large unusual noise is heard when upper structure stops swinging
- H-32 Swing drift on a slope is large while swing holding brake is applied
- H-33 Swing drift on a slope is large while swing holding brake is released
- H-34 Attachment hydraulic circuit cannot be changed while attachment is installed
- H-35 Oil flow in attachment circuit cannot be controlled
- H-36 All work equipment do not operate
- Troubleshooting of engine (S-mode)
- Information mentioned in troubleshooting table (S mode)
- S-1 When starting switch is turned to START position, engine does not crank
- S-2 Engine cranks but no exhaust smoke comes out
- S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
- S-4 Engine startability is poor
- S-5 Engine does not pick up smoothly
- S-6 Engine stops during operation
- S-7 Engine runs rough or is unstable
- S-8 Engine lacks power
- S-9 Exhaust smoke is black (KDPF clogs up early)
- S-10 Engine oil consumption is excessive
- S-11 Engine oil becomes contaminated early
- S-12 Fuel consumption is excessive
- S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
- S-14 Engine oil pressure drops
- S-15 Fuel is contaminated in engine oil
- S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)
- S-17 Coolant temperature rises too high (overheating)
- S-18 Unusual noise is heard
- S-19 Vibration is excessive
- S-20 Air cannot be bled from fuel circuit
- S-21 Active regeneration is executed frequently
- S-22 Active regeneration takes time
- S-23 White smoke is exhausted during active regeneration
- 50 Disassembly and assembly
- Table of contents
- Related information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tools list
- Sketches of special tools
- Engine and cooling system
- Removal and installation of supply pump assembly
- Removal and installation of injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of radiator assembly
- Removal and installation of hydraulic oil cooler assembly
- Removal and installation of aftercooler assembly
- Removal and installation of engine and main pump assembly
- Removal and installation of engine front oil seal
- Removal and installation of engine rear oil seal
- Removal and installation of fuel cooler assembly
- Removal and installation of fuel tank assembly
- Removal and installation of engine hood assembly
- Removal and installation of KDPF assembly
- Disassembly and assembly of KDPF assembly
- Removal and installation of KCCV assembly
- Removal and installation of air cleaner assembly
- Power train
- Removal and installation of travel motor and final drive assembly
- Disassembly and assembly of final drive
- Removal and installation of swing motor and swing machinery assembly
- Disassembly and assembly of swing machinery
- Removal and installation of swing circle assembly
- Undercarriage and frame
- Separation and connection of track shoe assembly
- Removal and installation of sprocket
- Removal and installation of idler and idler cushion assembly
- Disassembly and assembly of idler assembly
- Disassembly and assembly of idler cushion
- Disassembly and assembly of track roller assembly
- Disassembly and assembly of carrier roller
- Removal and installation of revolving frame assembly
- Removal and installation of counterweight assembly
- Hydraulic system
- Removal and installation of center swivel joint assembly
- Disassembly and assembly of center swivel joint
- Removal and installation of hydraulic tank assembly
- Removal and installation of main pump assembly
- Removal and installation of control valve assembly
- Disassembly and assembly of control valve
- Removal and installation of junction block assembly for Intelligent Machine Control
- Removal and installation of pressure sensor for Intelligent Machine Control
- Removal and installation of boom spool stroke sensor
- Removal and installation of arm spool stroke sensor
- Disassembly and assembly of work equipment PPC valve
- Disassembly and assembly of travel PPC valve
- Work equipment
- Removal and installation of work equipment assembly
- Disassembly and assembly of work equipment cylinder assembly
- Cab and its attachments
- Removal and installation of operator's cab assembly
- Removal and installation of operator cab glass (adhered glass)
- Removal and installation of front window assembly
- Removal and installation of floor frame assembly
- Removal and installation of air conditioner unit assembly
- Removal and installation of operator's seat
- Removal and installation of seat belt
- Removal and installation of front wiper assembly
- Electrical system
- Removal and installation of air conditioner compressor assembly
- Removal and installation of air conditioner condenser assembly
- Removal and installation of engine controller assembly
- Removal and installation of pump controller assembly
- Removal and installation of machine monitor assembly
- Removal and installation of pump swash plate sensor
- Removal and installation of mass air flow and temperature sensor
- Removal and installation of KOMTRAX terminal assembly
- Removal and installation of ICT sensor controller assembly
- Removal and installation of junction harness of control box
- Removal and installation of control box harness
- Removal and installation of work equipment controller assembly
- Removal and installation of GNSS receiver
- Removal and installation of radio device and site link
- Removal and installation of GNSS antenna
- Removal and installation of IMU sensor
- 60 Maintenance standard
- Table of contents
- Engine and cooling system
- Engine mount
- Cooling system
- Power train
- Swing circle
- Swing machinery
- Final drive
- Sprocket
- Undercarriage and frame
- Track frame and idler cushion
- Idler
- Track roller
- Carrier roller
- Track shoe
- Hydraulic system
- Hydraulic tank
- Main pump
- Control valve
- Swing motor
- Travel motor
- Work equipment and swing PPC valve
- Travel PPC valve
- 1st-line attachment PPC valve (with EPC valve)
- 2nd-line attachment PPC valve
- Solenoid valve
- Attachment circuit selector valve (for high-pressure circuit)
- Attachment circuit selector valve (for low-pressure circuit)
- Center swivel joint
- Work equipment
- Work equipment
- Boom cylinder
- Stroke sensing boom cylinder
- Stroke sensing arm cylinder
- Stroke sensing bucket cylinder
- Stroke sensor for boom cylinder
- Stroke sensor for arm cylinder
- Stroke and reset sensor for bucket cylinder
- 80 Appendix
- Table of contents
- Air conditioner components
- Precautions for refrigerant
- Air conditioner component
- Configuration and function of refrigeration cycle
- Outline of refrigeration cycle
- Air conditioner unit
- Dual pressure switch
- Air conditioner controller
- Compressor
- Air conditioner condenser
- Sunlight sensor
- Outer temperature sensor (outside air temperature sensor)
- Procedure for testing and troubleshooting
- Circuit diagram and arrangement of connector pins
- System diagram
- Input and output signals of the air conditioner controller
- Parts and connectors layout
- Testing air leakage (duct)
- Testing with self-diagnosis function
- Testing vent (mode) changeover
- Testing FRESH/RECIRC air changeover
- Testing sunlight sensor
- Testing (dual) pressure switch for refrigerant
- Testing relays
- Troubleshooting chart 1
- Troubleshooting chart 2
- Information in troubleshooting table
- Failure code list related to air conditioner
- Failure code [879AKA] A/C Inner Sensor Open Circuit
- Failure code [879AKB] A/C Inner Sensor Short Circuit
- Failure code [879BKA] A/C Outer sensor Open Circuit
- Failure code [879BKB] A/C Outer sensor Short Circuit
- Failure code [879CKA] Ventilating Sensor Open Circuit
- Failure code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879DKZ] Sunlight sensor Open or Short Circuit
- Failure code [879EMC] Ventilation Damper Abnormality
- Failure code [879FMC] Air Mix Damper Abnormality
- Failure code [879GKX] Refrigerant Abnormality
- A-1 Troubleshooting for power supply system (Air conditioner does not operate)
- A-2 Troubleshooting of compressor system (Air is not cooled)
- A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
- A-4 Troubleshooting for FRESH/RECIRC air changeover
- Troubleshooting with gauge pressure
- Connection of service tool
- Precautions for disconnecting and connecting air conditioner piping
- Handling of compressor oil
- Desiccant replacement
- 90 Diagrams and drawings
- Table of contents
- Hydraulic circuit diagram
- Symbols in hydraulic circuit diagram
- Hydraulic circuit diagram
- Electric circuit diagram
- Symbols in electric circuit diagram
- Electrical circuit diagram
- Electric circuit diagram of air conditioner unit
- INDEX
Komatsu
