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SEN05842-01

HYDRAULIC PC210LC -10


EXCAVATOR
SERIAL NUMBERS 450001 and up
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number

PC210LC-10 450001 and up

00 Index and foreword


1 00 Index and foreword

PC210LC-10 00-1
00 Index and foreword
Index

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

00-2 PC210LC-10
00 Index and foreword
Index

Attachment circuit selector valve (for low pressure circuit).................................................... 10-183


Center swivel joint ............................................................................................................ 10-186
Accumulator .................................................................................................................... 10-188
Work equipment ..................................................................................................................... 10-189
Work equipment............................................................................................................... 10-189
Work equipment shim....................................................................................................... 10-190
Bucket play adjustment shim............................................................................................. 10-191
Cab and its attachments .......................................................................................................... 10-192
Cab mount and cab tipping stopper ................................................................................... 10-192
ROPS cab ....................................................................................................................... 10-193
Electrical system .................................................................................................................... 10-194
Electrical control system ................................................................................................... 10-194
Machine monitor system ................................................................................................... 10-245
KOMTRAX system ........................................................................................................... 10-267
Sensor ............................................................................................................................ 10-270
20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-18
30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Engine and cooling system .......................................................................................................... 30-8
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ......................................................................................................... 30-9
Testing exhaust gas color ................................................................................................... 30-11
Measuring and adjusting valve clearance ............................................................................. 30-13
Testing compression pressure............................................................................................. 30-16
Testing blowby pressure ..................................................................................................... 30-20
Testing engine oil pressure ................................................................................................. 30-21
Testing EGR valve and KVGT oil pressures .......................................................................... 30-22
Measuring fuel pressure ..................................................................................................... 30-23
Measuring fuel delivery, return and leakage .......................................................................... 30-29
Bleeding air from fuel system .............................................................................................. 30-34
Checking fuel circuit for leakage .......................................................................................... 30-36
Handling cylinder cutout mode operation.............................................................................. 30-37
Handling no injection cranking operation .............................................................................. 30-38
Checking and adjusting air conditioner compressor belt tension ............................................. 30-39
Replacing fan belt .............................................................................................................. 30-41
Power train............................................................................................................................... 30-42
Testing swing circle bearing clearance ................................................................................. 30-42
Undercarriage and frame........................................................................................................... 30-43
Testing and adjusting track shoe tension .............................................................................. 30-43
Hydraulic system ...................................................................................................................... 30-44
Releasing remaining pressure from hydraulic circuit .............................................................. 30-44
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-45
Testing oil pressure of control circuit .................................................................................... 30-49
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-52
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-55
Testing output pressure of solenoid valve ............................................................................. 30-60
Testing PPC valve output pressure ...................................................................................... 30-64
Adjusting play of work equipment and swing PPC valves....................................................... 30-66
Testing pump swash plate sensor ........................................................................................ 30-67
Isolating the parts causing hydraulic drift in work equipment................................................... 30-68
Testing oil leakage ............................................................................................................. 30-69

PC210LC-10 00-3
00 Index and foreword
Index

Bleeding air from hydraulic circuit ........................................................................................ 30-72


Cab and its attachments ............................................................................................................ 30-74
Checking cab tipping stopper .............................................................................................. 30-74
Adjusting mirrors ................................................................................................................ 30-75
Electrical system ...................................................................................................................... 30-77
Special functions of machine monitor ................................................................................... 30-77
Adjusting rearview camera angle ....................................................................................... 30-148
Handling voltage circuit of engine controller........................................................................ 30-150
Handling battery disconnect switch .................................................................................... 30-151
Testing diodes ................................................................................................................. 30-152
Pm clinic ................................................................................................................................ 30-153
Pm Clinic service ............................................................................................................. 30-153
40 Troubleshooting............................................................................................................................ 40-1
Table of contents ........................................................................................................................ 40-2
General information on troubleshooting ........................................................................................ 40-9
Troubleshooting points ......................................................................................................... 40-9
Sequence of events in troubleshooting................................................................................. 40-11
Testing before troubleshooting ............................................................................................ 40-13
Inspection procedure before troubleshooting ........................................................................ 40-15
Preparation work for troubleshooting of electrical system....................................................... 40-34
Classification and procedure for troubleshooting ................................................................... 40-38
Symptom of probable failure and troubleshooting No............................................................. 40-41
Information in troubleshooting table ..................................................................................... 40-44
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................... 40-46
Connector list and layout .................................................................................................... 40-48
Connector contact identification........................................................................................... 40-59
T-branch box and T-branch adapter table ............................................................................. 40-95
Fuse location table ........................................................................................................... 40-101
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................. 40-103
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)............................................................................................................. 40-106
Fabrication of short-circuit connector (for CA1883 and CA3135)........................................... 40-107
Failure codes table........................................................................................................... 40-108
Troubleshooting by failure code (Display of code) ...................................................................... 40-117
Failure code [879AKA] A/C Inner Sensor Open Circuit ........................................................ 40-117
Failure code [879AKB] A/C Inner Sensor Short Circuit......................................................... 40-118
Failure code [879BKA] A/C Outer Sensor Open Circuit........................................................ 40-119
Failure code [879BKB] A/C Outer Sensor Short Circuit ........................................................ 40-120
Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................... 40-121
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-122
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .............................................. 40-123
Failure code [879EMC] Ventilation Damper Abnormality ...................................................... 40-124
Failure code [879FMC] Air Mix Damper Abnormality ........................................................... 40-125
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-126
Failure code [989L00] Engine Controller Lock Caution1....................................................... 40-127
Failure code [989M00] Engine Controller Lock Caution2...................................................... 40-128
Failure code [989N00] Engine Controller Lock Caution3 ...................................................... 40-129
Failure code [A1U0N3]: KDPF Dry Request (HC Release)................................................... 40-130
Failure code [A1U0N4] KDPF Dry Request (HC Release).................................................... 40-132
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-134
Failure code [AB00KE] Charge Voltage Low....................................................................... 40-136
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-138
Failure code [B@BAZK] Eng Oil Level Low ........................................................................ 40-139
Failure code [B@BCNS] Engine Coolant Overheat ............................................................. 40-140
Failure code [B@BCZK] Radiator Coolant Level Low .......................................................... 40-141
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-143
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-144
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-145
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-147

00-4 PC210LC-10
00 Index and foreword
Index

Failure code [CA131] Throttle Sensor High Error................................................................. 40-149


Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-151
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-153
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-155
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-157
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-159
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-161
Failure code [CA221] Ambient Press Sens High Error ......................................................... 40-163
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-165
Failure code [CA227] Sensor 2 Supply Volt High Error......................................................... 40-167
Failure code [CA234] Eng Overspeed ................................................................................ 40-168
Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................... 40-169
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-170
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-171
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-173
Failure code [CA295] Ambient Press Sens In Range Error................................................... 40-175
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-176
Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................. 40-178
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-180
Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................. 40-182
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-184
Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................. 40-186
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-188
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-189
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-190
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-192
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-194
Failure code [CA386] Sensor 1 Supply Volt High Error......................................................... 40-196
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-197
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-199
Failure code [CA435] Eng Oil Press Sw Error ..................................................................... 40-201
Failure code [CA441] Battery Voltage Low Error ................................................................. 40-202
Failure code [CA442] Battery Voltage High Error................................................................. 40-204
Failure code [CA449] Rail Press Very High Error................................................................. 40-205
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-206
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-208
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-210
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-211
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-213
Failure code [CA553] Rail Press High Error ........................................................................ 40-215
Failure code [CA555] Crankcase Press High Error 1 ........................................................... 40-216
Failure code [CA556] Crankcase Press High Error 2 ........................................................... 40-217
Failure code [CA559] Rail Press Low Error......................................................................... 40-218
Failure code [CA595] Turbo Speed High Error 2 ................................................................. 40-220
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-221
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-223
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-225
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-227
Failure code [CA697] ECM Int Temp Sensor High Error ....................................................... 40-229
Failure code [CA698] ECM Int Temp Sensor Low Error........................................................ 40-230
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-231
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-233
Failure code [CA1117] Persistent Data Lost Error................................................................ 40-238
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-239
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-241
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-244
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-246
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-248
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-250

PC210LC-10 00-5
00 Index and foreword
Index

Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-252
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-254
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-256
Failure code [CA1921] KDPF Soot Load High Error 1.......................................................... 40-259
Failure code [CA1922] KDPF Soot Load High Error 2.......................................................... 40-262
Failure code [CA1942] Crankcase Press Sens In Range Error ............................................. 40-267
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-268
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-271
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-273
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-275
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-276
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-278
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-281
Failure code [CA2311] IMV Solenoid Error ......................................................................... 40-282
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-283
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-285
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-287
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-288
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-290
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-292
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-294
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-296
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-298
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-301
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-303
Failure code [CA2387] KVGT Servo Error .......................................................................... 40-305
Failure code [CA2554] Exh Manifold Press Sens In Range Error .......................................... 40-306
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-307
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-309
Failure code [CA2637] KDOC Face Plugging ..................................................................... 40-311
Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-313
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-316
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-317
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-318
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-320
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-322
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-326
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-329
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-332
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-335
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-338
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-341
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-344
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-347
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-350
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-353
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-357
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-360
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-364
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-368
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-372
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-375
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-379
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-381
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-383
Failure code [D110KB] Battery Relay Output Voltage .......................................................... 40-384
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-386
Failure code [D811MC] KOMTRAX Error............................................................................ 40-389
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-390

00-6 PC210LC-10
00 Index and foreword
Index

Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)........................ 40-391


Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .......................... 40-393
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ............................................................ 40-394
Failure code [DA20MC] Pump Controller............................................................................ 40-395
Failure code [DA22KK] Pump Solenoid Power Low Error..................................................... 40-396
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...................................................... 40-398
Failure code [DA29KQ] Model Selection Abnormality .......................................................... 40-401
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ........................ 40-403
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ........................... 40-405
Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................. 40-406
Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................. 40-409
Failure code [DAF0MB] Monitor ROM Abnormality.............................................................. 40-410
Failure code [DAF0MC] Monitor Error ................................................................................ 40-411
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-412
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-414
Failure code [DAFGMC] GPS Module Error........................................................................ 40-415
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-416
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor)................................ 40-418
Failure code [DAFQKR] CAN2 Discon (Monitor) ................................................................. 40-419
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-420
Failure code [DAZQKR] CAN2 Discon (AC)........................................................................ 40-421
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-426
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-431
Failure code [DGH2KB] Hyd Oil Sensor Short .................................................................... 40-435
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ............................................. 40-437
Failure code [DHPAMA] F Pump Press Sensor Abnormality................................................. 40-438
Failure code [DHPBMA] R Pump Press Sensor Abnormality ................................................ 40-441
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....................................................... 40-444
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ................................... 40-446
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality................................... 40-449
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality....................................... 40-452
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ..................................... 40-455
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...................................... 40-458
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .................................... 40-461
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ................................ 40-464
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ............................... 40-467
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality .............................. 40-470
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ............................... 40-473
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ............................... 40-476
Failure code [DKR0MA] F pump S/P sensor Abnormality..................................................... 40-479
Failure code [DKR1MA] R pump S/P sensor Abnormality .................................................... 40-481
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ........................................ 40-483
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ........................................ 40-485
Failure code [DV20KB] Travel Alarm Short Circuit............................................................... 40-487
Failure code [DW43KA] Travel Speed Sol Open Circuit ....................................................... 40-489
Failure code [DW43KB] Travel Speed Sol Short Circuit ....................................................... 40-491
Failure code [DW45KA] Swing holding brake Sol Open Circuit ............................................. 40-493
Failure code [DW45KB] Swing holding brake Sol Short Circuit ............................................. 40-496
Failure code [DW91KA] Travel Junction Sol Open Circuit .................................................... 40-499
Failure code [DW91KB] Travel Junction Sol Short Circuit..................................................... 40-501
Failure code [DWA2KA] Attachment Sol Open Circuit.......................................................... 40-503
Failure code [DWA2KB] Attachment Sol Short Circuit.......................................................... 40-505
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..................................................... 40-507
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...................................................... 40-509
Failure code [DWK2KA] Variable Back Press Sol Open Circuit............................................. 40-511
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ............................................. 40-513
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ................................................. 40-515
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ................................................. 40-517
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.......................................................... 40-519

PC210LC-10 00-7
00 Index and foreword
Index

Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.......................................................... 40-521


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

00-8 PC210LC-10
00 Index and foreword
Index

E-35 Service mode cannot be selected .............................................................................. 40-599


E-36 Any of work equipment, swing and travel does not work............................................... 40-600
E-37 Any of work equipment, swing and travel cannot be locked .......................................... 40-602
E-38 Machine cannot swing while swing brake cancel switch is canceled ............................. 40-603
E-39 Swing brake does not operate while swing brake cancel switch is locked ...................... 40-605
E-40 One-touch power maximizing function does not work or monitor is not displayed ........... 40-607
E-41 One-touch power maximizing function cannot be canceled .......................................... 40-609
E-42 Travel alarm does not sound when machine travels..................................................... 40-610
E-43 Alarm does not stop sounding while machine is stopped.............................................. 40-611
E-44 Horn does not sound ................................................................................................ 40-612
E-45 Horn does not stop sounding..................................................................................... 40-614
E-46 Wiper monitor does not light up or go out when wiper switch is operated ....................... 40-615
E-47 Wiper does not operate when wiper switch is operated ................................................ 40-616
E-48 Window washer does not operate when window washer switch is operated................... 40-618
E-49 BOOM LOWER indication is not displayed properly with monitoring function ................. 40-619
E-50 ARM DUMP indication is not displayed properly with monitoring function ...................... 40-620
E-51 ARM IN indication is not displayed properly with monitoring function............................. 40-621
E-52 BOOM RAISE indication is not displayed properly with monitoring function ................... 40-622
E-53 BUCKET CURL indication is not displayed properly with monitoring function ................. 40-623
E-54 BUCKET DUMP indication is not displayed properly with monitoring function ................ 40-624
E-55 SWING indication is not displayed properly with monitoring function ............................. 40-625
E-56 TRAVEL indication is not displayed properly with monitoring function............................ 40-626
E-57 Service is not displayed properly with monitoring function ............................................ 40-627
E-58 Attachment hydraulic circuit cannot be changed.......................................................... 40-630
E-59 KOMTRAX system does not operate normally ............................................................ 40-631
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-633
Information described in troubleshooting table (H-mode) ..................................................... 40-633
System chart for hydraulic system ..................................................................................... 40-634
Failure mode and cause table ........................................................................................... 40-636
H-1 All of work equipment, swing and travel operation lacks speed or power ......................... 40-644
H-2 Engine speed drops significantly or engine stalls .......................................................... 40-647
H-3 All work equipment, swing and travel does not work ...................................................... 40-650
H-4 Unusual sound is heard from around hydraulic pump .................................................... 40-651
H-5 Fine control performance or response is poor ............................................................... 40-652
H-6 Boom speed or power is low ....................................................................................... 40-654
H-7 Arm speed or power is low .......................................................................................... 40-658
H-8 Bucket speed or power is low...................................................................................... 40-663
H-9 Work equipment does not move in single operation....................................................... 40-666
H-10 Hydraulic drift of boom is large .................................................................................. 40-667
H-11 Hydraulic drift of arm is large ..................................................................................... 40-668
H-12 Hydraulic drift of bucket is large ................................................................................. 40-669
H-13 Time lag of work equipment is large ........................................................................... 40-670
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ................................................................................................................. 40-672
H-15 One-touch power maximizing function does not operate .............................................. 40-673
H-16 In combined operation of work equipment, equipment having heavier load moves
slower................................................................................................................ 40-674
H-17 In combined operations of swing and boom RAISE, boom rising speed is low................ 40-675
H-18 In combined operations of swing and travel, travel speed drops largely......................... 40-676
H-19 Machine does not travel straight ................................................................................ 40-677
H-20 Travel speed is slow ................................................................................................. 40-680
H-21 Machine is hard to steer or travel power is low ............................................................ 40-682
H-22 Travel speed does not change, or travel speed is too slow or fast ................................. 40-685
H-23 One of tracks does not run ........................................................................................ 40-686
H-24 Upper structure does not swing to the right or left ........................................................ 40-688
H-25 Upper structure swing only to the right or left .............................................................. 40-689
H-26 Swing acceleration or swing speed is low in both directions (right and left) .................... 40-690
H-27 Swing acceleration performance is poor or swing speed is slow in only one
direction............................................................................................................. 40-691

PC210LC-10 00-9
00 Index and foreword
Index

H-28 Upper structure overruns excessively when it stops swinging (both right and
left).................................................................................................................... 40-692
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ........... 40-693
H-30 Shock is large when upper structure stops swinging.................................................... 40-694
H-31 Large unusual noise is heard when upper structure stops swinging .............................. 40-695
H-32 Swing drift on a slope is large while swing holding brake is applied............................... 40-696
H-33 Swing drift on a slope is large while swing holding brake is released............................. 40-697
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed................ 40-698
H-35 Oil flow in attachment circuit cannot be controlled ....................................................... 40-699
Troubleshooting of engine (S-mode)......................................................................................... 40-700
Information mentioned in troubleshooting table (S mode)..................................................... 40-700
S-1 When starting switch is turned to START position, engine does not crank ....................... 40-701
S-2 Engine cranks but no exhaust smoke comes out........................................................... 40-702
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start).................................................................................................................. 40-703
S-4 Engine startability is poor ............................................................................................ 40-704
S-5 Engine does not pick up smoothly ............................................................................... 40-706
S-6 Engine stops during operation ..................................................................................... 40-708
S-7 Engine runs rough or is unstable ................................................................................. 40-710
S-8 Engine lacks power .................................................................................................... 40-711
S-9 Exhaust smoke is black (KDPF clogs up early) ............................................................. 40-713
S-10 Engine oil consumption is excessive .......................................................................... 40-715
S-11 Engine oil becomes contaminated early...................................................................... 40-716
S-12 Fuel consumption is excessive .................................................................................. 40-717
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-718
S-14 Engine oil pressure drops ......................................................................................... 40-719
S-15 Fuel is contaminated in engine oil .............................................................................. 40-720
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)................................. 40-721
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-722
S-18 Unusual noise is heard ............................................................................................. 40-723
S-19 Vibration is excessive ............................................................................................... 40-724
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-725
S-21 Active regeneration is executed frequently ................................................................. 40-726
S-22 Active regeneration takes time................................................................................... 40-727
S-23 White smoke is exhausted during active regeneration ................................................. 40-728
50 Disassembly and assembly ........................................................................................................... 50-1
Table of contents ........................................................................................................................ 50-2
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tools list ................................................................................................................. 50-10
Sketches of special tools .................................................................................................... 50-15
Engine and cooling system ........................................................................................................ 50-19
Removal and installation of supply pump assembly............................................................... 50-19
Removal and installation of injector assembly....................................................................... 50-24
Removal and installation of cylinder head assembly.............................................................. 50-33
Removal and installation of radiator assembly ...................................................................... 50-53
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-55
Removal and installation of aftercooler assembly .................................................................. 50-58
Removal and installation of engine and main pump assembly ................................................ 50-60
Removal and installation of engine front oil seal .................................................................... 50-72
Removal and installation of engine rear oil seal..................................................................... 50-76
Removal and installation of fuel cooler assembly .................................................................. 50-79
Removal and installation of fuel tank assembly ..................................................................... 50-80
Removal and installation of engine hood assembly ............................................................... 50-83
Removal and installation of KDPF assembly......................................................................... 50-86
Disassembly and assembly of KDPF ................................................................................... 50-94
Removal and installation of KCCV assembly ...................................................................... 50-102
Removal and installation of air cleaner assembly ................................................................ 50-106

00-10 PC210LC-10
00 Index and foreword
Index

Power train............................................................................................................................. 50-109


Removal and installation of travel motor and final drive assembly ......................................... 50-109
Disassembly and assembly of final drive ............................................................................ 50-110
Removal and installation of swing motor and swing machinery assembly .............................. 50-118
Disassembly and assembly of swing machinery.................................................................. 50-121
Removal and installation of swing circle assembly .............................................................. 50-128
Undercarriage and frame......................................................................................................... 50-129
Separation and connection of track shoe assembly ............................................................. 50-129
Removal and installation of sprocket.................................................................................. 50-132
Removal and installation of idler and idler cushion assembly ............................................... 50-133
Disassembly and assembly of idler assembly ..................................................................... 50-134
Disassembly and assembly of idler cushion........................................................................ 50-137
Disassembly and assembly of track roller assembly ............................................................ 50-139
Disassembly and assembly of carrier roller......................................................................... 50-141
Removal and installation of revolving frame assembly ......................................................... 50-144
Removal and installation of counterweight assembly ........................................................... 50-146
Hydraulic system .................................................................................................................... 50-149
Removal and installation of center swivel joint assembly ..................................................... 50-149
Disassembly and assembly of center swivel joint ................................................................ 50-152
Removal and installation of hydraulic tank assembly ........................................................... 50-153
Removal and installation of main pump assembly ............................................................... 50-157
Removal and installation of control valve assembly ............................................................. 50-161
Disassembly and assembly of control valve........................................................................ 50-168
Disassembly and assembly of work equipment PPC valve................................................... 50-173
Disassembly and assembly of travel PPC valve.................................................................. 50-175
Work equipment ..................................................................................................................... 50-178
Removal and installation of work equipment assembly ........................................................ 50-178
Disassembly and assembly of work equipment cylinder....................................................... 50-181
Cab and its attachments .......................................................................................................... 50-187
Removal and installation of operator's cab assembly........................................................... 50-187
Removal and installation of operator cab glass (adhered glass) ........................................... 50-192
Removal and installation of front window assembly ............................................................. 50-202
Removal and installation of floor frame assembly................................................................ 50-208
Removal and installation of air conditioner unit assembly..................................................... 50-214
Removal and installation of operator's seat......................................................................... 50-218
Removal and installation of seat belt .................................................................................. 50-220
Removal and installation of front wiper assembly ................................................................ 50-222
Electrical system .................................................................................................................... 50-229
Removal and installation of air conditioner compressor assembly......................................... 50-229
Removal and installation of air conditioner condenser assembly .......................................... 50-232
Removal and installation of engine controller assembly ....................................................... 50-234
Removal and installation of pump controller assembly......................................................... 50-236
Removal and installation of machine monitor assembly ....................................................... 50-239
Removal and installation of pump swash plate sensor ......................................................... 50-241
Removal and installation of mass air flow and temperature sensor ....................................... 50-242
Removal and installation of KOMTRAX terminal assembly .................................................. 50-243
60 Maintenance standard................................................................................................................... 60-1
Table of contents ........................................................................................................................ 60-2
Engine and cooling system .......................................................................................................... 60-3
Engine mount ...................................................................................................................... 60-3
Cooling system .................................................................................................................... 60-4
Power train................................................................................................................................. 60-5
Swing circle ......................................................................................................................... 60-5
Swing machinery ................................................................................................................. 60-6
Final drive ........................................................................................................................... 60-8
Sprocket............................................................................................................................ 60-10
Undercarriage and frame........................................................................................................... 60-12
Track frame and idler cushion ............................................................................................. 60-12
Idler .................................................................................................................................. 60-14

PC210LC-10 00-11
00 Index and foreword
Index

Track roller ........................................................................................................................ 60-16


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

00-12 PC210LC-10
00 Index and foreword
Index

Failure code [879EMC] Ventilation Damper Abnormality ........................................................ 80-62


Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-63
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-64
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)................................................ 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ............................................................................................................ 80-70
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-72
Troubleshooting with gauge pressure................................................................................... 80-74
Connection of service tool................................................................................................... 80-77
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-79
Handling of compressor oil.................................................................................................. 80-81
Desiccant replacement ....................................................................................................... 80-83
90 Diagrams and drawings................................................................................................................. 90-1
Table of contents ........................................................................................................................ 90-2
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Hydraulic circuit diagram....................................................................................................... 90-7
Electric circuit diagram ................................................................................................................ 90-9
Symbols in electric circuit diagram ......................................................................................... 90-9
Electric circuit diagram........................................................................................................ 90-13
Electric circuit diagram for air conditioner unit ....................................................................... 90-25
Index.................................................................................................................................................................... 1

PC210LC-10 00-13
00 Index and foreword
Foreword, safety and general information

Foreword, safety and general information (ALL-0370-001-A-00-A)

Important safety notice (ALL-1120-012-A-01-A)

(Rev. 2012/01)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
shop manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of the special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special cautions during the work. The work
indicated by the caution mark should be performed according to the instructions with special attention to
the cautions. Should hazardous situation occur or be anticipated during such work, be sure to keep safe
first and take every necessary measure.

General precautions knowledge of welding perform the work. When


performing welding work, always wear welding
k Inappropriate handling causes an extreme gloves, apron, shielding goggles, cap, etc.
danger. Read and understand what is • Before starting work, warm up your body
described in the operation and maintenance thoroughly to start work under good condition.
manual before operating the machine. Read • Avoid continuing work for long hours and take
and understand what is described in this rests with proper intervals to keep your body in
manual before starting the work. good condition. Take a rest in a specified safe
place.
• Before performing any greasing or repairs, read
all the safety labels stuck to the machine. For Safety points
the locations of the safety labels and detailed 1 Good arrangement
explanation of precautions, see the operation 2 Correct work clothes
and maintenance manual.
3 Observance of work standard
• Locate a place in the repair workshop to keep
4 Practice of making and checking signals
the tools and removed parts. Always keep the
Prohibition of operation and handling by
tools and parts in their correct places. Always 5
unlicensed workers
keep the work area clean and make sure that Safety check before starting work
6
there is no dirt, water or oil on the floor. Smoke
Wearing protective goggles (for cleaning or
only in the areas provided for smoking. Never 7 grinding work)
smoke while working.
Wearing shielding goggles and protectors (for
• When performing any work, always wear the 8 welding work)
safety shoes and helmet. Do not wear loose
9 Good physical condition and preparation
work cloths, or clothes with buttons missing.
Precautions against work which you are not
1. Always wear the protective eyeglasses when 10 used to or you are used to too much
hitting parts with a hammer.
2. Always wear the protective eyeglasses when Preparation
grinding parts with a grinder, etc. • Before adding oil or making any repairs, place
• When performing any work with two or more the machine on a firm and level ground, and
workers, always agree on the working procedure apply the parking brake and chock the wheels or
before starting. While working, always keep tracks to prevent the machine from moving.
conversations of the work between your fellow • Before starting work, lower the work equipment
workers and your self on any step of the work. (blade, ripper, bucket, etc.) to the ground. If it is
During the work, hang the warning tag of not possible to lower the equipment to the
"UNDER WORKING" in the operator's ground, insert the lock pin or use blocks to
compartment. prevent the work equipment from falling. And be
• Only qualified workers must perform the work sure to lock all the work equipment control levers
and operation which require license or and hang a warning tag on them.
qualification. • When performing the disassembling or
• Keep the tools in good condition. And learn the assembling work, support the machine securely
correct way to use the tools, and use the proper with blocks, jacks, or stands before starting the
ones among them. Before starting the work, work.
thoroughly check the tools, forklift truck, service • Remove all of mud and oil from the steps or
car, etc. other places used to get on and off the machine
• If welding repairs is required, always have a completely. Always use the handrails, ladders of
trained and experienced welder with good

00-14 PC210LC-10
00 Index and foreword
Foreword, safety and general information

steps when getting on or off the machine. Never • When removing piping, prevent the fuel or oil
jump on or off the machine. When the scaffold is from spilling out. If any fuel or oil drips onto the
not provided, use steps or stepladder to secure floor, wipe it off immediately. Fuel or oil on the
your footing. floor can cause you to slip and can even cause
fires.
Precautions during work • As a general rule, do not use gasoline to wash
• For the machine equipped with the battery parts. Do not use gasoline to clean the electrical
disconnect switch, check that the system parts, in particular.
operating lamp is turned off before starting the • Reinstall the parts removed to their original
work. Then, turn the battery disconnect switch to places. Replace the damaged parts and the
the OFF (Q) position and remove the switch key. parts which must not be used with new ones.
For the machine not equipped with the battery When installing the hoses and wiring harnesses,
disconnect switch, remove the cable from the be careful that they are not damaged by
battery before starting the work. Be sure to contacting with other parts when the machine is
remove the negative end (-) of the battery cable operated.
first. • When connecting the high pressure hoses and
• Release the remaining pressure in the circuits tubes, make sure that they are not twisted. The
completely before the work when the parts in the damaged high pressure hoses and tubes are
circuits of oil, fuel, coolant and air are very dangerous when they are installed. So, be
disconnected or removed. When the cap of the extremely careful when connecting the high
oil filter, drain plug or oil pressure pickup plug is pressure pipings. In addition, check that their
removed, loose them slowly to prevent the oil connections are correct.
from spurting out. • When assembling or installing the parts, be sure
• When removing or installing the checking plug or to tighten the bolts to the specified torque. When
the piping in the fuel circuit, wait 30 seconds or installing the protective parts such as guards, or
longer after the engine is shut down and start the parts which vibrate violently or rotate at high
the work after the remaining pressure is speeds, be sure to check that they are installed
released from the fuel circuit. correctly.
• Immediately after the engine is shut down, the • When aligning two holes, never insert your
coolant and oil in the circuits are hot. Be careful fingers or hand into the holes. Align the holes
not to get scalded by the hot coolant and oil. with care so that your fingers are not caught in
Start the work after checking that the coolant the hole.
and oil are cooled down sufficiently. • When measuring hydraulic pressure, check that
• Start the work after the engine is shut down. Be the measuring tools are correctly installed.
sure to shut down the engine when working on • Pay attention to safety when removing and
or around the rotating parts in particular. When installing the tracks of the track type machines.
checking the machine without shutting down the When removing the track, it separates suddenly.
engine (measuring oil pressure, engine speed, The workers should not stand at either end of
oil or coolant temperature), take extreme care the track.
not to get caught in the rotating parts or the • If the engine is operated for a long time in a
working equipment. closed place which is not ventilated well, you
• The hoist or crane must be used to sling the may suffer from gas poisoning. Accordingly,
components weighing 25 kg or heavier. Check open the windows and doors to ventilate the
the slings (wire rope, nylon sling, chain and place well.
hook) for damage before the work. Use the
slings with ample capacity and install them to Precautions for slinging work and making
the proper places. Operate the hoist or crane signals
slowly to prevent the component from hitting any • Only one appointed worker must make signals
other part. Do not work with any part still raised and co-worker must communicate with each
by the hoist or crane. other frequently. The appointed signaler must
• When removing the part which is under internal make specified signals clearly at the place
pressure or reaction force of the spring, always where the signaler is well seen from the
leave two bolts in diagonal positions. Loosen operator's seat and where the signaler can see
those two bolts gradually and alternately and the working condition easily. The signaler must
release the pressure, then, remove the part. always stand in front of the load and guide the
• When removing the part, be careful not to break operator safely.
or damage the electrical wiring. The damaged 1. Do not stand under the load.
wiring may cause electrical fires. 2. Do not step on the load.
• Check the slings before starting sling work.

PC210LC-10 00-15
00 Index and foreword
Foreword, safety and general information

• Keep putting on the gloves during sling work. • Use the specified eye bolts and fix wire ropes,
(Put on the leather gloves, if available.) chains, etc. to them with shackles, etc.
• Measure the weight of the load by the eye and • Apply wire ropes to the middle portion of the
check its center of gravity. hook.
• Use the proper sling according to the weight of
a Slinging near the tip of the hook may cause
the load and method of slinging. If too thick wire
the rope to slip off the hook during hoisting.
ropes are used to sling a light load, the load may
The hook has the maximum strength at the
slip and fall.
middle part.
• Do not sling a load with one wire rope only. If do
so, the load may rotate or the sling gets loose
and the sling may slip off. Install two or more
wire ropes symmetrically.

k Slinging with one rope may cause turning


of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original slinging position on the load,
which can result in a dangerous accident.
• Hanging angle must be 60 degrees or smaller as
a rule.
• When hanging a heavy load (25kg or heavier),
the hanging angle of the rope must be narrower • Do not use twisted or kinked wire ropes.
than that of the hook. • When slinging up a load, observe the following.
a When slinging a load with two ropes or more, 1. Wind up the rope slowly until the wire rope
the larger the hanging angle is, the larger the tensions. When putting your hands on the
tension of each rope. The figure bellow wire ropes, do not grasp them but press them
shows the variation of allowable load in kN down from above. If you grasp them, your
{kg} when hoisting is made with two ropes, fingers may be caught.
each of which is allowed to sling up to 9.8 kN 2. After the wire ropes are stretched, stop the
{1000kg} a load vertically, at various hanging crane and check the condition of the slung
angles. When the two ropes sling a load load, wire ropes, and pads.
vertically, up to19.6 kN {2000 kg} of total 3. If the load is unstable or the wire rope or
weight can be suspended. This weight is chains are twisted, lower the load and lift it
reduced to 9.8 kN {1000 kg} when the two up again.
ropes make a hanging angle of 120 degrees. 4. Do not lift up the load at an angle.
If the two ropes sling a 19.6 kN {2000 kg} • When lowering a load, pay attention to the
load at a hanging angle of 150 degrees, each following.
rope is subjected to a force as large as 39.2 1. When lifting down a load, stop it temporarily
kN {4000 kg}. at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.

Precautions for using mobile crane


a Read the Operation and Maintenance Manual of
the crane carefully in advance and operate the
crane safely.

• When installing wire ropes to an angular load,


apply pads to protect the wire ropes. If the load
is slippery, apply proper material to prevent the
wire rope from slipping.

00-16 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Precautions for using overhead traveling crane Nominal


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

PC210LC-10 00-17
00 Index and foreword
Foreword, safety and general information

• Check that the O-ring is not damaged or


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

For tightening torques, see "Others",


"Precautions for disconnection and connection
of air conditioner piping".

00-18 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Fire prevention (ALL-0000-001-K-27-A)

Action if fire occurs (ALL-0000-17A-K-01-A)


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

PC210LC-10 00-19
00 Index and foreword
Foreword, safety and general information

KDPF is a system for purifying soot in exhaust


gas. The exhaust gas discharged during the
purification process (regeneration) can be higher
temperature than that of existing models. Do not
bring any flammable material close to the outlet
of the exhaust pipe.
• If there are thatched houses, dry leaves or
pieces of paper around the job site, set the
system to the "Regeneration Disable" before
starting operation to prevent fire hazard of
highly heated exhaust gas caused by KDPF
regeneration.
See the operation and maintenance manual
for the setting procedure.
• Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte,
or coolant, always use lighting equipment
with anti-explosion specifications.
• When taking the electrical power for the
lighting equipment from the machine itself,
follow the instructions in the operation and
maintenance manual.
Dispose of waste materials (ALL-0000-99A-K-
02-A)

To prevent pollution, pay full attention to the way to


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

Some kinds of rubber and plastics may produce


poisonous gas harmful to human body when they
are burned.
• As for rubber, plastics, or parts (hoses, cables,
and wiring harnesses, etc.) which contain those
materials, ask the industrial waste treatment
firms for their disposals in accordance with the
local regulations.

00-20 PC210LC-10
00 Index and foreword
Foreword, safety and general information

How to read the shop manual (ALL-0320-010-A-01-A)

(Rev. 2012/01)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.

Composition of shop manual


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

Symbol
Important safety and quality portions are marked with the following symbols so that the shop manual is used
practically.
Symbol Item Remarks
Safety The special safety precautions required for performing work are
k described.
The special technical precautions or other precautions for preserving
a Caution standards required when performing work are described
The weight of part or component and the cautions required when
4 Weight selecting hoisting wire or when working posture is important are
described.
Tightening The tightening torques that require special attention during assembly
3 torque work are described.

PC210LC-10 00-21
00 Index and foreword
Foreword, safety and general information

Symbol Item Remarks


The places to be coated with adhesives, etc. during assembling are
2 Coat
indicated.
Oil, coolant The places to which oil is supplied and the quantity of the oil are
5 indicated.

6 Drain The places from which oil is drained and quantity of the oil are indicated.

Unit
• In this shop manual, the units are indicated with International System of units (SI).
• For reference, Gravitational System of units which is used to be used is indicated in parentheses of { }.

00-22 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Explanation of terms for maintenance standard (ALL-0330-006-A-01-A)

(Rev. 2012/01)
• The chapter of maintenance standard shows judgement criteria to determine the products to be replaced
or to be reused. The judgement criteria are described by using the following terms.

Standard dimension and tolerance


• To be accurate, the finished dimension of a part
is slightly different from one to another.
• To specify the finished dimension of a part, a
certain dimension is set for the part and an
allowable difference from that dimension is
indicated.
• The above dimension set is called the "standard
dimension" and the range of difference from the
standard dimension is called the "tolerance".
• The standard dimension and tolerance are
indicated by attaching the symbols of + or - and
a number on the right side of the standard
dimension.
Example:
Standard dimension Tolerance
-0.022
120
-0.126
• The tolerance may be indicated in the text and a
table as "standard dimension (upper limit of
tolerance/lower limit of tolerance)."
Example: 120(-0.022/-0.126)
• Usually, the dimension of a hole and the
dimension of a shaft to be inserted into the hole
are indicated by the same standard dimension
and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance. Standard interference
• Indication of dimension of rotating shaft and hole • When the diameter of a hole of a part shown in
and their related drawing. the given standard dimension and tolerance
Example: table is smaller than that of the shaft to be
inserted, the difference between those
Standard Tolerance diameters is called the "interference".
dimension Shaft Hole • Subtract the maximum dimension of the hole
-0.030 +0.046 from the minimum dimension of the shaft and
60
-0.076 0 call it (A). Subtract the minimum dimension of
the hole from the maximum dimension of the
Standard clearance and standard value shaft and call it (B). The range between (A) and
• The clearance made when new parts are (B) is the "standard interference".
assembled is called the standard clearance, • After repairing or replacing some parts, measure
which is indicated by the range from the the dimension of their hole and shaft and check
minimum clearance to the maximum clearance. that the interference is in the standard range.
• When some parts are repaired, the clearance is
generally adjusted to the standard clearance. Repair limit and allowable value or allowable
• The values indicating performance and function dimension
of new products or equivalent are called the • The dimensions of parts change because of the
"standard value", which is indicated by a range wear or deformation while they are used. When
or a target value. the dimension changes exceeding certain value,
• When some parts are repaired, the value of the parts can not be used any longer. This value
performance/function is set to the standard is called "repair limit".
value. • If a part is worn to the repair limit, it must be
replaced or repaired.

PC210LC-10 00-23
00 Index and foreword
Foreword, safety and general information

• The performance and function of the products


lower while they are used. When the value of the
performance and function lowers exceeding a
certain limit and it influences the operation etc.,
this value is called the allowable value or
allowable dimension.
• A product whose dimension is out of the
allowable value, must be repaired. However,
since the allowable values are generally
estimated through various tests or experiences
in most cases, the judgement must be made in
consideration of the operating condition and
customer's requirement.

Allowable clearance
• Parts can be used until the clearance between
them is increased to a certain limit. The limit at
which those parts cannot be used is called the
"allowable clearance".
• If the clearance between the parts exceeds the
allowable clearance, they must be replaced or
repaired.

Allowable interference
• The allowable maximum interference between
the hole of a part and the shaft of another part to
be assembled is called the "allowable
interference".
• The allowable interference shows the repair limit
of the part of smaller tolerance.
• The parts whose interferences are out of the
allowable interference must be replaced or
repaired.

00-24 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Handling equipment of fuel system devices (PC-AD00-2A4-K-00-A)

(Rev. 2012/01)
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. If foreign material enters this system, it
may cause a failure. Use special care to prevent
entry of the foreign material when servicing the
fuel system.

Use care for working environment


• Avoid filter change or repairing the machine in
rain or high winds, or at places where there is a
lot of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left as they
are or plugged with cloths as foreign material
may enter or environment may be polluted by
the oil leaked. Do not discard the waste oil
somewhere or other. Hand it over to your
customer for disposal, or dispose it by yourself.

How to clean parts when dirt is stuck


• If any dirt or dust sticks the parts of the fuel
system, clean it off thoroughly with clean fuel.

Precautions for replacing fuel filter cartridge


• Be sure to use the Komatsu genuine fuel filter
cartridge.
• The common rail fuel injection system (CRI)
consists of more precise parts than the parts
used in the conventional fuel injection pump and
nozzle. In order to prevent foreign material from
entering this system, the filter employs a
specially high performance of filter element. If a
filter element other than the genuine one is used,
the fuel system may have a failure. Accordingly,
never use such a filter element.

PC210LC-10 00-25
00 Index and foreword
Foreword, safety and general information

Handling of intake system parts (PC220-A900-2A4-K-00-A)

(Rev.2012/01)
• The Komatsu Variable Geometry Turbocharger
(KVGT) consists of more precise parts (variable
mechanism) than the parts used in the
conventional turbocharger. If foreign material
enters this system, it may cause a failure. Use
special care to prevent entry of the foreign
material when servicing the air intake system.

Be careful of working environment


• Avoid the repair work of the machine in rain or
strong wind or at the places where there is a lot
of dust.
Sealing openings
• Plug the pipes and the openings of the
components which are removed, with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never perform repair works under
the condition that the openings are left open or
plugged with rag since foreign material may
enter.

00-26 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Handling of hydraulic equipment (ALL-C000-2A4-P-01-A)

(Rev. 2012/01)
• With the increase in pressure and precision of the hydraulic components, the most common cause of a
failure is dirt (foreign material) in the hydraulic circuit. Therefore, the special care must be taken when
adding hydraulic oil,or when disassembling or assembling the hydraulic components.

Be careful of working environment


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

Disassembly and maintenance work in the field


• When disassembly or maintenance work of the
hydraulic is performed in the field, there is
danger of dust entering the components. It is
also difficult to check the performance of the
components after repairs, so it is desirable to
use the component exchange service. The
disassembly and assembly of the hydraulic
components must be performed in the specially
arranged dustproof workshop and the Preventing intrusion of foreign materials during
performance test of the components must be refilling operations.
performed with the special testing equipment. • Care must be taken when adding hydraulic oil so
that foreign material does not enter. Keep the oil
filler port and the area around it, oil supply pump
and oil container clean. If an oil cleaning device
is used, it is possible to remove the dirt that is
collected during storage. It is a surer means.

Sealing openings
• Plug the pipes and the openings of the
components which are removed with the caps,
tapes, vinyl bags, etc. to prevent foreign material
from entering. Never leave the openings of the
pipes and hoses without being covered or Replacing hydraulic oil while its temperature is
high
plugged with cloth as foreign material may enter
• When the hydraulic oil is warm, it flows easily. In
them or environment may be polluted by the oil
addition, sludge can also be drained from the
leaked. Do not discard the waste oil somewhere
circuit together with the oil. So, it is better to
or other. Hand it over to your customer for
change the hydraulic oil while it is warm. When
disposal, or dispose it by yourself.
changing the hydraulic oil, the old oil must be
drained as much as possible. (Drain the oil not
only from the hydraulic tank, but also from the
filter housing and the drain plug hole in the
circuit.) If the old oil is left in the system, the
contaminant and sludge in the oil mix with the
new oil and shorten the life of the new hydraulic
oil.

PC210LC-10 00-27
00 Index and foreword
Foreword, safety and general information

Flushing operations
• After disassembling the equipment or when
changing the hydraulic oil with new one, flush
the system to remove the contaminant and
sludge left in the hydraulic circuit as well as the
oil which includes them. Normally, flushing is
performed twice. Primary flushing is performed
by use of the flushing oil and the secondary
flushing is performed by use of the specified
hydraulic oil.

Cleaning operations
• After repairing the hydraulic equipment (pump,
control valve, etc.) or when the machine is in
operation, perform oil cleaning to remove the
sludge or contaminant in the hydraulic oil circuit.
The oil cleaning equipment can remove the ultra
fine (approximately 3 μm) particles that the filter
built in the hydraulic equipment can not remove.
So, it is an extremely effective device.

00-28 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Method of disconnecting and connecting of push-pull type coupler (ALL-


C930-001-P-00-A)
(Rev. 2012/01)

k Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the
hydraulic tank.

k Even if the remaining pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil container.

Type 1 (ALL-C930-925-P-01-A)

Disconnection Connection
1. Hold adapter (1) and push hose joint (2) into 1. Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3). (Fig. 1) mating adapter (3) aligning them with each other.
(Fig. 4)
a It can be pushed in by approximately 3.5mm.
a Do not hold rubber cap part (4).
a Do not hold rubber cap portion (4).
2. After inserting the hose fitting in the adapter on
2. While pushing hose joint (2) into adapter (3),
the other side perfectly, pull it back to check the
push rubber cap (4) against adapter (3) until
connecting condition. (Fig. 4)
"click" is heard. (Fig. 2)
3. Hold hose adapter (1) or hose (5) and pull it out. a When the hose fitting is pulled back, the
(Fig. 3) rubber cap will move toward the hose,
however, it is not a problem.
a Since some hydraulic oil flows out, prepare
an oil container.

PC210LC-10 00-29
00 Index and foreword
Foreword, safety and general information

Type 2 (ALL-C930-925-P-02-A)

Disconnection Connection
1. While holding the fitting, push body (7) in straight 1. While holding the fitting, push body (7) in straight
until sliding prevention ring (6) hits contact until sliding prevention ring (6) hits contact
surface (a) at the hexagonal part on the male surface (a) at the hexagonal part on the male
side. (Fig. 6) side to connect it. (Fig. 9)
2. While keeping the condition of Step 1, turn lever
(8) to the right (clockwise). (Fig. 7)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (7) to disconnect it. (Fig. 8)

00-30 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Type 3 (ALL-C930-925-P-03-A)

Disconnection Connection
1. While holding the fitting, push body (9) in straight 1. While holding the fitting, push body (9) in straight
until sliding prevention ring (8) hits contact until sliding prevention ring (8) hits contact
surface (b) at the hexagonal portion on the male surface (a) at the hexagonal portion on the male
side. (Fig. 10) side to connect them. (Fig. 13)
2. While keeping the condition of Step 1, push
cover (10) straight until it hits contact surface (b)
of the hexagonal portion on the male side. (Fig.
11)
3. While keeping the conditions of Steps 1 and 2,
pull out whole body (9) to disconnect it. (Fig. 12)

PC210LC-10 00-31
00 Index and foreword
Foreword, safety and general information

Handling of electrical equipment (ALL-E000-2A4-P-01-A)

(Rev. 2012/01)

• To maintain the performance of the machine over a long period, and to prevent failures or troubles before
they occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be
performed. This section deals particularly with correct repair procedures for mechatronics components
and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in
"Handling of electrical equipment".

Precautions for handling electric equipment

Handling wiring harnesses and connectors


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

Main failures occurring in wiring harness


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

00-32 PC210LC-10
00 Index and foreword
Foreword, safety and general information

blow it with compressed air and spray it with


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

High-pressure water entering connector


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

Entry of water, mud or dirt when disconnecting a


connector
• If any water, mud or dirt is stuck to the outside
surface of a connector, it can enter inside the
connector when the connector is disconnected.
Before disconnecting the connector, wipe off any
stuck water or dirt by using a piece of dry cloth
or blow it with compressed air.
Oil, mud or dirt stuck to connector
• If any oil or grease is stuck to the connector and
an oil film is formed on the mating surface of the 2. When removing from clips
male and female pins, the oil prevents electricity • Both of the connector and clip have stoppers,
from passing through, resulting in defective which are engaged with each other when the
contact. If any oil or grease, mud or dirt is stuck connector is connected.
to the connector, wipe it off with a dry cloth or

PC210LC-10 00-33
00 Index and foreword
Foreword, safety and general information

• Check that there is no oil, dirt or water stick


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

3. Action to take after removing connectors


• After removing the connector, cover it with
the vinyl bag to prevent entry of dust, dirt,oil
or water in the contact portion. 3. Correct the protrusion of the boot and
misalignment of the wiring harness
a If the machine is left disassembled for a • For connectors fitted with the boot, correct
long time, it is particularly easy for any extrusion of the boot. In addition, if the
improper contact to occur, so always wiring harness or the clamp is out of the
cover the connector. position, put it in its original position.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.

Connecting connectors
1. Check the connector visually.

00-34 PC210LC-10
00 Index and foreword
Foreword, safety and general information

• If the connector clamp is removed, be sure to • If there is any oil or dirt on the wiring harness,
return it to its original position. And check wipe it off with a dry cloth. Avoid washing by
that it is securely installed. using steam. If the wire harness must be
washed in water, do not apply high pressure
water or steam directly to the wiring harness. If
water gets directly on the connector, do as
follows.
1. Disconnect the connector and wipe off the water
with a dry cloth.
a If the connector is to be blown with dry
compressed air, there is a risk that oil in the
air may cause defective contact of the
conditioner, remove oil and water in the air
before starting air blow.

Deutsch connector (DT8-pin, DT12-pin)


Disconnection
1. While pressing locks (a) and (b) from each side
respectively, pull out female connector (2).

2. Dry the inside of the connector with a dryer.


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

3. Perform a continuity test on the connector.


After drying, leave the wiring harness
disconnected and perform a continuity test to
check for any short circuits between pins caused
by water.
a After the connector is completely dried, blow
the contact restorer and reassemble them.
Drying wiring harness

PC210LC-10 00-35
00 Index and foreword
Foreword, safety and general information

2. While pressing lock (L2), pull out connector (1).


Handling of connectors used on engine

Slide, lock type (Type 1) (FRAMATOME-3,


FRAMATOME-2)
Disconnection
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1)
toward you.
a In the case that even if lock (L2) is pressed,
connector (1) cannot be pulled out toward
you unless part A floats, float part A with a
small flat-head screwdriver while pressing
lock (L2), and then pull out connector (1)
toward you.
a Lock (L2) is located in the back of connector
(1).

Connection
1. Insert the connector securely until a click is
heard. Connection
1. Insert the connector securely until a click is
Slide, lock type (Type 2) (FRAMATOME-24) heard.
Disconnection
1. Slide down lock (red) (L1). Pull lock type (PACKARD-2)
Disconnection
1. Disconnect the connector (2) by pulling lock (B)
(on the wiring harness side) of connector (2)
outward.

00-36 PC210LC-10
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Foreword, safety and general information

Connection Connection
1. Insert the connector securely until a click is 1. Insert the connector securely until a click is
heard. heard.
Push lock type (1) (BOSCH-3) Push lock type (2) (SUMITOMO-4)
Disconnection Disconnection
1. While pressing lock (C), pull out connector (3) in 1. While pressing lock (C), pull out connector (4) in
the direction of the arrow. the direction of the arrow.
• 114 series Connection
1. Insert the connector securely until a click is
heard.

• 107 series

Push lock type (3) (AMP-3)


Disconnection
1. While pressing lock (E), pull out connector (5) in
the direction of the arrow.
Example) Fuel pressure sensor in common rail:
PFUEL etc (AMP-3)

a If the lock is located on the underside, use


flat-head screwdriver [1] since you cannot
insert your fingers.
While pushing up lock (C) of the connector
with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.

PC210LC-10 00-37
00 Index and foreword
Foreword, safety and general information

Example) Injection pressure control valve of


supply pump: PCV (SUMITOMO-2)

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

Connection Handling controller


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

• Cover the control connectors with tape or a vinyl


bag. Never touch the connector contacts.
• During rainy weather, do not leave the controller
in a place where it is exposed to rain.
• Do not place the controller on oil, water, or soil,
or in a place that can be heated to a high

00-38 PC210LC-10
00 Index and foreword
Foreword, safety and general information

temperature even for a short period of time.


(Place it on a suitable dry stand.)

• Precautions when performing arc welding


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

Precautions for troubleshooting electrical


circuits
• Be sure to turn the starting switch to the "OFF"
position before disconnecting or connecting the
connectors.
• Before performing troubleshooting, check all the
related connectors for loose connection.
a Check the related connectors for their
performance by disconnecting and
connecting them several times.
• Be sure to connect all the disconnected
connectors before proceeding to the next step.
a If the starting switch is turned to the "ON"
position with the connectors disconnected,
the failure which is not related to the part
which is actually failed.
• When performing the troubleshooting for the
circuit (measurement of voltage, resistance,
continuity, current, etc.), shake the related wiring
harnesses and connectors several times and
check that the multimeter reading does not
change.
a If there is any value change on the
multimeter, there may be a defective contact
in the circuit.

PC210LC-10 00-39
00 Index and foreword
Foreword, safety and general information

How to read electric wire code (ALL-E500-030-P-00-A)


(Rev. 2012/01)
• In the electrical circuit diagram, material, thickness and color of each electric wire are indicated by
symbols. The wire code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of
0.85
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
AEX
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols are not
indicated on the diagram.)
Indicates size of wire by nominal No.
0.85
Size (Nominal No.) is shown in Table 2.
Indicates color of wire by color code.
L
Color codes are shown in Table 3.

Type, symbol, and material


• AV and AVS are different in thickness and outside diameter of the coating. CAVC has a circular
compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of
the coating. And AEX is similar to AV in thickness and outside diameter of the coating but different from AV
and AVS in material of the coating.
(Table 1)
Temperature
Type Sym- Conductor Example of use
Insulator material range (°C) in
bol material
use
Low-voltage For large current wiring
wire for AV
automobile (nominal No. 5 and above)
Thin-cover
low-voltage
General wiring
wire for AVS
automobile (nominal No. 3 and lower)
Soft polyvinyl chloride -30 to +60
(Type 1) Annealed
Thin-cover copper for
low-voltage electric For mid- to small-size
wire for CAVS appliance excavators
automobile (nominal No. 1.25 and lower)
Type 2
Heat-
resistant low- (Safety factor:
Heat-resistant cross
voltage wire AEX linked polyethylene -50 to +110 Wiring at high-temperature
for place
automobile

00-40 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Dimension
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/ 20/ 30/ 11/ 50/ 16/ 37/ 26/ 58/ 41/ 65/
7/0.32
Diameter of 0.18 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
strand
Conductor Cross-
sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 —
Coating D

AV Standard — — — — — — — 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 — 3.8 4.6

Nominal No. 8 15 20 30 40 50 60 85 100


Number of
strands/ 108/ 127/ 169/ 217/
50/0.45 84/0.45 41/0.80 70/0.80 85/0.80
Diameter of 0.80 0.80 0.80 0.80
strand
Conductor Cross-
sectional 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard — — — — — — — — —
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6

Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25


Number of
strands/ 7/round 11/round 16/round
— — —
Diameter of compression compression compression
strand
Conductor Cross-
sectional — 0.56 — 0.88 — 1.29
area (mm2)
d (approx.) — 0.9 — 1.1 — 1.4
Coating D

CAVS Standard — 1.6 — 1.8 — 2.1

a "f" of nominal No. denotes "flexible".

PC210LC-10 00-41
00 Index and foreword
Foreword, safety and general information

Color codes table


(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow & Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White

a Remarks: In a color code consisting of two colors, the first color is the color of the background and the
second color is the color of the marking.
Examples)
GW means that the background is "Green" and marking is "White".

Types of circuits and color codes


Type of wire AVS, AV, CAVS AEX
Charge R WG — — — — R —
Ground B — — — — — B —
Start R — — — — — R —
Light RW RB RY RG RL — D —
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB — L —
Type of — — —
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW — — —
O — — — — — — —
Appendix Gr — — — — — — —
P — — — — — — —
Sb — — — — — — —
Dg — — — — — — —
Ch — — — — — — —

00-42 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Precautions when performing operation (ALL-1160-927-A-00-A)

(Rev. 2012/01)
• When performing "removal or installation" and "disassembly or assembly" of the components, observe the
following general cautions.

Precautions for removal work


• If the coolant contains antifreeze, dispose of it correctly as chemicals. Do not drain the coolant to the
sewage rashly.
• After disconnecting the hoses or tubes, plug them to prevent dirt or dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the match marks which indicate the installing position, and put match marks on the places where
they seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses to show their installing positions to prevent any mistake when
installing.
• Check the number and thickness of the shims, and keep them in a safe place.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and
alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any
foreign material from entering after removal.
a Precautions when handling piping during disassembly
Use the plugs indicated below for the pipes disconnected at the disassembly.
Face seal type hoses and tubes
Nominal No. Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
Split flange type hoses and tubes
Nominal No. Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500

PC210LC-10 00-43
00 Index and foreword
Foreword, safety and general information

If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal No. Part No.
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34

Precautions for installation work


• Tighten all of the bolts and nuts (sleeve nuts) to the specified torque (KES).
• Install the hoses without twist and interference, and securely fasten the clamps located in-between if they
are.
• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the part, and apply two to three drops of adhesive to the
threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dirt or damage.
• Clean all of the parts, and correct any damage, dents, burrs, or rust found on them.
• Coat the rotating parts and sliding parts with engine oil.
• Coat the surfaces of the press-fitting parts with molybdenum disulfide lubricant (LM-P).
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dirt, or water, then
connect them securely.
• Use the eye bolts with no fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent excessive tightening on
one side.
a When the hydraulic cylinder is used for the first time after reassembly of the hydraulic equipment such as
the hydraulic cylinder, pump, etc. and piping after removing them for repair, be sure to perform air bleeding
of the hydraulic circuit according to the following procedure.
1. Start and run the engine at low idle.
2. Repeat the operation to extend and retract each cylinder of the work equipment to approximately 100
mm before the stroke end four to five times.
3. Operate the hydraulic cylinder three to four times to the end of its stroke.

00-44 PC210LC-10
00 Index and foreword
Foreword, safety and general information

a After the completion of repair and when operating the machine which is stored long term, perform the air
bleeding with the same procedure as the one described above.

PC210LC-10 00-45
00 Index and foreword
Foreword, safety and general information

Precautions at the time of completing work


Refilling of coolant, oil and grease
• When the coolant is drained, tighten the drain valve securely, then refill the coolant reservoir with the
coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping,
and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the oil reservoir with the oil Komatsu
recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the
specified level again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after
rebuilding the parts, by referring to "Testing and adjusting".
• Supply the specified amount of grease to the work equipment parts.
Check of installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If any bolt is loose, retighten it.
a For the tightening torques, see the "Disassembly and assembly".
Check of engine piping for damage and looseness
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Intake and exhaust for air suction and exhaust gas leakage.
system
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Cooling system for water leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the part.
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints
Fuel system for fuel leakage.
If any part is loosely installed or damaged, retighten the bolts or repair the parts.
Check of KDPF or muffler and exhaust pipe for damage and looseness
• Visually check the KDPF or muffler, exhaust pipe and their mounting parts for a crack and damage. If any
part is damaged, replace it.
• Check the mounting bolts, nuts, and clamps of the KDPF or muffler, exhaust pipe and their mounting parts
for looseness.
If any part is loosely installed, retighten the bolts.
Check of KDPF or muffler function
• Check the KDPF or the muffler for unusual noise comparing to the noise when they are new.
If any unusual noise is heard, repair KDPF or muffler, referring to "Troubleshooting" and "Disassembly and
assembly".

00-46 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Practical use of KOMTRAX (ALL-Q210-13V-K-00-A)


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

Merit of using KOMTRAX


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

How to use KOMTRAX practically


With KOMTRAX, following support activities will be available.
1. Quick response to sudden request of repair
1) When receiving a repair request from a user, check the displayed caution and failure code, etc. through
KOMTRAX.
2) Arrange the necessary tools, replacement parts, etc, immediately in accordance with the displayed
failure code.
3) By using the map of KOMTRAX, find the location of the failed machine and visit the customer there.
2. Proactive maintenance
1) Check the service summary screen of KOMTRAX, and find the machine which has high priority failure
code indicated by a red or yellow flag.
2) Check the condition of the machine with the customer and make a plan to visit.
3) Arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure
code.
3. Practice of periodic maintenance and periodic inspection service
1) Check the service summary screen of KOMTRAX, and find the machine of which the usage limits for
the consumable parts indicated by red flags are over.
2) Submit an estimate sheet for the consumable parts to be replaced and the labor cost for the
replacement work to the customer.
3) Propose the periodic inspection (PM clinic, etc.) according to the service meter reading.

How to operate KOMTRAX


For the operating method of each screen of KOMTRAX, see "KOMTRAX basic operation manual".

PC210LC-10 00-47
00 Index and foreword
Foreword, safety and general information

Standard tightening torque table (ALL-M140-03B-P-01-A)

(Rev. 2012/01)

Table of tightening torque for bolts and nuts


Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table below.
1. The following table applies to the bolts in Fig. A.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (Nm) (kgm)
6 10 (10) 11.8 to 14.7 1.2 to 1.5
8 13 (12) 27 to 34 2.8 to 3.5
10 17 (14) 59 to 74 6.0 to 7.5
12 19 (17) 98 to 123 10.0 to 12.5
14 22 157 to 196 16 to 20
16 24 245 to 309 25 to 31.5
18 27 343 to 427 35 to 43.5
20 30 490 to 608 50 to 62
22 32 662 to 829 67.5 to 84.5
24 36 824 to 1,030 84 to 105
27 41 1,180 to 1,470 120 to 150
30 46 1,520 to 1,910 155 to 195
33 50 1,960 to 2,450 200 to 250
36 55 2,450 to 3,040 250 to 310
39 60 2,890 to 3,630 295 to 370

a Values with ( ) in the "Width across flats" column are for (*) marked bolt (flange bolt) shown in Fig. A.
2. The following table applies to the bolts in Fig. B.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (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
Fig. A Fig. B

a Values with parentheses are applied to the width across flats of (*) marked bolts (flanged bolts)

00-48 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Table of tightening torque for split flanged bolts


a Unless otherwise specified, tighten the split flange bolt to the torque shown in the table below.
Thread Width Tightening torque
diameter across flats
(mm) (mm) (Nm) (kgm)
10 14 59 to 74 6.0 to 7.5
12 17 98 to 123 10.0 to 12.5
16 22 245 to 309 25 to 31.5

Table of tightening torque for O-ring boss piping joints


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

Table of tightening torque for O-ring boss plugs


a Unless otherwise specified, tighten the plug for O-ring boss to the torque shown in the table below.
Thread Width Tightening torque (Nm {kgm})
Nominal No. diameter across flats
(mm) mm Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 — 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 — 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 — 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

PC210LC-10 00-49
00 Index and foreword
Foreword, safety and general information

Table of tightening torque for hose (taper seal type and face seal type)
a Unless otherwise specified, tighten the hose fittings (taper seal type and face seal type) to the torque
shown in the following table.
a The table is applied to the threads coated with engine oil (wet threads)
Tightening torque (Nm {kgm}) Taper seal Face seal
Width
Nominal across Nominal No. - Thread root
No. of Thread size threads per
flats Range Target diameter
hose (mm) (mm) inch, type of (reference)
thread
34 to 54 {3.5 to 5.5} 44 {4.5} — 9/16 -18UN 14.3
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 — —
22 54 to 93 {5.5 to 9.5} 74 {7.5} — 11/16 -16UN 17.5
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 — —
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/16 -16UN 20.6
05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4
06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 1-3/16 -12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 — —
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 — —
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 — —

Table of tightening torque for face seal joints


a The tightening torque table below applies to the seal joint (sleeve nut type)
a The table is applied to the threads coated with engine oil (wet threads).
Outer Tightening torque (Nm {kgm}) Face seal
Width
diameter of Nominal No. - Thread root
across flats
pipe Range Target threads per inch, diameter
(mm)
(mm) type of thread (Reference)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/16 -18UN 14.3
10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/16 -16UN 17.5
12 24 {27} 43 to 47 {4.4 to 4.8} 45 {4.6} 13/16 -16UN 20.6
15 {16} 30 {32} 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4
22 {20} 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 1-3/16 -12UN 30.2
Reference: The face seal joint of the dimension in ( ) is also used, depending on the specification.

00-50 PC210LC-10
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Tightening torque table for bolts and nuts on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric threads bolts and nuts used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
14 — —

Tightening torque table for I-joints on 102,107 and 114 series engines
a Unless otherwise specified, tighten the metric I-joints used on the 102, 107 and 114 series engines to the
torque shown in the following table.
Thread diameter Tightening torque
(mm) (Nm) (kgm)
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

Tightening torque table for tapered screws on 102,107 and 114 series engines
a Unless otherwise specified, tighten the tapered inch thread screws used on the 102, 107 and 114 series
engines to the torques shown in the following table.
Material In cast iron or steel In aluminum
Tightening torque Tightening torque
Thread diameter (inch)
(Nm) (kgm) (Nm) (kgm)
1/16 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10
1/8 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20
1/4 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20
3/8 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31
1/2 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41
3/4 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51

PC210LC-10 00-51
00 Index and foreword
Foreword, safety and general information

List of abbreviation (ALL-0360-005-A-00-A)


(Rev. 2012/01)
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts,
components, and functions whose meaning is not immediately clear. The spelling is given in full with an
outline of the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text(marked witha).
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of abbreviations used in the shop manual


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

00-52 PC210LC-10
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Foreword, safety and general information

Purpose of use (major


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

PC210LC-10 00-53
00 Index and foreword
Foreword, safety and general information

Purpose of use (major


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

00-54 PC210LC-10
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Foreword, safety and general information

Purpose of use (major


Abbrevia- Full Spelling applicable machine (*), or Explanation
tion equipment/device)
Power Tilt and power Work equipment Function that performs hydraulic control of the
PTP tilt and pitch of the bulldozer blade.
Pitch dozer (D)
Structure that protects operator fastening seat
belt from being crushed when machine tips
Roll-Over Protective Cab and canopy over (Structure to protect operator when
ROPS
Structure machine tips over)
Performance standardized in ISO 3471
Abbreviation for "International system of units"
International unit
SI Unit Unit system that is employed worldwide, and
system
"one unit against one factor"
Actuator that moves a part with a movable iron
SOL Solenoid Electric core in the coil (solenoid), which is moved by
energizing the coil.
Two Way Valve Hydraulic and electric Solenoid valve that switches the direction of
TWV
flow.
*1: Code for applicable machine family
D: Bulldozer
HD: Dump truck
HM: Articulated dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection
S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature

PC210LC-10 00-55
00 Index and foreword
Foreword, safety and general information

Abbreviation Actual word spelled out


T/C Torque Converter
T/M Transmission

00-56 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Conversion table (ALL-2150-931-A-00-A)


(Rev. 2012/01)

Method of using the conversion table


• The unit conversion table enables the simple conversion in the figures between the different units. For
further details of the method of use of the conversion table, see the examples given below.
Example: Method of using the conversion table to convert a unit from millimeters to inches
Conversion of 55 mm into inches
1. Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2. Locate the number 5 in the row across the top, take this as (B), then draw a vertical line down from (B).
3. Take the point where the two lines cross as (C). This point (C) gives the value when converting the unit
from millimeters to inches. Therefore, 55 mm = 2.165 in.
Conversion of 550 mm into inches
1. The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the
left) to get 55 mm.
2. Then convert 55 mm to 2.165 in by the same procedure as above.
3. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to get the original value. This gives 550 mm = 21.65 in. Therefore, 550 mm = 21.65
in.
Millimeters to inches
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

PC210LC-10 00-57
00 Index and foreword
Foreword, safety and general information

Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilograms to pounds
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

l to U.S. Gallons
1 l= 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

00-58 PC210LC-10
00 Index and foreword
Foreword, safety and general information

l to U.K. Gallons
1 l= 0.21997 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

PC210LC-10 00-59
00 Index and foreword
Foreword, safety and general information

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542

00-60 PC210LC-10
00 Index and foreword
Foreword, safety and general information

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice
versa is to see the number in the center column of the following table. The figures on the following table
show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of
Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

PC210LC-10 00-61
00 Index and foreword
Foreword, safety and general information

00-62 PC210LC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number

PC210LC-10 450001 and up

01 Specification
2 01 Specification

PC210LC-10 01-1
01 Specification
Table of contents

Table of contents (ALL-0310-002-A-00-A)


01 Specification................................................................................................................................. 01-1
Table of contents ........................................................................................................................ 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Working range drawings ....................................................................................................... 01-4
Specifications ...................................................................................................................... 01-5
Weight table ........................................................................................................................ 01-8
Table of fuel, coolant, and lubricants ...................................................................................... 01-9

01-2 PC210LC-10
01 Specification
Specification drawing

Specifications (ALL-2111-001-A-00-A)

Specification drawing (ALL-2110-001-A-00-A)

PC210LC-10 (PC200_10-2110-931-A-00-A)

Item Unit PC210LC-10


Machine weight kg 21,600
Bucket capacity m3 0.8
Engine model — Komatsu SAA6D107E-2 diesel engine
Engine flywheel horsepower
• Net [ISO 9249/SAE J1349] kW {HP}/min-1 118 {158}/2,000 {2,000}
• Gross [SAE J1995] {rpm} 123 {165}/2,000 {2,000}
A Overall length mm 9,625
Overall height (including head
B mm 2,970
guard)
C Overall width mm 3,080
D Shoe width mm 700
E Cab height mm 3,045
F Tail swing radius mm 2,940
G Overall length of track mm 4,450
Distance between tumbler mm 3,655
H
centers
I Over handrail height mm 3,135
Min. ground clearance mm 440
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Swing speed min-1 {rpm} 12.4 {12.4}

a The engine flywheel horsepower is indicated in the net value and gross value. Gross value is the flywheel
horsepower measured of the bear engine. While, net value is the value measured of the engine under the
same condition essentially as the condition that it is installed on the machine.

PC210LC-10 01-3
01 Specification
Working range drawings

Working range drawings (ALL-2110-001-A-02-A)

PC210LC-10 (PC200_10-2110-931-A-01-A)

Item Unit PC210LC–10


A Max. digging reach mm 9,875
B Max. digging depth mm 6,620
C Max. digging height mm 10,000
D Max. vertical wall digging depth mm 5,980
E Max. dumping height mm 7,110
F Min. dumping height mm 2,645
Max. digging reach at ground mm 9,700
G
level

01-4 PC210LC-10
01 Specification
Specifications

Specifications (ALL-2111-001-A-00-A)

PC210LC-10 (PC200_10-2111-931-A-00-A)

Machine model PC210LC-10


Serial number 450001 and up
Bucket capacity m3 0.8
Machine weight kg 21,600
Performance
Machine model PC210LC-10
Serial number 450001 and up
Max. digging depth mm 6,620
Working ranges

Max. vertical wall digging depth mm 5,980


Max. digging reach mm 9,875
Max. digging reach at ground mm 9,700
level
Max. digging height mm 10,000
Max. dumping height mm 7,110
Max. digging force 138.3 {14,100}
kN {kg}
(with power maximizing function) (149.1 {15,200})
Swing speed min-1 {rpm} 12.4 {12.4}
Swing operation max. slope angle deg. 25
Travel speed (Lo/Mi/Hi) km/h 3.0/4.1/5.5
Gradeability deg. 35
Ground pressure (standard shoe) kPa {kg/cm2} 38.2 {0.39}
Dimensions
Machine model PC210LC-10
Serial number 450001 and up
Overall length mm 9,625
Overall width mm 3,080
Overall height (for transport) (*1) mm 3,135
Cab height (*1) mm 3,045
Ground clearance of upper structure
mm 1,085
(*2)
Min. ground clearance mm 440
Tail swing radius mm 2,940
Min. swing radius of work equipment mm 3,040
Top height at min. swing radius of
mm 8,005
work equipment
Overall width of track mm 2,980
Overall length of track mm 4,450
Track gauge mm 2,380
Distance between tumbler centers mm 3,655
Cab height (*3) mm 2,250
Standard shoe width mm 700
*1: Excluding grouser height (26 mm) included.
*2: Not excluding grouser height (26 mm) not included.
*3: Excluding engine hood.

PC210LC-10 01-5
01 Specification
Specifications

Engine
Machine model PC210LC-10
Serial number 450001 and up
Model SAA6D107E–2
4-cycle, water-cooled, in-line vertical,
Type direct injection type with turbocharger
and air-cooled aftercooler
No. of cylinders - bore x stroke mm 6-107x124
Piston displacement l {cc} 6.69 {6,690}
Flywheel horsepower
• Net [ISO 9249/SAE J1349] 118 {158}/2,000 {2,000}
kW {HP}/min-1 {rpm}
• Gross [SAE J1995] 123 {165}/2,000 {2,000}
Performance

Max. torque Nm {kgm}/in-1 {rpm} 634 {65}/1,500 {1,500}


Max. speed with no load
• At mounted on machine 1,850 ± 50
rpm
• At bear engine 2,060 ± 50
Min. speed with no load rpm 1,050 ± 25
Min. fuel consumption ratio g/kWh {g/HPh} 215 {160}
Starting motor 24 V, 5.5 kW
Alternator 24 V, 60 A
Battery (*2) 12 V, 140 Ah x 2
Radiator core type CF90-4
*4: When swing is locked.
*5: The battery capacity (Ah) is indicated in the 5-hour rate.
a The engine flywheel horsepower is indicated in the net value and gross value. Gross value is the flywheel
horsepower measured of the bear engine. While, net value is the value measured of the engine under the
same condition essentially as the condition that it is installed on the machine.
Undercarriage
Machine model PC210LC-10
Serial number 450001 and up
Carrier roller 2 (each side)
Track roller 9 (each side)
Assembly type triple grouser, 49 (each
Track shoe side)

01-6 PC210LC-10
01 Specification
Specifications

Hydraulic system
Machine model PC210LC-10
Serial number 450001 and up
Variable displacement piston type (HPV
Hydraulic pump

Type x number
125 + 125) x 2
Delivery l/min 245 x 2

Set pressure MPa {kg/cm2} 37.2 {380}

Type x number 6-spool type x1


Control valve

Operating method Hydraulic

Variable displacement piston type (HMV


Hydraulic motor

Travel motor 120 - 2) x 2


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

Piston rod diameter mm 90


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

Type Double-acting piston


Cylinder bore mm 135
Arm (*4)

Piston rod diameter mm 95


Stroke mm 1,490
Max. distance between pins mm 3,565
Min. distance between pins mm 2,075
Type Double-acting piston
Cylinder bore mm 115
Bucket

Piston rod diameter mm 80


Stroke mm 1,120
Max. distance between pins mm 2,800
Min. distance between pins mm 1,680
Hydraulic tank Box-shaped sealed type
Hydraulic oil filter Tank return side
Hydraulic oil cooler Air cooled type (CF91)
*6: With head side cushion.
*7: With head side cushion and bottom side cushion.

PC210LC-10 01-7
01 Specification
Weight table

Weight table (ALL-2120-001-A-01-A)

PC210LC-10 (PC200_10-2120-931-A-00-A)

k This weight table is prepared for your reference when handling or transporting the components.
Unit:kg
Machine model PC210LC-10
Serial number 450001 and up
Engine assembly 886
• Engine 690
• Damper 6
• Main pump 190
Radiator and oil cooler assembly 150
Hydraulic tank and filter assembly (excluding hydraulic oil) 120
Fuel tank assembly (excluding fuel) 155
Revolving frame 2,115
Operator's cab (including head guard and front half guard) 430
Operator seat 35
Counterweight 3,600
Swing machinery 169
Control valve 235
Swing motor 51.5
Travel motor 93 × 2
Center swivel joint 36
Track frame assembly (excluding piping) 4,957
2,662
• Track frame
273
• Swing circle
• Idler 101 × 2
• Idler cushion 127 × 2
• Carrier roller 13 × 4
• Track roller
• Final drive (including travel motor and sprocket) 36 × 18
355 × 2
Track shoe assembly
• Triple grouser shoe (700 mm {31.50 in}) 1,530 × 2
Boom assembly 1,506
Arm assembly 795
Bucket assembly 759
Boom cylinder assembly 204 × 2
Arm cylinder assembly 224
Bucket cylinder assembly 133
Bucket link (large) assembly 83
Bucket link (small) assembly 22 × 2
Boom foot pin 42
Boom cylinder bottom pin 8×2
Boom cylinder head pin 28
Arm cylinder bottom pin 10
Arm cylinder head pin 12
Boom and arm connecting pin 26
Bucket cylinder bottom pin 8
Bucket pin 20 × 2
Bucket link pin 13 × 2

01-8 PC210LC-10
01 Specification
Table of fuel, coolant, and lubricants

Table of fuel, coolant, and lubricants (PC200_10-RA19-05A-K-00-A)

a For details of the notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.

Unit: l
PC210LC-10
Reservoir
Specified Refill
Engine oil pan 25.4 23.1
Swing machinery case 7.1 6.5
Final drive case (right and left respectively) 5.4 5.0
Damper case 0.65 0.65
Hydraulic system 236 132
Cooling system 30.7 30.7
Fuel tank 400 —

PC210LC-10 01-9
01 Specification
Table of fuel, coolant, and lubricants

01-10 PC210LC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number

PC210LC-10 450001 and up

10 Structure and function


3 10 Structure and function

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

Table of contents (ALL-0310-002-A-00-A)


10 Structure and function ................................................................................................................... 10-1
Table of contents ........................................................................................................................ 10-2
Engine and cooling system .......................................................................................................... 10-3
Engine related parts ............................................................................................................. 10-3
KVGT.................................................................................................................................. 10-5
EGR system piping drawing ................................................................................................ 10-12
EGR system circuit diagram ................................................................................................ 10-14
EGR valve......................................................................................................................... 10-16
EGR cooler........................................................................................................................ 10-18
KCCV layout drawing ......................................................................................................... 10-19
KCCV ventilator ................................................................................................................. 10-21
KDPF................................................................................................................................ 10-23
Cooling system .................................................................................................................. 10-27
Power train............................................................................................................................... 10-29
Power train system............................................................................................................. 10-29
Swing circle ....................................................................................................................... 10-31
Swing machinery ............................................................................................................... 10-32
Final drive ......................................................................................................................... 10-34
Undercarriage and frame........................................................................................................... 10-36
Track frame and idler cushion ............................................................................................. 10-36
Hydraulic system ...................................................................................................................... 10-38
Hydraulic equipment layout drawing .................................................................................... 10-38
Valve control...................................................................................................................... 10-40
Hydraulic tank.................................................................................................................... 10-42
CLSS ................................................................................................................................ 10-44
Main pump ........................................................................................................................ 10-49
Control valve ..................................................................................................................... 10-74
Swing motor .................................................................................................................... 10-131
Travel motor .................................................................................................................... 10-143
PPC valve ....................................................................................................................... 10-156
Solenoid valve ................................................................................................................. 10-178
Attachment circuit selector valve (for high pressure circuit) .................................................. 10-181
Attachment circuit selector valve (for low pressure circuit).................................................... 10-183
Center swivel joint ............................................................................................................ 10-186
Accumulator .................................................................................................................... 10-188
Work equipment ..................................................................................................................... 10-189
Work equipment............................................................................................................... 10-189
Work equipment shim....................................................................................................... 10-190
Bucket play adjustment shim............................................................................................. 10-191
Cab and its attachments .......................................................................................................... 10-192
Cab mount and cab tipping stopper ................................................................................... 10-192
ROPS cab ....................................................................................................................... 10-193
Electrical system .................................................................................................................... 10-194
Electrical control system ................................................................................................... 10-194
Machine monitor system ................................................................................................... 10-245
KOMTRAX system ........................................................................................................... 10-267
Sensor ............................................................................................................................ 10-270

10-2 PC210LC-10
10 Structure and function
Engine related parts

Engine and cooling system (ALL-R401-001-K-00-A)

Engine related parts (PC200_10-A001-041-K-00-A)

1. EGR cooler (*2)

PC210LC-10 10-3
10 Structure and function
Engine related parts

2 Engine oil filter


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

Damper type Wet type


Oil used for damper TO30
Damper oil capacity (l) 0.65

10-4 PC210LC-10
10 Structure and function
KVGT

KVGT (WA380-AA10-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger and it is variable displacement
turbocharger.
a The shape is subject to machine models.

PC210LC-10 10-5
10 Structure and function
KVGT

1. Blower housing
2. KVGT speed sensor
3. Hydraulic actuator
4. Turbine housing
5. Plate
6. Vane
7. Nozzle ring
8. Push rod
9. Shaft
10. Blower impeller
11. Turbine impeller
12. Piston
A: Air intake inlet
B: Air intake outlet
C: Exhaust inlet
D: Exhaust outlet
Operation (ENG107-AA10-044-K-00-A)

1. Air cleaner
2. KVGT
3. KDPF
4. EGR cooler
5. EGR valve
C: Blower impeller
T: Turbine impeller
• The new exhaust gas regulation not only requires to control emissions at high engine speeds but also at
low engine speeds. To meet the requirements, the EGR ratio is increased. (EGR ratio = volume of EGR/
intake air flow)
• To obtain a high EGR ratio especially at low engine speeds, the turbine inlet pressure (P3) must be higher
than the boost pressure (P2). A variable displacement turbocharger (KVGT), in which the exhaust gas
pressure hitting the turbine impeller (T) can be adjusted, is introduced.
• The charged pressure rises faster, also contributing to suppress the generation of PM (particles) due to
insufficient oxygen at low engine speeds.
• The turbine impeller (T) drives the blower impeller (C) via a shaft. In turn the blower impeller (C) sends a
large amount of air to the cylinders for combustion. When the air flow from KVGT (2) increases, more fuel
can be injected, and the engine output increases.
• Since the density of the air and the amount of oxygen increases when the air is cooled, more fuel can be
injected, and the engine output increases.

10-6 PC210LC-10
10 Structure and function
KVGT

a Adequate amount of clean high quality oil is required to maintain the KVGT performance. Be sure to use
Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.

• Exhaust gas enters from (C) of turbine housing (4), flows through section (P) and out from (D). Section (P)
is surrounded by plate (5) and nozzle ring (7) fixed on turbine housing (4), and vane (6).
• The passage area changes when push rod (8) slides right or left.
• The hydraulic actuator (3) moves piston (12) in the actuator up/down by using the oil pressure controlled
at the EPC valve installed to the EGR valve, and also controls the right/left slide of push rod (8).
• Exhaust gas hits vane (6), and then turbine impeller (11) drives blower impeller (10) via shaft (9). This
works as a compressor and the air entered from (A) is compressed and sent out from (B).
• When the exhaust gas pressure at the inlet (C) of turbine housing (4) is low (at low engine speeds), push
rod (8) slides to the right to narrow section (P).
• Then the exhaust gas pressure to turbine impeller (11) increases, the turbocharger speed also increases,
and more air (oxygen) is inhaled.
• The turbocharger speed is sensed by KVGT speed sensor (2).

When nozzle ring is closed


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

PC210LC-10 10-7
10 Structure and function
KVGT

When nozzle ring is open


• At high engine speeds, exhaust gas inlet passage (P) is widened (L2).
• As the engine speed and the turbine inlet pressure (exhaust gas pressure) increases, exhaust gas inlet
passage (P) widens (L2) to effectively apply the exhaust gas pressure to turbine impeller (11).

a Nozzle ring (7), vane (6), and push rod (8) are integrated and slide together but do not rotate.
a KVGT position sensor is installed to hydraulic actuator (3). The KVGT position sensor is calibrated
together with the variable mechanism in the KVGT, and values are stored in the memory inside the KVGT
position sensor. If any of the hydraulic actuator (3), KVGT position sensor, or KVGT body fails, replace the
whole KVGT.

10-8 PC210LC-10
10 Structure and function
KVGT

Hydraulic actuator operation


• Hydraulic actuator (6) is moved by the oil pressure controlled by EPC valve (8) installed to EGR valve
(10).
• The force for the movement is the oil pressure supplied from boost oil pump (12).
a The shape in the following figure is subject to machine models.

• Position of hydraulic actuator (6) is sensed by KVGT position sensor (5) and the signals are fed back to
engine controller (7).

PC210LC-10 10-9
10 Structure and function
KVGT

1. Air cleaner
2. Mass air flow and temperature sensor
3. KVGT
4. KVGT speed sensor
5. KVGT position sensor
6. Hydraulic actuator
7. Engine controller
8. EPC valve (for KVGT)
9. KDPF
10. EGR system (EGR cooler, EGR valve)
11. EGR orifice temperature sensor
12. Boost oil pump
C: Blower impeller
T: Turbine impeller

KVGT control system


• Based on information from KVGT position sensor (5), mass air flow and temperature sensor (2), and
KVGT speed sensor (4), etc., the engine controller (7) moves hydraulic actuator (6) by using the oil
pressure controlled by EPC valve (8), to move the piston.
• A good response at high altitudes is maintained by sensing high elevations with the ambient pressure
sensor, and automatically controlling the fuel injection and the KVGT.
• The KVGT is protected by controlling its speed to prevent overspeeds.

Lubrication
• Cooled oil from the engine oil cooler is sent through the supply pipe to the KVGT for lubrication.
• Oil is sent to the bearing housing to lubricate the shaft bearing and thrust bearing.
• Return oil is drained from the return pipe connected to the bottom of the bearing housing and falls to the oil
pan.

10-10 PC210LC-10
10 Structure and function
KVGT

Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Coolant return flows from the center housing and joins the flow at the EGR cooler outlet piping, then flows
through the water inlet connector to the water pump.

PC210LC-10 10-11
10 Structure and function
EGR system piping drawing

EGR system piping drawing (WA380-A9J0-04D-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation.


a The shape is subject to machine models.

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

• EGR valve (driven hydraulically)


Controls the gas flow from the exhaust system to the air intake system. Since the exhaust pressure is
higher than the boost pressure, the exhaust gas flows to the air intake side.
• EGR cooler

10-12 PC210LC-10
10 Structure and function
EGR system piping drawing

Cools the exhaust gas.


Engine coolant is used for cooling.
• Air intake connector
Returns the air from the air-cooled aftercooler and exhaust gas from the EGR valve to the air intake side.
• Each sensor
Controls the EGR according to the operating condition.
Troubleshoots the system.
• Controls each part of the EGR circuit and controls the EGR rate according to the operating condition to
ensure clean exhaust at all times.
• Since the EGR circuit is monitored and troubleshooted, a serious trouble is prevented.

PC210LC-10 10-13
10 Structure and function
EGR system circuit diagram

EGR system circuit diagram (ENG107-A9J0-052-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. Air cleaner
2. KDPF
3. Ambient pressure sensor
4. Aftercooler
5. EGR orifice temperature sensor
6. EGR cooler
7. EGR valve
8. Hydraulic actuator (power piston)
9. EPC valve (for EGR valve)
10. EGR valve lift sensor
11. EPC valve (for KVGT)
12. Exhaust manifold
13. Boost oil pump
14. Intake manifold
15. Charge (boost) pressure and temperature sensor
16. Engine controller
C: Blower impeller
T: Turbine impeller
Operation (ENG107-A9J0-044-K-00-A)

• The engine controller outputs signals for opening EGR valve (7) most properly according to the load on
the engine to attain both clean exhaust gas and low fuel consumption.
• When EGR valve (7) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (12)
through EGR piping to EGR cooler (6).

10-14 PC210LC-10
10 Structure and function
EGR system circuit diagram

• The exhaust gas cooled by EGR cooler (6) flows through EGR valve (7) and mixes with the intake air in
the air intake connector, and then flows in the air intake manifold (14).

PC210LC-10 10-15
10 Structure and function
EGR valve

EGR valve (ENG107-A9K1-041-K-00-A)

a The shape is subject to machine models.

1. Valve
2. Spring
3. Power piston
4. Spool
5. Spring
6. EGR valve lift sensor
7. EPC valve (for EGR valve)
8. EPC valve (for KVGT)
A: EGR gas inlet (from EGR cooler)
B: EGR gas outlet (to intake manifold)
C: Servo drive oil inlet
D: Servo drive oil outlet
E: KVGT control oil pressure outlet
F: KVGT drive oil pressure outlet

Structure
• The EGR valve consists of the EGR gas flow control mechanism and the EPC valves
• There are two EPC valves, one for the EGR valves control and one for the KVGTcontrol.

10-16 PC210LC-10
10 Structure and function
EGR valve

Operation (ENG107-A9K1-044-K-00-A)

• Oil from the boost oil pump flows into the EGR valve from port (C). Control pressure from the EPC valve
flows into port (E).
• Spool (4) is pressed to the right by the force of spring (5), and EGR valve (1) is closed by the force of
spring (2) Therefore, exhaust gas from the EGR cooler does not flow to the intake side.
• To open EGR valve (1), first the control pressure from the EPC valve enters port (E). Spool (4) moves to a
position whereat this control pressure and the force of spring (5) are balanced.
• The hydraulic circuit in power piston (3) opens, and then the oil from the boost oil pump entering from port
(C) pushes power piston (3) to the left.
• Oil from the boost oil pump acts on power piston (3) and generates force (Fp).
• When force (Fp) becomes larger than force (Fs) of spring (2), EGR valve (1) opens and then exhaust gas
will flow to the intake side.
• Since the hydraulic circuit to spool (4) is closed by movement of power piston (3), power piston (3) stops at
a position determined by spool (4).
• The valve position is controlled by the engine controller by controlling the spool position with the control
pressure of the EPC valve.
• A servo mechanism prevents external force applied to valve (1) from acting on spool (4), which is in
contact with power piston (3).
• Position of spool (4) is sensed by the EGR valve lift sensor.

PC210LC-10 10-17
10 Structure and function
EGR cooler

EGR cooler (ENG107-A9L0-041-K-00-A)

a The shape is subject to machine models.

1. Tube
A: EGR gas inlet
B: Air vent
C: Coolant outlet
D: EGR gas outlet (to EGR valve)
E: Coolant inlet

1. Flat tube
2. Inner fin
Operation (ENG107-A9L0-044-K-00-A)

• The EGR gas enters from (A) and flows through 11 flat tubes (1).
• Coolant enters from (E) and flows around flat tube (1) in shell and then goes out from (C).
• The EGR gas is effectively cooled by flat tubes (1) with inner fins (2) and flows out from EGR gas outlet
(D).

10-18 PC210LC-10
10 Structure and function
KCCV layout drawing

KCCV layout drawing (PC200_10-A180-04D-K-00-A)

KCCV: Abbreviation for KOMATSU Closed Crankcase Ventilation


a The shape is subject to machine models.

1. KCCV ventilator
2. KVGT
3. Blowby duct
4. Flywheel housing
5. Check valve
6. CDR valve
7. Crankcase pressure sensor
A: Blowby gas (from flywheel housing)
B: Engine oil-free blowby gas (to KVGT)
C: Engine oil (to oil pan)
• Formerly, blowby gas has been released to the atmosphere. However, since the tightened exhaust gas
regulation also regulates blowby gas, the blowby gas recirculation system is adopted.
• Since blowby gas (A) contains engine oil mist, which may cause the following problems when recirculated
to KVGT (2), a filter is provided at KCCV ventilator (1) to remove the oil.
1. Degraded performance of turbocharger and aftercooler due to adherence of engine oil
2. Abnormal engine combustion
3. Malfunction of sensors due to aherence of engine oil

PC210LC-10 10-19
10 Structure and function
KCCV layout drawing

Operation (ENG107-A180-044-K-00-A)

a The figure on the left shows the flow of blowby gas released to the atmosphere from conventional engines.
The figure on the right shows the flow of blowby gas recirculated to the intake system by the KCCV
ventilator.

1. Air cleaner
2. KVGT
3. Aftercooler
4. Cylinder block (crankcase)
5. Breather
6. KCCV ventilator
7. Oil pan
• Engine oil mist is removed from blowby gas (A) in cylinder block (4) by the filter in KCCV ventilator (6), and
then the cleaned gas (B) is recirculated to the intake side of the KVGT.
• Removed engine oil (C) flows through a check valve and falls to the oil pan.

10-20 PC210LC-10
10 Structure and function
KCCV ventilator

KCCV ventilator (PC200_10-A18H-041-K-00-A)

a The shape is subject to machine models.

1. Case
2. CDR valve
3. Crankcase pressure sensor
4. Relief valve
5. Impactor
6. Filter
7. Heater tube
A: Blowby gas inlet (from flywheel housing)
B: Blowby gas outlet (to KVGT intake side)
C: Oil drain port (to oil pan)
D: Coolant inlet
E: Coolant outlet
Function (PC200_10-A18H-042-K-00-A)

• When blowby gas is recirculated to the intake side of the KVGT, the pressure inside the crankcase
becomes negative, and dust may be sucked in through the crankshaft seals. Therefore, CDR valve
(regulator valve) controls the pressure inside the crankcase.
• If the filter in the KCCV ventilator clogs, pressure inside the crankcase increases and oil may leak, so clog
of filter is detected by crankcase pressure sensor.
• There are two types of filters that differ by the filter replacement method; the top load type (removed
upward) and the bottom load type (removed downward).
• Warming KCCV ventilator with the warmed engine coolant can prevent the blowby gas passage from
being plugged by the frozen gas.

PC210LC-10 10-21
10 Structure and function
KCCV ventilator

Operation (ENG107-A18H-044-K-00-A)

• Blowby gas enters from (A). The larger drops of oil mist are removed from the blowby gas when it flows
through the impactor (5) holes in filter (6).
• Smaller drops of oil mist are removed by filter (6).
• Removed oil flows down along the case wall to oil drain port (C) and then flows to the oil pan.
• The CDR valve operates when the pressure inside the crankcase becomes negative, to prevent excessive
negative pressure in the crankcase.
• Crankcase pressure sensor (3) senses the blowby gas pressure (crankcase pressure).
• When the engine controller determines that the filter is clogged from crankcase pressure sensor (3)
signals, failure code CA555 is issued. If the pressure increases further, failure code CA556 is issued.
• Relief valve (4) is installed in case (1). It operates to protect the KCCV ventilator and engine when filter (6)
is blocked.
CDR valve (ENG107-A18A-041-K-00-A)

CDR: Abbreviation for Crankcase Depression Regulator

1. Diaphragm
2. Spring
A: Crankcase side
B: KVGT side (intake side)
• The CDR valve is a regulator valve which prevents excessive negative crankcase pressure (P1).
• Normally, diaphragm (1) is pushed up by spring (2) and blowby gas flows from crankcase side (A) to
KVGT side (intake side) (B).
• When intake air flow at KVGT side (intake side) (B) increases and crankcase pressure (P1) decreases,
force of spring (2) yields to ambient pressure (P2). The diaphragm shuts the passage and temporarily
blocks the flow.
• Then, when blowby gas accumulates in the crankcase and pressure (P1) recovers, the diaphragm is
pushed up again and blowby gas starts to flow again.

10-22 PC210LC-10
10 Structure and function
KDPF

KDPF (WA380-A9H0-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter


a The shape is subject to machine models.

1. Inlet unit
2. KDOC inlet temperature sensor
3. KDOC outlet temperature sensor
4. KCSF unit
5. Connector box
6. KDPF outlet temperature sensor
7. Outlet unit
8. KDPF differential pressure sensor port
9. KDPF differential pressure sensor
10. KDPF differential pressure sensor port
11. KDOC unit
12. Hanger bracket
13. Sensor bracket
14. Sensor bracket band
15. Water drain port
A: From KVGT
B: Exhaust
C: Water drain
• The KDPF consists of the following components: inlet unit (1) to introduce exhaust gas, KDOC unit (11)
that houses an oxidation catalyst, KCSF unit (4) that houses a soot collecting filter with a catalyzer, and
outlet unit (7) that sends out exhaust gas and has a "dam" to prevent rain water from entering KCSF unit
(4).
• KDOC unit (11) consists of a ceramic honeycomb coated with oxidation calatyst material.

PC210LC-10 10-23
10 Structure and function
KDPF

• The ceramic honeycomb supports the oxidization of NO (nitrogen monoxide) into NO 2 (nitrogen dioxide),
and also contributes to burn the injected fuel during automatic regeneration and manual stationary
regeneration (*1).
• The ceramic honeycomb is guarded by a mat made of special fiber to prevent damage caused by engine
and machine vibrations.
• The mat also prevents overheating of the KDPF outer periphery by insulating the heat generated at the
ceramic honeycomb during operation.
• KCSF unit (4) also consists of a ceramic honeycomb coated with oxidation catalyst material, like the
KDOC unit (11). This ceramic honeycomb collects soot.
• Inside the KCSF, there are many cells partitioned by ceramic walls. Cells plugged at the inlet side and
cells plugged at the outlet side are alternately arranged.
• Three temperature sensors and one differential pressure sensor (an integrated KDPF differential pressure
and KDPF outlet pressure sensor) are installed to the KDPF.
• Temperature signals from the three temperature sensors are used in combination to monitor the KDOC
and KCSF operations and to perform various troubleshootings.
• The differential pressure sensor detects the amount of soot deposited in the KCSF by sensing the
pressure difference across the KCSF. Like the temperature sensors, this sensor is also used for various
troubleshootings.
*1: Soot is cleaned (oxidized) during the process.
k During engine operation and for a while after engine shutdown, the surface of the KDPF and
adjacent pipings are very hot. When working near the KDPF, be careful not to get burned.

Function (ENG107-A9H0-042-K-00-A)

A: Flow of exhaust gas


1. KDOC (oxidation catalyzer)
2. KCSF
3. Plug (ceramic)
4. Cell
5. Ceramic honeycomb

10-24 PC210LC-10
10 Structure and function
KDPF

• The KDPF is installed to meet the very strict requirements of the latest exhaust gas regulation. The KDPF
purifies the exhaust gas by catching most of the PM (Particulate Matter such as soot) included in the
exhaust gas from the engine.
• KCSF (2) is made of ceramic. Inside the KCSF, there are many cells partitioned by ceramic walls. Cells
plugged at the inlet side and cells plugged at the outlet side are alternately arranged.
• The soot deposited in KCSF (2) is naturally oxidized and burned away by the effect of KDOC (1), in
operating conditions with relatively high exhaust gas temperatures. (This is referred to as "passive
regeneration".)
• When the exhaust temperature is relatively low, in conditions such as continued low load operations, the
deposit of soot in KCSF (2) increases.
• The engine controller continuously monitors the amount of deposited soot by estimating from the
operating conditions and calculating based on the KCSF differential pressure sensor signals.
• When the soot deposit exceeds a certain level, and the engine is operated with the exhaust gas
temperature exceeding a certain level, the engine controller executes "automatic regeneration" to burn
(oxidize) the soot.
• During automatic regeneration, the engine controller automatically controls the fuel injection timing and
the KVGT to raise the exhaust temperature. This is referred to as "exhaust temperature-raising control".
• As the exhaust temperature increases, the engine controller automatically performs calculations based on
the exhaust temperature at the KDOC inlet and flow of the exhaust gas, so that KCSF (2) can efficiently
burn (oxidize) the soot.
• KDOC (1) burns (oxidize) soot by utilizing the catalyzer.
• Automatic regeneration is not performed when regeneration is executed from the machine monitor, or
when the outside air temperature is extremely low, and when the exhaust gas temperature is not high
enough to burn soot because the engine has been operated at low loads for a while. Thus, soot deposit in
KCSF (2) will increase.
• If the soot deposit in KCSF (2) exceeds a certain level, it will be necessary to perform "manual stationary
regeneration" to burn away (oxidize) the soot.
• If the soot deposit exceeds the acceptable level, the exhaust gas flow will be restricted. This can increase
fuel consumption, degrade engine combustion, or cause other problems.
• If the soot deposit exceeds the limit to safely perform "manual stationary regeneration", the KDPF fails and
replacement becomes unavoidable. Make sure to follow the procedures in the Operation and
Maintenance Manual when performing "manual stationary regeneration".
Types of regeneration (WA380-A9H0-042-K-00-A)

a Regeneration refers to a process of purifying (oxidizing) the soot deposited in the soot collecting filter
(KCSF) inside the KDPF.
1. Passive regeneration
When the exhaust temperature is relatively high, the catalyst effect of the KDOC to oxidize soot will be
stronger and the soot deposit in the KCSF will be naturally burned away.
2. Active regeneration
1) Automatic regeneration
If the soot deposit exceeds a certain level, the engine controller switches to exhaust temperature-
raising control (*1), performs fuel dosing (*2), and automatically starts the regeneration process.
Another type of automatic regeneration is performed by the engine controller at certain intervals,
regardless of the amount of soot deposited in the KCSF.
*1: The fuel injection timing and the KVGT are controlled to raise the exhaust temperature.
*2: Fuel is injected to increase the exhaust temperature and accelerate the regeneration process. No.
1, 2, and 3 injectors are used for fuel dosing.
2) Manual stationary regeneration
When the exhaust temperature does not reach a certain level due to the machine operating condition,
or when regeneration is disabled by the operator, automatic regeneration will not be performed and the
soot deposit in the KCSF may increase. In such conditions, the machine monitor displays a manual
stationary regeneration request on the screen. The operator must perform regeneration by operating
the machine monitor on its screen. A regeneration feature is also provided for the technician who
should use this feature from the machine monitor menu after engine controller replacement, KDPF
replacement, and KCSF ash cleaning. (= Regeneration for service)
• A KDPF drying feature is provided to prevent excessive accumulation of unburned fuel in the KDPF
when the machine is operated for a long time with low exhaust temperature.

PC210LC-10 10-25
10 Structure and function
KDPF

• When certain conditions are met, the engine controller automatically switches control to increase
the exhaust temperature to dry the KCSF. If some of the conditions for automatic drying are not met,
manual stationary regeneration may be requested.
a Follow the procedures in the Operation and Maintenance Manual when starting and stopping
KDPF regeneration.
a Be sure to use ultra-low-sulfur diesel fuel. Non-specified fuels may cause KDPF failure.
a Be sure to use the specified Komatsu genuine oil for the KDPF. Non-specified oils may cause
KDPF clogging in a short time, resulting in increased fuel consumption or KDPF failure.
a Do not modify the KDPF itself or exhaust pipes. Modifications disturb normal operation of the
KDPF, leading to a failure.
a Do not apply impacts to the KDPF by stepping on, dropping, or striking it. The KDPF contains a
ceramic honeycomb, which can be damaged by strong impacts.
a The engine controller performs automatic regeneration even when the amount of soot deposit is
low. Since this is programmed to maintain the KDPF performance, this is normal.
a During automatic regeneration and manual stationary regeneration, the KVGT automatically
operates and the engine sound changes. The flow of exhaust gas through the KDPF changes
and the exhaust sound changes, but this is normal.
a During automatic regeneration and manual stationary regeneration, especially at low
temperatures, white smoke may come out from the exhaust pipe for a short time, but this is
normal. Be sure to perform regeneration at a well ventilated place since carbon monoxide can
be produced.
a During automatic regeneration and manual stationary regeneration, a strange odor may be
smelled from the exhaust pipe, but this is normal.
a During automatic regeneration and manual stationary regeneration, the exhaust temperature at
the exhaust pipe can exceed 650 °C. Make sure that there is no flammable material near the
exhaust system to prevent fire. Make sure that nobody is standing in front of the exhaust pipe,
and pay sufficient attention to safety of the environment.
a KDPF temperature values are shown below for reference.
DOC_In (KDOC inlet DOC_Out (KDOC outlet KDPF_Out (KDPF outlet
temperature sensor) temperature sensor) temperature sensor)
Not regenerating (idling) 100 to 250 °C
Regenerating (under
exhaust temperature-raising 100 to 250 °C 400 to 550 °C
control: 1,000 rpm)

10-26 PC210LC-10
10 Structure and function
Cooling system

Cooling system (PC200_10-B000-041-K-00-A)

1. Reservoir tank
2. Oil cooler
3. Radiator cap

PC210LC-10 10-27
10 Structure and function
Cooling system

4. Radiator
5. Aftercooler
6. Fuel cooler inlet
7. Fuel cooler
8. Fuel cooler outlet
9. Condenser
10. Air conditioner condenser switching bracket
11. Oil cooler inlet
12. Aftercooler outlet hose
13. Fan guard
14. Radiator inlet hose
15. Oil cooler outlet
16. Aftercooler inlet hose
17. Shroud
18. Fan
19. Radiator outlet hose
20. Radiator drain plug
Specifications (PC200_10-B000-030-K-00-A)

Radiator Oil cooler Aftercooler Fuel cooler


Core type Aluminum wave type Drawn cup
CF90-4 CF91
4 rows
Fin pitch (mm) 3.5/2 3.5/2 3.5/2 4.0/2
Total heat
dissipation area (m2) 60.87 10.61 x 2 9.98 0.30
Pressure valve
cracking pressure 0.05 {0.5} — — —
(MPa {kg/cm2})
Vacuum valve
cracking pressure –0.005 {-0.05} — — —
(MPa {kg/cm2})

10-28 PC210LC-10
10 Structure and function
Power train system

Power train (ALL-C100-001-K-00-A)

Power train system (PC220-C100-041-K-00-A)

1. Control valve
1a. Self-pressure reducing valve
1b. Merge-divider valve
1c. Travel junction valve
2. Main pump
3. Engine
4. Travel motor
5. Final drive
6. Swing motor
6a. Swing 2-stage relief valve
7. Center swivel joint
8. Idler

PC210LC-10 10-29
10 Structure and function
Power train system

9. PPC lock solenoid valve


10. 2-stage relief solenoid valve
11. Swing brake solenoid valve
12. Travel speed increase solenoid valve
13. Travel junction solenoid valve
14. Swing 2-stage relief solenoid valve
15. Attachment selector solenoid valve (a machine ready for installing attachments)
16. Swing machinery
17. Swing circle

10-30 PC210LC-10
10 Structure and function
Swing circle

Swing circle (PC200_10-J110-041-K-00-A)

1. Swing circle pinion grease filler port


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

Reduction ratio -96 / 13 = -7.385


Grease G2-LI
Grease quantity (l) 14.6

PC210LC-10 10-31
10 Structure and function
Swing machinery

Swing machinery (PC200_10-J130-041-K-00-A)

1. Swing pinion (number of teeth: 13)


2. No. 2 planetary carrier
3. No. 2 sun gear (number of teeth: 18)

10-32 PC210LC-10
10 Structure and function
Swing machinery

4. No. 2 planetary gear (number of teeth: 19)


5. No. 1 planetary carrier
6. No. 1 planetary gear (number of teeth: 20)
7. Swing motor
8. Breather
9. Oil level gauge doubling oil filler port cap
10. No. 1 sun gear (number of teeth: 17)
11. Ring gear (number of teeth: 58)
12. Swing machinery case
13. Drain plug
Specification (PC200_10-J130-030-K-00-A)

Reduction ratio ((17 + 58)/17) x ((18 + 58)/18) = 18.627


Swing reduction ratio 18.627 x (96/13) = 137.553
Swing speed
12.4
(rpm)

PC210LC-10 10-33
10 Structure and function
Final drive

Final drive (PC220-DF10-041-K-00-A)

1. Level plug
2. No. 1 planetary gear (number of teeth: 42)
3. Drain plug

10-34 PC210LC-10
10 Structure and function
Final drive

4. No. 1 sun gear shaft (number of teeth: 10)


5. No. 2 sun gear (number of teeth: 21)
6. No. 1 planetary carrier
7. Cover
8. Ring gear (number of teeth: 95)
9. No. 2 planetary carrier
10. Ring nut
11. Hub
12. Sprocket
13. Floating seal
14. Travel motor
15. No. 2 planetary gear (number of teeth: 36)
Specifications (PC220-DF10-030-K-00-A)

Reduction ratio -((10 + 95)/10) x ((21 + 95)/21) + 1 = -57.000

PC210LC-10 10-35
10 Structure and function
Track frame and idler cushion

Undercarriage and frame (ALL-DT00-001-K-00-A)

Track frame and idler cushion (PC200_10-DT20-041-K-00-A)

1. Idler
2. Track frame
3. Carrier roller
4. Final drive
5. Track roller
6. Track shoe
7. Center guard
8. Idler cushion
9. Front guard

10-36 PC210LC-10
10 Structure and function
Track frame and idler cushion

Specification (PC200_10-DT20-030-K-00-A)

• Number of track rollers


Model Quantity (each side)
PC210LC–10 9
• Standard shoe
Model PC210LC-10
Shoe width (mm) 700
Link pitch (mm) 190
Number of shoes (each side) 49

PC210LC-10 10-37
10 Structure and function
Hydraulic equipment layout drawing

Hydraulic system (ALL-C000-001-K-00-A)

Hydraulic equipment layout drawing (PC220-C000-04D-K-00-A)

1. Bucket cylinder

10-38 PC210LC-10
10 Structure and function
Hydraulic equipment layout drawing

2. Arm cylinder
3. R.H. PPC valve for work equipment
4. Swing motor
5. Hydraulic tank
6. Main pump
7. Control valve
8. Accumulator (for PPC circuit)
9. Oil cooler
10. Travel motor
11. Solenoid valve
12. L.H. PPC valve for work equipment
13. Attachment 2 PPC valve (*1)
14. Travel PPC valve
15. Attachment 1 PPC valve (*1)
16. Center swivel joint
17. Boom cylinder
*1: Machine ready for installation of attachment

PC210LC-10 10-39
10 Structure and function
Valve control

Valve control (PC-PK01-041-K-00-A)

1. Attachment 1 control pedal (*1)


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

10-40 PC210LC-10
10 Structure and function
Valve control

14. Travel PPC valve


15. Travel pedal
16. Attachment 1 PPC valve (*1)
17. Lock pin (*1)
*1: Machine ready for installation of attachment

PC210LC-10 10-41
10 Structure and function
Hydraulic tank

Hydraulic tank (PC200_10-PM30-041-K-00-A)

1. Main pump
2. Hydraulic tank
3. Filler cap
4. Sight gauge
5. Drain plug
6. Bypass valve
7. Strainer
8. Filter element
9. Suction strainer
Specifications (PC220-PM30-030-K-00-A)

Hydraulic tank capacity (l) 190


Amount of oil in hydraulic tank (l) 132
Bypass valve set pressure (MPa {kg/cm2}) 0.15 ± 0.03 {1.5 ± 0.3}

10-42 PC210LC-10
10 Structure and function
Hydraulic tank

Oil filler cap (PC-AD1C-041-K-00-A)

1. Filter element
2. Bottom plate
3. Gasket
4. Seam valve
5. Spring

Prevention of negative pressure in tank


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

Prevention of pressure rise in tank


• When the hydraulic circuit is working, the pressure in the hydraulic tank increases as the hydraulic
cylinders operate, and the oil level and temperature increase in the tank. If the pressure in the tank rises
above the set value, bottom plate (2) is pushed up to release the pressure in the tank.
(Exhaust valve set pressure: 16.7 ± 6.86 kPa {0.17 ± 0.07 kg/cm2 })

PC210LC-10 10-43
10 Structure and function
CLSS

CLSS (ALL-PNJ1-001-K-00-A)

CLSS: Abbreviation for Closed center Load Sensing System


Structure of CLSS (ALL-PNJ1-041-K-00-A)

CLSS: Abbreviation for Closed center Load Sensing System

Features
• Fine control not influenced by load
• Control performance that allows digging even when fine control operation is turned on
• Ease of combined operation enabled by the flow divider function that is determined by the opening areas
of spools during combined operations
• Energy saving by variable pump control

Configuration
• CLSS consists of variable capacity piston pump, control valve, and actuators.
• The main pump consists of pump itself, PC valve and LS valve.

10-44 PC210LC-10
10 Structure and function
CLSS

Basic principle

Pump swash plate angle control


• The pump swash plate angle (pump delivery) is controlled so that LS differential pressure (dPLS), which is
the difference between pump delivery pressure (PP) and LS pressure (PLS)) (load pressure of actuator) at
control valve outlet, is constant.
• [LS differential pressure (dPLS) = Pump delivery pressure (PP) - LS pressure (PLS)]

• The pump swash plate angle shifts toward the maximum position if LS differential pressure (dPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• If it becomes higher than the set pressure (when the actuator load pressure is low), the pump swash plate
angle shifts toward the minimum position.

PC210LC-10 10-45
10 Structure and function
CLSS

LS differential pressure (d
d PLS) and pump swash plate angle

a See “Main pump“ for the explanation of the operation.

Pressure compensation control

10-46 PC210LC-10
10 Structure and function
CLSS

• A pressure compensation valve is installed to the outlet port side of each control valve to balance the load
pressure.
• When actuators are operated in combination, the pressure difference (dP) between the upstream (inlet
port) and downstream (outlet port) of the spool of each valve becomes the same regardless the size of the
load (pressure).
• The flow of oil from the pump is divided (compensated) in proportion to the areas of openings (S1) and
(S2) of each valve.

System diagram
a The illustration shows the state when actuator (7) is relieved at the stroke end in the merge mode.

1. Front pump
2. Rear pump
3. Main relief valve
4. Unload valve
5. Merge-divider valve
6. Control valve

PC210LC-10 10-47
10 Structure and function
CLSS

7. Actuator
8. Pump circuit
9. LS circuit
10. Tank circuit
11. Valve
12. Spring
13. LS bypass plug
14. LS valve
15. PC valve

10-48 PC210LC-10
10 Structure and function
Main pump

Main pump (PC220-C200-041-K-00-A)

Model: HPV125 + 125

IMF: Front pump PC mode selector current


IMR: Rear pump PC mode selector current

PC210LC-10 10-49
10 Structure and function
Main pump

ISIG: LS set pressure selector current


PAF: Front pump delivery port
PAR: Rear pump delivery port
PBF: Front pump pressure input port
PD3R: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PENF: Front pump control pressure pickup port
PENR: Rear pump control pressure pickup port
PEPC: EPC source pressure input port
PEPB: EPC source pressure pickup port
PFC: Front pump delivery pressure pickup port
PLSF: Front pump load pressure input port
PLSFC: Front pump load pressure pickup port
PLSR: Rear pump load pressure input port
PLSRC: Rear pump load pressure pickup port
PMF: Front pump PC mode selector pressure pickup port
PMR: Rear pump PC mode selector pressure pickup port
PRC: Rear pump delivery pressure pickup port
PS: Pump suction port
PSIG: LS set selector pressure pickup port
1. Front pump
2. Rear pump
3. LS - EPC valve
4. Front pump PC - EPC valve
5. Rear pump PC - EPC valve
6. Rear pump PC valve
7. Rear pump swash plate sensor
8. Rear pump LS valve
9: Front pump LS valve
10. Front pump swash plate sensor
11: Front pump PC valve

10-50 PC210LC-10
10 Structure and function
Main pump

1. Front shaft
2. Cradle
3. Front case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. End cap
10. Rear shaft
11. Rear case
12. PC valve
13. Servo piston
14. Slider

PC210LC-10 10-51
10 Structure and function
Main pump

15. Spline
16. Bearing
17. LS valve
Outline
• This pump consists of two variable capacity swash plate piston pumps, PC valve, LS valve, EPC valve,
and swash plate sensor.

Function
• The pump converts the engine speed and torque transmitted to its shaft (1) into oil pressure and delivers
pressurized oil corresponding to the load.
• It is possible to change the delivery by changing the swash plate angle.

Structure
• Cylinder block (7) is supported to shaft (1) by spline (15).
• Shaft (1) is supported by each bearing (16) at the front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped together with shoe (5).
• Piston (6) and shoe (5) constitute a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) transmits high pressure oil to cylindrical surface (B) with cradle (2), which is secured to the
case, and forms a static pressure bearing when it slides.
• Piston (6) performs reciprocal motion in the axial direction inside each cylinder chamber of cylinder block
(7).
• Cylinder block (7) seals the pressurized oil to valve plate (8) and performs relative rotation.
• The oil pressure balance on the valve plate is maintained properly.
• The pressurized oil is sucked in and discharged from each cylinder chamber in cylinder block (7) through
valve plate (8).
Operation (PC220-C200-044-K-00-A)

• Cylinder block (7) rotates together with shaft (1) and shoe (5) slides on plane (A).
• Rocker cam (4) moves along cylindrical surface (B). As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7) changes.
• Angle (a) is called the swash plate angle.

• If swash plate angle (a) is made between center line (X) of rocker cam (4) and the axis of cylinder block (7),
plane (A) functions as a cam against shoe (5).
• Piston (6) reciprocates inside cylinder block (7) and a difference is made between volumes (E) and (F) in
cylinder block (7).
• Each piston (6) sucks and discharges oil by (F) - (E).
• Oil is discharged while cylinder block (7) rotates and the volume of chamber (E) decreases.
• The volume of chamber (F) grows larger and, in this process, the oil is sucked.

10-52 PC210LC-10
10 Structure and function
Main pump

• As center line (X) of rocker cam (4) matches the axis of cylinder block (7) (swash plate angle = 0), the
difference between volumes (E) and (F) inside cylinder block (7) equals 0.
• Suction and delivery of pressurized oil is not carried out in this state. Namely pumping action is not
performed. (Actually, however, the swash plate angle is not set to 0 deg.)

Control of delivery
• If swash plate angle (a) increases, the difference between volumes (E) and (F) increases, and pump
delivery (Q) increases.
• Swash plate angle (a) is changed by servo piston (13).
• Servo piston (13) moves in a linear reciprocating movement according to the signal pressure from the PC
valve and LS valve.
• This linear reciprocating movement is transmitted to rocker cam (4) through slider (14).
• Being supported by cradle (2) on the cylindrical surface, rocker cam (4) slides on the surface while
continuing revolving movement.
• Output pressure (PEN) of the LS valve is transmitted to the pressure chamber of the large diameter piston
side.
• The areas receiving the pressure on the right and left sides of servo piston (13) are different from each
other, and delivery pressure (self pressure) (PP) of the main pump is constantly transmitted to the
pressure chamber of the small diameter piston side.
• The movement of servo piston (13) is controlled by the relationship of pressure between small diameter
piston side (PP) and large diameter piston side (PEN) and by the ratio of the areas receiving the pressure
of the small diameter piston and large diameter piston.

PC210LC-10 10-53
10 Structure and function
Main pump

10-54 PC210LC-10
10 Structure and function
Main pump

LS valve (PC-C2J0-041-K-00-A)

LS: Abbreviation for Load Sensing

PA: Pump port


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

Function (PC-C2J0-042-K-00-A)
• The LS (load sensing) valve detects the load and controls the pump delivery.
• This valve controls main pump delivery (Q) according to differential pressure (dPLS) [= PP - PLS], called
the LS differential pressure (the difference between main pump delivery pressure (PP) and control valve
outlet port pressure (PLS)).
• This valve receives main pump delivery pressure (PP), pressure (PLS) (called the LS pressure) coming
from the control valve output, and pressure (PSIG) (called the LS set selector pressure) from the
proportional solenoid valve.
• The relation between the pump delivery (Q) and the differential pressure (dPLS) [= (PP) - (PLS)] between
the main pump pressure (PP) and LS pressure (PLS) is changed by the LS set pressure selector current
(ISIG) of the LS-EPC valve as shown in the figure below.
• When the (ISIG) changes from 0 A to 1 A, the spring setting force will change accordingly, to let the center
of the standard value range of the pump delivery selector point vary within the range from 0.27 MPa {2.78
kg/cm2} to 1.7 MPa {17.75 kg/cm2}.

PC210LC-10 10-55
10 Structure and function
Main pump

Operation (PC-C2J0-044-K-00-A)

When control valve is in “NEUTRAL“ position

• The LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) on the outlet of
control valve is transmitted to spring chamber (B), and pump delivery pressure (PP) is transmitted to port
(H) of sleeve (8).
• Magnitude of the force resulting from this LS pressure (PLS), force of spring (4) and the pump delivery
pressure (self pressure) (PP) determine the position of spool (6).

10-56 PC210LC-10
10 Structure and function
Main pump

• However, magnitude of the output pressure (PSIG) (called the LS set selector pressure) of the EPC valve
for the LS valve entering port (G) also changes the position of spool (6).(Setting force of the spring is
changed)
• Before the engine is started, servo piston (12) is pushed to the left. (See the following figure)
• If the control lever is at the neutral position when the engine is started, LS pressure (PLS) is set to 0 MPa
{0 kg/cm2}. (It is connected to the drain circuit through the control valve spool.)
• Spool (6) is pushed to the right, and port (C) and port (D) are connected.
• Pump delivery pressure (PP) is transmitted to the larger diameter end of the pump from the port (K).
• The same pump delivery pressure (PP) is transmitted to the smaller diameter end at the port (J).
• According to the area difference of servo piston (12), the servo piston is moved to the right, in the direction
which makes the swash plate angle minimum. (See the previous figure.)

PC210LC-10 10-57
10 Structure and function
Main pump

When pump delivery is increased

• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve opening area increases and
pump delivery pressure (PP) decreases), the combined force exerted by LS pressure (PLS) and spring (4)
pushes spool (6) to the left.
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain
pressure (PT). (PC valve operation will be explained later.)
• The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and
pump pressure (PP) is constantly transmitted to port (J) on the small diameter end. Accordingly, servo
piston (12) is pushed to the left and the swash plate is moved to increase the delivery.
• At this time, when the output pressure from the EPC valve for the LS valve is transmitted to port (G), a
force is applied on piston (7) to move the piston to the right.
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential
pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6)
are connected.

10-58 PC210LC-10
10 Structure and function
Main pump

When pump delivery is decreased

• When servo piston (12) moves to the right (the direction that reduces pump delivery) and LS differential
pressure (dPLS) increases (for example, when the control valve opening area decreases and pump
delivery pressure (PP) increases), the force exerted by pump delivery pressure (PP) pushes spool (6) to
the right.
• The movement of spool (6) transmits pump delivery pressure (PP) to the large diameter end of the piston
through port (C), port (D) and port (K).
• Pump delivery pressure (PP) is also transmitted to port (J) of the small diameter end of the piston, but
because of the difference in area between the large diameter end and the small diameter end on servo
piston (12), it is pushed to the right. As the result, the servo piston (12) moves into the direction of reducing
the swash plate angle.
• When the LS set selector pressure (PSIG) is transmitted to port (G), the spring (4) setting force is
weakened.

PC210LC-10 10-59
10 Structure and function
Main pump

When servo piston is balanced

• The symbols (A1), (A0) and (PEN) represent the area receiving the pressure at the large diameter end of
the piston, the area receiving the pressure at the small diameter end and the pressure transmitted to the
large diameter end of the piston, respectively.
• When the force exerted by main pump pressure (PP) of the LS valve is balanced with the combined force
exerted by LS pressure (PLS) and spring (4), and the relationship becomes (A0) x (PP) = (A1) x (PEN),
servo piston (12) stops in that position.
• The swash plate of the pump is held at the intermediate position. [The swash plate stops at a position
where the openings from port (D) to port (E) and from port (C) to port (D) of spool (6) are approximately
equal]
• The relationship between the area receiving the pressure at both ends of servo piston (12) is (A0) : (A1) =
3 : 5, and the pressures transmitted to both ends of the piston when the piston is balanced is (PP) : (PEN)
C 5 : 3.
• The force of spring (4) is adjusted so that spool (6) can be balanced at the specified center when (PP) -
(PLS) = 1.7 MPa {17.75 kg/cm2}.
• When (PSIG) [LS-EPC valve output pressure, 0 to 2.9 MPa {0 to 30 kg/cm 2}] is transmitted to port (G), the
balanced position changes in proportion to the (PSIG) pressure within a range of (PP) - (PLS) = 1.7 MPa
{17.75 kg/cm2} to 0.27 MPa {2.78 kg/cm2}.

10-60 PC210LC-10
10 Structure and function
Main pump

PC valve (PC-C2K0-041-K-00-A)

PC: Abbreviation for Pressure Compensation

PA: Pump port


PA2: Pump pressure pilot port
PDP: Drain port
PM: Mode selector pressure pilot port
PPL: Control pressure output port (to LS valve)
1. Plug
2. Servo piston assembly
3. Pin
4. Spool
5. Retainer
6. Seat
7. Cover
8. Wiring

Function (PC-C2K0-042-K-00-A)
• The PC valve limits the oil flow to a certain level (depends on the delivery pressure) even if the travel of
the control valve is increased extremely. This is to ensure the horsepower absorbed by the pump not to
exceed the engine horsepower, when pump delivery pressures (PP1) (self pressure) and (PP2) (other
pump's pressure) are high.
• If the pump delivery pressure (PP) increases due to increased load during work, this valve decreases the
pump delivery.
• And if the pump delivery pressure goes low, it increases the pump delivery.
• The relation between the average delivery pressure of front and rear pumps [(PP1) + (PP2)] / 2 and pump
delivery (Q) is as shown in the following figure, as a parameter for each current (X) value applied to the
PC-EPC valve solenoid.
• The controller continues counting the actual engine speed.
• If the engine speed is slowed down due to increased load, the controller reduces the pump delivery to
recover the speed.
• When the load increases and the engine speed decreases below a preset value, the controller increases
the command current to the PC-EPC valve solenoid depending on the amount of engine speed decrease,
to decrease the swash plate angle.

PC210LC-10 10-61
10 Structure and function
Main pump

Operation (PC-C2K0-044-K-00-A)

When the pump controller is normal

When load on the actuator is small and pump pressures (PP1) and (PP2) are low

Actuation of PC-EPC valve solenoid (1)


• Command current (X) from the pump controller flows to the PC-EPC valve solenoid (1).
• This command current (X) acts on the PC-EPC valve to generate signal pressure to vary the force pushing
piston (2).

10-62 PC210LC-10
10 Structure and function
Main pump

• Spool (3) stops at a position where the combined force exerted by springs (4) and (6) is equalized to the
combined force exerted by pump pressure (PP1) (self pressure) and pump pressure (PP2) (other pump's
pressure) acting on spool (3).
• Depending on this position, the pressure output from the PC valve [port (C) pressure] varies.
• The amperage of the command current (X) depends on the type of work (lever operation), work mode
selection, engine speed setting, and the actual engine speed.
a Other pump's pressure denotes the pressure of the pump situated on the opposite side.
For the front pump pressure, the other pump's pressure is that of the rear pump. And for the rear pump
pressure, the other pump's pressure is that of the front pump.

Action of spring
• The spring force of springs (4) and (6) in the PC valve depends on the position of the swash plate.
• When servo piston (9) moves to the right, spring (6) is compressed.
• When the piston moves further to the right, the piston comes in contact with seat (5) and spring (6) is fixed.
• Then, only spring (4) operates.
• When servo piston (9) compresses or decompresses springs (4) and (6), the spring force varies.
• When the command current (X) input to PC-EPC valve solenoid (1) varies, the thrust pushing piston (2)
varies.
• The spring forces of springs (4) and (6) are also varied by the PC-EPC valve solenoid command current
(X).
• Port (C) on the PC valve is connected to port (E) on the LS valve.
• Self pressure (PP1) is transmitted to the small diameter end of servo piston (9) and port (B), and other
pump's pressure (PP2) is transmitted to port (A).
• When pressures (PP1) and (PP2) are low, spool (3) is on the left.

PC210LC-10 10-63
10 Structure and function
Main pump

• Port (C) and port (D) are connected, and the pressure entering the LS valve becomes drain pressure (PT).
• When port (E) of the LS valve is connected to port (G), the pressure from port (J) entering the large
diameter end of the piston becomes drain pressure (PT), and servo piston (9) moves to the left.
• The pump delivery goes to increase.
• Springs (4) and (6) extend according to the movement of servo piston (9), and the reaction force of spring
decreases.
• When the reaction force of spring decreases, spool (3) moves to the right. Ports (C) is disconnected from
port (D), and pump delivery pressure port (B) is connected to port (C).
• Since the pressure in port (C) and the pressure at the large diameter side of the piston increase, servo
piston (9) stops moving to the left.
• Accordingly, the stop position (= pump delivery) of servo piston (9) is determined by the position where the
force exerted by pressures (PP1) and (PP2), the thrust generated by the PC-EPC valve solenoid, and the
force exerted by springs (4) and (6) acting on the spool (3) are balanced.

When load on the actuator is large and pump pressures (PP1) and (PP2) are high

Outline
• When the load is large and the pump delivery pressures (PP1) and (PP2) are high, the thrust moving
spool (3) to the right increases, and spool (3) comes to a position as shown above.
• The pressure from port (C) to the LS valve becomes approximately half of pump pressure (PP2), because
a part of the pressure from port (B) flows through the LS valve and port (C) to port (D), as shown above.
• When spool (3) moves to the left, the opening of ports (C) and (D) widens.
• The pressure in port (C) (=J) decreases, and the movement of servo piston (9) to the right stops.

10-64 PC210LC-10
10 Structure and function
Main pump

• Servo piston (9) stops at a position further to the right than the position when pump pressures (PP1) and
(PP2) are low.

Operation
• When ports (E) and (G) of the LS valve are connected, the pressure is transmitted from port (J) to the
large diameter end of servo piston (9), and servo piston (9) stops moving.
• When pump pressure (PP2) increases more and spool (3) moves further to the right, pump pressure (PP1)
flows to port (C) to minimize the pump delivery.
• When servo piston (9) moves to the right, springs (4) and (6) are compressed, and spool (3) is pushed
back.
• The relationship between the average pump pressure (PP1 + PP2)/2 and servo piston (9) in terms of their
positions can be represented by the polygonal line in the figure because springs (4) and (6) form the 2-
stage springs.
• The relationship between the average pump pressure (PP1 + PP2)/2 and average pump delivery (Q)
becomes as shown below.

• If command current (X) sent to PC-EPC valve solenoid (1) increases further, the relationship between
average pump pressure (PP1 + PP2)/2 and pump delivery (Q) is shifted parallel in proportion to the thrust
of PC-EPC valve solenoid.
• Namely, the thrust of PC-EPC valve solenoid (1) is added to the pushing force to the right because of the
pump pressure transmitted to the spool (3), so the relationship between the average pump pressure (PP1
+ PP2)/2 and the pump delivery (Q) moves from (A) to (B) as the command current (X) is increased.

PC210LC-10 10-65
10 Structure and function
Main pump

When the pump controller malfunctions and the emergency pump drive switch is at “ON“ position

When load on the main pump is small

• If the pump controller fails, turn the emergency pump drive switch to "ON" position to select the resistor
side.
• In this case, power is taken directly from the battery, however, the current is too high as is, a resistor is
needed to control the current supplied to PC-EPC valve solenoid (1).
• Since the current is constant, the thrust applied to piston (2) is constant.
• When main pump pressures (PP1) and (PP2) are low, the combined force exerted by PC-EPC valve
solenoid (1) thrust and the pump pressure is smaller than the combined force exerted by the springs.
Spool (3) stays balanced at the left.
• Port (C) is connected to port (D) at drain pressure, and the pressure at the large diameter end of servo
piston (9) comes to drain pressure (PT) through the LS valve.
• Since the pressure at the small diameter end of the piston is large, servo piston (9) moves in the direction
to increase the delivery.

10-66 PC210LC-10
10 Structure and function
Main pump

When load on the main pump is large

• As mentioned before, when the emergency pump drive switch is turned to "ON" position, the command
current (X) sent to PC-EPC valve solenoid (1) is constant.
• Therefore, the thrust applied by piston (2) to spool (3) comes to constant.
• When main pump pressures (PP1) and (PP2) increase, spool (3) moves to a position further to the right
than when the main pump load is small, and stays balanced as shown above.
• Since the pressure from port (B) flows into port (C), servo piston (9) moves to the right (delivery
decreases), and stops at a position further to the right than when the pump load is small.
• When the emergency pump drive switch is turned to "ON" position, the curve indicating the relation
between the pump delivery pressure (PP) and delivery (Q) is plotted in accordance with the current
supplied through the resistor to the PC-EPC valve solenoid.
• When the emergency pump drive switch is turned to "ON" position, the curve is plotted as (B), which is
shifted toward the left than curve (A) for a normal pump controller.

PC210LC-10 10-67
10 Structure and function
Main pump

10-68 PC210LC-10
10 Structure and function
Main pump

LS (PC)-EPC valve (PC200_10-C2M0-041-K-00-A)

LS: Abbreviation for Load Sensing


PC: Abbreviation for Pressure Compensation
EPC: Abbreviation for Electromagnetic Proportional Control

C: To LS (PC) valve
P: From self-pressure reducing valve
T: To hydraulic tank
1. Connector
2. Coil
3. Valve body
4. Spring
5. Spool
6. Rod
7. Plunger

PC210LC-10 10-69
10 Structure and function
Main pump

Function (PC-C2M0-042-K-00-A)
• The EPC valve consists of the proportional solenoid and the hydraulic valve.
• When the EPC valve receives signal current (i) from the controller, it develops EPC output pressure
proportional to the amperage of the current and supplies the pressure to the control valve.

10-70 PC210LC-10
10 Structure and function
Main pump

Operation (PC-C2M0-044-K-00-A)

When signal current is zero amp. (coil is de-energized)

• When the signal current from the controller is not flowing through coil (2), coil (2) is de-energized.
• Spool (5) is pushed to the left side by spring (4).
• Port (P) is closed, and the pressurized oil from the self-pressure reducing valve does not flow to the LS
(PC) valve.
• The pressurized oil from the LS (PC) valve is drained to the tank through port (C) and then port (T).

PC210LC-10 10-71
10 Structure and function
Main pump

When signal current is minute (coil is energized)

• When a small signal current flows through coil (2), coil (2) is energized and a thrust pushing plunger (7) to
the right is generated.
• Rod (6) pushes spool (5) to the right, and the pressurized oil flows from port (P) to port (C).
• The pressure at port (C) increases and the total of the force applied to the surface of spool (5) and the
reaction force exerted by spring (4) becomes larger than the thrust of plunger (7).
• Spool (5) is pushed to the left, and port (P) is shut off from port (C).
• Port (C) connects to port (T).
• Spool (5) moves to a position where the thrust of plunger (7) becomes equal to the total of the force
exerted by pressure at port (C) and the reaction force exerted by spring (4).
• The circuit pressure between the EPC valve and LS (PC) valve is controlled in proportion to the amperage
of signal current.

10-72 PC210LC-10
10 Structure and function
Main pump

When signal current is maximum (coil is energized)

• Coil (2) is energized when signal current is supplied to coil (2).


• As the amperage of signal current is maximum, the thrust of plunger (7) is also maximized.
• Spool (5) is pushed to the right by rod (6).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and LS (PC) valve is maximized.
• Port (T) closes, and no pressurized oil flows to the tank.

PC210LC-10 10-73
10 Structure and function
Control valve

Control valve (PC200_10-C030-041-K-00-A)

a In this section, only the 7-spool valve (6-spool valve + service valve) is shown.

A1: To bucket cylinder head


A2: To L.H. travel motor

10-74 PC210LC-10
10 Structure and function
Control valve

A3: To boom cylinder bottom


A4: To swing motor
A5: To R.H. travel motor
A6: To arm cylinder head
A-1: To attachment
ATT: From attachment
B1: To bucket cylinder bottom
B2: To L.H. travel motor
B3: To boom cylinder head
B4: To swing motor
B5: To R.H. travel motor
B6: To arm cylinder bottom
B-1: To attachment
BP1: From LS select solenoid valve
BP5: From attachment selector solenoid valve
C: To oil cooler
P1: From R.H. work equipment PPC valve (bucket DUMP)
P2: From R.H. work equipment PPC valve (bucket CURL)
P3: From travel PPC valve (L.H. travel REVERSE)
P4: From travel PPC valve (L.H. travel FORWARD)
P5: From R.H. work equipment PPC valve (boom RAISE)
P6: From R.H. work equipment PPC valve (boom LOWER)
P7: From L.H. work equipment PPC valve (swing RIGHT)
P8: From L.H. work equipment PPC valve (swing LEFT)
P9: From travel PPC valve (R.H. travel REVERSE)
P10: From travel PPC valve (R.H. travel FORWARD)
P11: From L.H. work equipment PPC valve (arm OUT)
P12: From L.H. work equipment PPC valve (arm IN)
P-1: From R.H. attachment PPC valve
P-2: From R.H. attachment PPC valve
PLS1: To rear pump LS valve
PLS2: To front pump LS valve
PLSC: LS pressure pickup port
PP1: From rear pump
PP2: From front pump
PP1S: Front pump oil pressure sensor mounting port
PPC: Pilot source pressure pickup port
PP2S: Rear pump oil pressure sensor mounting port
PPS2: To front pump LS valve
PR: To solenoid valve, PPC valve, and EPC valve
PST: From travel junction solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
T: To hydraulic tank
T1: To hydraulic tank
TS: To hydraulic tank
TSW: From swing motor

PC210LC-10 10-75
10 Structure and function
Control valve

IS1: Pump merge-divider EPC valve (for main spool) drive signal
IS2: Pump merge-divider EPC valve (for LS spool) drive signal
IS3: Variable back pressure solenoid valve drive signal
1. Variable back pressure valve
2: Variable back pressure solenoid valve
3. Pump merge-divider EPC valve (for LS spool)
4. Pump merge-divider EPC valve (for main spool)
5. Arm hydraulic drift prevention valve (if equipped)
6. Boom hydraulic drift prevention valve
7. Service valve
8. Cover A
9. 7-spool valve
10. Arm quick return valve
11. Cover B
12. Merge-divider valve

10-76 PC210LC-10
10 Structure and function
Control valve

1. Pressure compensation valve (arm OUT)


2. Pressure compensation valve (R.H. travel REVERSE)
3. Pressure compensation valve (swing RIGHT)
4. Pressure compensation valve (boom RAISE)

PC210LC-10 10-77
10 Structure and function
Control valve

5. Pressure compensation valve (L.H. travel REVERSE)


6. Pressure compensation valve (bucket DUMP)
7. Pressure compensation valve (service)
8. Pressure compensation valve (bucket CURL)
9. Pressure compensation valve (L.H. travel FORWARD)
10. Pressure compensation valve (boom LOWER)
11. Pressure compensation valve (swing LEFT)
12. Pressure compensation valve (R.H. travel FORWARD)
13. Pressure compensation valve (arm IN)
14. Main relief valve
15. Unload valve
16. Main relief valve
17. Spool (service)
18. Spool (bucket)
19. Spool (L.H. travel)
20. Spool (boom)
21. Spool (swing)
22. Spool (R.H. travel)
23. Spool (arm)

10-78 PC210LC-10
10 Structure and function
Control valve

1. Suction valve (arm OUT)


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

PC210LC-10 10-79
10 Structure and function
Control valve

10. Suction safety valve (boom LOWER)


11. Suction valve (R.H. travel FORWARD)
12. Suction safety valve (arm IN)
13. LS shuttle valve (arm)
14. LS shuttle valve (R.H. travel)
15. LS selector valve
16. LS shuttle valve (boom)
17. LS shuttle valve (L.H. travel)
18. LS shuttle valve (bucket)
19. LS shuttle valve (service)
20. LS check valve

10-80 PC210LC-10
10 Structure and function
Control valve

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

Arm valve
5. Arm hydraulic drift prevention valve (if equipped)
6. LS shuttle valve
7. Arm quick return valve
8. Pressure compensation valve (IN)

PC210LC-10 10-81
10 Structure and function
Control valve

9. Spool
10. Suction safety valve (IN)
11. Cooler check valve
12. Regeneration circuit check valve
13. Suction valve (OUT)
14. Pressure compensation valve (OUT)

R.H. travel valve


15. LS shuttle valve
16. Pressure compensation valve (FORWARD)
17. Spool
18. Suction valve (FORWARD)
19. Suction valve (REVERSE)
20. Pressure compensation valve (REVERSE)

Swing valve
21. LS selector valve
22. Pressure compensation valve (L.H.)
23. Spool
24. Pressure compensation valve (R.H.)

10-82 PC210LC-10
10 Structure and function
Control valve

1. Return spring
2. Merge-divider valve (for LS)
3. Valve (sequence valve)
4. Spring (sequence valve)
5. Merge-divider valve (main)
6. Return spring

Boom valve
7. Boom hydraulic drift prevention valve
8. LS shuttle valve

PC210LC-10 10-83
10 Structure and function
Control valve

9. Pressure compensation valve (LOWER)


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

L.H. travel valve


15. Merge-divider valve (travel junction valve)
16. Return spring
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 (CURL)
25. Spool
26. Suction safety valve (CURL)
27. Suction safety valve (DUMP)
28. Pressure compensation valve (DUMP)

10-84 PC210LC-10
10 Structure and function
Control valve

Service valve
1. LS shuttle valve
2. Pressure compensation valve
3. Spool
4. 2-stage suction safety valve
5. Suction safety valve
6. Unload valve
7. Main relief valve
8. LS bypass plug

Structure
• The control valves of the following types are set.
6-spool valve (without service valve)
7-spool valve (6-spool valve with service valve)
• This control valve consists of a 6-spool valve (unit type) and a set of service valve. A merge-divider valve,
a variable back pressure valve and a boom hydraulic drift prevention valve are installed to it.
• Since all the valves are assembled together with connecting bolts and their passes are connected to each
other inside the assembly, the assembly is compact and easy to maintain.
• With one spool provided for one work equipment, this control valve is simple in structure.

PC210LC-10 10-85
10 Structure and function
Control valve

Hydraulic circuit diagram and names of valves (PC200_10-C030-054-K-00-A)

1. Arm valve
2. R.H. travel valve

10-86 PC210LC-10
10 Structure and function
Control valve

3. Swing valve
4. Boom valve
5. L.H. travel valve
6. Bucket valve
7. Service valve
8. Arm valve spool
9. R.H. travel valve spool
10. Swing valve spool
11. Boom valve spool
12. L.H. travel valve spool
13. Bucket valve spool
14. Service spool
15. Pressure compensation valve
16. Suction valve
17. Check valve (for boom regeneration circuit)
18. Check valve (for arm regeneration circuit)
19. Pump merge-divider EPC valve (for LS spool)
20. Pump merge-divider EPC valve (for main spool)
21. LS shuttle valve
22. LS bypass plug
23. LS selector valve
24. Merge-divider valve
25. Arm quick return valve
26. Arm hydraulic drift prevention valve (if equipped)
27. Self-pressure reducing valve
28. Travel junction valve
29. Variable back pressure valve
30: Variable back pressure solenoid valve
31. Cooler check valve
32. Boom hydraulic drift prevention valve
33. Main relief valve (for boom, L.H. travel, bucket, and attachment circuits)
Set pressure: 35.4 ± 0.5 MPa {360.5 ± 5 kg/cm2}
When one-touch power max. switch is set to ON position: 38.0 ± 0.5 MPa {387 ± 5 kg/cm 2}
34. Main relief valve (for arm, R.H. travel, and swing circuits)
Set pressure: 35.4 ± 0.5 MPa {360.5 ± 5 kg/cm2}
When one-touch power max. switch is set to ON position: 38.0 ± 0.5 MPa {387 ± 5 kg/cm 2}
35. Unload valve (for boom, L.H. travel, bucket, and attachment circuits)
Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
36. Unload valve (for arm, R.H. travel, and swing circuits)
Cracking pressure: 2.5 ± 0.5 MPa {26 ± 5 kg/cm2}
37. Suction safety valve
Set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}
38. Suction safety valve
Set pressure: 38.9 ± 0.5 MPa {397 ± 5 kg/cm2}
39. Suction safety valve
Set pressure: 31.4 ± 0.5 MPa {320 ± 5 kg/cm2}
40. Suction 2-stage safety valve

PC210LC-10 10-87
10 Structure and function
Control valve

1st stage set pressure: 24.5 ± 0.5 MPa {250 ± 5 kg/cm2}


2nd stage set pressure: 20.6 ± 0.5 MPa {210 ± 5 kg/cm2}
41. Safety valve for hydraulic drift prevention valve
Set pressure: 38.9 ± 0.5 MPa {397 ± 5 kg/cm2}

10-88 PC210LC-10
10 Structure and function
Control valve

Unload valve (PC220-PQD5-041-K-00-A)

1. LS circuit
2. Valve
3. Pump circuit
4. Tank circuit
5. Spring

Function (PC220-PQD5-042-K-00-A)
• When all control valves are at HOLD, this valve serves to drain as same amount of oil as the pump
delivery with swash plate angle at the minimum.
• The pump pressure becomes the pressure corresponding to the set load of spring (5) in the valve (referred
to as P1).
• Since LS pressure is drained from LS bypass valve, LS pressure C tank pressure C 0 MPa {0 kg/cm2}.

Operation (ALL-PQD5-044-K-00-A)
• Pressure of pump circuit (3) is received by the end of valve (2).
• Since the control valve is in NEUTRAL position, pressure of LS circuit (1) is 0 MPa {0 kg/cm 2}.
• Pressurized oil of pump circuit (3) stops at valve (2), and the pressure rises as no relief is available.
• If this pressure grows larger than the force of spring (5), valve (2) moves to the left.
• Ports (b) and (c) are interconnected, and the pump pressurized oil flows to tank circuit (4).
• The pressurized oil of LS circuit (1) passes from orifice (a) through port (c) and is drained to tank circuit
(4).
• When this valve is actuated, the LS pressure becomes nearly equal to the tank pressure.
• Since the pump delivery pressure - LS circuit pressure during unloading is larger than pump LS control
pressure, the signal is output to minimize the pump swash plate angle.
• During operation (when a given work is done within the delivery available with the minimum swash plate
angle), the delivery pressure corresponding to the minimum pump swash plate angle is set to LS pressure
+ P1 pressure.
• The LS differential pressure (dPLS) with the swash plate angle at the minimum becomes P1 pressure.

Operation of relief valve


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

PC210LC-10 10-89
10 Structure and function
Control valve

10-90 PC210LC-10
10 Structure and function
Control valve

Introduction of LS pressure (PC220-C2A4-041-K-00-A)


LS: Abbreviation for Load Sensing

1. Main pump
2. Main spool
3. Pressure compensation valve
4. Valve
5. Check valve
6. LS circuit
7. LS shuttle valve

Function (PC220-C2A4-042-K-00-A)
• The upstream pressure (spool meter-in downstream pressure) of pressure compensation valve (3) is
transmitted and led to LS shuttle valve (7) as LS pressure.
• Connected to actuator port (B) through valve (4), and makes LS pressure C actuator load pressure.
• In main spool (2), leading hole (a) with a small diameter also acts as an orifice.
• LS pressure works as source pressure when closing unload vale while control lever is operated, and this
pressure also functions as operating pressure when pressure compensation valve is compensated.

Operation (PC220-C2A4-044-K-00-A)
• When main spool (2) is operated, the pump pressure is transmitted to port (c) through leading hole (a) and
is led to LS circuit.
• When the pump pressures rises to reach the load pressure of port (B), check valve (5) opens and the
pressurized oil flows.

PC210LC-10 10-91
10 Structure and function
Control valve

LS bypass plug (PC220-PNSH-041-K-00-A)

LS: Abbreviation for Load Sensing

1. Main pump
2. Main spool
3. Pressure compensation valve
4. LS shuttle valve
5. LS bypass plug
6. LS circuit

Function (ALL-PNSH-042-K-00-A)
• This valve relieves the residual pressure in LS pressure circuit (6) from orifices (a) and (b).
• Slows down the rising rate of LS pressure to prevent a sudden change of hydraulic pressure.
• Depending on the bypass flow from LS bypass plug (5), pressure loss is generated due to the circuit
resistance from orifice (c) of main spool (2) to LS shuttle valve (4).
• Effective LS differential pressure drops to improve a dynamic stability of the actuator.

10-92 PC210LC-10
10 Structure and function
Control valve

Pressure compensation valve (PC220-L6D0-040-K-00-A)


When the work equipment is operated independently and the load pressure is the maximum
(When the load pressure is higher than other work equipment during a combined operation)

1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Spring
6. LS shuttle valve
Function
• Pressure compensation valve works as the load check valve.
• If the pump pressure (LS pressure) is lower than the load pressure at port (c), shuttle valve (3) in pressure
compensation valve piston (4) interconnects spring chamber (E) and port (C).
• The force of spring (5) operates piston (4) and valve (2) to the closing direction.

Integrated pressure compensation valve


• When a high peak pressure or continuous and repetitive peak pressure (as in breaker operation) is
generated in the actuator circuit, valve (2) may collide with valve chamber seat (C), producing high stress
in the parts.
• To prevent this, a pressure compensation valve with integrated valve (2) and piston (4) is used.
• With this machine, this valve is adopted for the travel valve, bucket valve (cylinder bottom), and the
service valve.

PC210LC-10 10-93
10 Structure and function
Control valve

When compensated
(When the load pressure is lower than other work equipment during a combined operation)

Function
• The pressure compensation valve closes by the LS pressure of port (D), and the spool meter-in
downstream pressure of port (B) becomes equivalent to the maximum pressure of other work equipment.
• Since the spool meter-in upstream pressure of port (A) is the pump pressure, the spool meter-in
differential pressure [upstream pressure port (A) pressure] - downstream pressure [port (B) pressure]
becomes equivalent to all the spools in operation.
• Pump flow is divided according to the ratio of the meter-in opening areas.

Operation
• Spring chamber (E) is interconnected to port (D).
• Piston (4) and valve (2) are moved in the closing direction (to the right) by the LS circuit pressure of port
(F) from other work equipment.
• Valve upstream pressure (= spool meter-in downstream pressure) of port (B) is controlled with the LS
pressure.

10-94 PC210LC-10
10 Structure and function
Control valve

Area ratio of pressure compensation valve

Function
• The state of division changes according to the area ratio of pressure compensation portions (A1) and (A2).
Area ratio = (A2)/(A1)
• When the area ratio is equal to 1: As the spool meter-in downstream pressure is equal to the maximum
load pressure, the oil flow is divided in the ratio as same as the opening area ratio.
• When the area ratio is more than 1: As the spool meter-in downstream pressure is higher than the
maximum load pressure, the oil flow to the compensated side is divided in a ratio lower than the opening
area ratio.
• When the area ratio is below 1: As the spool meter-in downstream pressure is lower than the maximum
load pressure, the oil flow to the compensated side is divided in a ratio higher than the opening area ratio.

PC210LC-10 10-95
10 Structure and function
Control valve

Shuttle valve in pressure compensation valve (PC220-L6D3-040-K-00-A)


When holding pressure at port (A) becomes higher than LS pressure in spring chamber (B)

1. Main pump
2. Valve
3. Shuttle valve
4. Piston
5. Pressure compensation valve

Operation
• Shuttle valve (3) is pressed to the right side by the pressure of port (A). As a result, port (A) is
disconnected from port (C).
• Holding pressure at port (A) is transmitted to the spring chamber (B) to push piston (4) to the left so that
piston (4) is not separated from valve (2).

10-96 PC210LC-10
10 Structure and function
Control valve

When traveling

Structure
• Since no holding pressure is generated at port (A) of the travel circuit, a pressure compensation valve
without shuttle valve (5) is adopted.

PC210LC-10 10-97
10 Structure and function
Control valve

Boom regeneration circuit (PC220-L511-040-K-00-A)


When cylinder head pressure is lower than bottom pressure (hydraulic drift, etc.)

1. Main pump
2. Boom valve spool
3. Pressure compensation valve
4. Suction safety valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit is installed across the cylinder bottom and cylinder head to increase flow to the
cylinder head when the boom is lowered.

Operation
• When the cylinder head pressure is lower than the bottom pressure, some of pressurized oil (A) from the
cylinder bottom flows to drain circuit (B) from the notch of boom spool (2).
• The remaining oil flows to regeneration circuit (C), opens check valve (6) and flows to the cylinder bottom
through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).

10-98 PC210LC-10
10 Structure and function
Control valve

When cylinder head pressure is higher than bottom pressure (digging operation, etc.)

Function
• Check valve (6) provided to regeneration circuit (C) closes to shut off the flow from the cylinder bottom to
the head.

PC210LC-10 10-99
10 Structure and function
Control valve

Arm regeneration circuit (PC220-L911-040-K-00-A)


When cylinder head pressure is higher than bottom pressure

1. Main pump
2. Arm valve spool
3. Pressure compensation valve
4. Suction safety valve
5. Suction valve
6. Check valve
7. LS shuttle valve
Function
• The regeneration circuit installed between the cylinder head and cylinder bottom increases the oil flowing
to the cylinder bottom (pump delivery + regeneration flow) during arm IN operation in order to accelerate
the cylinder.

Operation
• When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the
cylinder head flows to drain circuit (B) through the notch of arm spool (2).
• The remaining oil flows to the regeneration circuit (C), opens check valve (6), and flows to the cylinder
bottom through circuit (D).
• Flow from regeneration circuit (C) merges into the oil from pump (1) in circuit (E).

10-100 PC210LC-10
10 Structure and function
Control valve

When cylinder head pressure is lower than bottom pressure

Function
• Check valve (6) installed to regeneration circuit (C) closes and shuts off the oil flowing from the cylinder
head to the bottom.

PC210LC-10 10-101
10 Structure and function
Control valve

Merge-divider valve (PC220-PP30-040-K-00-A)


When oil flowing from two pumps are merged [pump merge-divider valve changeover signals (IS1)
and (IS2) are OFF]

1. Main spool
2. Spring
3. LS spool
4. Spring
5. LS circuit (for bucket valve)
6. LS circuit (for bucket valve)
7. LS circuit (for arm valve)
8. LS circuit (for arm valve)
9. Pump merge-divider EPC valve (for main spool changeover)
10. Pump merge-divider EPC valve (for LS spool changeover)

Function
• This valve merges the pressurized oil (P1) and (P2) from the two pumps or divides them (enables them to
flow to respective control valve groups).
• This valve merges or divides LS circuit pressures as well.

10-102 PC210LC-10
10 Structure and function
Control valve

Operation
• Since drive signal (IS1) of the EPC valve for the main spool is OFF, the output pressure of the pump
merge-divider EPC valve is 0 MPa {0 kg/cm2}.
• Main spool (1) is pressed to the right by spring (2). As a result, ports (E) and (F) are interconnected.
• Pressurized oil (P1) and (P2) discharged from the two pumps merge at ports (E) and (F), and flow to the
control valve which requires the oil.
• Since drive signal (IS2) of the EPC valve for LS spool (3) is also OFF, LS spool (3) is pressed to the right
by spring (4). As a result, ports (A) and (B) are interconnected and ports (B) and (C) are interconnected.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to all the pressure compensation valves.

When oil flowing from two pumps are divided [pump merge-divider valve changeover signals (IS1)
and (IS2) are ON]

Operation
• Since drive signal (IS1) of the main spool is ON, main spool (1) is moved to the left by the output pressure
from the pump merge-divider EPC valve. As a result, port (E) is disconnected from port (F).
• The pressurized oil from the two pumps are sent to respective control valve groups.
Pressure P1: To bucket, left travel, boom
Pressure P2: To swing, right travel, arm
• When drive signal (IS2) of the EPC valve for LS spool (3) becomes ON, LS spool (3) is also moved to the
left by the output pressure from the pump merge-divider EPC valve. As a result, ports (A) and (C) are
interconnected, and other ports remain disconnected from each other.
• The LS pressures transmitted from respective control valve spools through LS circuits (5), (6), (7), and (8)
are transmitted to respective control valves.

PC210LC-10 10-103
10 Structure and function
Control valve

LS selector valve (PC220-J6PA-041-K-00-A)

LS: Abbreviation for Load Sensing

a The illustration shows the condition when the combined operation of swing and R.H. travel is performed.
[When pilot pressure (BP) is supplied]
1. Valve
2. Spring
3. Piston
4. Piston
5. Swing valve spool
6. R.H. travel valve spool
7. Arm valve spool
8. LS shuttle valve
9. LS circuit

Function (PC220-J6PA-042-K-00-A)
• This valve prevents the high LS pressure of the swing valve from entering the LS circuits of work
equipment valves when the swing and work equipment are in combined operation.
• This valve serves to improve operability of the work equipment by blocking the high pressure generated
during swing operation.

Operation (ALL-J6PA-044-K-00-A)

When pilot pressure (BP) is shut off


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

10-104 PC210LC-10
10 Structure and function
Control valve

When pilot pressure (BP) is supplied


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

PC210LC-10 10-105
10 Structure and function
Control valve

Self-pressure reducing valve (PC220-PL30-042-K-00-A)


Function
• This valve serves to reduce the delivery pressure of main pump and provide it for solenoid valves, EPC
valves, etc. for use as the control pressure.

Operation (ALL-PL30-044-K-00-A)

When engine is stopped


• Poppet (11) is pressed against the seat by spring (12), so port (PR) is disconnected from port (TS).
• Valve (14) is pressed to the left by spring (13), so port (P2) is disconnected from (TS).
• Valve (7) is pressed to the left by spring (8), so port (P2) is disconnected from port (A2).

10-106 PC210LC-10
10 Structure and function
Control valve

When load pressure (P2) is low


a When all control levers are in NEUTRAL position, or when load pressure (A2) is lower than output
pressure (PR) of the self-pressure reducing valve

PC210LC-10 10-107
10 Structure and function
Control valve

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

When load pressure (P2) is high


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

10-108 PC210LC-10
10 Structure and function
Control valve

When abnormally high pressure is generated


• If pressure (PR) of the self-pressure reducing valve becomes abnormally high, ball (16) contracts spring
(15) and separates from the seat.
• This allows the pressurized oil to flow to drain port (TS) from port (PR), lowering pressure (PR).
• As a result, components such as PPC valves and solenoid valves are protected from abnormally high
pressure.

PC210LC-10 10-109
10 Structure and function
Control valve

10-110 PC210LC-10
10 Structure and function
Control valve

Travel junction valve (PC220-C6C0-042-K-00-A)


Function
• When travel control lever is operated for straight-travel, travel junction valve does not receive the pilot
pressure (PST) from travel junction solenoid valve, thus right and left travel circuits interconnect each
other, and equal amount of oil is supplied to right and left travel motors to secure straight-travel ability.
• When travel control lever is operated for turning, travel junction valve receives the pilot pressure (PST)
from travel junction solenoid valve, thus right and left travel circuits are shut off each other, and
independent amount of oil is supplied to right and left travel motors to secure turning ability.

PC210LC-10 10-111
10 Structure and function
Control valve

Operation (ALL-C6C0-044-K-00-A)

When pilot pressure (PST) is shut off (travel junction)

• If pilot pressure (PST) from the travel junction solenoid valve is shut off, travel junction spool (2) is pressed
back towards right by the force of spring (1). As a result, ports (PTL) and (PTR) are interconnected.
• If the oil flow rates to the R.H. and L.H. travel motors become different from each other, the oil flows
through the opening of travel junction spool (2) from port of higher pressure side to port of lower pressure
side supplying the difference of oil to the lower pressure side so that the oil flow rates to both motors will
be equalized.

10-112 PC210LC-10
10 Structure and function
Control valve

When pilot pressure (PST) is supplied (travel independent)

• When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2)
compresses spring (1) to the left side and ports (PTL) and (PTR) are disconnected.
• The oil flow rate to both right and left motors becomes independent.

PC210LC-10 10-113
10 Structure and function
Control valve

Travel PPC shuttle valve (PC220-C6V1-042-K-00-A)

PPC: Abbreviation for Proportional Pressure Control

Function
• If boom RAISE, arm IN or OUT, bucket CURL or DUMP operation is performed when the machine is
traveling up a steep, the pilot pressure from the travel PPC valve serves to restrict the travel of respective
spools of boom, arm and bucket valves so that the oil flow rates to respective cylinders are restricted.
• To limit the travel of the boom, arm or bucket spool, the pilot pressure from the travel PPC valve passes
through the internal circuit of respective control valves and acts on the spool.

Operation (ALL-C6V1-044-K-00-A)

When travel levers are in NEUTRAL

• The oil in the stroke limiting signal chamber (a) passes through orifices (5) and (6) of respective pistons (3)
and (4) build in the travel spring case, and then is drained through the travel PPC valve.
• When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left until it contacts the end face of spring case (2) (st0).

10-114 PC210LC-10
10 Structure and function
Control valve

When travel lever is operated

• If the right travel lever is moved to REVERSE (or FORWARD) position, the pilot pressure from the travel
PPC valve moves spool (7) to the left (or right).
• Spool (7) pushes piston (3) and orifice (5) is closed. As a result, stroke limiting signal chamber (a) and the
drain circuit from the travel PPC valve are disconnected.
• At this time, the pilot pressure from the travel PPC valve passes through orifice (6) of piston (4), acts on
the left end of piston (8) and pushes piston (8) to the right.
• When boom RAISE (or arm IN or OUT, bucket CURL or DUMP) operation is performed, spool (1) moves
to the left.
• Maximum travel of the spool is limited to (st1) that has reduction in travel by the amount of movement (st2)
of piston (8) to the right.

PC210LC-10 10-115
10 Structure and function
Control valve

Boom hydraulic drift prevention valve (PC220-L6C0-042-K-00-A)


Function
• While boom is not operated by the right work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from boom cylinder bottom through spool (1) to prevent the boom from
drifting hydraulically.

Operation (ALL-L6C0-044-K-00-A)

In boom “RAISE“ operation

• When operating boom “RAISE“, the pressurized oil from the control valve exerts a left-hand force on the
right side of ring-shaped area (S), of which outside diameter is poppet (5) diameter (d1) and of which
inside diameter is seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, the pressurized oil from the control valve passes through the opening of poppet (5) and flows
to the boom cylinder bottom.

10-116 PC210LC-10
10 Structure and function
Control valve

In boom “NEUTRAL“ operation

• When the boom is operated to “NEUTRAL“ position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of boom cylinder bottom exerts a right-hand force on the left side of ring-shaped
area (S), of which outside diameter is poppet (5) diameter (d1) and of which inside diameter is seat
diameter (d2).
• The combined force of right-hand force on area (S) and the spring force of spring (4) moves poppet (5) to
the right.
• The circuit from control valve to boom cylinder bottom shuts off, then the oil pressure of the boom cylinder
bottom side is kept.

PC210LC-10 10-117
10 Structure and function
Control valve

In boom “LOWER“ operation

• When operating boom “LOWER“, the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the boom cylinder bottom flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.

10-118 PC210LC-10
10 Structure and function
Control valve

Arm hydraulic drift prevention valve (PC220-L9K0-042-K-00-A)

(if equipped)

Function
• While arm is not operated by the left work equipment control lever, the hydraulic drift prevention valve
prevents pressurized oil to leak from arm cylinder head through spool (1) to prevent the arm from drifting
hydraulically.

Operation (PC-L9K0-044-K-00-A)

In arm “OUT“ operation

• During arm “OUT“ operation, the pressurized oil from the control valve exerts a left-hand force on the right
side of area (S) of ring-shaped surface, of which outside diameter is equal to diameter (d1) of poppet (5)
and of which inside diameter is equal to seat diameter (d2).
• The left-hand force on area (S) compresses spring (4) and moves poppet (5) to the left.
• As a result, pressurized oil from the control valve flows to the arm cylinder head through the opening of
poppet (5).

PC210LC-10 10-119
10 Structure and function
Control valve

In arm “NEUTRAL“ operation

• When the arm is operated to “NEUTRAL“ position, the pressurized oil flowing inside poppet (5) through
orifice (a) of poppet (5) is stopped by pilot piston (2).
• The holding pressure of arm cylinder head exerts a right-hand force on the left side of ring-shaped area
(S), of which outside diameter is equal to diameter (d1) of poppet (5) and of which inside diameter is equal
to seat diameter (d2).
• The combined force of right-hand force on area (S) and the reaction force of spring (4) moves poppet (5)
to the right.
• The circuit from control valve to arm cylinder head shuts off, then the oil pressure of the arm cylinder head
side is kept.

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10 Structure and function
Control valve

In arm “IN“ operation

• When arm is operated “IN“, the pilot pressure from the PPC valve pushes pilot piston (2).
• The pressurized oil of the arm cylinder head flows from orifice (c) to drain port (T) through orifice (a) and
chamber (b).
• Chamber (b) inside poppet and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• As the pressure of chamber (b) becomes less than the pressure of port (B), poppet (5) opens.
• As poppet (5) opens, the pressurized oil from port (B) flows to port (A) and then flows to the control valve.

PC210LC-10 10-121
10 Structure and function
Control valve

Suction safety valve for hydraulic drift prevention valve (PC220-L9K2-044-K-00-A)


Operation when abnormally high pressure is generated

• If abnormally high pressure is generated in the boom cylinder bottom circuit, the pressurized oil in port (B)
opens check valve (6) to actuate safety valve (3).
• When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the
pressurized oil of the boom cylinder bottom circuit pressure or arm cylinder head circuit pressure,
whichever has higher pressure, opens check valve (6) or (6A) to actuate safety valve (3).

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10 Structure and function
Control valve

Arm quick return valve (PC220-L9K1-042-K-00-A)


Function
• Large amount of oil is returned from the cylinder bottom when arm OUT operation is performed.
• The valve reduces this pressure loss.

Operation (ALL-L9K1-044-K-00-A)

In arm “OUT“ operation

• In arm “OUT“ operation, the pilot pressure from the PPC valve pushes pilot piston (1).
• The pressurized oil in chamber (b) inside the valve is drained through orifice (c).
• The pressurized oil of the arm cylinder bottom side flows from orifice (c) to drain port (T) through orifice (a)
and chamber (b).
• Chamber (b) and drain port (T) are interconnected, and the pressure of chamber (b) drops.
• If the pressure in chamber (b) drops lower than that of port (A), the force exerted on the pressure receiving
surface of [Area (S2) of fd2 (surface of seat diameter)] on the port (A) side exceeds the combined force of
the force exerted on the pressure receiving surface [Area (S1) of fd1] on the chamber (b) side of valve (2)
and the spring force.
• The result is, (Force exerted on surface of fd2 > Force exerted on surface of fd1 + Force of spring).
• Valve (2) is pressed to the right and pressurized oil flows from port (A) to port (B).
• The pressurized oil of the arm cylinder bottom side is drained directly to the tank from port (B).

PC210LC-10 10-123
10 Structure and function
Control valve

In arm “NEUTRAL“ operation

• When the arm is operated from arm “OUT“ to “NEUTRAL“, the pilot pressure from PPC valve is shut off.
• The pressurized oil that flows in through orifice (a) in valve (2) and is drained, is stopped by pilot piston (1).
• The holding pressure of the arm cylinder bottom side exerts a left-hand force on the right side of ring-
shaped surface, whose area is equal to the area of (S2 - S1) of valve (2).
• The combined force of the force exerted on the ring-shaped surface and the spring force of the spring (3)
moves valve (2) to the left and shuts off port (A) and port (B).

10-124 PC210LC-10
10 Structure and function
Control valve

Variable back pressure valve (PC220-PQ81-042-K-00-A)

Function
• This valve creates back pressure in the drain circuit to prevent cavitation caused by negative pressure in
each actuator circuit (motors, cylinders, etc.).
• In order to reduce output loss, this valve reduces the back pressure in the drain circuit when any operation
other than the travel and swing is performed.

Operation (ALL-PQ81-044-K-01-A)

When engine is stopped


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

When engine is running (during swing or travel operation)


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

PC210LC-10 10-125
10 Structure and function
Control valve

When engine is running (other than swing or travel operation)


• The pressurized oil from self-pressure reducing valve (1) flows to variable back pressure solenoid valve
(3).
• Since drive signal (IS3) of variable back pressure solenoid valve (3) is “ON“, the pressurized oil (PR) from
self-pressure reducing valve (1) flown to spring chamber (C) of variable back pressure valve (4) is drained
through variable back pressure solenoid valve (3).
• Only the reaction force of spring (5) pushes valve (6) to the right.
• Pressure (PA) of drain circuit (A) of the control valve acts on the right end face of valve (6) (surface of fd1)
to push valve (6) to the left.
• Valve (6) balances at a position where it creates back pressure (PA) determined as follows; PA = Reaction
force of spring (5) / Area of surface fd1
• Accordingly, the oil flow rate from drain circuit (A) of the control valve to port (T) is limited. In other words,
the set pressure of variable back pressure valve (4) is adjusted.

10-126 PC210LC-10
10 Structure and function
Control valve

PC210LC-10 10-127
10 Structure and function
Control valve

Main relief valve (PC220-PQ91-041-K-00-A)

1. Spring
2. Poppet

Function (PC220-PQ91-042-K-00-A)
• This valve has two selectable settings for its set pressure.
• If the extra power is necessary, this valve is set to the high-pressure setting when pilot pressure (P) is
applied to it from the 2-stage relief solenoid valve.
• The relief valve set pressure is determined by the load at installed length of spring (1). (1st stage set
pressure)
• When the 1st stage set pressure is set correctly, the 2nd stage set pressure does not need to be set.
Setting the 1st stage set pressure completes the setting of the 2nd stage set pressure.

Operation (PC-PQ91-044-K-00-A)

When pilot pressure (P) is shut off (low pressure setting)


• The set pressure is determined by the load at installed length of spring (1).

When pilot pressure (P) is supplied (high pressure setting)


• The load at installed length of spring (1) is added with the force exerted by pilot pressure (P) applied to the
area of diameter (d1) of poppet (2), raising the set pressure to higher level.

10-128 PC210LC-10
10 Structure and function
Control valve

2-stage suction-safety valve (PC220-PQJ2-041-K-00-A)


[Installed to port (B) of the service valve]

1. Spring
2. Piston
3. Spring
4. Holder

Function (PC220-PQJ2-042-K-00-A)
• This valve has two settings for its set pressure.
• This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
• ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
• The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
• The set pressure of the low-pressure setting is determined by the travel of the piston.

Operation (ALL-PQJ2-044-K-00-A)

When pilot pressure (P) is shut off (high pressure setting)


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

PC210LC-10 10-129
10 Structure and function
Control valve

When pilot pressure (P) is supplied (low pressure setting)


• When pilot pressure (P) is supplied, the pilot pressure is transmitted to part (A) through passage (B).
• The pilot pressure acts on the pressure receiving diameter at part (A) [(d1) – (d2)] of piston (2).
• Piston (2) compresses spring (3) by receiving pilot pressure and moves to the right until it contacts holder
(4).
• Since spring (1) is expanded and reducing its load at installed length, the set pressure is lowered.
• The amount of pressurized oil for stroke of piston (2) is drained from passage (C) via chamber (D) .

10-130 PC210LC-10
10 Structure and function
Swing motor

Swing motor (PC-J610-041-K-00-A)

MA: From control valve (left swing port)


MB: From control valve (right swing port)
B: From swing holding brake solenoid
S: From control valve (variable back pressure valve)
T: To hydraulic tank
PI: From 2-stage relief solenoid valve
1. Reverse prevention valve
2. 2-stage swing relief valve

PC210LC-10 10-131
10 Structure and function
Swing motor

1. Brake spring
2. Drive shaft
3. Spacer
4. Case
5. Disc
6. Plate
7. Brake piston
8. Housing
9. Piston

10-132 PC210LC-10
10 Structure and function
Swing motor

10. Cylinder block


11. Valve plate
12. Center shaft
13. Center spring
14. Check valve
15. Shuttle valve
Specifications (PC220-J610-030-K-00-A)

Type KMF125ABE-6
Theoretical delivery (cm3/rev) 125

2-stage swing relief valve pressure (MPa {kg/cm2}) 28.4 {290}

Low-pressure setting 180


2-stage swing relief oil flow (l/min)
High-pressure setting 70
Rated speed (rpm) 1,694
Brake release pressure (MPa{kg/cm2}) 1.6 ± 0.4 {16 ± 4}

PC210LC-10 10-133
10 Structure and function
Swing motor

Swing holding brake (PC-J6A0-044-K-00-A)


When solenoid valve is “de-energized“

• When the swing holding brake solenoid valve is de-energized, the pressurized oil from the self-pressure
reducing valve is blocked.
• Port (B) is connected to tank circuit (T).
• Brake piston (7) is pushed downward by brake spring (1).
• Disc (5) and plate (6) are pushed against each other to apply the brake.

10-134 PC210LC-10
10 Structure and function
Swing motor

When solenoid valve is “energized“

• When the swing holding brake solenoid valve is energized, the valve is switched.
• The pressurized oil from self-pressure reducing valve enters port (B), and flows into brake chamber (a).
• After entering chamber (a), the pressurized oil compresses brake spring (1) and moves brake piston (7)
upward.
• Disc (5) is separated from plate (6), releasing the brake.

Relief valve (PC220-J6B1-041-K-00-A)


• The relief valve portion consists of check valves (2) and (3), shuttle valves (4) and (5), and relief valve (1).

Function (PC220-J6B1-044-K-00-A)
• When the swing is stopped, control valve (6) blocks the motor outlet circuit, but the motor rotation is
continued by inertial force.
• If the pressure of motor outlet circuit becomes abnormally high, it may cause damage to the motor.
• In order to prevent the motor damage, the relief valve relieves the abnormally high pressure to port (S)
from the motor outlet (high-pressure side).

PC210LC-10 10-135
10 Structure and function
Swing motor

Operation (PC-J6B1-044-K-00-A)

When swing is started

• When the swing control lever is moved to the “swing RIGHT position“, the pressurized oil from the pump is
supplied to port (MA) through control valve (6).
• The pressure in port (MA) rises, the starting torque is generated in the motor, and the motor starts to
rotate.
• During swing acceleration, the pilot pressure from 2-stage relief solenoid valve (7) is applied to port (PI) to
limit the relief volume.
• The pressurized oil from the outlet of the motor returns to the tank through port (MB) and control valve (6).

10-136 PC210LC-10
10 Structure and function
Swing motor

When swing is stopped

• When the swing control lever is returned to “NEUTRAL“ from “swing RIGHT“ position, the supply of
pressurized oil from the pump to port (MA) is stopped.
• The pressurized oil from the motor outlet cannot return to the tank since the return circuit to the tank is
blocked by control valve (6). Thus, pressure in port (MB) increases.
• If the pressure in port (MB) becomes too high, the pressurized oil returns to the hydraulic tank through
relief valve (1) and port (S).
• Rotation resistance is exerted on the motor and the brake starts working.
• If the pressure in port (MB) becomes higher than that in port (MA), it presses shuttle valve (4).
• The pressure in chamber (C) becomes the same as that in port (MB), and increases to the set pressure of
relief valve (1).
• A high braking torque works on the motor, thereby stopping the motor.
• While relief valve (1) is actuated, the relieved pressurized oil and the pressurized oil from port (S) are
routed to port (MA) through the check valve (3).
• Thus, cavitations in port (MA) is prevented.

PC210LC-10 10-137
10 Structure and function
Swing motor

2-stage swing relief valve (PC-JA1A-041-K-00-A)

1. Valve seat
2. Valve
3. Poppet
4. Spring
5. Spring
6. Piston

Function (PC220-JA1A-042-K-00-A)
• This valve has two selectable settings for set pressure.
• The set pressure of this valve is determined by the load at installed length of spring (4).
• During swing acceleration, this valve receives pilot pressure (PI) from the 2-stage swing relief solenoid
valve and decreases the relief quantity (drain quantity).
• If pressure (P) is constant, energy loss can be reduced by decreasing oil flow (Q), or relief quantity (drain
quantity), according to the formula of [Energy loss = Pressure (P) x Oil flow (Q)]. Decrease in energy loss
leads to improvement of fuel consumption.

A: When pilot pressure is “shut off“ (low-pressure setting)


B: When pilot pressure is “transmitted“ (high-pressure setting)
P: 28.4 MPa {290 kg/cm2}
Q1: 180 l/min
Q2: 70 l/min

10-138 PC210LC-10
10 Structure and function
Swing motor

Operation (PC220-JA1A-044-K-00-A)

When pilot pressure (PI) is shut off (low pressure setting)


• The set pressure is determined by the load at installed length of spring (4).

When pilot pressure (PI) is supplied (high pressure setting)


• During swing acceleration, pilot pressure (PI) from the 2-stage swing relief solenoid valve acts on the
power receiving area (d2 – d1).
• Spring (4) is compressed, the load at installed length of the spring is increased, and then the passage
between valve (2) and valve seat (1) is narrowed while the pump delivery is decreased by the controller.
As a result, the flow rate to hydraulic relief decreases when relief pressure is constant.

PC210LC-10 10-139
10 Structure and function
Swing motor

Swing motor reverse prevention valve (PC-J6B2-041-K-00-A)

MA: From control valve (left swing port)


MB: From control valve (right swing port)

10-140 PC210LC-10
10 Structure and function
Swing motor

T1: To hydraulic tank


T2: To hydraulic tank
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug (MA side)
5. Spool (MB side)
6. Spring (MB side)
7. Plug (MB side)

Explanatory drawing of effects

Function (PC220-J6B2-042-K-00-A)
• At the stop of swing operation, the upper structure may swing back. This is due to inertia of the mass of
the upper structure, the backlash and rigidity of the swing machinery system, and compressibility of the
hydraulic oil. This valve prevents such movement.
• The valve contributes to prevention of load spillage when the swing is stopped and also contributes to
reduction in the cycle time (enhances the positioning performance, enabling you to proceed to the next
work quicker than ever).

PC210LC-10 10-141
10 Structure and function
Swing motor

Operation (PC220-J6B2-044-K-00-A)

When brake pressure is generated in port (MB)

• Pressure (MB) is led to chamber (d) through notch (g).


• As (fD1 > fD2) holds in regards to circle areas of spool (5), spring (6) is compressed and spool (5) is
moved to the left.
• Port (MB) and chamber (e) are interconnected to each other.
• Since pressure (MA) is lower than the set pressure of spring (3), spool (2) does not move and the
pressurized oil is blocked. Thus the braking force is ensured.

When motor reversing pressure is generated in port (MA)

• The trapped pressure in port (MB) turns the motor in the opposite direction. (1st reverse rotation)
• Reversing pressure is generated in port (MA). Pressure (MA) is transmitted to chamber (a).
• As (fD3 > fD4) holds in regard to circle areas of spool (2), spring (3) is compressed and spool (2) is
moved to the right.
• Port (MA) and chamber (b) are interconnected to each other.
• Port (b) is interconnected to port (f) through the drilled hole (h) in spool (5). This bypasses the reversing
pressure in port (MA) to port (T), thereby preventing the 2nd reverse rotation of the motor.

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10 Structure and function
Travel motor

Travel motor (PC200_10-C400-041-K-00-A)

L.H. travel motor


PA: From control valve (L.H. travel FORWARD port)
PB: From control valve (L.H. travel REVERSE port)
R.H. travel motor
PA: From control valve (R.H. travel REVERSE port)
PB: From control valve (R.H. travel FORWARD port)
P: From travel speed increase solenoid valve
T: To hydraulic tank
B: Plug (Brake release pressure port)
MA: Port pressure pickup port
MB: Port pressure pickup port

PC210LC-10 10-143
10 Structure and function
Travel motor

1. Regulator piston
2. Regulator valve
3. Motor case
4. Suction safety valve
5. Check valve
6. Rocker cam
7. Retainer guide
8. Output shaft
9. Pin

10-144 PC210LC-10
10 Structure and function
Travel motor

10. Retainer
11. Piston
12. Cylinder block
13. Valve plate
14. Counterbalance valve spool
15. Ring
16. Brake piston
17. Plate
18. Disc
19. Ball retainer
Specification (PC200_10-C400-030-K-00-A)

Model HMV120-2
Min. 82
Theoretical delivery (cm3/rev)
Max. 120
Rated pressure: MPa {kg/cm2} 37.3 {380}
Min. 2,565
Rated speed (rpm)
Max. 1,595
Brake release pressure
1.18 {12}
(MPa {kg/cm2})
Travel speed changeover pressure
0.78 {8.0}
(MPa {kg/cm2})

PC210LC-10 10-145
10 Structure and function
Travel motor

Operation of travel motor (PC-C400-044-K-00-A)


Travel speed at low-speed setting (motor swash plate angle is at maximum)

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

10-146 PC210LC-10
10 Structure and function
Travel motor

Travel speed at high-speed setting (motor swash plate angle is at minimum)

• When the solenoid valve is energized, the pilot pressure oil from the self-pressure reducing valve flows to
port (P).
• Regulator valve (9) is pressed to the left.
• The pressurized oil from the control valve flows through passage (d) of regulator valve (9), and enters
regulator piston (15).
• Regulator piston (15) is pressed to the right.
• Rocker cam (4) tilts toward the minimum swash plate angle position. The motor capacity is minimized and
the travel speed is set to high-speed setting when the rocker cam reaches the position.

PC210LC-10 10-147
10 Structure and function
Travel motor

Operation of parking brake (PC-C4A0-044-K-00-A)


When starting travel

• When the travel lever is operated, the pressurized oil from the pump acts on counterbalance valve spool
(19) to make the parking brake circuit.
• The oil flows into chamber (e) of brake piston (12), compresses spring (11), and pushes piston (12) to the
left.
• Since the force pressing plate (13) and disc (14) against each other is eliminated, they are separated and
the brake is released.

10-148 PC210LC-10
10 Structure and function
Travel motor

When stopping travel

• When the travel lever is returned to NEUTRAL, counterbalance valve spool (19) returns to the neutral
position, and the parking brake circuit is blocked.
• The pressurized oil in chamber (e) of brake piston (12) is drained to the case through orifice (f) of brake
piston (12).
• Brake piston (12) is pressed to the right by spring (11).
• Plate (13) and disc (14) are pressed against each other, and the brake is applied.
• When brake piston (12) is returned, the flow of pressurized oil is restricted by slow return valve (22).
• This makes a delay in the application of the parking brake. The parking brake is applied after the machine
has stopped.

PC210LC-10 10-149
10 Structure and function
Travel motor

Brake valve (ALL-C4Q0-041-K-00-A)

• Brake valve is comprised of suction safety valves (18A) and (18B), and counterbalance valve (18).

Counterbalance valve (PC220-C4N0-042-K-00-A)

Function

• When the machine travels down a slope, its travel speed tends to get faster than the motor (engine) speed
because of the downward force generated from its own weight.
• Traveling the machine with the engine running at a low speed may induce idle run of the motor that allows
the machine to run out of control, posing a danger.
• These valves serve to prevent the above problem by enabling the machine to travel at a speed that
matches the engine speed (pump delivery).

10-150 PC210LC-10
10 Structure and function
Travel motor

Operation (PC-C4N0-044-K-00-A)

Operation when pressurized oil is supplied

• When the travel lever is operated, the pressurized oil is supplied from the control valve to port (PA).
• The oil opens suction safety valve (18A), and then flows from motor inlet port (MA) to motor outlet port
(MB).
• Since the motor outlet circuit is blocked by suction safety valve (18B) and spool (19), the pressure of the
supply side circuit increases.

PC210LC-10 10-151
10 Structure and function
Travel motor

• The pressurized oil of the supply side circuit flows through orifices (E1) and (E2) of spool (19) to chamber
(S1).
• When the pressure in chamber (S1) becomes higher than the spool selector pressure (reaction force of
spring (20)), spool (19) is pushed to the right.
• Both motor outlet port (MB) and port (PB) are connected to outlet passage (B1). As the result, the motor
outlet side opens and the motor rotates.

10-152 PC210LC-10
10 Structure and function
Travel motor

Braking while travelling downhill

• When the machine almost run out of control during downhill travel, the motor runs idle and the pressure of
the inlet side circuit decreases.
• The pressure in chamber (S1) decreases through orifices (E1) and (E2).
• When the pressure in chamber (S1) becomes lower than the spool selector pressure, spool (19) is
returned to the left by the reaction force of spring (20) and outlet passage (B1) is throttled.
• The pressure of the motor outlet side circuit increases and rotational resistance is generated in the motor,
preventing the machine from running out of control.
• Spool (19) moves to a position where the two forces acting on the spool balance with each other; one is
the force exerted by the pressure in the motor outlet port and the other is the sum of the force due to
machine's own weight and the force exerted by the pressure in the motor inlet port.
• Narrowing down the motor outlet side circuit in this way allows the machine to travel at a speed that
matches the pump delivery.

Suction safety valve (PC220-C660-042-K-00-A)

Function
• While the machine is stopped (or when it is travelling downhill), the counterbalance valve blocks the
passage between the inlet and outlet circuits of the motor.
• Since the motor is rotated by inertial force, the pressure in the motor outlet port is abnormally increased,
potentially causing damage to the motor and piping.
• The safety valve releases this abnormal pressure to the inlet port of the motor to prevent damage of the
equipment.

PC210LC-10 10-153
10 Structure and function
Travel motor

Operation (PC-C660-044-K-00-A)

When machine stops traveling (or traveling downhill) (when motor rotating clockwise)

• When the travel lever is set to NEUTRAL position, pressure (PA) in the motor inlet port decreases and the
pressure in chamber (S1) also decreases.
• When pressure drops below the changeover pressure of spool (19), spool (19) is pushed to the left by
reaction force of sprig (20) and narrows outlet passage (B1).
• Since inertial force maintains motor rotation, pressure (MB) of the outlet port side circuit increases.

• The pressurized oil pushes open check valve (17) and flows to the inlet side circuit on the opposite side
through notch (A1) of spool (19).
• If the pressure becomes higher than the set pressure of suction safety valve (18A), poppet (1) opens.
• When motor rotates counterclockwise, it operates reverse for clockwise rotation.

10-154 PC210LC-10
10 Structure and function
Travel motor

When starting travel (or when traveling normally)

• When the travel lever is operated, the pressurized oil from the pump moves spool (19) to the right.
• The pressurized oil flows to suction safety valve (18B) through check valve (16) and port (A2).
• Since the pressurized oil flowing through the circuit is throttled at notch (20), the pressure difference
between the inlet side and outlet side increases.
• The pump pressure rises and the large drawbar pull is obtained.

PC210LC-10 10-155
10 Structure and function
PPC valve

PPC valve (ALL-CW10-001-P-00-A)

PPC: Abbreviation for Proportional Pressure Control


Work equipment and swing PPC valve (PC-PL28-041-K-00-A)

PPC: Abbreviation for Proportional Pressure Control

L.H. work equipment control lever


P: From self-pressure reducing valve
P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)

10-156 PC210LC-10
10 Structure and function
PPC valve

P3: To control valve (LEFT swing port)


P4: To control valve (RIGHT swing port)
T: To hydraulic tank
R.H. work equipment control lever
P: From self-pressure reducing valve
P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic oil tank

PC210LC-10 10-157
10 Structure and function
PPC valve

1. Spool
2. Piston
3. Disc
4. Nut (for lever connection)

10-158 PC210LC-10
10 Structure and function
PPC valve

5. Joint
6. Plate
7. Retainer
8. Valve body
9. Filter

Operation (PC-PL28-044-K-00-A)

When control lever is in NEUTRAL position


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

When control lever is in fine control range

(When moved from NEUTRAL to fine control range)


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

PC210LC-10 10-159
10 Structure and function
PPC valve

• In addition, the pressure in port (P1) increases in proportion to the control lever travel.
• Accordingly, the control valve spool moves to a position at which the pressure in port (A) [equal to the
pressure in port (P1)] is balanced with the reaction force of the control valve spool return spring.

When control lever is in fine control range

(When returned to fine control range)


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

10-160 PC210LC-10
10 Structure and function
PPC valve

When control lever is moved to stroke end


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

PC210LC-10 10-161
10 Structure and function
PPC valve

10-162 PC210LC-10
10 Structure and function
PPC valve

Travel PPC valve (PC-C6V0-041-K-00-A)

PPC: Abbreviation for Proportional Pressure Control

P: From self-pressure reducing valve


P1: To control valve (L.H. travel REVERSE port)
P2: To control valve (L.H. travel FORWARD port)
P3: To control valve (R.H. travel REVERSE port)
P4: To control valve (R.H. travel FORWARD port)
T: To hydraulic tank

PC210LC-10 10-163
10 Structure and function
PPC valve

1. Plate
2. Case
3. Piston
4. Seal
5. Spool
6. Damper

10-164 PC210LC-10
10 Structure and function
PPC valve

Operation (PC-C6V0-044-K-00-A)

When control lever is in NEUTRAL position


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

When control lever is in fine control range

(When moved from NEUTRAL to fine control range)


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

PC210LC-10 10-165
10 Structure and function
PPC valve

When control lever is in fine control range

(When returned to fine control range)


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

10-166 PC210LC-10
10 Structure and function
PPC valve

When control lever is moved to stroke end


• Lever (5) depresses piston (4), and retainer (9) depresses spool (1).
• Fine control hole (f) is disconnected from drain chamber (D), and it is connected to pump pressure
chamber (PP).
• The pilot pressure oil from the self-pressure reducing valve passes through fine control hole (f) and flows
from port (P1) to port (A) and pushes the control valve spool.
• The oil returning from port (B) flows from port (P2) into drain chamber (D) through fine control hole (f').

PC210LC-10 10-167
10 Structure and function
PPC valve

10-168 PC210LC-10
10 Structure and function
PPC valve

1st-line attachment PPC valve (with EPC valve) (PC200_10-PL29-041-K-00-A)

(if equipped)
PPC: Abbreviation for Proportional Pressure Control
EPC: Abbreviation for Electromagnetic Proportional Control
a For details of operation, see “Work equipment and swing PPC valve“.

PC210LC-10 10-169
10 Structure and function
PPC valve

P: From self-pressure reducing valve


P1: To control valve (service valve 1 port)
P2: To control valve (service valve 1 port)
T: To hydraulic tank

10-170 PC210LC-10
10 Structure and function
PPC valve

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Valve body
7. EPC valve

EPC valve (PC200_10-PL2B-041-K-00-A)


(if equipped)
EPC: Abbreviation for Electromagnetic Proportional Control

P: From self-pressure reducing valve


C: To PPC valve (R.H. attachment)
T: To hydraulic tank
1. Valve body

PC210LC-10 10-171
10 Structure and function
PPC valve

2. Spool
3. Spring
4. Coil
5. Plunger
6. Push pin
7. Connector

Function (PC-PL2B-042-K-00-A)
• The EPC valve consists of the proportional solenoid portion and the hydraulic valve.
• When a signal current (i) from the pump controller is received, the EPC output pressure proportional to the
amperage of current is generated and output to the control valve.

Operation (PC200_10-PL2B-044-K-00-A)

When signal current is zero amp. (coil is de-energized)


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

10-172 PC210LC-10
10 Structure and function
PPC valve

When signal current is minute (coil is energized)


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

PC210LC-10 10-173
10 Structure and function
PPC valve

When signal current is maximum (coil is energized)


• Coil (4) is energized when the signal current flows through coil (4).
• As the signal current is the maximum, the thrust of plunger (5) is also maximized.
• Spool (2) is pushed to the light by push pin (4).
• The pressurized oil flows from port (P) to port (C) at the maximum rate, and the circuit pressure between
the EPC valve and control valve is maximized.
• Port (T) is blocked, so no pressurized oil flows to the hydraulic tank.

10-174 PC210LC-10
10 Structure and function
PPC valve

PC210LC-10 10-175
10 Structure and function
PPC valve

2nd-line attachment PPC valve (PC-PL2A-041-K-00-A)

(if equipped)
PPC: Abbreviation for Proportional Pressure Control
a For details of operation, see "Work equipment and Swing PPC valve".

P: From self-pressure reducing valve


P1: To control valve (service valve 2 port)
P2: To control valve (service valve 2 port)
T: To hydraulic tank

10-176 PC210LC-10
10 Structure and function
PPC valve

1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Valve body

PC210LC-10 10-177
10 Structure and function
Solenoid valve

Solenoid valve (ALL-PQPT-041-K-00-A)

a The figure shows the valve for a machine ready for installation of attachment.

P1: From self-pressure reducing valve


A1: To PPC valve

10-178 PC210LC-10
10 Structure and function
Solenoid valve

A2: To control valve [Port (PX1) and (PX2)]


A3: To swing motor [Port (B)]
A4: To travel motor [Port (P)]
A5: To control valve [Port (PST)]
A6: To swing motor 2-stage relief valve
A7: To attachment circuit selector valve
T: To hydraulic tank
ACC: To accumulator (for PPC circuit)
1. PPC lock solenoid valve
2. 2-stage relief solenoid valve
3. Swing holding brake solenoid valve
4. Travel speed increase solenoid valve
5. Travel junction solenoid valve
6. Swing 2-stage relief solenoid valve
7. Attachment circuit selector solenoid valve (for machines ready for installation of attachment)
Solenoid valve
8. Coil (ON/OFF type)
9. Push pin
10. Valve spool
11. Sleeve
12. Block
13. Plug
Check valve
14. Plug
15. Plunger
Operation (ALL-PQPT-044-K-00-A)

Operation of check valve

• This valve is installed between port (P) and the PPC solenoid valve. When the engine is stopped, plunger
(1) is pushed back to the left by the reaction force of spring (2), so the passage between ports (ACC) and
(P) is blocked, keeping the pressure in the accumulator.
• When the engine is running, plunger (1) is pushed to the right with the pilot pressure that is sent to port (P),
so port (P) is connected to port (ACC).

PC210LC-10 10-179
10 Structure and function
Solenoid valve

Operation of solenoid valve

When solenoid valve is “de-energized“ (circuit is blocked)

• Coil (1) is de-energized when no signal current flows through coil (1).
• Spool (2) is pushed back to the left by reaction force of spring (3).
• As the passage between ports (P) and (A) is blocked, the pilot pressure is not fed to the actuator through
port (A). At the same time, the passage to port (T) is made, so the oil from the actuator is drained to the
hydraulic tank.

When solenoid valve is “energized“ (circuit is made)

• Coil (1) is energized when the signal current flows through coil (1).
• Spool (2) is pushed to the right by push pin (4).
• The passage between ports (P) and (A) is made, so the pilot pressure flows to the actuator through port
(A). At the same time, the passage to port (T) is blocked, so the oil from the actuator does not flow to the
hydraulic tank.

10-180 PC210LC-10
10 Structure and function
Attachment circuit selector valve (for high pressure
circuit)

Attachment circuit selector valve (for high pressure circuit) (ALL-PQJ5-041-K-00-A)

(if equipped)

PI: From attachment circuit selector solenoid valve


ACC: To accumulator
ATT: To attachment
TS: To hydraulic tank
1. Spool

Function (PC220-PQJ5-042-K-00-A)

• For a machine equipped with a breaker, this valve allows the oil from the breaker to return directly to the
hydraulic tank without passing through the main valve.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to interconnect the
attachment to the main valve.
Operation (ALL-PQJ5-044-K-00-A)
When attachment other than breaker is installed

PC210LC-10 10-181
10 Structure and function
Attachment circuit selector valve (for high pressure
circuit)

• Spool (1) is pressed to the left by the force of spring (2).


• Since port (ATT) is disconnected from port (ACC), no oil flows to the accumulator.

When breaker is installed

• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is interconnected to port (ACC) and oil flows to the accumulator, so oil pulsation is absorbed by
the accumulator.

10-182 PC210LC-10
10 Structure and function
Attachment circuit selector valve (for low pressure
circuit)

Attachment circuit selector valve (for low pressure circuit) (PC-PQJ3-041-K-00-A)

(if equipped)

PI: From attachment circuit selector solenoid valve


V: To control valve attachment 1 port
ACC: To accumulator
ATT: To attachment
T: To hydraulic tank
TS: To hydraulic tank
1. Spool

Function (PC220-PQJ3-042-K-00-A)

• For a machine equipped with a breaker, this valve serves to interconnect between the main circuit from the
control valve to the breaker and the accumulator.
• For a machine equipped with other attachment (crusher, etc.), this valve serves to disconnect the main
circuit from the accumulator.

PC210LC-10 10-183
10 Structure and function
Attachment circuit selector valve (for low pressure
circuit)

Operation (PC-PQJ3-044-K-00-A)
When attachment other than breaker is installed

• Spool (1) is pressed to the left by the force of spring (2).


• Port (ATT) is interconnected to port (V) and is disconnected from port (T). Thus, the attachment is
interconnected to the control valve.

10-184 PC210LC-10
10 Structure and function
Attachment circuit selector valve (for low pressure
circuit)

When breaker is installed

• Pilot pressure (PI) from the attachment circuit selector solenoid valve compresses spring (2), and spool (1)
moves to the right to its stroke end.
• Port (ATT) is disconnected from port (V) and is interconnected to port (T).
• The pressurized oil returning from the breaker returns directly to the hydraulic tank via port (T) without
passing through the control valve.

PC210LC-10 10-185
10 Structure and function
Center swivel joint

Center swivel joint (PC220-J8E0-041-K-00-A)

A1: To L.H. travel motor port (PB)


A2: From control valve (L.H. travel FORWARD port)
B1: To L.H. travel motor [Port (PA)]
B2: From control valve (L.H. travel REVERSE port)
C1: To R.H. travel motor [Port (PA)]
C2: From control valve (R.H. travel FORWARD port)
D1: To R.H. travel motor [port (PB)]
D2: From control valve (R.H. travel REVERSE port)
E1: To L.H. and R.H. travel motor [port (P)]
E2: From travel speed increase solenoid valve
DR1: From L.H. and R.H. travel motor [port (T)]
DR2: To hydraulic tank
1. Cover

10-186 PC210LC-10
10 Structure and function
Center swivel joint

2. Slipper seal
3. Rotor
4. Dust seal
5. O-ring
6. Cover
7. Shaft

PC210LC-10 10-187
10 Structure and function
Accumulator

Accumulator (PC-PL40-001-K-00-A)

PPC accumulator (PC-PL40-041-K-00-A)

PPC: Abbreviation for Proportional Pressure Control

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Specifications (PC-PL40-030-K-00-A)

Gas to be used Nitrogen gas


Volume of gas (cc) 300
Charged pressure 1.18 {12}
(MPa {kg/cm2}) (at 80°C)
Max. operating pressure
6.86 {70}
(MPa {kg/cm2})

Function (PC-PL40-042-K-01-A)

• The accumulator is installed on the solenoid valve. If the engine is stopped with the work equipment raised,
the pressure of the compressed nitrogen gas in the accumulator develops the pilot pressure to be supplied
to the control valve. Therefore, the spool can be operated to lower the work equipment by its own weight.

10-188 PC210LC-10
10 Structure and function
Work equipment

Work equipment (ALL-L000-001-K-00-A)

Work equipment (PC-L410-041-K-00-A)

1. Bucket
2. Bucket link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder

PC210LC-10 10-189
10 Structure and function
Work equipment shim

Work equipment shim (PC220-L413-040-K-00-A)


Outline
• There are two types of the work equipment shims; one is the iron shims and the other is the plastic shims.
• The work equipment shims are inserted so that the clearance in each joint of the work equipment will be
the standard value.
Function
Iron shims
• The iron shims are primarily inserted in the parts that need to be greased every 100 hours.
• One purpose of the iron shims is to reduce the play of the work equipment in the lateral direction.
a The shims need to be inserted on only the right or left side and do not need to be inserted on the
adjustment side, depending on the adjusting quantity of the clearance.

Plastic shims
• The plastic shims are primarily inserted in the parts that need to be greased every 500 hours.
• The purposes of the plastic shims are to reduce the play of the work equipment in the lateral direction and
prevent squeaks and scuffing caused by rubbing of the steel parts at the end faces of the joint portions.
• Combined with the greasing interval extension bushings, the plastic shims prevent squeaks caused by
lack of grease and extend the greasing intervals.
• The plastic shims are inserted in every contact face of each part so that the steel parts at the end faces of
the joint portion will not come in contact with each other.
a Combined with the greasing interval extension bushings and dust seals, the plastic shims extend the
greasing interval to 500 hours.

10-190 PC210LC-10
10 Structure and function
Bucket play adjustment shim

Bucket play adjustment shim (PC220-LBKB-040-K-00-A)


Outline
• The separated iron shims are used for the connection of arm and bucket.
• By adjusting the number of shims, play at connecting part can be adjusted.
a Play can be reduced by deleting some shims when the play becomes large.

PC210LC-10 10-191
10 Structure and function
Cab mount and cab tipping stopper

Cab and its attachments (ALL-K000-001-K-00-A)

Cab mount and cab tipping stopper (PC-K138-041-K-00-A)

1. Front damper
2. Rear damper
3. Cab tipping stopper

Structure
• 4 dampers are located in front and rear of cab (2 each), and fix cab and floor frame onto revolving frame.
• Oil-filled damper is used to absorb vibration.
• Cab tipping stopper (3) installed at a place in the rear section aims to secure the cab when the machine
tips over.
• As shown in following table, various dampers are available upon its mounting location.
Color of identifying seal
Location of damper Bent of craw
(printing)
Front left Not bent Yellow (215)
Front right Bent Blue (200)
Rear left Not bent Yellow (215)
Rear right Not bent Yellow (215)

10-192 PC210LC-10
10 Structure and function
ROPS cab

ROPS cab (PC-K000-041-K-00-A)

ROPS: Abbreviation for Roll-Over Protective Structure

1. Front window
2. Windshield wiper
3. Head lamp
4. Ceiling window
5. KOMTRAX communication antenna
6. KOMTRAX GPS antenna
7. Radio antenna
8. Door
9. Mirror
Function (PC220-K000-042-K-00-A)

• ROPS cab is a structure which protects the operator fastening a seat belt not to be crushed when the
machine tips over.

PC210LC-10 10-193
10 Structure and function
Electrical control system

Electrical system (ALL-RA1D-001-K-01-A)

Electrical control system (PC220-C050-001-K-00-A)

Machine control system diagram (PC220-C050-051-K-00-A)

a Items marked with "*1" in drawing are the optional equipment.

10-194 PC210LC-10
10 Structure and function
Electrical control system

PC210LC-10 10-195
10 Structure and function
Electrical control system

10-196 PC210LC-10
10 Structure and function
Electrical control system

Engine control function (PC220-AK60-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Engine shutdown secondary switch
8. Engine controller
9. Lock lever
10. PPC lock switch
11. Starting motor cut-off relay (for PPC lock)
12. Starting motor cut-off relay (for personal code)
13. Fuel control dial
14. Safety relay
15. Starting motor
16. Fuel supply pump
17. Sensors
18. Machine monitor
19. KOMTRAX terminal
20. Pump controller

Function
• The neutral safety circuit is employed to secure safety when the engine is started.
a The engine does not start until the lock lever is set to the “LOCK“ position.
• The KOMTRAX engine cut circuit is employed to disable the engine from starting when the KOMTRAX
terminal receives an engine cut command issued through external operation.
• When you cannot stop the engine due to stuck starting switch (6), engine shutdown secondary switch (7)
is usable for stopping the engine.

Starting the engine


• If starting switch (6) is turned to “ON“ position , engine controller (8) sends command current to fuel supply
pump (16).

PC210LC-10 10-197
10 Structure and function
Electrical control system

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

Engine speed control


• Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8)
selects lower throttle signal, and sends command current to fuel supply pump (16).
Fuel supply pump (16) adjusts the fuel injection rate to control the engine speed.

Engine stop
• If starting switch (6) is turned to “OFF“ position, the current from ACC terminal of starting switch (6) to
engine controller (8) is cut off, and consequently the command current to fuel supply pump (16) is cut off.
Fuel supply pump (16) stops fuel feed, decreasing the engine speed until the engine stops.

Stopping the engine with engine shutdown secondary switch


• If engine shutdown secondary switch (7) is turned to “Stop Engine“ position, the current from ACC terminal
of starting switch (6) to engine controller (8) is forcibly cut off.
Above induces the same state as when starting switch (6) is turned to “OFF“ position, stopping the engine.

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Electrical control system

Engine and pump combined control function (PC200_10-C3W0-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Sensors
14. Front pump swash plate sensor
15. Rear pump swash plate sensor
16. One-touch power max. switch
17. Front pump oil pressure sensor
18. Rear pump oil pressure sensor

PC210LC-10 10-199
10 Structure and function
Electrical control system

19. Oil pressure sensor


20. Oil pressure switch
21. Front pump
21a. Servo
21b. LS valve
21c. PC valve
22. Rear pump
22a. Servo
22b. LS valve
22c. PC valve
23. Control valve
23a. Self-pressure reducing valve
23b. Merge-divider valve
23c. Travel junction valve
24. Front pump PC-EPC valve
25. Rear pump PC-EPC valve
26. LS-EPC valve
Input and output signals
a: Front pump PC-EPC valve drive signal
b: Rear pump PC-EPC valve drive signal
c: Solenoid valve GND
d: CAN signal
e: LS-EPC valve drive signal
f: Swash plate sensor signal
g: Oil pressure sensor signal
h: One-touch power max. switch signal
i: Oil pressure switch signal
j: 1st throttle signal
k: Supply pump control signal
l: Sensor signals

Function
• This function allows the operator to select any of the six working modes of P, E, L, ATT-P, ATT-E and B
with the working mode selector switch of the machine monitor. The most suitable combination of engine
torque (T) and pump absorption torque can be selected depending on the work contents of the machine. If
“None“ is selected for the attachment in the default setting of the service mode, one of the three modes of
P, E and L is selectable.
• The pump controller calculates the pump absorption upper limit torque based on the working mode, speed
setting by the fuel control dial, and actual engine speed, and controls the pump to maintain it near the
setting matching point for each mode even at high loads.
• When the engine speed is lowered, the controller prevents the engine from stopping by throttling the pump
absorption torque.

10-200 PC210LC-10
10 Structure and function
Electrical control system

Control method in each mode


P, E, L, ATT-P and ATT-E modes
Matching point
Working mode Matching point
P and ATT-P 100.7 kW/1,700 rpm
(During work) {135 HP/1,700 rpm}
E and ATT-E 86.1 kW/1,680 rpm
(During work) {115.4 HP/1,680 rpm}
• In P, E, ATT-P and ATT-E modes, the engine speed is always controlled so that it is kept around the
matching point specified for each mode.
• At light loads, the engine operates at high speeds. As the load increases, the engine speed decreases
while the torque is increased, until the matching point with pump absorption torque upper limit (PT) is
reached. [See (1) in graph]
• As the load increases further, the engine speed decreases further. [See (2) in graph]
• The controller lowers the pump absorption upper limit torque (PT) to reduce the load on the engine. [See
(3) in graph]

PC210LC-10 10-201
10 Structure and function
Electrical control system

• As the engine load decreases, the engine speed increases. [See (4) in graph]
• The controller raises the pump absorption upper limit torque (PT) to maintain it near the matching point.
[See (5) in graph]
• To save fuel consumption, the controller lowers the engine matching speed (Nm) at low loads (low delivery
and torque). [See (6) in graph]

B and L modes
Working mode Partial output point
B 75 %
L 70 %
Matching point
Working mode Matching point
77.2 kW/1,655 rpm
B
{103.5 HP/1,655 rpm}
73.55 kW/1,650 rpm
L
{98.60 HP/1,650 rpm}
• In B or L mode, engine output is controlled to a constant level.

10-202 PC210LC-10
10 Structure and function
Electrical control system

• The controller controls the pump absorption upper limit torque (PT) to keep the engine torque constant
along the equal engine horsepower curve.

Control function when travelling


• The engine speed (N) increases when if machine travels in P or ATT-P mode.
• Traveling the machine in E, ATT-E or B mode leaves the working mode unchanged, but raises the pump
absorption torque and engine speed (N) to values same as those in P mode.
• If the machine travels in L mode, the working mode and engine speed (N) do not change, but the pump
absorption torque is increased.

PC210LC-10 10-203
10 Structure and function
Electrical control system

Control function that becomes available when emergency pump drive switch is turned on.
• Even if any abnormality occurs in the controller and no work is possible because the main pump does not
work properly, operating emergency pump drive switch (1) temporarily enables to maintain functions of the
machine with absorption torque quite similar to those in the E mode.
In this case, a constant current flows from the battery to the PC-EPC valve, so the oil pressure is sensed
by only the PC-EPC valve.
a: Emergency (when abnormal)
b: Normal (when normal)
a Emergency pump drive switch (1) is an alternative type. If the machine is operated at “Emergency (a)“
position when the machine is normal condition, Action Level “L03“ will be shown on the display.

10-204 PC210LC-10
10 Structure and function
Electrical control system

PC210LC-10 10-205
10 Structure and function
Electrical control system

Pump and valve control function (PC220-C3W1-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Sensors
14. Front pump swash plate sensor
15. Rear pump swash plate sensor
16. Front pump
16a. Servo
16b. LS valve

10-206 PC210LC-10
10 Structure and function
Electrical control system

16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve
18a. Self-pressure reducing valve
18b. Merge-divider valve
18c. Travel junction valve
18d. Main relief valve
18e. Variable back pressure valve
19. Front pump PC-EPC valve
20. Rear pump PC-EPC valve
21. LS-EPC valve
22. Pump merge-divider EPC valve (for main spool)
23. Pump merge-divider EPC valve (for LS spool)
24. Travel junction solenoid valve
25. 2-stage relief solenoid valve
26: Variable back pressure solenoid valve

Input and output signals


a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve GND
d. CAN signal
e. LS-EPC valve drive signal
f. Swash plate sensor signal
g. Pump merge-divider EPC valve (for main spool) drive signal
h. Pump merge-divider EPC valve (for LS spool) drive signal
i. Travel junction solenoid valve drive signal
j. 2-stage relief solenoid valve drive signal
k. Variable back pressure solenoid valve drive signal
l. 1st throttle signal
m. Fuel supply pump control signal
n. Sensor signals

Function
• The LS control function, cut-off function, and 2-stage relief function enable the machine to maintain the
optimum matching under various working conditions.

LS control function
• According to the actuator operation, the output pressure from the LS-EPC valve to LS valve varies in order
to change the selector point for pump delivery [LS set differential pressure (DLS)] in the LS valve.
• The build-up time of pump delivery will be optimized, and the ease of combined operation and fine control
will be improved.

PC210LC-10 10-207
10 Structure and function
Electrical control system

A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig) = 1.8 MPa {18 kg/cm2}

Cut-off function
• This function increases PC-EPC current (J) to reduce the flow rate at relief, improving fuel consumption.
Operating for turning on cut-off function
When the one-touch power maximizing function is not activated and the average of front pump and rear
pump oil pressure sensor values is 27.9 MPa {285 kg/cm2} or higher.
The cut-off function does not work, however, while the machine is travelling, swing lock switch is in “ON“
position.

A: PC-EPC current at cut-off


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

Variable back pressure function


• Set pressure of the back pressure valve varies depending on the operating conditions of the machine.
Operating conditions Setting of back pressure valve
When swinging and travelling High-pressure setting
When operation other than swinging or travelling Low-pressure setting

10-208 PC210LC-10
10 Structure and function
Electrical control system

One-touch power maximizing function (PC220-PT23-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Sensors
14. One-touch power max. switch
15. Front pump oil pressure sensor
16. Rear pump oil pressure sensor
17. Front pump
17a. Servo
17b. LS valve
17c. PC valve
18. Rear pump
18a. Servo
18b. LS valve
18c. PC valve

PC210LC-10 10-209
10 Structure and function
Electrical control system

19. Control valve


19a. Self-pressure reducing valve
19b. Merge-divider valve
19c. Travel junction valve
19d. Main relief valve
20. Front pump PC-EPC valve
21. Rear pump PC-EPC valve
22. 2-stage relief solenoid valve

Input and output signals


a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve GND
d. CAN signal
e. 2-stage relief solenoid valve drive signal
f. Pump oil pressure sensor signal
g. One-touch power max. switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Sensor signals

Function
• By operating the one-touch power max. switch on the L.H. work equipment control lever knob, the power
is increased for a limited time.
• This can be used to increase digging force for a limited time, for example, when digging out a rock during
excavating work.
• If the one-touch power max. switch is pressed in P mode, E mode, ATT-P mode or ATT-E mode when the
load pressure is high, the hydraulic force will be increased by approx. 7%, and the horsepower will be
increased by approx. 12% to boost the digging force.
• The functions are automatically set as follows.
Function Setting
Engine and pump combined control Matching at rated output point
34.8 MPa {355 kg/cm2}
2-stage relief function O
37.2 MPa {380 kg/cm2}
Cut-off function Cancel

a This function maintains the power maximizing operation as long as the one-touch power max. switch is
pressed. This function, however, is cancelled in about 8.5 seconds regardless of pressing of the switch.

10-210 PC210LC-10
10 Structure and function
Electrical control system

Auto-deceleration function (PC-AF60-042-K-00-A)

1. Pump controller
2. Engine controller
3. Machine monitor
4. Fuel control dial
5. Fuel supply pump
6. Sensors
7. Oil pressure switch
8. Oil pressure sensor
9. Main pump
10. Control valve
10a. Self-pressure reducing valve
10b. Merge-divider valve
10c. Travel junction valve
11. PPC lock solenoid valve
Input and output signals
a. CAN signal
b. Oil pressure sensor signal
c. Oil pressure switch signal
d. 1st throttle signal
e. Fuel supply pump control signal
f. Sensor signals

PC210LC-10 10-211
10 Structure and function
Electrical control system

Function
• When all the control levers are set to NEUTRAL position for waiting for a dump truck or work, the engine
speed is automatically reduced to its controlled speed, and fuel consumption and noise are lowered.
• When any control lever is operated, the engine speed returns immediately to the speed set with the fuel
control dial.
Operation

When control lever in NEUTRAL position


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

When control lever is operated


• If any control lever is operated when the engine speed is maintained at the controlled speed (approx.
1,050 rpm), the engine speed increases immediately to the speed set with the fuel control dial.

A: All work equipment control levers in “NEUTRAL“


B: All work equipment control levers in “OPERATED“
C: Fuel control dial set speed
D: Controlled engine speed (approx. 1,050 rpm)
E: 4 sec.
F: Max. 2 sec.
G: Max. 1 sec.

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10 Structure and function
Electrical control system

Engine automatic warm-up function (PC-AP13-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Air conditioner unit
11. Emergency pump drive switch
12. Fuel control dial
13. Fuel supply pump
14. Sensors
15. Hydraulic oil temperature sensor
16. Front pump
16a. Servo
16b. LS valve
16c. PC valve
17. Rear pump
17a. Servo
17b. LS valve
17c. PC valve
18. Control valve

PC210LC-10 10-213
10 Structure and function
Electrical control system

18a. Self-pressure reducing valve


18b. Merge-divider valve
18c. Travel junction valve
19. Front pump PC-EPC valve
20. Rear pump PC-EPC valve

Input and output signals


a: Front pump PC-EPC valve drive signal
b: Rear pump PC-EPC valve drive signal
c: Solenoid valve GND
d: CAN signal
e: Hydraulic oil temperature signal
f: 1st throttle signal
g: Fuel supply pump control signal
h: Sensor signals

Function
• This is a function that raises the engine speed automatically to warm up the engine if the coolant
temperature is low after start-up of the engine.
• There are two types of the engine automatic warm-up function depending on the purpose; one is "Heater
warm-up" and the other is "Normal warm-up"
• The purpose of the heater warm-up is to raise the coolant temperature and improve the heater efficacy.
• The purpose of the normal warm-up is to warm up the engine to prevent it from being damaged by
operation in low temperature.

Operating conditions 1
Machine specification: with air conditioner
Air conditioner: blower “ON“
Coolant temperature: below 55°C
Ambient temperature: below 5°C
Manual stationary regeneration: OFF
oot accumulation: Max. 2 g/l
O O
If any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up is disabled (normal warm-up) Heater warm-up is enabled
Operating conditions 2 (all required for operation) O
Coolant temperature: below 30°C
O
Engine speed: Max. 1,200 rpm
O O
Operation Operation

Engine speed: 1,200 rpm Engine speed: Min. 1,300 rpm

O O
Condition for cancellation Condition for cancellation
(Canceled when either one of the following (Canceled when either one of the following
conditions is met.) conditions is met.)
Coolant temperature: Min. 30°C Coolant temperature: Min. 60°C
Auto Duration of automatic warming-up: Min.
Ambient temperature: Min. 10°C
10 minutes

10-214 PC210LC-10
10 Structure and function
Electrical control system

Fuel control dial: held at over 70% of full


Manual speed (MAX.) for 3 seconds or more

O O
Cancellation
Engine speed: as desired

PC210LC-10 10-215
10 Structure and function
Electrical control system

Overheat prevention function (PC-B717-042-K-00-A)

a See "Engine automatic warm-up function" for the system circuit diagram.
• Prevents overheating to protect the engine and hydraulic components by reducing load on the pump and
lowering the engine speed if the coolant or hydraulic oil temperature becomes too high.

Operating condition Operation/Remedy Resetting condition

Hydraulic oil temperature:


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

Operating condition Operation/Remedy Resetting condition

Coolant temperature: Below


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

Operating condition Operation/Remedy Resetting condition

Coolant temperature: Below


Working mode: P, E, ATT-P and 102°C
Coolant temperature: Min. ATT-E modes Hydraulic oil temperature:
102°C o Engine speed: Keep as is o Below 102°C
or • Torque control signal • Under above condition,
Hydraulic oil temperature: decreases the pump controller is returned to the
Min. 102°C absorption torque to reduce condition before operation
the load on the engine. of function (automatic
reset).

Operating condition Operation/Remedy Resetting condition

Coolant temperature: Below


Working mode: B mode 102°C
Coolant temperature: Min. Engine speed: Keep as is Hydraulic oil temperature:
102°C o Alarm monitor: Lights up o Below 102°C
or • Torque control signal • Under above condition,
Hydraulic oil temperature: decreases the pump controller is returned to the
Min. 102°C absorption torque to reduce condition before operation
the load on the engine. of function (automatic
reset).

10-216 PC210LC-10
10 Structure and function
Electrical control system

Operating condition Operation/Remedy Resetting condition

Coolant temperature: Below


105°C
Hydraulic oil temperature:
Coolant temperature: Min. Working mode: Any mode Below 105°C
105°C o o Fuel control dial: Return the
Engine speed: Low idle
or pointer to low idle (MIN)
Alarm monitor: Lights up position.
Hydraulic oil temperature:
Min. 105°C Alarm buzzer: Sounds • Under above condition,
controller is returned to the
condition before operation
of function (manual reset).

PC210LC-10 10-217
10 Structure and function
Electrical control system

Turbocharger protection function (PC200_10-AA90-042-K-00-A)

a See "Engine automatic warm-up function" for the system circuit diagram.
• Prevents seizure of the turbocharger by limiting the engine speed if the engine speed is increased
exponentially when starting the engine.

Operating condition Operation


o Turbocharger protection
Engine oil pressure: Below 50 kPa {0.51 kg/cm2}
(See the figure below)

A: Start engine
B: Duration of turbocharger protection (approx. 0 - 20 sec.)
C: Modulating time (approx. 1 sec.)
D: 500 rpm
E: Approx. 1,050 rpm
F: 1,650 rpm (*1)
*1: Working mode: P mode
Fuel control dial: Full speed (MAX) position
When travel lever is operated

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10 Structure and function
Electrical control system

Swing control function (PC-JA01-042-K-01-A)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Swing brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
10. Oil pressure switch
11. Oil pressure sensor
12. Main pump
13. Control valve
13a. Self-pressure reducing valve
13b. Merge-divider valve
13c. Travel junction valve
14. Swing motor
14a. 2-stage relief valve
15. Swing holding brake solenoid valve
16. 2-stage swing relief solenoid valve

Input and output signals


a. Swing brake cancel switch signal
b. Swing holding brake solenoid valve drive signal
c. CAN signal
d. Swing lock switch signal
e. 2-stage swing relief solenoid valve drive signal
f. Oil pressure sensor signal
g. Oil pressure switch signal

PC210LC-10 10-219
10 Structure and function
Electrical control system

Function
Swing lock and swing holding brake function
• On machines with swing lock (manual), swing can be locked at any position by turning swing lock switch
(1) to “ON“ position.
• Interlocked with the swing operation, the swing holding brake (automatic lock) prevents hydraulic drift from
occurring after the swing stops.
• Interlocked with the L.H. and R.H. work equipment control levers and attachment control pedals
operations, the swing holding brake is canceled to reduce the load on the swing equipment during
excavation work.

Swing lock
OFF ON
switch
Swing lock Not lighting Lights up
monitor
Function Swing holding brake Swing lock
• When the L.H. and R.H. work equipment • Swing holding brake works and locks the
control levers and attachment control swing of the upper structure.
pedals are set to NEUTRAL position, the • Even if the L.H. work equipment control
swing holding brake works in approx. 5 lever is operated for swing, the swing
sec. holding brake cannot be canceled, and
Operation
• When the L.H. and R.H. work equipment the upper structure does not swing.
control lever or attachment control pedal is
operated, the swing holding brake is
canceled and the upper structure
becomes free to swing.

A: When work equipment control lever or attachment control pedal is operated (Swing holding brake
“canceled“)
B: When work equipment control levers and attachment control pedals are in “NEUTRAL“ position
C: Swing holding brake “applied“
D: Approx. 5 sec.

10-220 PC210LC-10
10 Structure and function
Electrical control system

Swing holding brake cancel function


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

Quick warm-up function


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

PC210LC-10 10-221
10 Structure and function
Electrical control system

2-stage swing relief function


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

A: When pilot pressure is “shut off“ (low-pressure setting)


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

A: Oil flow at low-pressure setting


B: Oil flow at high-pressure setting
C: Flow necessary for swing
Z: Area where the loss by relief flow is reduced (fuel consumption improved)

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10 Structure and function
Electrical control system

Travel control function (PC200_10-C7H1-042-K-00-A)

1. Pump controller
2. Engine controller
3. Machine monitor
4. Fuel control dial
5. Fuel supply pump
6. Sensors
7. Front pump oil pressure sensor
8. Rear pump oil pressure sensor
9. Oil pressure sensor
10. Travel alarm
11. Front pump
11a. Servo
11b. LS valve
11c. PC valve
12. Rear pump
12a. Servo
12b. LS valve
12c. PC valve
13. Control valve
13a. Self-pressure reducing valve
13b. Merge-divider valve
13c. Travel junction valve
14. Travel motor
15. Travel speed increase solenoid valve

PC210LC-10 10-223
10 Structure and function
Electrical control system

16. Travel junction solenoid valve


17. LS-EPC valve
Input and output signals
a. Oil pressure sensor signal
b. CAN signal
c. LS-EPC valve drive signal
d. Solenoid valve GND
e. Travel junction solenoid valve drive signal
f. Travel speed increase solenoid valve drive signal
g. Oil pressure sensor signal
h. Travel alarm buzzer operation signal
i. 1st throttle signal
j. Fuel supply pump control signal
k. Sensor signals

Function
Travel speed selector function
1. Travel speed “Manual“ change
• Switching the travel speed selector switch to “Hi“, “Mi“ or “Lo“ changes the motor capacity, which
changes the machine travel speed.
Lo Mi Hi
Travel speed selector switch
(low speed) (medium speed) (high speed)
Motor flow rate (%) 75 70 100
Motor capacity (Max.) (Min.) (Min.)
Travel speed (km/h) 3.0 4.1 5.5
2. Travel speed “Automatic“ change
1) Automatic change corresponding to engine speed
• If you adjust the engine speed to 1,500 rpm or less with the fuel control dial, the travel speed does
not switch to “Hi“ when the machine is traveling in “Mi“, and automatically changes to “Mi“ when the
machine is travelling in “Hi“.
2) Automatic change according to pump delivery pressure
• If the travel circuit oil pressure increases on an uphill with the travel speed selector switch in “Hi“,
and the travel circuit oil pressure of 33.3 MPa {340 kg/cm 2} or above continues for 0.5 seconds or
more, the travel motor capacity is switched to that for medium speed travel (equivalent to “Mi“)
automatically (the travel speed switch position remains in “Hi“).
• If the travel circuit oil pressure decreases on a level ground or downhill during low speed travel
caused by the automatic speed change due to increase in the load on the travel circuit, and the
travel circuit oil pressure of 19.6 MPa {200 kg/cm2} or below continues for 0.5 seconds or more, the
travel motor capacity is switched back to that for speed of “Hi“ automatically.

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Electrical control system

A: 16.7 MPa {170 kg/cm2}


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

Travel junction function


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

PC210LC-10 10-225
10 Structure and function
Electrical control system

PPC lock function (PC-PX16-042-K-00-A)

PPC: Abbreviation for Proportional Pressure Control

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Starting switch
7. Lock lever
8. PPC lock switch
9. Main pump
10. Control valve
10a. Self-pressure reducing valve
10b. Merge-divider valve
10c. Travel junction valve
11. PPC lock solenoid valve
Function
• Interlocked with the lock lever, PPC lock switch is turned off when the lock lever is moved to “LOCK“
position.
• When the PPC lock switch is turned off, current to the PPC lock solenoid valve is shut off. Even if each
control lever or pedal is operated, the work equipment and machine do not move.

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System operating lamp function (PC-AW1Q-042-K-00-A)

1. Battery disconnect switch


2. Battery
3. Fusible link
4. Fuse box
5. System operating lamp
6. Machine monitor
7. Engine controller
8. Pump controller
9. KOMTRAX terminal
10. ID Key controller

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

Lighting up and going out of system operating lamp


• Voltage of 24 V is always applied to the one end of the system operating lamp (LED).
• When any controller is in operation, the output from the controller to the system operating lamp becomes
Low (0 V). This allows electric current to flow through the diode, lighting up the system operating lamp.
• When all controllers are resting, the output from each controller to the system operating lamp becomes Hi
(24 V). The electric current does not flow through the diode, and the system operating lamp goes out.
a The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the
minute leakage of current and not an abnormal phenomenon.
• The KOMTRAX terminal performs communication periodically even if the starting switch is kept in the
“OFF“ position, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the conditions including
the communication status and machine stop time. So the lamp can be lit as long as approximately 1 hour.

PC210LC-10 10-227
10 Structure and function
Electrical control system

a When you want to cut off the battery circuit for maintenance but the system operating lamp keeps on
lighting up, turn the starting switch to the “ON“ position once, then turn it to the “OFF“ position. The
lamp will go out in 2 minutes longest.
After the system operating lamp goes out, turn the battery disconnect switch immediately to the “OFF“
position.

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Electrical control system

Attachment flow control function (PC-PT24-042-K-00-A)

(Machine with provision for attachment)

1. Battery disconnect switch


2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Resistor for PC-EPC valve
7. Pump controller
8. Engine controller
9. Machine monitor
10. Emergency pump drive switch
11. Fuel control dial
12. Fuel supply pump
13. Sensors
14. Oil pressure switch
15. Front pump
15a. Servo
15b. LS valve
15c. PC valve
16. Rear pump
16a. Servo
16b. LS valve
16c. PC valve
17. Control valve

PC210LC-10 10-229
10 Structure and function
Electrical control system

17a. Self-pressure reducing valve


17b. Merge-divider valve
17c. Travel junction valve
18. Attachment selector solenoid valve
19. PPC lock solenoid valve
20. Oil flow rate adjuster EPC valve for attachment
21. Front pump PC-EPC valve
22. Rear pump PC-EPC valve
23. Attachment circuit selector valve (high pressure side)
24. Attachment circuit selector valve (low pressure side)
25. Attachment
26. Accumulator
Input and output signals
a. Front pump PC-EPC valve drive signal
b. Rear pump PC-EPC valve drive signal
c. Solenoid valve GND
d. CAN signal
e. Attachment selector solenoid valve drive signal
f. Oil flow rate adjuster EPC valve drive signal for attachment
g. Oil pressure switch signal
h. 1st throttle signal
i. Fuel supply pump control signal
j. Sensor signals

Function
• Setting of the working mode and oil flow rate on the machine monitor allows controlling the oil flow rate to
the attachment when the attachment control pedal is fully depressed.
• Attachment operation switches depending on the working mode as shown below.
Working mode Attachment operation
ATT–P, ATT–E Double-acting
B Single-acting

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10 Structure and function
Electrical control system

System component parts (ALL-RA1C-001-K-00-A)

Engine controller (PC220-AP70-041-K-00-A)

Input and output signals (PC-AP70-03C-K-00-A)


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

PC210LC-10 10-231
10 Structure and function
Electrical control system

Pin No. Signal name Signal category


17 CAN_C (-) E
18 CAN_B (-) (KOMNET/r) E
19 (*1) —
20 (*1) —
21 Sensor power supply (12 V) A
22 GND C
23 Mass air flow and temperature sensor B
24 Water-in-fuel sensor B
25 (*1) —
26 Ne (crankshaft) speed sensor (+) B
27 (*1) —
28 (*1) —
29 (*1) —
30 IMV(+) D
31 Engine oil pressure switch B
32 GND C
33 (*1) —
34 (*1) —
35 (*1) —
36 Sensor power supply (5 V) A
37 NE (crankshaft) speed sensor (-) C
38 (*1) —
39 (*1) —
40 IMV (-) C
41 (*1) —
42 (*1) —
43 Injector #4 (+) D
44 Injector #5 (+) D
45 Injector #6 (+) D
46 Injector #3 (+) D
47 Injector #2 (+) D
48 Injector #1 (+) D
49 (*1) —
50 (*1) —
51 (*1) —
52 (*1) —
53 Injector #4 (-) C
54 Injector #5 (-) C
55 Injector #6 (-) C
56 Injector #3 (-) C
57 Injector #2 (-) C
58 Injector #1 (-) C
59 GND C
60 Sensor power supply (5 V) A
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(2)[ECM J2(CN-CE02)]
Pin No. Signal name Signal category
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —

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10 Structure and function
Electrical control system

Pin No. Signal name Signal category


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

PC210LC-10 10-233
10 Structure and function
Electrical control system

Pin No. Signal name Signal category


57 (*1) —
58 (*1) —
59 EGR valve lift sensor B
60 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
DRC26-60P(3)[CN-CE03]
Pin No. Signal name Signal category
1 Continuous power supply (24 V) A
2 Continuous power supply (24 V) A
3 Starting switch ACC signal B
4 Intake air heater relay (+) D
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 System operating lamp D
10 (*1) —
11 Continuous power supply (24 V) A
12 Continuous power supply (24 V) A
13 GND C
14 (*1) —
15 (*1) —
16 (*1) —
17 CAN_A (+) (KOMNET/c) E
18 CAN_A (-) (KOMNET/c) E
19 GND C
20 (*1) —
21 GND C
22 GND C
23 (*1) —
24 (*1) —
25 (*1) —
26 (*1) —
27 (*1) —
28 (*1) —
29 (*1) —
30 (*1) —
31 GND C
32 GND C
33 (*1) —
34 (*1) —
35 (*1) —
36 (*1) —
37 (*1) —
38 (*1) —
39 (*1) —
40 (*1) —
41 GND C
42 Sensor power supply (5 V) A
43 GND C
44 (*1) —

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10 Structure and function
Electrical control system

Pin No. Signal name Signal category


45 KDOC inlet temperature sensor B
46 (*1) —
47 (*1) —
48 KDOC outlet temperature sensor B
49 Idle validation signal 1 B
50 Idle validation signal 2 B
51 Throttle signal B
52 Sensor power supply (5 V) A
53 (*1) —
54 KDPF outlet temperature sensor B
55 KDPF differential pressure sensor B
56 (*1) —
57 (*1) —
58 KDPF outlet pressure sensor B
59 (*1) —
60 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.

PC210LC-10 10-235
10 Structure and function
Electrical control system

Pump controller (PC-C3V1-041-K-00-A)

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10 Structure and function
Electrical control system

Input and output signals (PC-C3V1-03C-K-00-A)


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

PC210LC-10 10-237
10 Structure and function
Electrical control system

Pin No. Signal name Input/Output signal


51 Arm OUT PPC oil pressure sensor Input
52 (*1) —
53 R.H. travel REVERSE oil pressure sensor Input
54 (*1) —
55 (*1) —
56 Wiper motor reverse (W) Input
57 (*1) —
58 Model selection 5 Input
59 Model selection 1 Input
60 (*1) —
61 Starting switch C signal Input
62 External start signal Input
63 NC —
64 CAN (C)_L Input/Output
65 (*1) —
66 (*1) —
67 (*1) —
68 Rear pump swash plate sensor Input
69 Bucket CURL PPC oil pressure sensor Input
70 (*1) —
71 (*1) —
72 R.H. travel FORWARD PPC oil pressure sensor Input
73 (*1) —
74 (*1) —
75 Wiper motor stop (P) Input
76 Cab front window open limit switch Input
77 Model selection 4 Input
78 (*1) —
79 PPC lock switch Input
80 Starting switch ACC signal Input
81 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
AMP-40P [CN-CP02]
Pin No. Signal name Input/Output signal
82 (*1) —
83 (*1) —
84 (*1) —
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 (*1) —
88 LS-EPC valve Output
89 Pump merge-divider EPC valve (LS) Output
90 (*1) —
91 (*1) —
92 (*1) —
93 Travel speed increase solenoid valve Output
94 Swing 2-stage relief solenoid valve Output
95 (*1) —
96 Front pump PC-EPC valve Output
97 Attachment oil flow rate adjustment EPC valve Output
98 (*1) —

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10 Structure and function
Electrical control system

Pin No. Signal name Input/Output signal


99 (*1) —
100 System-in-use signal Output
101 Swing holding brake solenoid valve Output
102 (*1) —
103 (*1) —
104 Rear pump PC-EPC valve Output
105 (*1) —
106 (*1) —
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 (*1) —
111 (*1) —
112 Pump merge-divider EPC valve (main) Output
113 Variable back pressure solenoid valve Output
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Solenoid power supply Input
117 GND (solenoid) Input
118 Solenoid power supply Input
119 Wiper motor (+) Output
120 GND (solenoid) Input
121 Solenoid power supply Input
*1: Never connect these pins. Malfunctions or failures may occur.

PC210LC-10 10-239
10 Structure and function
Electrical control system

Fuel control dial (PC-AGJ7-041-K-01-A)

1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector

Function (PC-AGJ7-042-K-00-A)
• This dial is installed in the right console box. Turning knob (1) causes potentiometer (5) shaft to rotate.
• As the potentiometer shaft is turned, the resistance of the variable resistor in potentiometer (5) changes
and a throttle signal is sent to the engine controller.
• The hatched areas in the graph are abnormality detection areas. If the throttle voltage is within the area,
the engine speed drops down to low idle.

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10 Structure and function
Electrical control system

Resister for PC-EPC valve (PC200_10-C3VR-041-K-00-A)


PC: Abbreviation for Pressure Compensation
EPC: Abbreviation for Electromagnetic Proportional Control

1. Resistance
2. Connector

Specifications (PC220-C3VR-030-K-00-A)
Resistance: 20 z

Function (PC-C3VR-042-K-00-A)
• When the emergency pump drive switch or the emergency work equipment drive switch is turned to “ON“
position, this resistor sends an electric current to each PC-EPC valve that is appropriate for their condition.
a No electric current flows in the normal condition.

PC210LC-10 10-241
10 Structure and function
Electrical control system

CAN terminating resistor (PC220-Q2V1-041-K-00-A)


CAN: Abbreviation for Controller Area Network

1. Connector (with built-in resistor)

Specifications (PC220-Q2V1-030-K-00-A)
Resistance: 120 z

Function (PC220-Q2V1-042-K-00-A)
• This resistance controls the reflection of the high-frequency signals at the end of CAN communication line
not to generate noise on the CAN communication signals sending and receiving between controllers.
a If this resistance is missing, an error occurs on CAN communication and the machine cannot be
operated.

Engine oil pressure switch (PC-ABK6-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Specifications (PC220-ABK6-030-K-00-A)
Contact type: Normally closed

Function (PC-ABK6-042-K-00-A)

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10 Structure and function
Electrical control system

• This oil pressure switch is installed to the cylinder block. It detects engine oil pressure, and turns the
switch to "ON" position when the pressure goes below the specified value.

PC210LC-10 10-243
10 Structure and function
Electrical control system

PPC oil pressure switch (PC-E610-041-P-00-A)


PPC: Abbreviation for Proportional Pressure Control

1. Plug
2. Switch
3. Connector

Specifications (PC220-E610-030-P-00-A)
Contact type: Normally open
Operating (ON) pressure: 490 ± 98.1 kPa {5.0 ± 1.0 kg/cm2}
Resetting (OFF) pressure: 294 ± 49.0 kPa {3.0 ± 0.5 kg/cm2}

Function (PC220-E610-042-P-00-A)
• Two sensors are installed to attachment PPC valve. They detect PPC oil pressure during attachment
operation and turn the switch to “ON“ position if the pressure is equal or higher than the specified
pressure.

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10 Structure and function
Machine monitor system

Machine monitor system (PC-Q170-042-K-01-A)

1. Machine monitor
2. Battery
3. Pump controller
4. Engine controller
5. Air conditioner controller
6. KOMTRAX terminal
7. Sensors and switches
8. Wiper motor and window washer motor
9. Camera
Input and output signals
a. Power supply
b. CAN signal
c. Sensor and switch signals
d. Drive signal
e. Camera signal

Function
• The monitor system keeps the operator informed of all machine functions, by monitoring the machine
conditions by using the sensors and switches installed in various parts of the machine and processing
them instantly to display on the machine monitor.

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10 Structure and function
Machine monitor system

The information displayed on the machine monitor falls into the following types:
1. Alarm when the machine has trouble
2. Machine status display (coolant temperature, hydraulic oil temperature, fuel level, etc.)
3. Display of camera image
• The switches on the machine monitor have an operating function to control the machine.

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10 Structure and function
Machine monitor system

Machine monitor (PC-Q180-042-K-01-A)

Function
• The machine monitor has monitor display function, mode selection function and switch function for
electrical parts etc. Also it has an alarm buzzer.
• The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output the
information.
• The machine monitor consists of a display and switches: the display is of LCD type, and the switches are
of flat sheet switch.
• If a failure occurs in the machine monitor itself, controller or wiring circuit between monitor and controller,
the monitor does not display properly.

Precautions on the machine monitor display


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

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10 Structure and function
Machine monitor system

Input and output signals (PC-Q180-03C-K-00-A)


070-18P[CN-CM01]
Pin No. Signal name Input/Output signal
1 Continuous power supply (24 V) Input
2 Continuous power supply (24 V) Input
3 GND (continuous power supply) —
4 GND (continuous power supply) —
5 External start signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) —
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 (*1) —
15 Fuel level sensor Input
16 Charge level (Alternator R terminal) Input
17 (*1) —
18 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CM02]
Pin No. Signal name Input/Output signal
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input
4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 (*1) —
7 CAN (C) terminating resistor terminal —
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal —
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output
*1: Never connect these pins. Malfunctions or failures may occur.
070-20P [CN-CM03]
Pin No. Signal name Input/Output signal
1 (*1) —
2 (*1) —
3 (*1) —
4 (*1) —
5 (*1) —
6 (*1) —
7 (*1) —
8 (*1) —
9 (*1) —
10 (*1) —
11 (*1) —
12 (*1) —

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Machine monitor system

Pin No. Signal name Input/Output signal


13 (*1) —
14 (*1) —
15 (*1) —
16 (*1) —
17 (*1) —
18 (*1) —
19 (*1) —
20 (*1) —
*1: Never connect these pins. Malfunctions or failures may occur.
070-8P [CN-CM04]
Pin No. Signal name Input/Output signal
1 Camera power supply (8 V) Output
2 Camera NTSC signal 1 Input
3 Camera NTSC signal 2 Input
4 Camera NTSC signal 3 Input
5 GND (Camera power supply) —
6 Switching camera 2 to original/mirror image Output
7 Switching camera 3 to original/mirror image Output
8 Shield GND —

PC210LC-10 10-249
10 Structure and function
Machine monitor system

Display (PC-Q1LA-042-K-00-A)

A: Standard screen
B: Check before starting screen
C: Maintenance interval warning screen
D: Warning screen
E: Guidance screen
F: Camera image screen
a Camera image screen (F) shown in the figure is when two or more cameras are installed
1. Message monitor
2. KDPF regeneration monitor
3. Engine stop monitor
4. Seatbelt monitor
5. Air conditioner monitor
6. Wiper monitor

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Machine monitor system

7. Swing lock monitor


8. Engine preheating monitor
9. Service meter
10. Auto-deceleration monitor
11. Working mode monitor
12. Travel speed monitor
13. Fuel level gauge
14. Fuel level monitor
15. Eco gauge
16. Fuel consumption gauge
17. Hydraulic oil temperature monitor
18. Hydraulic oil temperature gauge
19. Engine coolant temperature monitor
20. Engine coolant temperature gauge
21. Radiator coolant level monitor
22. Charge level monitor
23. Engine oil pressure monitor
24. Engine oil level monitor
25. Air cleaner clogging monitor
26. Water separator monitor
27. Clock
28. Maintenance interval warning monitor
29. System status monitor
30. Action level monitor
31. ECO guidance

PC210LC-10 10-251
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Machine monitor system

Gauge
Gauge Display item Description Remarks
Temperature Background • Indicates
Range
(°C) color corresponding
W1 105 Red temperature range.
(*1) • Alarm buzzer sounds
W2 102 Red
Engine coolant when the temperature
W3 100 Blue is 105°C or higher.
temperature
gauge W4 85 Blue • If the monitor
W5 60 Blue background appears
white, warm-up the
W6 30 White engine.
Temperature Background • Indicates
Range
(°C) color corresponding
H1 105 Red temperature range.
(*1) • Alarm buzzer sounds
H2 102 Red
when the temperature
Hydraulic oil H3 100 Blue is 105°C or higher.
temperature H4 85 Blue • If the monitor
gauge H5 40 Blue background appears
white, warm up the
H6 20 White hydraulic
components.
Range Quantity (l) Background • Indicates
color corresponding
F1 304 Blue remaining fuel level.
(*1) F2 245 Blue
Fuel level gauge F3 200 Blue
F4 100 Blue
F5 60 Blue
F6 41 Red
• Indicates
instantaneous fuel
Segment Load level consumption
(average of fuel
consumption per 3
minutes) in 10 steps.
(*2) Light to (It is displayed when
Green 1 to 8
Eco gauge medium the user menu's
“ECO guidance“ o
“Display setting“ o
“Eco gauge display“
Orange 9 , 10 Heavy is set.)

• Indicates
accumulated engine
operating hours (the
Service meter 00000.0 h to 99999.9 h alternator is running).
(F4 switch changes it
to clock display.)

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Gauge Display item Description Remarks


• Displays time.
• 12-hour display (AM/PM) (F4 switch changes it
Clock • 24-hour display to service meter
display.)
• Indicates average
fuel consumption.
(Display is switched
when the user menu's
“ECO guidance“ o
“Display setting“ o
“Fuel gauge display“
are specified.)
(*2)
• 1 day
Fuel
• Split
consumption
• Not installed
gauge

*1: If the gauge signal is not available due to open circuit in CAN communication line, the gauge pointer
disappears.
*2: Display item is switched when the user menu's “ECO guidance“ o “Display setting“ are specified.

PC210LC-10 10-253
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Machine monitor system

Caution monitor
Description
Monitor
Symbol Display item display Action level Remarks
Range
(Background monitor
color)
Lights up • Background color
Min. 102°C (Red) L02 changes depending
Min. 30°C or Lights up on the temperature
— detected.
below 102°C (Blue)
(*1) • Alarm buzzer sounds
Engine coolant when the temperature
temperature is 105°C or higher.
Lights up • If the monitor
Below 30°C —
(White) background appears
white, warm-up the
engine.
Lights up • Background color
Min. 102°C (Red) L02 changes depending
Min. 20°C or Lights up on the temperature
— detected.
below 102°C (Blue)
• Alarm buzzer sounds
(*1) when the temperature
Hydraulic oil is 105°C or higher.
temperature • If the monitor
Lights up background appears
Below 20°C —
(White) white, warm up the
hydraulic
components.

Lights up • Background color


Below 41 l —
(*1) (Red) changes depending
Lights up on the remaining fuel
Fuel level —
Min. 41 l (Blue) level.
When • When failure is
abnormal detected with the
(*1) Lights up (*3) engine stopped, the
(When below (Yellow)
Radiator coolant specified L01 monitor lights up on
level level) the screen.
When normal Lights out —
• The monitor lights up
When charge
is defective on the screen and
alarm buzzer sounds
(*1) (Charge Lights up when failure is
(Red) L03
Battery charge voltage < detected while the
condition battery engine running.
voltage)
When normal Lights out —
When • The monitor lights up
abnormal on the screen and
(*1) Lights up alarm buzzer sounds
(When below (Red) L03
Engine oil specified when failure is
pressure level) detected while the
— engine running.
When normal Lights out

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Description
Monitor
Symbol Display item display Action level Remarks
Range
(Background monitor
color)
When • When failure is
abnormal detected with the
Lights up (*3) engine stopped, the
(*1) (When below (Yellow) L01 monitor lights up on
Engine oil level specified
level) the screen.
When normal Lights out —
When • When failure is
abnormal detected with the
(*1) Lights up (*3) engine running, the
(When above (Yellow)
Clogging of air specified L01 monitor lights up on
cleaner level) the screen.
When normal Lights out —
When • When failure is
abnormal detected with the
(There is engine running, the
water Lights up monitor lights up on
(*1) — the screen.
collected (Red)
Water separator above the
specified
amount.)
When normal Lights out —
When • The display changes
exceeding Lights up depending on the

maintenance (Red) time to/after the
interval maintenance.
• After the starting
Maintenance (*2) switch is turned to
interval warning “ON“ position , the
When Lights up monitor turns on if the
exceeding —
(Yellow) monitor light-up
maintenance conditions are met,
notifying time and then goes out in
30 seconds.
When action • When failure is
level “L04“ or Lights up detected in the
(Red) L04 and L03
“L03“ is machine system, the
System status detected monitor lights up.
• When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
When action • When failure is
level “L04“ or Lights up detected in the
(Red) L04 and L03
“L03“ is engine system, the
State of engine detected monitor lights up.
system • When the
When action (*3)
Lights up background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.

PC210LC-10 10-255
10 Structure and function
Machine monitor system

Description
Monitor
Symbol Display item display Action level Remarks
Range
(Background monitor
color)
When action • When failure is
level “L04“ or Lights up detected in the
(Red) L04 and L03
“L03“ is hydraulic system, the
State of detected monitor lights up.
hydraulic system • When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
When action • When failure is
level “L04“ or Lights up detected in the KDPF
(Red) L04 and L03
“L03“ is system, the monitor
State of KDPF detected lights up.
system • When the
When action Lights up (*3) background color is
level “L01“ is (Yellow) L01 red, the alarm buzzer
detected
sounds.
When action • The monitor lights up
level “L04“ or Lights up when soot is
(Red) L03
“L03“ is deposited inside
detected KDPF or cleaning
Deposition of function is abnormally
soot on KDPF degraded.
When action Lights up (*3) When the
level “L01“ is (Yellow) L01 background color is
detected
red, the alarm buzzer
sounds.
• The monitor lights up
Engine Engine Lights up and alarm buzzer
overspeed overspeed is (Red) L02 sounds when engine
detected overspeed is
detected.
• When failure is
State of air When air (*3) detected in the air
Lights up
conditioner conditioner is conditioner system,
(Yellow) L01
system abnormal the monitor lights up.
When action Lights up • When failure is
level “L04“ is (Red) L04 detected on the
detected machine, the monitor
When action Lights up lights up.
level “L03“ is (Red) L03 When the
detected background color is
Action level
When action Lights up red, the alarm buzzer
level “L02“ is (Red) L02 sounds.
detected
When action Lights up (*3)
level “L01“ is (Yellow)
detected L01

*1: It is included in the check before starting items. After the staring switch is turned to “ON“ position, the
monitor turns on for two seconds, and changes to the standard screen if no failure is found.
*2: The notifying time is changeable from the items in “Maintenance mode display setting“ of the service mode.
*3: Monitor goes out after lighting up for 2 seconds.

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Pilot monitor
Symbol Display item Description Remarks
• It operates automatically • Indicates preheat
at a low temperature. operating status.
Automatic (Symbol lights up as long
preheating as for approx. 30
seconds)
• It goes off after the engine
is started.
Elapsed time
Preheating after turning
the starting Monitor
switch to display
Manual “HEAT
preheating (Preheating)“
0 to 30 sec. Lights up
30 to 40 sec. Flashes
After 40 sec.
Lights out
or longer
One-touch • Indicates the
power max. Monitor display operating status of
switch one-touch power
One-touch Lights up maximizing function.
power max.
ON (Goes out if pressed for 8.5
seconds)
OFF Lights out
Swing lock Swing brake Monitor • Indicates swing lock
switch cancel switch display operating status.
OFF OFF Lights out
Swing lock ON OFF Lights up
OFF ON Flashes
ON ON Flashes
• Indicates front glass
INT: Intermittent operation
wiper operating
Wiper ON: Continuous operation condition.
Lights out: Holds in position
• Indicates air
Lights up: ON conditioner and air
Air conditioner blower operating
Lights out: OFF
status.
• Indicates whether
seatbelt is fastened.

Lights up: Not fastened


Seatbelt
Lights out: Fastened

• Indicates the engine


Lights up: When engine is stopped operating status.
Engine stop
Lights out: While engine is running

• Indicates
KDPF Lights up: KDPF is being regenerated regenerating state of
regeneration Lights out: KDPF regeneration is finished KDPF.

PC210LC-10 10-257
10 Structure and function
Machine monitor system

Symbol Display item Description Remarks


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

• State of the message


Message Lights up: There is unread message. is displayed.
(Unread) Lights out: No message

Message • State of the message


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

P: Heavy-duty operation • Displays working


E: Low-fuel consumption operation mode.
L: Fine operation
Working mode B: Breaker operation
ATT-P: Double-acting attachment operation
ATT-E: Double-acting attachment and low-
fuel consumption operation
• Displays travel speed
Lo: Low speed
setting.
Travel speed Mi: Middle speed
Hi: High speed
• Idle stop guidance • Guidance for
• Guidance on deterrence of hydraulic relief supporting the
ECO guidance • E-mode recommendation guidance machine operation
• Travel partial recommendation guidance and control are
• Low oil level guidance displayed.

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Switches (PC-Q1C0-042-K-00-A)

No. Name Function Operation


Switches the auto-deceleration • When working mode is “L“, this switch
Auto-deceleration function ON/OFF. is always “OFF“ after engine started.
1 switch OFF io ON
Lights up: ON
[Numeric keypad: 1]
Lights out: OFF
Displays the working mode selector P: Heavy-duty operation
screen. E: Low-fuel operation
(*1) L: Fine operation
Working mode selector B: Breaker operation
2 switch ATT-P: Double-acting attachment
[Numeric keypad: 2] operation
ATT-E: Double-acting attachment and
low-fuel operation
Changes the travel speed. • Speed is sequentially changed as
Travel speed selector Lo lights up: Low speed shown below.
3 switch Lo (Low speed) o Mi (Medium
Mi lights up: Medium speed speed) o Hi (High speed) o Lo (Low
[Numeric keypad: 3]
Hi lights up: High speed speed)
Stops the alarm buzzer. • The alarm buzzer stops sounding.
Buzzer cancel switch (Some alarm buzzer does not stop • The alarm buzzer sounds again if
4 another error worth alarming is
[Numeric keypad: 4] sounding even if the switch is
pressed.) detected.
Operates the front glass wiper. • Pressing the switch sequentially
(*2) changes the wiper operation.
INT: Intermittent operation
5 Wiper switch OFF (Stop) o INT (Intermittent) o
ON: Continuous operation ON (Continuous) o OFF (Stop)
[Numeric keypad: 5]
Lights out: Holds in position
(*2) Sprays washer fluid onto the front ON: Washer fluid is sprayed and
6
Window washer switch window glass. windshield wiper works continuously.

PC210LC-10 10-259
10 Structure and function
Machine monitor system

No. Name Function Operation


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

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Guidance icon and function switch (PC-Q1C1-042-K-00-A)


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

Switching clock/service Switches clock/service meter display.


meter

Switching to camera Switches to camera image display screen.


screen

Enters selected/setting item.


Background colors allow confirming the type of information
Enter transmitted.
• Gray: When the condition is normal
• Green: When energy saving guidance is displayed

Return Returns to the previous screen or status.

Selects the item right above the current item


Switching the select item
(To the bottom item from the top item.)

Selects the item right below the current item


Switching the select item
(To the top item from the bottom item.)

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

Selects the page right above the current page.


Switching the select item
(To the bottom page from the top page.)

PC210LC-10 10-261
10 Structure and function
Machine monitor system

Guidance
Item Function
icon

Selects the page right below the current page.


Switching the select item
(To the top page from the bottom page.)

Clear Clears selected/displayed item.

Sets selected item back to default.


Restores default value
(Used for screen adjustment.)

Set Performs setting.

Starts function.
Start (Used for starting measurement of split fuel consumption on the fuel
consumption display screen.)

Stops operation.
Stop (Used for stopping measurement of split fuel consumption on fuel
consumption display screen.)

Saving Saves setting

Switching to the name


Switches the current screen to the name setting screen
setting screen

Switching to ATT1 oil flow Switching the current screen to attachment 1 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)

Switching to ATT2 oil flow Switching the current screen to attachment 2 oil flow setting screen.
setting screen (Enabled only when attachments 1 and 2 are equipped)

Holds the value of the target item of monitoring.


HOLD
(Used when monitoring is turned on)

Resets the currently held value of the target item of monitoring.


Resetting the hold
(Used when monitoring is turned on)

Switching the fuel


Switches the graphs on the fuel consumption record screen.
consumption record screen

Switching to oil flow setting Switches to the attachment and breaker oil flow setting screen.
screen

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Guidance
Item Function
icon
Switches to the currently occurring failures list screen.
Switching to the currently Background colors allow confirming the type of information
occurring failures list transmitted.
screen • Red: When an action level of L2, L3 or L4 is displayed
• Yellow: When the action level of L1 is displayed

Display No. 1 camera Selects No. 1 camera image display screen.


screen

Display No. 2 camera Selects No. 2 camera image display screen.


screen

Display No. 3 camera Selects No. 3 camera image display screen.


screen

Display No. 1 and No. 2 Display both images of No. 1 and No. 2 cameras simultaneously.
camera screens

PC210LC-10 10-263
10 Structure and function
Machine monitor system

Operator mode function (PC-Q193-042-K-00-A)


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

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Z: When a maintenance time overdue is detected for an item.


a For how to operate the operator mode functions, see the Operation and Maintenance Manual or “Operator
mode (Outline)“ section in Testing and adjusting.
a For how to set the engine start lock on/off, see " Password setting/cancel manual" .

PC210LC-10 10-265
10 Structure and function
Machine monitor system

Service mode function (PC-Q194-042-K-00-A)


• The functions in this mode are not displayed usually on the screen. Information display and various
settings can be made only by the technician through the special operation of the switches.
This mode is used for special setting, testing, adjusting, or troubleshooting.
• Items available in the service mode are as follows:
Monitoring / Pre-defined
Monitoring / Custom
Abnormality Record “Mechanical Systems“
“Electrical Systems“
Maintenance Record
Maintenance Mode Setting
Phone Number Entry
Default “Key-on Mode“
“Unit“
“With/Without Attachment“
“Camera“
Diagnostic Tests “Cylinder Cut-out“
“Regeneration for Service“
“KDPF Memory Reset“
Adjustment “Pump Absorption Torque (F)“
“Pump Absorption Torque (R)“
“Low Speed“
“Attachment Flow Adjustment“
“Cal F pump swash plate sensor“
“Cal R pump swash plate sensor“
No Injection
KOMTRAX Settings “Terminal Status“
“GPS & Communication Status“
“Modem Status“
Service Message

a For how to operate the service mode functions, see “Service mode“ section in Testing and adjusting.

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KOMTRAX system

KOMTRAX system (PC-Q210-042-K-00-A)

• The KOMTRAX system consists of the KOMTRAX terminal, communication antenna and GPS antenna.
• This system transmits various machine information by use of the radio communication. This system allows
the KOMTRAX operator to refer the information and provide various services to the customers.
• Information transmittable from the KOMTRAX system are as follows.
1. Operation map
2. Service meter reading
3. Location information
4. Abnormality record
a To provide the services, you need to make an arrangement for starting the KOMTRAX service separately.

PC210LC-10 10-267
10 Structure and function
KOMTRAX system

KOMTRAX terminal (PC220-Q220-042-K-00-A)

Type: TC330

1. GPS antenna connection


2. Machine harness connection (070-18P)
3. Machine harness connection (070-12P)
4. Communication antenna connection

Input and output signals (PC220-Q220-03C-K-00-A)


070-18P[CN-CK01]
Pin No. Signal name Input/Output signal
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input/Output
11 CAN (C)_L Input/Output
12 (*1) -
13 (*1) -
14 External start signal Input/Output
15 System operation lamp Output
16 (*1) -
17 (*1) -
18 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.
070-12P [CN-CK02]
Pin No. Signal name Input/Output signal
1 GND -
2 GND -
3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -

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KOMTRAX system

Pin No. Signal name Input/Output signal


9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.

Function (PC-Q220-042-K-00-A)
• This terminal utilizes satellite communications technology.
• The terminal is an equipment which transmits various machine information obtained through network
signals and input signals, as well as GPS positioning data. The terminal can transmit data via the
communication antenna.
• The status of the terminal can be checked by using the menu of “KOMTRAX setting“ in the service mode
of the machine monitor .
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• This terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its
display section.
a When commencing operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice about the name of the country to Komatsu Ltd.
a When operating the system in Japan, install a terminal dedicated for use in Japan.

PC210LC-10 10-269
10 Structure and function
Sensor

Sensor (ALL-E700-001-P-00-A)

Ambient pressure sensor (ENG-AAP2-041-K-00-A)

1. Connector
2. Sensor

Function (ENG-AAP2-042-K-00-A)
• This sensor, installed to the air intake cover at the engine top side, detects the ambient pressure to output
the corresponding variable voltage.

Output characteristics

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Sensor

Charge (boost) pressure and temperature sensor (ENG-AAM7-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (ENG-AAM7-042-K-00-A)
• This sensor is installed to the engine intake manifold. It detects the engine intake air pressure and its
temperature, and outputs signals as a variable voltage for pressure, and as variable resistance for
temperature.
a "Charge pressure and temperature" are the engine intake air pressure and temperature of a turbocharged
engine. These are also referred to as "boost pressure and temperature" or "intake air pressure and
temperature".

Output characteristics

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10 Structure and function
Sensor

Coolant temperature sensor (ENG-BA87-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (ENG-BA87-042-K-00-A)
• This sensor, installed on the cylinder head of the engine, converts the temperature variation into the
resistance variation, and outputs the corresponding signals.
Ne (crankshaft) speed sensor (ENG-AG42-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (ENG-AG42-042-K-00-A)
• This sensor, installed to the crankshaft pulley on the engine front cover, outputs the pulse voltage due to
the gear rotation.

10-272 PC210LC-10
10 Structure and function
Sensor

Bkup (camshaft) speed sensor (ENG-AG62-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (ENG-AG62-042-K-00-A)
• This sensor, installed to the ring of camshaft on the engine front cover, outputs the pulse voltage due to
the gear rotation.
Common rail pressure sensor (ENG-AE28-041-K-00-A)

1. Connector
2. Sensor

Function (ENG-AE28-042-K-00-A)
• This sensor, installed to the common rail in the engine, detects the fuel pressure to output the
corresponding variable voltage.

PC210LC-10 10-273
10 Structure and function
Sensor

Exhaust manifold pressure sensor (ENG-AAN5-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (ENG-AAN5-042-K-00-A)
• This sensor, installed to the pressure outlet tube installed to the exhaust manifold of the engine, detects
the exhaust pressure to output the corresponding variable voltage.
EGR orifice temperature sensor (ENG-A9U5-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. Connector
2. Sensor
3. Washer

Function (ENG-A9U5-042-K-00-A)
• This sensor, installed on the EGR gas piping between EGR cooler and EGR valve of the engine, converts
the temperature variation into the resistance variation, and outputs the corresponding signals.

10-274 PC210LC-10
10 Structure and function
Sensor

EGR valve lift sensor (ENG-A9S2-041-K-00-A)

EGR: Abbreviation for Exhaust Gas Recirculation

1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector

Function (ENG-A9S2-042-K-00-A)
• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the
corresponding variable voltage.

Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.

PC210LC-10 10-275
10 Structure and function
Sensor

KVGT speed sensor (ENG-AAQ4-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. Sensor
2. O-ring
3. Connector

Function (ENG-AAQ4-042-K-00-A)
• This sensor, installed to KVGT in the engine, outputs the pulse voltage due to the rotation of KVGT
turbine.
a The 3-pole connector is applied for this sensor, however, available pins are the pin No. 1 and No. 2 only,
and it has no pin No. 3.
KVGT position sensor (ENG-AAQ3-041-K-00-A)

KVGT: Abbreviation for KOMATSU Variable Geometry Turbocharger

1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector

Function (ENG-AAQ3-042-K-00-A)
• This sensor, installed to KVGT in the engine, detects the location of the nozzle ring which is built in KVGT
to output the corresponding variable voltage.

10-276 PC210LC-10
10 Structure and function
Sensor

Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.

Mass air flow and temperature sensor (ENG-A96H-041-K-00-A)

1. Connector
2. O-ring
3. Sensor

Function (ENG-A96H-042-K-00-A)
• This sensor, installed to the outlet side of air cleaner, converts the variations of intake air flow and
temperature into the resistance variation, and outputs the corresponding signals.
a The “MAF (Mass Air Flow)“ means the “intake air flow“.

PC210LC-10 10-277
10 Structure and function
Sensor

KDPF differential pressure and outlet pressure sensor (ENG-A9HL-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. High-pressure port
2. Low-pressure port
3. Connector
4. Sensor

Function (ENG-A9HL-042-K-00-A)
• This sensor, installed to KDPF, detects the inlet pressure and outlet pressure of KDPF to output the
corresponding variable voltage.
• The output pressure difference is the difference between the KDPF inlet pressure which is detected at
high-pressure port (1) and the KDPF outlet pressure which is detected at low-pressure port (2).
• The KDPF outlet pressure is output as a pressure which is detected at low-pressure port (2).
KDOC inlet temperature sensor (ENG-A9HG-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor
2. Connector

Function (ENG-A9HG-042-K-00-A)
• This sensor, installed to the inlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.

10-278 PC210LC-10
10 Structure and function
Sensor

KDOC outlet temperature sensor (ENG-A9HH-041-K-00-A)

KDOC: Abbreviation for KOMATSU Diesel Oxidation Catalyst

1. Sensor
2. Connector

Function (ENG-A9HH-042-K-00-A)
• This sensor, installed to the outlet side of KDOC which is built in KDPF, converts the temperature variation
into the resistance variation, and outputs the corresponding signals.
KDPF outlet temperature sensor (ENG-A9HJ-041-K-00-A)

KDPF: Abbreviation for KOMATSU Diesel Particulate Filter

1. Sensor
2. Connector

Function (ENG-A9HJ-042-K-00-A)
• This sensor, installed to the outlet side of KDPF, converts the temperature variation into the resistance
variation, and outputs the corresponding signals.

PC210LC-10 10-279
10 Structure and function
Sensor

Crankcase pressure sensor (ENG-A18C-041-K-00-A)

1. Connector
2. Sensor
3. O-ring

Function (ENG-A18C-042-K-00-A)
• This sensor, installed to the inlet side of KCCV head portion, detects the crankcase pressure (blowby
pressure) to output the corresponding variable voltage.
Engine oil level sensor (ENG-AB45-041-K-00-A)

1. Connector
2. Bracket
3. Float
4. Switch

Function (ENG-AB45-042-K-00-A)
• This sensor, installed on the side face of the oil pan, turns “OFF“ by the lowered float, if the oil level
becomes lower than specified.

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10 Structure and function
Sensor

Fuel level sensor (PC-AD41-041-K-00-A)

1. Connector
2. Float
3. Arm
4. Valve body
5. Spring
6. Variable resistor

Function (PC-AD41-042-K-00-A)
• This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
• The movement of the float activates the variable resistor through the arm. As a result, the source voltage
is changed according to the resistance change due to the arm angle change and is output as a signal.

PC210LC-10 10-281
10 Structure and function
Sensor

Coolant level sensor (PC-B252-041-K-00-A)

1. Float
2. Sensor
3. Connector
4. Reservoir tank

Function (PC-B252-042-K-00-A)
• This sensor is integrated with reservoir tank, and is activated by the lowered float, if the coolant level
becomes lower than specified.

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10 Structure and function
Sensor

Hydraulic oil temperature sensor (PC-PMT1-041-K-00-A)

1. Connector
2. Plug
3. Thermistor

Function (PC-PMT1-042-K-00-A)
• This sensor, installed on the suction pipe of main pump, senses the temperature variation as the change
in thermistor resistance, and outputs the corresponding signals.
Front pump oil pressure sensor (PC-C3W4-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (PC-C3W4-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the front pump and outputs
variable voltage signal.

PC210LC-10 10-283
10 Structure and function
Sensor

Output characteristics

Rear pump oil pressure sensor (PC-C3W5-041-K-00-A)

1. O-ring
2. Sensor
3. Connector

Function (PC-C3W5-042-K-00-A)
• The sensor is installed in the control valve. It detects the delivery pressure of the rear pump and outputs
variable voltage signal.

Output characteristics

10-284 PC210LC-10
10 Structure and function
Sensor

PPC oil pressure sensor (PC-E720-041-P-00-A)

PPC: Abbreviation for Proportional Pressure Control

1. O-ring
2. Sensor
3. Connector

Function (PC-E720-042-P-00-A)
• PPC oil pressure sensors, 8 of which are installed to interconnect blocks in the pilot circuit between control
valves and PPC valve, and 4 of which are installed to travel PPC valves, detect the pilot pressures, and
output the corresponding variable voltage.

Output characteristics

PC210LC-10 10-285
10 Structure and function
Sensor

Air cleaner clogging sensor (PC-A968-041-K-01-A)

1. Adapter
2. Hood
3. Indicator
4. Connector

Function (PC-A968-042-K-00-A)
• This sensor is installed on the air cleaner outlet side. The switch is turned to “ON“ position, if the air
cleaner is clogged and the pressure level drops to the specified level (negative pressure).
Front pump swash plate sensor (PC-C3W9-041-K-00-A)

1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)

Function (PC200_10-C3W9-042-K-00-A)
• This senor is installed to the front pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.

10-286 PC210LC-10
10 Structure and function
Sensor

Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.

• The relation between oil flow of pump and output voltage is as shown in the following graph.

Rear pump swash plate sensor (PC-C3WB-041-K-00-A)

1. Sensor case
2. Spool
3. Lead wire
4. Connector
L: Operation stroke (9 mm)

PC210LC-10 10-287
10 Structure and function
Sensor

Function (PC200_10-C3WB-042-K-00-A)
• This senor is installed to the rear pump side of the main pump. It detects the stroke of servo piston and
outputs variable voltage signal.
• The output voltages are sent to the pump controller which converts the voltages into the pump swash
plate angles (oil flow) to process them.

Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.

• The relation between oil flow of pump and output voltage is as shown in the following graph.

10-288 PC210LC-10
10 Structure and function
Sensor

Water-in-fuel sensor (PC-AEB3-041-K-00-A)

1. Connector
2. Tube
3. Sensor
4. O-ring

Function (PC-AEB3-042-K-00-A)
• This sensor is installed to the cup of fuel prefilter.
• This sensor outputs a signal when detecting water exists in the fuel beyond the specified level.

PC210LC-10 10-289
10-290 PC210LC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number

PC210LC-10 450001 and up

20 Standard value tables


4 20 Standard value tables

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

Table of contents (ALL-0310-002-A-00-A)


20 Standard value tables.................................................................................................................... 20-1
Table of contents ........................................................................................................................ 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
Standard value table for electrical system............................................................................. 20-18

20-2 PC210LC-10
20 Standard value tables
Standard value table for engine

Standard service value table (ALL-A000-001-K-00-A)

Standard value table for engine (PC200_10-A000-033-K-00-A)

Machine model PC210LC-10


Engine SAA6D107E-2
Category

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

• Coolant temperature: 30 to 102°C


• Hydraulic oil temperature: 45 to 55°C kPa Min. 120 Min. 93
Boost pressure
• Swing lock switch: ON {mmHg} {Min. 900} {Min. 700}
• Arm IN relief + One-touch power max. ON

Engine
outlet
• Coolant temperature: 30 to (between Bosch
102°C — 2.7
turbochar- index
Exhaust gas • At relief with arm IN ger and
color • Swing lock switch: ON KDPF inlet)
• After kept for 5 seconds at
KDPF outlet
normal condition Bosch
(exhaust — 0.5
pipe outlet) index
Intake valve mm 0.25 0.152 to 0.381
• Coolant temperature :
Valve clearance Normal temperature Exhaust mm 0.51 0.381 to 0.762
Engine

valve
Compres- MPa Min. 2.41 Min. 1.69
sion
Compression • Engine oil temperature: 40 to pressure {kg/cm2} {Min. 24.6} {Min. 17.2}
pressure 60°C
Engine rpm
speed 250 to 280 250 to 280
• Coolant temperature: 30 to 102°C
Blowby • Hydraulic oil temperature: 45 to 55°C kPa Max. 0.98 Max. 1.96
pressure • Arm IN relief + One-touch power max. ON {mmH2O} {Max. 100} {Max. 200}
• KCCV circuit disconnected
MPa Min. 0.29 Min. 0.25
• Coolant temperature: 30 to High idle
Engine oil {kg/cm2} {Min. 3.0} {Min. 2.5}
pressure 102°C
MPa Min. 0.10 Min. 0.07
• SAE15W-40 oil Low idle
{kg/cm2} {Min. 1.0} {Min. 0.7}
EGR valve and
MPa Min. 1.2 Min. 1.2
KVGT drive oil • Coolant temperature: 30 to
102°C {kg/cm2} {Min. 12.0} {Min. 12.0}
pressure Low idle
• Hydraulic oil temperature: 45
KVGT control oil MPa 0.3 to 1.0 0.3 to 1.0
to 55°C
pressure {kg/cm2} {3.1 to 10.2} {3.1 to 10.2}
Engine oil
• Whole speed range (inside oil pan) °C 80 to 110 MAX.120
temperature
Auto- Auto-
• Between fan pulley and alternator pulley tensioner tensioner
Fan belt tension • Deflection when pressed with finger at 98 mm
N {10 kg} (Automatic (Automatic
adjustment) adjustment)

PC210LC-10 20-3
20 Standard value tables
Standard value table for engine

Machine model PC210LC-10


Engine SAA6D107E-2
Category

Standard
Item Measurement condition Unit value for new Repair limit
machine
Air conditioner • Between compressor pulley and fan pulley
compressor belt • Deflection when pressed with finger at 60 mm 6.3 to 8.7 6.3 to 8.7
tension N {6.2 kg}

20-4 PC210LC-10
20 Standard value tables
Standard value table for machine

Standard value table for machine (PC200_10-0000-033-K-00-A)

Engine speed
Machine model PC210LC–10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Coolant temperature: 30 to 102°C
• Hydraulic oil temperature: 45 to 55°C
At 2-pump relief • Engine: High idle rpm 1,850 ± 100 1,850 ± 100
Rotating speed • Power mode (P)
• Swing lock switch: OFF
• At relief with arm IN
• Coolant temperature: 30 to 102°C
• Hydraulic oil temperature: 45 to 55°C
Speed at 2-pump
• Engine: High idle rpm
relief + One-touch 1,950 ± 100 1,950 ± 100
• Power mode (P)
power max. is ON
• Arm IN relief + Left knob switch in ON
position
Speed when auto- • Engine: High idle
deceleration is • Auto-deceleration switch in ON position rpm 1,050 ± 100 1,050 ± 100
operated • All control levers at NEUTRAL
Control valve spool stroke
Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Engine stopped RAISE mm 11.5 ± 0.5 11.5 ± 0.5
Boom control valve • For measuring point, see LOWER mm 9.5 ± 0.5 9.5 ± 0.5
"Control valve". DIGGING mm 11.5 ± 0.5 11.5 ± 0.5
Arm control valve
DUMP mm 9.5 ± 0.5 9.5 ± 0.5
DIGGING
Bucket control valve mm 9.5 ± 0.5 9.5 ± 0.5
DUMP
Left swing
Swing control valve mm 9.5 ± 0.5 9.5 ± 0.5
Right swing
Forward
Travel control valve mm 9.5 ± 0.5 9.5 ± 0.5
Reverse

PC210LC-10 20-5
20 Standard value tables
Standard value table for machine

Travel of control lever


Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
Boom control lever • Engine stopped mm 85 ± 10 85 ± 10
Arm control lever • Center of lever knob mm 85 ± 10 85 ± 10
Bucket control lever • Read max. value through travel end mm 85 ± 10 85 ± 10
(excluding play at NEUTRAL).
Swing control lever mm 85 ± 10 85 ± 10
Travel control lever mm 115 ± 12 115 ± 12
Work
mm Max. 15 Max. 20
Play of control lever equipment
Traveling mm Max. 20 Max. 25
Operating effort of control lever and pedal
Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: 45 to 55°C N 15.7 ± 3.9 Max. 24.5
Boom control lever • Engine: High idle {kg} {1.6 ± 0.4} {Max. 2.5}
• Control lever: At center of grip
N 15.7 ± 3.9 Max. 24.5
Arm control lever • Pedal: At tip of pedal
• Read max. value through travel end. {kg} {1.6 ± 0.4} {Max. 2.5}
N 12.7 ± 2.9 Max. 21.6
Bucket control lever
{kg} {1.3 ± 0.3} {Max. 2.2}
N 12.7 ± 2.9 Max. 21.6
Swing control lever
{kg} {1.3 ± 0.3} {Max. 2.2}
N 24.5 ± 5.9 Max. 39.2
Travel control lever
{kg} {2.5 ± 0.6} {Max. 4.0}
N 74.5 ± 18.6 Max. 107.6
Travel control pedal
{kg} {7.6 ± 1.9} {Max. 11}

20-6 PC210LC-10
20 Standard value tables
Standard value table for machine

Oil pressure
Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: 45 to 55°C
• Engine: High idle MPa 3.5 ± 1.0 3.5 ± 1.0
Unload pressure • Power mode (P)
• Hydraulic pump output pressure with all {kg/cm 2} {36 ± 10} {36 ± 10}
control levers in NEUTRAL position
• Hydraulic oil temperature: 45 34.8 (+1.5 /
to 55°C At normal MPa -1.2) 33.1 to 37.2
• Engine: High idle relief {kg/cm } {355 (+15 /
2 {338 to 380}
• Power mode (P) -12)}
Boom relief pressure • Hydraulic pump outlet
37.3 (+1.5 /
pressure with all
At power MPa -1.2) 36.1 to 39.7
measurement circuits
relieved maximizing {kg/cm } {380 (+15 /
2 {368 to 405}
-12)}
34.8 (+1.5 /
At normal MPa -1.2) 33.1 to 37.2
relief {kg/cm2} {355 (+15 / {338 to 380}
Arm relief pressure -12)}
37.3 (+1.5 /
At power MPa -1.2) 36.1 to 39.7
maximizing {kg/cm2} {380 (+15 / {368 to 405}
-12)}
34.8 (+1.5 /
At normal MPa -1.2) 33.1 to 37.2
relief {kg/cm } {355 (+15 /
2 {338 to 380}
-12)}
Bucket relief pressure
37.3 (+1.5 /
At power MPa -1.2) 36.1 to 39.7
maximizing {kg/cm } {380 (+15 /
2 {368 to 405}
-12)}
• Hydraulic oil temperature: 45 to 55°C MPa 29.3 ±1.5 27.4 to 31.3
Swing relief pressure • Engine: High idle {kg/cm2} {300 ± 15} {280 to 320}
• Power mode (P)
38.7 (+1.0 /
• Hydraulic pump outlet pressure with all
MPa -2.0) 36.8 to 40.2
Travel relief pressure measurement circuits relieved
• Sudden turning back must be avoided {kg/cm 2} {395 (+10 / {375 to 410}
-20)}
• Hydraulic oil temperature: 45 to 55°C
• Engine: High idle 3.23 (+0.2 /
Control circuit oil MPa 2.75 to 3.43
• Self-pressure reducing valve outlet -0.3)
pressure {kg/cm2} {28 to 35}
pressure with all control levers in {33 (+2 / -3)}
NEUTRAL position
• Hydraulic oil temperature: 45 All control MPa 3.5 ± 1.0 3.5 ± 1.0
to 55°C levers in
{kg/cm2} {36 ± 10} {36 ± 10}
• Engine: High idle NEUTRAL
• Power mode (P)
LS differential 1.8 (+0.05 / 1.8 (+0.05 /
• Travel speed: Hi
pressure Travel MPa -0.1) -0.1)
• Run either track idle
• LS differential pressure = levers at
{kg/cm2} {18 (+0.5 / {18 (+0.5 /
Pump pressure - LS half stroke
-1.0)} -1.0)}
pressure

PC210LC-10 20-7
20 Standard value tables
Standard value table for machine

Swing
Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: 45 to 55°C
• Engine: High idle deg. Max. 100 Max. 130
Overswing • Power mode (P)
• Overswing of swing circle after one turn (mm) (-) (-)
• For measuring posture, see "Swing 1"
• Hydraulic oil temperature: 45 90 degrees sec. 3.1 ± 0.3 Max. 3.7
to 55°C
• Engine: High idle
• Power mode (P)
Swing drift on a slope • Time required to pass 90 180
degrees and 180 degrees sec. 4.4 ± 0.4 Max. 5.5
degrees
points after starting swing
• For measuring posture, see
"Swing 1"
• Hydraulic oil temperature: 45 to 55°C
• Engine: High idle
Time required to finish • Power mode (P)
sec. 24.2 ± 2.5 Max. 30
swinging • Time required to complete five turns after
one turn
• For measuring posture, see "Swing 1"
• Hydraulic oil temperature: 45 to 55°C
• Engine stopped
• On slope of 15 deg., set upper structure
Amount of Hydraulic crosswise and make matchmarks on inner
mm 0 0
drift of swing race and outer race of swing circle.
• Distance that matchmarks move apart
after 5 minutes
• For measuring posture, see "Swing 2"
• Hydraulic oil temperature: 45 to 55°C
Leakage from swing • Engine: High idle
• Swing lock switch: ON l/min Max. 5 Max. 10
motor
• Leakage in 1 minute during swing relief

20-8 PC210LC-10
20 Standard value tables
Standard value table for machine

Traveling
Machine model PC210LC–10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: 55.9 (+3.9/-
Lo sec. 48.6 to 63.8
Within operating range 7.3)
• Engine: High idle Mi sec. 40.8 ± 4.1 36.7 to 48.9
Travel speed (idle • Power mode (P)
running) • Time required to make five
idle turns of track off ground
after one idle turn Hi sec. 28.8 ± 1.5 27.3 to 32.3
• For measuring posture, see
"Travel 1"
• Hydraulic oil temperature: 24 (+1.7 /
Lo sec. 20.9 to 26.7
Within operating range -3.1)
• Engine: High idle Mi sec. 17 ± 2.5 14.5 to 20.5
Travel speed (actual • Power mode (P)
running) • Time required for traveling 20
m after 10 m trial run Hi sec. 13 ± 1.0 12.0 to 15.0
• For measuring posture, see
"Travel 2"
• Hydraulic oil temperature: Within
operating range
• Engine: High idle
• Power mode (P)
Travel deviation • Travel speed: Lo mm Max. 150 Max. 250
• Travel deviation (x) in travel of 20 m after
running up 10 m on firm and level ground
• For measuring posture, see "Travel 2" and
"Travel 3"
• Hydraulic oil temperature: Within
operating range
• Engine stopped
Machine drift on a • Place machine on slope of 12 deg. with
mm 0 0
slope sprocket on uphill side.
• Travel distance by hydraulic drift of travel
for 5 minutes
• For measuring posture, see "Travel 4"
• Hydraulic oil temperature: Within
operating range
Leakage from travel • Engine: High idle l/min 13.6 27.2
motor • Lock sprocket with pin, etc.
• Leakage in 1 minute during travel relief

PC210LC-10 20-9
20 Standard value tables
Standard value table for machine

Work equipment
• Hydraulic drift of work equipment
Machine model PC210LC-10
Standard
Item Measurement condition Unit value for new Repair limit
machine
Whole work • Hydraulic oil temperature: Within operating
mm Max. 600 Max. 900
equipment range
Hydraulic drift of • Measure on level and flat surface.
• Bucket filled up with dirt and sand, or at the mm Max. 18 Max. 27
boom cylinder
Hydraulic drift of rated load (0.8 m3: 1,440 kg)
• Horizontal boom top face, fully retracted mm Max. 160 Max. 240
boom cylinder
arm, fully extended bucket cylinder
• Engine stopped
• Work equipment control lever in NEUTRAL
position
• Fall amount for 15 minutes as measured
every 5 minutes starting immediately after
initial setting
Hydraulic drift of • Whole work equipment: Hydraulic drift
measured at tooth tip mm Max. 40 Max. 58
bucket cylinder
• Boom cylinder: Retraction amount of
cylinder
• Arm cylinder: Extension amount of cylinder
• Bucket cylinder: Retraction amount of
cylinder
• For measuring posture, see "Work
equipment 1"
• Work equipment speed
Machine model PC210LC-10
Standard
Item Measurement condition Unit value for new Repair limit
machine
• Hydraulic oil temperature: RAISE sec. 3.6 ± 0.4 Max. 4.7
Within operating range
• Engine: High idle
• Power mode (P)
• Time required to move boom
Boom speed
between RAISE stroke end LOWER sec. 2.9 ± 0.3 Max. 3.7
and ground touch point of
bucket
• For measuring posture, see
"Work equipment 2"
• Hydraulic oil temperature: DIGGING sec. 3.5 ± 0.4 Max. 4.5
Within operating range
• Engine: High idle
• Power mode (P)
Arm speed • Time required to move bucket
between DUMP stroke end DUMP sec. 2.7 ± 0.3 Max. 3.5
and CURL stroke end
• For measuring posture, see
"Work equipment 3"
• Hydraulic oil temperature: DIGGING sec. 2.6 ± 0.3 Max. 3.3
Within operating range
• Engine: High idle
• Power mode (P)
Bucket speed • Time required to move bucket
between DUMP stroke end DUMP sec. 1.9 ± 0.2 Max. 2.7
and CURL stroke end
• For measuring posture, see
"Work equipment 4"

20-10 PC210LC-10
20 Standard value tables
Standard value table for machine

• Time lag
Machine model PC210LC-10
Standard
Item Measurement condition Unit value for new Repair limit
machine
• Hydraulic oil temperature: Within operating
range
• Engine at low idle
• Power mode (P)
• Set boom at full RAISE position. Move
Boom time lag boom control lever to LOWER position. sec. Max. 1.0 Max. 1.2
Measure length of time before front of
machine starts lifting off the ground after
work equipment touches the ground.
• For measuring posture, see "Work
equipment 5"
• Hydraulic oil temperature: Within operating
range
• Engine at low idle
• Power mode (P)
• Set arm to the max. DUMP position. Move
Arm time lag arm control lever to IN position. The time sec. Max. 2.0 Max. 2.8
required from when the arm is stopped once
at an approximately vertical orientation until
it starts moving to the IN side again.
• For measuring posture, see "Work
equipment 6"
• Hydraulic oil temperature: Within operating
range
• Engine at low idle
• Power mode (P)
• Set bucket at full DUMP position. Move
bucket control lever to CURL position. The
Bucket time lag sec. Max. 1.0 Max. 3.6
time required from when the bucket is
stopped once at an approximately vertical
orientation until it starts moving to the CURL
side again.
• For measuring posture, see "Work
equipment 7"
• Oil leakage
Machine model PC210LC-10
Standard
Item Measurement condition Unit value for new Repair limit
machine
Cylinder internal • Hydraulic oil temperature: Within operating
oil leakage range cc/min 4.5 20
• Engine: High idle
Center swivel joint • Leakage amount for 1 minute during relief of cc/min 10 50
cylinder to be measured or travel motor

PC210LC-10 20-11
20 Standard value tables
Standard value table for machine

Performance of combined operation


Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: Within
operating range
• Engine: High idle
Travel deviation in
• Power mode (P)
combined operation of mm
• Travel speed: Lo Max. 200 Max. 220
work equipment and
• Travel deviation (x) in travel of 20 m after
travel
running up 10 m on firm and level ground
• For measuring posture, see "Travel 2" and
"Travel 3"
Pump swash plate sensor
Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: All control
Within operating range levers at V 1.35 ± 0.20 1.35 ± 0.63
• Engine: High idle NEUTRAL
• Power mode (P) When
Pump swash plate
• Travel speed: Hi running
sensor output voltage
• Run either track idle track idle
off ground V 3.35 ± 0.20 3.35 ± 0.63
(lever at
travel end).
Characteristics of PC flow control
Machine model PC210LC-10
Standard
value for Repair limit
Item Measurement condition Unit
new
machine
• Hydraulic oil temperature: Within
operating range
• Engine: High idle
• Power mode (P)
Time required for • Bucket with rated load (0.8 m3: 1,440 kg)
swinging from 0 to 90 • On hard and level ground, set arm 4.2 ± 0.4
sec.
deg. with boom vertically and lower back of bucket to (Reference value)
RAISE ground
• Time required for swinging from 0 to 90
deg. with boom RAISE
• For measuring posture, see "Work
equipment 8"

20-12 PC210LC-10
20 Standard value tables
Standard value table for machine

Hydraulic pump
Machine model PC210LC-10
Discharge Discharge
Item Measurement condition Unit Standard Repair limit
value
• Pump speed (rpm): 1,700 rpm
• PC-EPC current value (mA): 440 mA
• Test pump discharge pressure (MPa {kg/
cm2})
: P1 Q Q
Performance of
• Discharge pressure of another pump (MPa l/min
hydraulic pump (See graph) (See graph)
{kg/cm2})
: P2
• Average discharge pressure (MPa {kg/
cm2})
: Pp=(P1+P2)/2

a Bring pump discharge pressure P1 and P2 as close as possible to the average pressure when measuring.
Avoid measuring the near turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump discharge and the engine speed at the time of
measurement, and use them as a base for calculating the pump discharge at the specified speed.

PC210LC-10 20-13
20 Standard value tables
Standard value table for machine

Posture of machine for measuring performance and measurement


procedure (PC220_10-0000-321-K-00-A)
Control valve: Spool travel

Swing 1: Overrun when stopping swing, time required for starting swing, time required for swing

Swing 2: Amount of Hydraulic drift of swing

20-14 PC210LC-10
20 Standard value tables
Standard value table for machine

Travel 1: Travel speed (idle running)

Travel 2: Travel speed (actual run), travel deviation

Travel 3: Travel deviation

Travel 4: Hydraulic drift of travel

PC210LC-10 20-15
20 Standard value tables
Standard value table for machine

Work equipment 1: Hydraulic drift of the work equipment

Work equipment 2: Boom speed

Work equipment 3: Arm speed

Work equipment 4: Bucket speed

20-16 PC210LC-10
20 Standard value tables
Standard value table for machine

Work equipment 5: Boom time lag

Work equipment 6: Arm time lag

Work equipment 7: Bucket time lag

Work equipment 8: PC flow characteristics control

PC210LC-10 20-17
20 Standard value tables
Standard value table for electrical system

Standard value table for electrical system (D155-E000-001-P-00-A)

Controller (PC200_10-RA1E-033-K-00-A)
Equipment name Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position, and set the battery disconnect switch
to OFF position.
2. Insert T-adapter into connector CE03.
Continuous 3. Turn the battery disconnect switch to ON position.
Engine power 4. Measure voltage with the starting switch at OFF position and when starting
controller supply engine.
voltage Between CE03 (1) and (21) 20 to 30 V
Between CE03 (2) and (31) 20 to 30 V
Voltage
Between CE03 (11) and (21) 20 to 30 V
Between CE03 (12) and (31) 20 to 30 V
1. Turn the starting switch to OFF position, and disconnect the battery ground
Continuous cable.
power 2. Disconnect connector CP01, and connect T-adapter to female side.
supply 3. Connect the ground cable, and turn the starting switch to ON position.
voltage Between CP01(female) (1) and (2) 20 to 30 V
Voltage
Between CP01 (female) (4) and (5) 20 to 30 V
Pump
controller 1. Turn the starting switch to OFF position, and disconnect the battery ground
cable.
Solenoid 2. Disconnect connector CP02, and connect T-adapter to female side.
power 3. Connect the ground cable, and turn the starting switch to ON position.
supply
Between CP02(female) (116) and ground 20 to 30 V
voltage
Voltage Between CP02(female) (118) and ground 20 to 30 V
Between CP02(female) (121) and ground 20 to 30 V
1. Turn the starting switch to OFF position, and set the battery disconnect switch
to OFF position.
Continuous 2. Insert T-adapter into connector CM01.
Machine power 3. Turn the battery disconnect switch to ON position, and turn the starting switch
monitor supply to ON position (connect ACC).
voltage
Between CM01 (1) and (3) 20 to 30 V
Voltage
Between CM01 (2) and (4) 20 to 30 V

20-18 PC210LC-10
20 Standard value tables
Standard value table for electrical system

Engine control (PC200_10-AG10-033-K-00-A)

Equipment name Procedure, measuring location, criteria and remarks


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

PC210LC-10 20-19
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


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

1. Turn the starting switch to OFF position.


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

1. Turn the starting switch to OFF position.


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

1. Turn the starting switch to OFF position.


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

20-20 PC210LC-10
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


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

1. Turn the starting switch to OFF position.


2. Disconnect INJECTOR CYL5&6, and connect T-adapter to male side.
NO6. Injector Between INJECTOR CYL5&6 (male) (1) and (2) Max. 2 z
Resistance Between INJECTOR CYL5&6 (male) (1) and
ground Min. 100 kz

1. Turn the starting switch to OFF position.


2. Disconnect INJECTOR CYL1&2, and connect T-adapter to male side.
NO2. Injector Between INJECTOR CYL1&2 (male) (1) and (2) Max. 2 z
Resistance Between INJECTOR CYL1&2 (male) (1) and
ground Min. 100 kz

1. Turn the starting switch to OFF position.


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

1. Turn the starting switch to OFF position.


Charge (Boost) pressure 2. Insert T-adapter into connector ECMJ1.
sensor 3. Turn the starting switch to ON position.
Voltage Between ECMJ1 (15) and (59) Sensor output 0.3 to 4.7 V
1. Turn the starting switch to OFF position.
2. Disconnect connector OILPRESSURE SWITCH, and connect T-adapter to
Engine oil pressure switch male side.
Between OIL PRESSURE SWITCH (male) (1)
Voltage Max. 10 z
and ground
1. Turn the starting switch to OFF position.
2. Disconnect connector P44, and connect T-adapter to male side.
Engine oil level sensor
3. Turn the starting switch to ON position.
Resistance Between P44 (male) (1) and ground Max. 1 z
1. Turn the starting switch to OFF position.
2. Disconnect connector P24, and connect T-adapters to male side.
Coolant level sensor Between FULL
Max. 1 z
and LOW lines
Resistance Between P24 (male) (1) and (2)
Below LOW
Min.1 Mz
line
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector ECMJ1.
Ambient pressure sensor
3. Turn the starting switch to ON position.
Voltage Between ECMJ1 (16) and (60) Sensor output 0.5 to 4.5 V
1. Turn the starting switch to OFF position.
Exhaust manifold 2. Disconnect connector ECMJ2, and connect T-adapter to female side.
pressure sensor 3. Turn the starting switch to ON position.
Voltage Between ECMJ2 (34) and (47) Sensor output 0.2 to 4.7 V
1. Turn the starting switch to OFF position.
2. Disconnect connector P47, and connect T-adapter to female side.
Water-in-fuel sensor 3. Turn the starting switch to ON position.
installed to fuel pre-filter a If water is in water separator, drain it.
Between P47 (female) (1) and (2) 10 to 100 kz
Resistance
Between P47 (female) (1) and ground Min. 100 kz
Common rail pressure 1. Turn the starting switch to OFF position.
sensor 2. Insert T-adapter into connector ECMJ2.

PC210LC-10 20-21
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


3. Turn the starting switch to ON position.
Voltage Between ECMJ2 (21) and (44) Sensor output 0.2 to 4.8 V
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P57.
Crankcase pressure 3. Turn the starting switch to ON position.
sensor
Between P57 (female) (3) and
Voltage Sensor output 0.3 to 4.7 V
(2)
1. Turn the starting switch to OFF position.
KDPF differential 2. Insert T-adapter into connector E25.
pressure sensor 3. Turn the starting switch to the ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
1. Turn the starting switch to OFF position.
KDPF outlet pressure 2. Insert T-adapter into connector E25.
sensor 3. Turn the starting switch to the ON position.
Voltage Between E25 (3) and (1) 0.5 to 4.5 V
1. Turn the starting switch to OFF position.
Turbocharger speed 2. Disconnect connector VGT REV, and connect T-adapter to female side of
sensor connector.
Resistance Between VGT REV (female) (1) and (2) 600 to 1600 z
1. Turn the starting switch to OFF position.
2. Disconnect connector P20, and connect T-adapter to male side.
Fuel control dial (throttle
Between P20 (male) (1) and (3) 4.0 to 6.0 kz
sensor)
Voltage Between P20 (male) (2) and (3) 0.25 to 5.0 kz
Between P20 (male) (1) and (2) 0.25 to 5.0 kz
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector SEGR.
EGR valve lift sensor 3. Turn the starting switch to ON position.
Between SEGR (female) (C) Sensor output
Voltage 1.0 to 4.0 V
and (B)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector SVGT.
KVGT position sensor 3. Turn the starting switch to ON position.
Between SVGT (female) (C) Sensor output
Voltage 1.0 to 4.0 V
and (B)

20-22 PC210LC-10
20 Standard value tables
Standard value table for electrical system

Machine control (PC200_10-E000-033-P-00-A)


Equipment name Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position.
Travel speed selector 2. Disconnect connector V04, and connect T-adapter to male side.
solenoid Between V04 (male) (1) and (2) 20 to 60 z
Resistance
Between V04 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
Swing holding brake 2. Disconnect connector V03, and connect T-adapter to male side.
solenoid Between V03 (male) (1) and (2) 20 to 60 z
Resistance
Between V03 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector V05, and connect T-adapter to male side.
Travel junction solenoid
Between V05 (male) (1) and (2) 20 to 60 z
Resistance
Between V05 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
Attachment return 2. Disconnect connector V07, and connect T-adapter to male side.
selector solenoid Between V07 (male) (1) and (2) 20 to 60 z
Resistance
Between V07 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector V02, and connect T-adapter to male side.
2-stage relief solenoid
Between V02 (male) (1) and (2) 20 to 60 z
Resistance
Between V02 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
Variable back pressure 2. Disconnect connector V25, and connect T-adapter to male side.
solenoid Between V25 (male) (1) and (2) 20 to 60 z
Resistance
Between V25 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector V06, and connect T-adapter to male side.
Swing cut-off solenoid
Between V06 (male) (1) and (2) 20 to 60 z
Resistance
Between V06 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector V11, and connect T-adapter to male side.
F-PC-EPC solenoid
Between V11 (male) (1) and (2) 3 to 14 z
Resistance
Between V11 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector V12, and connect T-adapter to male side.
R-PC-EPC solenoid
Between V12 (male) (1) and (2) 3 to 14 z
Resistance
Between V12 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector V19, and connect T-adapter to male side.
LS-EPC solenoid
Between V19 (male) (1) and (2) 3 to 14 z
Resistance
Between V19 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
Attachment flow throttle 2. Disconnect connector V30, and connect T-adapter to male side.
EPC solenoid Between V30 (male) (1) and (2) 3 to 14 z
Resistance
Between V30 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
Merge-divider main EPC 2. Disconnect connector V23, and connect T-adapter to male side.
solenoid Between V23 (male) (1) and (2) 3 to 14 z
Resistance
Between V23 (male) (1) and ground Min. 1 Mz
Merge-divider LS EPC 1. Turn the starting switch to OFF position.
solenoid 2. Disconnect connector V24, and connect T-adapter to male side.

PC210LC-10 20-23
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


Between V24 (male) (1) and (2) 3 to 14 z
Resistance
Between V24 (male) (1) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector P22, and connect T-adapter to male side.
Between P22 (male) 10°C Approx. 90 kz
Hydraulic oil temperature (1) and (2) 30°C Approx. 35 kz
sensor a Temperature- 80°C Approx. 6.5 kz
Resistance
Resistance
100°C Approx. 3.5 kz
characteristics
Between P22 (male) (2) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P25.
Front pump pressure 3. Turn the starting switch to ON position.
sensor
Between P25 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Connect T-adapter to connector P26.
Rear pump pressure 3. Turn the starting switch to ON position.
sensor
Between P26 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P04.
Arm digging PPC
3. Turn the starting switch to ON position.
pressure sensor
Between P04 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P01.
Bucket digging PPC
3. Turn the starting switch to ON position.
pressure sensor
Between P01 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P06.
Boom RAISE PPC
3. Turn the starting switch to ON position.
pressure sensor
Between P06 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P02.
Boom LOWER PPC
3. Turn the starting switch to ON position.
pressure sensor
Between P02 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Connect T-adapter into connector P07.
Swing R.H. PPC pressure 3. Turn the starting switch to ON position.
sensor
Between P07 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P03.
Swing L.H. PPC pressure 3. Turn the starting switch to ON position.
sensor
Between P03 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P08.
Arm dump PPC pressure 3. Turn the starting switch to ON position.
sensor
Between P08 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)

20-24 PC210LC-10
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P05.
Bucket dump PPC
3. Turn the starting switch to ON position.
pressure sensor
Between P05 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P09.
Left travel FORWARD
3. Turn the starting switch to ON position.
PPC pressure sensor
Between P09 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P11.
Right travel FORWARD
3. Turn the starting switch to ON position.
PPC pressure sensor
Between P11 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P10.
Left travel REVERSE
3. Turn the starting switch to ON position.
PPC pressure sensor
Between P10 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Insert T-adapter into connector P12.
Right travel REVERSE
3. Turn the starting switch to ON position.
PPC pressure sensor
Between P12 (2)
Voltage Sensor output 0.5 to 4.5 V
and (1)
1. Turn the starting switch to OFF position.
2. Disconnect connector P27, and connect T-adapter to male side.
Between P27 (male) (A) and (B) Approx. 6 kz
Between P27 (female) (B) and (C) Approx. 6 kz
Resistance
Between P27 (female) (A) and (C) Approx. 170 z
Between P27 (male) (C) and ground Min. 1 Mz
1. Turn the starting switch to OFF position.
2. Disconnect connector P27, and connect T-adapter to male side.
3. Turn the starting switch to ON position.
Between P27 (C)
Voltage Sensor output Approx. 3 V
and (B)
Front pump swash plate
sensor 1. Turn the starting switch to OFF position.
2. Disconnect connector P27, and connect T-adapter to male side.
3. Turn the starting switch to ON position.
4. Start the engine.
Between P27 (C)
and (B)
a Position all
control levers in
Voltage NEUTRAL Sensor output Approx. 1.4 V
position to set
the swash plate
of pump at its
minimum angle.
1. Turn the starting switch to OFF position.
2. Disconnect connector P26, and connect T-adapter to male side.
Rear pump swash plate Between P26 (male) (A) and (B) Approx. 6 kz
sensor Between P26 (female) (B) and (C) Approx. 6 kz
Resistance
Between P26 (female) (A) and (C) Approx. 170 z
Between P26 (male) (C) and ground Min. 1 Mz

PC210LC-10 20-25
20 Standard value tables
Standard value table for electrical system

Equipment name Procedure, measuring location, criteria and remarks


1. Turn the starting switch to OFF position.
2. Connect T-adapter to connector P26.
3. Turn the starting switch to ON position.
Between P26 (C)
Voltage Sensor output Approx. 3 V
and (B)
1. Turn the starting switch to OFF position.
2. Disconnect connector P26, and connect T-adapter to male side.
3. Turn the starting switch to ON position.
4. Start the engine.
Between P26 (C)
and (B)
a Position all
control levers in
Voltage NEUTRAL Sensor output Approx. 1.4 V
position to set
the swash plate
of pump at its
minimum angle.

20-26 PC210LC-10
20 Standard value tables
Standard value table for electrical system

Machine monitor (PC200_10-Q170-033-K-00-A)


Equipment name Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground cable.
3. Insert T-adapter into connector CM01.
Battery charge 4. Connect the battery ground cable.
5. Start the engine and perform troubleshooting while running engine at medium
speed or higher.
Voltage Between CM01 (16) and (3) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Disconnect the battery ground cable.
3. Insert T-adapter into connector CM01.
4. Disconnect heater relay terminal R16A.
Preheating a To prevent current from flowing through heater when the starting switch is
turned to HEAT position
5. Connect the battery ground cable.
6. Turn the starting switch to HEAT position.
Voltage Between CM01 (12) and (3) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Disconnect connector CM01, and connect T-adapter to female side.
Fuel level (fuel level Between CM01 (female) (15) Fuel level: Approx. 12 z
sensor) and ground FULL
Resistance
a Fuel level sensor Fuel level:
85 to 110 z
characteristics EMPTY

PC210LC-10 20-27
20 Standard value tables
Standard value table for electrical system

20-28 PC210LC-10
SHOP MANUAL

HYDRAULIC EXCAVATOR
PC210LC-10
Model Serial Number

PC210LC-10 450001 and up

30 Testing and adjusting


5 30 Testing and adjusting

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

Table of contents (ALL-0310-002-A-00-A)


30 Testing and adjusting .................................................................................................................... 30-1
Table of contents ........................................................................................................................ 30-2
General information on testing and adjusting................................................................................. 30-3
Tools for testing and adjusting ............................................................................................... 30-3
Sketch of tools for testing and adjusting ................................................................................. 30-7
Engine and cooling system .......................................................................................................... 30-8
Testing engine speed ........................................................................................................... 30-8
Testing boost pressure ......................................................................................................... 30-9
Testing exhaust gas color ................................................................................................... 30-11
Measuring and adjusting valve clearance ............................................................................. 30-13
Testing compression pressure............................................................................................. 30-16
Testing blowby pressure ..................................................................................................... 30-20
Testing engine oil pressure ................................................................................................. 30-21
Testing EGR valve and KVGT oil pressures .......................................................................... 30-22
Measuring fuel pressure ..................................................................................................... 30-23
Measuring fuel delivery, return and leakage .......................................................................... 30-29
Bleeding air from fuel system .............................................................................................. 30-34
Checking fuel circuit for leakage .......................................................................................... 30-36
Handling cylinder cutout mode operation.............................................................................. 30-37
Handling no injection cranking operation .............................................................................. 30-38
Checking and adjusting air conditioner compressor belt tension ............................................. 30-39
Replacing fan belt .............................................................................................................. 30-41
Power train............................................................................................................................... 30-42
Testing swing circle bearing clearance ................................................................................. 30-42
Undercarriage and frame........................................................................................................... 30-43
Testing and adjusting track shoe tension .............................................................................. 30-43
Hydraulic system ...................................................................................................................... 30-44
Releasing remaining pressure from hydraulic circuit .............................................................. 30-44
Testing and adjusting oil pressure in work equipment, swing, and travel circuits....................... 30-45
Testing oil pressure of control circuit .................................................................................... 30-49
Testing and adjusting oil pressure in pump PC control circuit.................................................. 30-52
Testing and adjusting oil pressure in pump LS control circuit .................................................. 30-55
Testing output pressure of solenoid valve ............................................................................. 30-60
Testing PPC valve output pressure ...................................................................................... 30-64
Adjusting play of work equipment and swing PPC valves....................................................... 30-66
Testing pump swash plate sensor ........................................................................................ 30-67
Isolating the parts causing hydraulic drift in work equipment................................................... 30-68
Testing oil leakage ............................................................................................................. 30-69
Bleeding air from hydraulic circuit ........................................................................................ 30-72
Cab and its attachments ............................................................................................................ 30-74
Checking cab tipping stopper .............................................................................................. 30-74
Adjusting mirrors ................................................................................................................ 30-75
Electrical system ...................................................................................................................... 30-77
Special functions of machine monitor ................................................................................... 30-77
Adjusting rearview camera angle ....................................................................................... 30-148
Handling voltage circuit of engine controller........................................................................ 30-150
Handling battery disconnect switch .................................................................................... 30-151
Testing diodes ................................................................................................................. 30-152
Pm clinic ................................................................................................................................ 30-153
Pm Clinic service ............................................................................................................. 30-153

30-2 PC210LC-10
30 Testing and adjusting
General information on testing and adjusting

General information on testing and adjusting (ALL-3831-001-A-00-A)

Tools for testing and adjusting (PC200_10-5320-304-A-00-A)

Testing and Sym-

Q'ty
adjusting item bol Part No. Part name Remarks
Testing boost -101 to 200 kPa {-760 to 1,500
A 799-201-2202 Boost gauge kit 1 mmHg}
pressure
Testing 1 799-201-9002 Handy smoke checker 1
exhaust gas B Commercially Bosch index: 0 to 9
color 2 Smoke meter 1
available
Testing and 1 795-799-1131 Gear 1
adjusting valve C Commercially
2 Feeler gauge 1
clearance available
1 795-502-1590 Gauge assembly 1 0 to 7 MPa {0 to 70 kg/cm2}
2 795-799-6700 Puller 1
Testing
Adapter
compression D 3 795-790-4411 1
pressure 4 6754-11-3130 Gasket 1
Commercially
5 Hose 1 Inside diameter: approx. 15mm
available
1 799-201-1506 Blowby checker 1 0 to 10 kPa {0 to 1,000 mmH2O}
Testing blowby Commercially Plug
2 1 Hose inside diameter: 24 mm
pressure E available
Commercially Pipe outside diameter: 25.4 mm,
3 Plug 2 Pipe inside diameter: 20.4 mm
available
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
1 799-101-5160 • Nipple 1
799-101-5150 • Hose 1
Testing engine
oil pressure F 790-261-1150 • Hose 1
Pressure gauge: 60 MPa {600 kg/
2 790-261-1204 Digital hydraulic tester 1 cm2}
Pressure gauge: 1.0 MPa {10 kg/
3 799-401-2320 Gauge 1 cm2}
1 799-401-3100 Adapter 1
2 799-401-3200 Adapter 1
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
Measuring 799-101-5160 • Nipple 2 R1/8
EGR valve and • Hose
KVGT oil G 3 799-101-5150 1
790-261-1150 • Hose 1
pressures
Pressure gauge: 2.5 MPa {25 kg/
799-101-5140 • Gauge 1 cm2}
Pressure gauge: 60 MPa {600 kg/
4 790-261-1204 Digital hydraulic tester 1 cm2}

PC210LC-10 30-3
30 Testing and adjusting
General information on testing and adjusting

Testing and Sym-

Q'ty
adjusting item bol Part No. Part name Remarks
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
799-101-5160 • Nipple 1 R1/8
1 799-101-5150 • Hose 1
790-261-1150 • Hose 1
Pressure gauge: 2.5 MPa {25 kg/
799-101-5140 • Gauge 1 cm2}
Pressure gauge: 60 MPa {600 kg/
2 790-261-1204 Digital hydraulic tester 1 cm2}
Testing fuel 795-790-4430 Adapter 2
pressure H 3 O-ring
6215-81-9710 1
4 795-790-5110 Screw 1 M12 x 1.5 o R1/8
Pressure gauge: 1.0 MPa {10 kg/
5 799-401-2320 Gauge 1 cm2}
6 795-790-5120 Screw 1 M14 x 1.5 o R1/8
700-201-2202 Boost gauge kit 1
799-101-5160 • Nipple 1 R1/8
7 799-401-2610 • Hose 1
-101 to 200 kPa {-760 to 1,500
799-401-2311 • Gauge 1 mmHg}
1 795-790-4700 Tester kit 1
2 6164-81-5790 Joint 1
3 07206-30812 Joint bolt 1
4 6754-71-1130 Seal washer 1
Testing fuel Commercially
discharge, 5 Stopwatch 1
J available
return and Commercially
leakage 6 Hose 1 Inside diameter: approx. 14 mm
available
Commercially Measuring cylinder
7 1
available
Commercially
8 Hose 1 Inside diameter: approx. 8 mm
available
Measuring
swing circle Commercially Dial gauge
K 1
bearing available
clearance
Testing fuel Developer
circuit for Commercially
L for dye penetrant check 1
leakage available
(color checker)
Measuring and Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
adjusting oil
pressure in
work M 1 Pressure gauge: 60 MPa {600 kg/
equipment, 790-261-1204 Digital hydraulic tester 1 cm2}
swing, and
travel circuits

30-4 PC210LC-10
30 Testing and adjusting
General information on testing and adjusting

Testing and Sym-

Q'ty
adjusting item bol Part No. Part name Remarks
Pressure range: 5 MPa {50 Kg/
796T-440-1200 Sensor adapter 1 cm2}
796-440-1150 • Wiring harness 1
1 799-401-2350 • Washer 1
790-261-1130 • Coupling 1
Testing source Pressure range: 5 MPa {50 Kg/
7861-93-1840 • Pressure sensor 1 cm2}
pressure of N
control circuit 799-101-5220 Nipple 1 Size: 10 x 1.25 mm
2
07002-11023 O-ring 1
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
3
Pressure gauge: 60 MPa {600 kg/
790-261-1204 Digital hydraulic tester 1 cm2}
Measuring and Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
adjusting oil
pressure in P 1
Pressure gauge: 60 MPa {600 kg/
pump PC 790-261-1204 Digital hydraulic tester 1 cm2}
control circuit
Measuring and Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
adjusting oil 1
pressure in Q Pressure gauge: 60 MPa {600 kg/
790-261-1204 Digital hydraulic tester 1 cm2}
pump LS
control 2 799-401-2701 Differential pressure gauge 1 50 MPa {500 kg/cm2}
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
Measuring 1
solenoid valve Pressure gauge: 60 MPa {600 kg/
R 790-261-1204 Digital hydraulic tester 1 cm2}
output
pressure 799-401-3100 Adapter 1 Size: 02
2
02896-11008 O-ring 1
Pressure gauge: 2.5, 6, 40, 60
799-101-5002 Hydraulic tester 1 MPa {25, 60, 400, 600 kg/cm2}
Measuring 1
PPC valve Pressure gauge: 60 MPa {600 kg/
S 790-261-1204 Digital hydraulic tester 1 cm2}
output
pressure 799-401-3100 Adapter 1 Size: 02
2
799-401-3200 Adapter 1 Size: 03
Testing oil Commercially
T Measuring cylinder 1
leakage available
Testing coolant
temperature
— 799-101-1502 Digital thermometer 1 -99.9 to 1,299°C
and oil
temperature
Testing 79A-264-0021 Push-pull scale 1 0 to 294 N {0 to 30 kg}
operating effort
and —
79A-264-0091 Push-pull scale 1 0 to 490 N {0 to 50 kg}
depressing
effort
Testing stroke
— Commercially
and hydraulic Ruler 1
available
drift
Testing work
equipment — Commercially Stopwatch 1
speed available
Testing voltage — Commercially
Multimeter 1
and resistance available

PC210LC-10 30-5
30 Testing and adjusting
General information on testing and adjusting

Testing and Sym-

Q'ty
adjusting item bol Part No. Part name Remarks
Removal and
installation of
boost pressure — Commercially 3.26 mm Torx wrench
Torx wrench 1
and available (KTC Q4T15 or equivalent)
temperature
sensors
Removal and
installation of
engine oil — 795-799-6210 Socket 1 27 mm deep socket
pressure
switch
Removal and
installation of 19 mm deep socket
engine coolant — 795T-981-1010 Socket 1
temperature (MITOLOY 4ML-19 or equivalent)
sensor

30-6 PC210LC-10
30 Testing and adjusting
General information on testing and adjusting

Sketch of tools for testing and adjusting (PC200_10-3531-061-A-00-A)

Note) Komatsu will not be held responsible for special tools manufactured according to these sketches.
N1: Sensor adapter

—: Socket

PC210LC-10 30-7
30 Testing and adjusting
Engine and cooling system

Engine and cooling system (ALL-R401-001-K-00-A)

Testing engine speed (PC200_10-A000-360-K-00-A)

a Check the engine speed by using the 4) Operate the L.H. work equipment control
"Monitoring/Pre-defined" or "Monitoring lever to relieve the arm circuit at the IN stroke
Function" of the machine monitor. end and test the engine speed.
5. Measuring speed (around rated speed) at 2-
a Check the engine speed under the following
pump relief + one-touch power maximizing
conditions.
function
• Coolant temperature: 30 to 102°C
1) Start the engine and operate the arm cylinder
• Hydraulic oil temperature: 45 to 55°C
to arm IN stroke end.
Testing (PC200_10-A000-388-K-00-A) 2) Set the fuel control dial to high idle (MAX)
position and set the working mode to Power
1. Preparation
mode (P).
Operate the machine monitor so that it can
3) While operating the L.H. work equipment
monitor the engine speed.
control lever to relieve the arm circuit at arm
a For the machine monitor operating method, IN stroke end and pressing the one-touch
see the section of "Special functions of power maximizing switch, measure the
machine monitor". engine speed.
a Monitoring code: 01002 “Engine speed“ a The one-touch power maximizing function is
reset automatically in approximately 8.5
seconds even if the switch is kept pressed.
Accordingly, test the engine speed in that
period.
a You may measure with the swing lock switch
ON.
6. Measuring the engine speed when auto-
deceleration is activated
1) Start the engine, set the fuel control dial to
high idle (MAX) position, and turn the auto-
deceleration function ON.
2) Set all the levers and pedals for work
equipment control, swing control, and travel
2. Testing low idle speed in neutral and test the engine speed when
1) Start the engine and set the fuel control dial the auto-decelerator operates.
to low idle (MIN) position.
2) Set all the levers and pedals for work a The engine speed automatically lowers to a
equipment control, swing control, and travel certain level approximately 5 seconds after
in neutral and test the engine speed. all the levers and pedals are set to the
3. Testing high idle speed NEUTRAL position. This level is the auto-
deceleration speed.
1) Start the engine and set the fuel control dial
to high idle (MAX) position.
2) Set the working mode in Power Mode (P)
and set the auto-deceleration to OFF.
3) Set the swing lock switch to the ON position.
4) Set all the levers and pedals for work
equipment control, swing control, and travel
in neutral and test the engine speed.
4. Measuring engine speed at 2-pump relief
1) Start the engine and operate the arm cylinder
to arm IN stroke end.
2) Set the swing lock switch to the OFF
position.
3) Set the fuel control dial to high idle (MAX)
position and set the working mode to Power
mode (P).

30-8 PC210LC-10
30 Testing and adjusting
Engine and cooling system

Testing boost pressure (PC200_10-A900-360-K-00-A)

a Testing tools a Repeat opening the self-sealing portion on


Sym- the hose by inserting approximately half of
Part No. Part name the connection part of the gauge into the
bol
A 799-201-2202 Boost gauge kit hose to drain oil.
a When Pm kit (A) is available, you can use air
k Place the machine on a level ground and
bleeding coupling (790-261-1130) in the kit.
lower the work equipment to the ground.
a If oil is left in the hose, the gauge does not
k Be careful not to touch any hot part when work. Accordingly, be sure to drain the oil.
installing or removing the testing tools. 4. Set the working mode to the power mode (P)
and turn the swing lock switch ON.
a Measure the boost pressure under the following
conditions. a If the swing lock switch is turned to the ON
position, the main relief valve is set for high-
• Coolant temperature: 30 to 102°C pressure relief.
• Hydraulic oil temperature: 45 to 55°C
5. While running the engine at high idle, relieve the
• Swing lock switch: ON
arm circuit and measure the boost pressure.
• Arm IN relief + One-touch power max. ON
Boost pressure Min. 93 kPa {700 mmHg}
Testing (PC200_10-A900-362-K-00-A)
Testing by use of testing tools
1. Open the engine hood and remove boost
pressure pickup plug (1) from the intake air
connector.
a The method to fully open the engine hood is
described later.

6. After finishing the test, remove the testing tools


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

3. Run the engine at middle or higher speed and


drain oil from the hose.

PC210LC-10 30-9
30 Testing and adjusting
Engine and cooling system

How to fully open engine


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

a When closing engine hood (1), hold lock


plate (3) at hole (a), and tighten bolt (2).
3 Bolt (2):
59 to 74 Nm {6 to 7.5 kgm}

a At this time, locating pin (4) of lock plate (3) is


disengaged.
3. Use pin (5) to bring and hold lock plate (3) at
hole (b), and tighten bolt (2).

a The position of lock plate (3) must be


changed to close engine hood (1), otherwise
lock plate (3) will interfere with stay (6).

4. Open engine hood (1) wider and fix stay (6) at


the position shown in the figure (at the second
slit).

30-10 PC210LC-10
30 Testing and adjusting
Engine and cooling system

Testing exhaust gas color (PC200_10-A900-360-K-01-A)

a Testing tools of handy smoke checker B1 to collect the


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

k Place the machine on a level ground and


lower the work equipment to the ground.

k Be careful not to touch any hot part when


installing or removing the testing tools.

k When KDPF regeneration is started, the


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

a Measure the exhaust gas color under the


following conditions.
• Coolant temperature: 30 to 102°C
• Hold in stationary state for 5 seconds, then
collect the exhaust gas.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker B1. When recording official data, use
smoke meter B2.
Testing (PC200_10-A900-385-K-00-A)

1. Open engine hood and remove step (1) and plug 1) Connect the probe hose, receptacle of the
(2). accelerator switch and air hose to smoke
meter B2.
a The supplied air pressure must be 1.5
MPa {15 kg/cm2} or below.
2) Connect the power cable to the receptacle.
a Before connecting the power cable, make
sure that the power switch of the smoke
meter is turned OFF.
3) Insert probe [1] of the smoke meter B2 into
port (3) for the removed plug.
4) Loosen the cap nut of the suction pump and
place the filter paper.

2. Checking with handy smoke checker B1 a Place the filter paper securely so that the
exhaust gas does not leak.
1) Place a sheet of filter paper to smoke
5) Turn on the power switch of smoke meter B2.
checker B1.
2) Insert the exhaust gas intake pipe into plug
hole (3).
3) Start the engine, run it at high idle, and
perform the arm IN relief. Operate the handle

PC210LC-10 30-11
30 Testing and adjusting
Engine and cooling system

6) Start the engine and perform the arm IN relief.


Depress the pedal of smoke meter B2 to
collect the exhaust gas on the filter paper.
7) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
8) After finishing the test, remove the testing
tools and restore the machine.
3 Plug (2):
42.1 to 70.6 Nm {4.3 to 7.2 kgm}
2 Plug (2):
Seizure prevention compound (LC-G)

30-12 PC210LC-10
30 Testing and adjusting
Engine and cooling system

Measuring and adjusting valve clearance (ALL-A700-001-K-00-A)

a Testing instrument • Hose (7): KVGT control pressure circuit


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

k Turn the battery disconnect switch to the


OFF position and remove the key.

a Test and adjust the valve clearance under the


following condition.
• Coolant temperature: Normal temperature
Testing (PC200_10-A700-361-K-00-A)

1. Open the engine hood and remove step (1)


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

2. Disconnect connectors (2) to (5).


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

9. Remove plug (15) under the starting motor and


insert gear C1.
4. Disconnect hoses (7) and (8).

PC210LC-10 30-13
30 Testing and adjusting
Engine and cooling system

a If you can move the rocker arm of air intake


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

10.Rotate the crankshaft forward with gear C1 and


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

k Be sure to remove gear C1.


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

30-14 PC210LC-10
30 Testing and adjusting
Engine and cooling system

2. Insert feeler gauge C2 in the clearance between


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

4. After finishing adjustment, remove the testing


tools and return the removed parts.
a Be sure to remove gear C1 .
3 EGR circuit tube (6) (flange side):
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 EGR circuit tube (6) (tube side):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
3 Hose (7):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3 Hose (8):
15 ± 1 Nm {1.53 ± 0.1 kgm}
3 Cylinder head cover (11) mounting
nut:
24 ± 4 Nm {2.45 ± 0.41 kgm}

PC210LC-10 30-15
30 Testing and adjusting
Engine and cooling system

Testing compression pressure (ALL-A000-001-K-02-A)

a Testing tools
Sym-
Part No. Part name
bol
1 795-502-1590 Gauge assembly
2 795-799-6700 Puller
3 795-790-4411 Adapter
D
4 6754-11-3130 Gasket
5 Commercially Hose (inside diameter:
available approximately 15 mm)

k Place the machine on a level ground and


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

1. Remove the cylinder head cover and set the


piston in the target cylinder of testing to the
compression top dead center. For details, see
"Testing and adjusting valve clearance".
a Check that both the intake rocker arm and
exhaust rocker arm at the compression top
dead center are movable by hand by the
distance equivalent to the valve clearance.
2. After removing fuel spray prevention cap (1),
remove the sleeve nut and disconnect high-
pressure pipe (2).
a When measuring compression pressure, fuel
spurts from the disconnected portion of the
common rail side. Therefore you must
connect hose D5 and drain fuel to an oil pan.

k Do not bend high-pressure pipe when


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

30-16 PC210LC-10
30 Testing and adjusting
Engine and cooling system

11.Install crosshead assembly (5) and rocker arm


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

15.Connect gauge assembly D1 to adapter D3.


a If a small amount of oil is applied to the
connecting portions of gauge assembly D1
and adapter D3, air will not leak easily.

13.Connect connectors (11) to (15).


• Connector (11): KVGT position sensor
(SVGT)
• Connector (12): KVGT speed sensor
(VGT_REV)
• Connector (13): Connector box (INTER
CONNECT)
• Connector (14): EGR gas temperature
sensor (EXHAUST GAS TEMPERATURE)
16.Operate the machine monitor to set to “No
• Connector (15): Intermediate connector (INJ
Injection“.
CYL 1&2)
14.Connect hoses (16) and (17) and tube (18). a Turn the battery disconnect switch to the ON
• Hose (16): KVGT control pressure circuit position, then turn the starting switch to the
ON position.
3 Hose (16):
a For the method to set to “No Injection“, see
25 ± 1.5 Nm {2.55 ± 0.15 kgm}
"Special functions of machine monitor".
• Hose (16): KVGT drive pressure circuit
3 Hose (17):
15 ± 1 Nm {1.53 ± 0.1 kgm}
• Tube (18): EGR circuit
3 EGR circuit tube (18) (flange side):
24 ± 4 Nm {2.45 ± 0.41 kgm}
3 EGR circuit tube (18) (tube side):
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

17.Rotate the crankshaft by the starting motor and


measure the compression pressure.
a Read the compression pressure when the
gauge pointer stands still.
a The compression pressure is normal when it
is within the following standard value range.

PC210LC-10 30-17
30 Testing and adjusting
Engine and cooling system

1.69 MPa 4] When there is a worn part or an uneven


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

5) Apply engine oil to the O-ring of inlet


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

30-18 PC210LC-10
30 Testing and adjusting
Engine and cooling system

14)Install the cylinder head cover.


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

10)Install fuel spray prevention cap (1).


11)Install crosshead assembly (5) and rocker
arm assembly (4).
3 Rocker arm assembly (4) mounting
bolt (22):
36 ± 5 Nm {3.67 ± 0.51 kgm}
12)Adjust the valve clearance.
a See "Measuring and adjusting valve
clearance".
13)Tighten injector terminal nut (3).
3 Terminal nut (3):
1.5 ± 0.25 Nm {0.15 ± 0.03 kgm}
a Check that the injector wiring harness
does not interfere with the rocker arm.

PC210LC-10 30-19
30 Testing and adjusting
Engine and cooling system

Testing blowby pressure (PC200_10-A000-360-K-01-A)

a Testing tools 3 Clamp of hose (3):


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

k Place the machine on a level ground and


lower the work equipment to the ground.

a Measure the blowby pressure under the


following conditions.
• Coolant temperature: 30 to 102°C 4. Start the engine, set the work equipment mode
• Hydraulic oil temperature: 45 to 55°C to power mode (P), and turn the swing lock
Testing (PC200_10-A000-36C-K-00-A)
switch ON.

1. Open the engine hood and remove step (1). a If the swing lock switch is turned to the ON
position, the main relief valve is set for high-
pressure relief.
5. Measure the blowby pressure when the
hydraulic relief is made by arm IN operation at
engine high idle.
a Read the blowby gas pressure when the
gauge pointer stands still.
Blowby pressure Max. 1.96 kPa {200 mm H2O}

2. Disconnect hose (2) on the KCCV gas outlet


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

6. After finishing the test, remove the testing tools


and restore the machine.
3 Clamps of hoses (2) and (3):
4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

3. Disconnect hose (3) on the KCCV gas inlet side,


plug the KCCV hose insertion pipe with E3,
install tool and adapter [1] of blowby checker E1
to hose (3), and connect gauge [2].

30-20 PC210LC-10
30 Testing and adjusting
Engine and cooling system

Testing engine oil pressure (PC200_10-AB00-360-K-00-A)

a Tools for testing and adjusting


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

k Place the machine on a level ground and


lower the work equipment to the ground.
4. After finishing the test, remove the testing tools
a Measure the engine oil pressure under the and restore the machine.
following condition.
• Coolant temperature: 30 to 102°C
Testing (PC200_10-AB00-362-K-00-A)

1. Open the side cover on the right side of the


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

2. Start the engine and turn the auto-decelerator


OFF.
3. Run the engine and measure the engine oil
pressure at high idle and low idle.
a The engine oil pressure is normal if it is within
the following standard value range.
Min. 0.25 MPa
At high idle
{2.5 kg/cm2} or above
Min. 0.07 MPa
At low idle
{0.7 kg/cm2} or above

PC210LC-10 30-21
30 Testing and adjusting
Engine and cooling system

Testing EGR valve and KVGT oil pressures (PC200_10-A9K1-360-K-00-A)

a Testing tools 3. Install adapters G1 and G2, and then install


Sym- nipple [1] and hose [2] of hydraulic tester G3 and
Part No. Part name connect them to gauge [4].
bol
1 799-401-3100 Adapter 3 Adapter G1:
2 799-401-3200 Adapter 15 ± 1.0 Nm {1.53 ± 0.10 kgm}
799-101-5002 Hydraulic tester
799-101-5160 • Nipple 3 Adapter G2:
G 25 ± 1.5 Nm {2.55 ± 0.15 kgm}
3 799-101-5150 • Hose
790-261-1150 • Hose a Use gauge [4] of 2.5 MPa {25 kg/cm2}.
799-101-5140 • Gauge
a The nipple and hose of digital hydraulic tester
4 790-261-1204 Digital hydraulic tester
G4 can also be used.
k Place the machine on a level ground and
lower the work equipment to the ground.

a Test EGR valve and KVGT oil pressure under


the following conditions.
• Coolant temperature: 30 to 102°C
• Hydraulic oil temperature: 45 to 55°C
a The standard values for the EGR valve drive oil
pressure and the KVGT drive oil pressure are
the same, because they share the same circuit.
Testing (PC200_10-A9K1-362-K-00-A)

1. Open the engine hood and remove step (1) 4. Start the engine and measure the oil pressures
at low idle.
a When EGR valve and KVGT driving oil
pressure are within the following standard
range, they are normal.
Drive oil pressure of Min. 1.2 MPa
EGR valve and KVGT Min. {12.0 kg/cm2}
KVGT control oil 0.3 to 1.0 MPa
pressure {3.1 to 10.2 kg/cm2}

2. Disconnect hoses (2) and (3).


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

5. After finishing the test, remove the testing tools


and restore the machine.
3 Hose (2):
15 ± 1.0 Nm {1.53 ± 0.10 kgm}
3 Hose (3):
25 ± 1.5 Nm {2.55 ± 0.15 kgm}

30-22 PC210LC-10
30 Testing and adjusting
Engine and cooling system

Measuring fuel pressure (ALL-AE20-001-K-00-A)

a Testing tools
Sym-
Part No. Part Name
bol
799-101-5002 Hydraulic tester
799-101-5160 ・ Nipple
1 799-101-5150 ・ Hose
790-261-1150 ・ Hose
799-101-5140 ・ Gauge
2 790-261-1204 Digital hydraulic tester
795-790-4430 Adapter
3
H 6215-81-9710 O-ring
4 795-790-5110 Screw
5 799-401-2320 Gauge
6 795-790-5120 Screw
799-201-2202 Boost gauge kit
799-101-5160 ・ Nipple
7
799-401-2610 ・ Hose
799-401-2311 ・ Gauge

k When removing and installing the fuel system inspection equipment, stop the engine and wait for
30 seconds until the remaining pressure is released from the fuel circuit. (Do not start inspection
work immediately after the engine is stopped since remaining pressure is present.)

k Park the machine on level ground and lower the work equipment to the ground.

a Test only the fuel pressure in the low-pressure circuit from the feed pump through the fuel main filter to the
supply pump and in the return circuit between the supply pump/common rail/ injector and fuel tank.
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to
the injector is very high and dangerous, do not measure it.

PC210LC-10 30-23
30 Testing and adjusting
Engine and cooling system

A: Low-pressure circuit inspection position (fuel main filter inlet side)


B: Low-pressure circuit inspection position (fuel main filter outlet side)
C: Return circuit inspection position (supply pump drain port)
D: Negative pressure circuit inspection position (supply pump inlet)

30-24 PC210LC-10
30 Testing and adjusting
Engine and cooling system

207 to 650 kPa


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

4. After completing measurement, remove the


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

3. Start the engine and measure the pressure in


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

PC210LC-10 30-25
30 Testing and adjusting
Engine and cooling system

Testing low-pressure circuit (pressure


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

4. Obtain the pressure difference in the low-


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

3. Start the engine and measure the pressure on


the inlet aide and outlet side of the low-pressure
circuit with the engine at high idle.
a If the engine cannot be started, you can
measure the fuel pressure while rotating the
engine using the starting motor. However, to
protect the starting motor, do not rotate the
engine for more than 20 seconds
continuously.

30-26 PC210LC-10
30 Testing and adjusting
Engine and cooling system

Testing return circuit a If the engine cannot be started, you can


1. Remove cover (1). measure the fuel pressure while rotating the
engine using the starting motor. However, to
protect the starting motor, do not rotate the
engine for more than 20 seconds
continuously.
a If the pressure in the return circuit is in the
following range, it is proper.
At high idle Max. 18.6 kPa
Cranking {Max. 0.19 kg/cm2}

2. Remove joint bolt (2) of the fuel return hose


between the supply pump and fuel cooler.

5. After completing measurement, remove the


measuring tools and return the machine to the
original condition.
3 Joint bolt (2):
19.6 to 29.4 Nm {2 to 3 kgm}
3. Install screw H4, and nipple [1] and hose [2] of
hydraulic tester H1 instead of joint bolt (2), and
connect them to gauge H5.
a When installing screw H4, be sure to install
the seal washer.
3 Screw H4:
19.6 to 29.4 Nm {2 to 3 kgm}
a The nipples and hoses in digital hydraulic
tester H2 may be used.

4. Start and measure the pressure in the return


circuit while the engine is run at full speed.

PC210LC-10 30-27
30 Testing and adjusting
Engine and cooling system

Testing negative-pressure circuit


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

4. After completing measurement, remove the


measuring tools and return the machine to the
original condition.
2. Install screw H6, and nipple [1] and hose [2] of 3 Joint bolt (3):
boost gauge kit H7 instead of joint bolt (3), and 25.4 to 34.3 Nm {2.59 to 3.5 kgm}
connect them to gauge [3].
a When installing screw H6, be sure to install
the seal washer.
3 Screw H6:
25.4 to 34.3 Nm {2.59 to 3.5 kgm}
a The nipples and hoses in digital hydraulic
tester H2 may be used.

3. Start the engine and measure the pressure in


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

a If the pressure is higher than