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Komatsu PC210i -10, PC210LCi-10 Hydraulic Excavator Service Manual

2,419 pages · Publication SEN06515-03

$249.65
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Models
PC210i -10, PC210LCi-10
Serial coverage
451080 and up
Manual type
Service Manual
Pages
2,419
Publication
SEN06515-03
Condition
Brand new
Komatsu PC210i -10, PC210LCi-10 Hydraulic Excavator Service Manual, publication SEN06515-03

What's inside

From the manual's own table of contents: 362 sections, 700 entries. See sample pages (PDF, 965 KB)

Index and foreword
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table
Specification
Specifications
Specification drawing
Working range drawings
Weight table
Table of fuel, coolant, and lubricants
Structure and function
Engine and cooling system
Show all 362 sections
Engine related parts
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Cooling system
Power train
Power train system
Swing circle
Swing machinery
Final drive
Undercarriage and frame
Track frame and idler cushion
Hydraulic system
Hydraulic component layout
Valve control
Hydraulic tank
CLSS
Main pump
Control valve
Swing motor
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve (for high pressure circuit)4 topics
  • Attachment circuit selector valve (for low pressure circuit)
  • Center swivel joint
  • Accumulator
  • EPC valve for intelligent Machine Control
Work equipment2 topics
  • Work equipment shim
  • Bucket play adjustment shim
Cab and its attachments2 topics
  • Cab mount and cab tipping stopper
  • ROPS cab
Electrical system4 topics
  • Electrical control system
  • Machine monitor system
  • KOMTRAX system
  • Sensor
Standard value tables
Standard service value table3 topics
  • Standard value table for engine
  • Standard value table for machine
  • Standard value table for electrical system
Testing and adjusting
Related information on testing and adjusting30 topics
  • Tools for testing and adjusting
  • Sketch of tools for testing and adjusting
  • Testing engine speed
  • Testing boost pressure
  • Testing exhaust gas color
  • Testing and adjusting valve clearance
  • Testing compression pressure
  • Testing blowby pressure
  • Testing engine oil pressure
  • Testing EGR valve and KVGToil pressures
  • Measuring fuel pressure
  • Measuring fuel delivery, return and leakage
  • Bleeding air from fuel system
  • Testing fuel circuit for leakage
  • Handling cylinder cutout mode operation
  • Handling no-injection cranking operation
  • Testing and adjusting air conditioner compressor belt tension
  • Replacing fan belt
  • Testing swing circle bearing clearance
  • Testing and adjusting track tension
  • Releasing remaining pressure from hydraulic circuit
  • Testing and adjusting oil pressure in work equipment, swing, and travel circuits
  • Testing oil pressure of control circuit
  • Testing and adjusting oil pressure in pump PC control circuit
  • Testing and adjusting oil pressure in pump LS control circuit
  • Testing output pressure of solenoid valve
  • Testing PPC valve output pressure
  • Adjusting play of work equipment and swing PPC valves
  • Testing pump swash plate sensor
  • Isolating the parts causing hydraulic drift in work equipment
Testing oil leakage
Bleeding air from hydraulic circuit
Testing cab tipping stopper
Adjusting mirrors
Special functions of machine monitor
Special function of control box
KOMTRAX terminal start-up procedure
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service
Troubleshooting
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Testing before troubleshooting
Inspection procedure before troubleshooting
Preparation for troubleshooting of electrical system
Classification and procedure for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Diagnostic procedure for wiring harness open curcuit of pressure sensor system
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Failure code [989L00] Engine Controller Lock Caution1
Failure code [989M00] Engine Controller Lock Caution2
Failure code [989N00] Engine Controller Lock Caution3
Failure code [A1U0N3] HC Desorb Request 1
Failure code [A1U0N4] HC Desorb Request 2
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Engine Oil Pressure Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Engine Coolant Overheat
Failure code [B@BCZK] Radiator Coolant Level Low59 topics
  • Failure code [B@HANS] Hyd Oil Overheat
  • Failure code [CA115] Eng Ne and Bkup Speed Sens Error
  • Failure code [CA122] Chg Air Press Sensor High Error
  • Failure code [CA123] Chg Air Press Sensor Low Error
  • Failure code [CA131] Throttle Sensor High Error
  • Failure code [CA132] Throttle Sensor Low Error
  • Failure code [CA144] Coolant Temp Sens High Error
  • Failure code [CA145] Coolant Temp Sens Low Error
  • Failure code [CA153] Chg Air Temp Sensor High Error
  • Failure code [CA154] Chg Air Temp Sensor Low Error
  • Failure code [CA187] Sensor 2 Supply Volt Low Error
  • Failure code [CA221] Ambient Press Sensor High Error
  • Failure code [CA222] Ambient Press Sensor Low Error
  • Failure code [CA227] Sensor 2 Supply Volt High Error
  • Failure code [CA234] Eng Overspeed
  • Failure code [CA238] Ne Speed Sensor Supply Volt Error
  • Failure code [CA239] Ne Speed Sens Supply Volt High Error
  • Failure code [CA271] IMV/PCV1 Short Error
  • Failure code [CA272] IMV/PCV1 Open Error
  • Failure code [CA295] Ambient Press Sens In Range Error
  • Failure code [CA322] Inj #1(L#1) Open/Short Error
  • Failure code [CA323] Inj #5(L#5) Open/Short Error
  • Failure code [CA324] Inj #3(L#3) Open/Short Error
  • Failure code [CA325] Inj #6(L#6) Open/Short Error
  • Failure code [CA331] Inj #2(L#2) Open/Short Error
  • Failure code [CA332] Inj #4(L#4) Open/Short Error
  • Failure code [CA343] ECM Critical Internal Failure
  • Failure code [CA351] Injectors Drive Circuit Error
  • Failure code [CA352] Sensor 1 Supply Volt Low Error
  • Failure code [CA356] Mass Air Flow Sensor High Error
  • Failure code [CA357] Mass Air Flow Sensor Low Error
  • Failure code [CA386] Sensor 1 Supply Volt High Error
  • Failure code [CA428] Water in Fuel Sensor High Error
  • Failure code [CA429] Water in Fuel Sensor Low Error
  • Failure code [CA435] Eng Oil Press Sw Error
  • Failure code [CA441] Battery Voltage Low Error
  • Failure code [CA442] Battery Voltage High Error
  • Failure code [CA449] Rail Press Very High Error
  • Failure code [CA451] Rail Press Sensor High Error
  • Failure code [CA452] Rail Press Sensor Low Error
  • Failure code [CA488] Chg Air Temp High Torque Derate
  • Failure code [CA515] Rail Press Sens Sup Volt High Error
  • Failure code [CA516] Rail Press Sens Sup Volt Low Error
  • Failure code [CA553] Rail Press High Error
  • Failure code [CA555] Crankcase Press High Error 1
  • Failure code [CA556] Crankcase Press High Error 2
  • Failure code [CA559] Rail Press Low Error
  • Failure code [CA595] Turbo Speed High Error 2
  • Failure code [CA687] Turbo Speed Low Error
  • Failure code [CA689] Eng Ne Speed Sensor Error
  • Failure code [CA691] Intake Air Temp Sens High Error
  • Failure code [CA692] Intake Air Temp Sens Low Error
  • Failure code [CA697] ECM Int Temp Sensor High Error
  • Failure code [CA698] ECM Int Temp Sensor Low Error
  • Failure code [CA731] Eng Bkup Speed Sens Phase Error
  • Failure code [CA778] Eng Bkup Speed Sensor Error
  • Failure code [CA1117] Persistent Data Lost Error
  • Failure code [CA1664] KDOC Malfunction
  • Failure code [CA1691] Regeneration Ineffective
Failure code [CA1695] Sensor 5 Supply Volt High Error
Failure code [CA1696] Sensor 5 Supply Volt Low Error
Failure code [CA1843] Crankcase Press Sens High Error
Failure code [CA1844] Crankcase Press Sens Low Error
Failure code [CA1879] KDPF Delta P Sensor High Error
Failure code [CA1881] KDPF Delta P Sensor Low Error
Failure code [CA1883] KDPF Delta P Sens In Range Error
Failure code [CA1921] KDPF Soot Load High Error 1
Failure code [CA1922] KDPF Soot Load High Error 2
Failure code [CA1942] Crankcase Press Sens In Range Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2288] Turbo Speed High Error 1
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2373] Exhaust Manifold Press Sens High error
Failure code [CA2374] Exhaust Manifold Press Sens Low error
Failure code [CA2375] EGR Orifice Temp Sens High Error
Failure code [CA2376] EGR Orifice Temp Sens Low Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2554] Exh Manifold Press Sens In Range Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2961] EGR Orifice Temp High Error 1
Failure code [CA2973] Chg Air Press Sensor In Range Error
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error - Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [CA3741] Rail Press Valve Trip Error57 topics
  • Failure code [D110KB] Battery Relay Output Voltage
  • Failure code [D19JKZ] Personal Code Relay Abnormality
  • Failure code [D811MC] KOMTRAX Error
  • Failure code [D862KA] GPS Antenna Open Circuit
  • Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
  • Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
  • Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
  • Failure code [DA20MC] Pump Controller
  • Failure code [DA22KK] Pump Solenoid Power Low Error
  • Failure code [DA25KP] 5V Sensor 1 Power Abnormality
  • Failure code [DA29KQ] Model Selection Abnormality
  • Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
  • Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
  • Failure code [DA2QKR] CAN2 Discon (Pump Con)
  • Failure code [DA2RKR] CAN1 Discon (Pump Con)
  • Failure code [DAF0MB] Monitor ROM Abnormality
  • Failure code [DAF0MC] Monitor Error
  • Failure code [DAF8KB] Camera Power Supply Short Circuit
  • Failure code [DAF9KQ] Model Selection Abnormality
  • Failure code [DAFGMC] GPS Module Error
  • Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor)
  • Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor)
  • Failure code [DAFQKR] CAN2 Discon (Monitor)
  • Failure code [DAZ9KQ] A/C Model Selection Abnormality
  • Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
  • Failure code [DB2QKR] CAN2 Discon (Engine Con)
  • Failure code [DB2RKR] CAN1 Discon (Engine Con)
  • Failure code [DB90KT] W/E Controller Internal Failure
  • Failure code [DB90MC] W/E Controller Reset
  • Failure code [DB92KK] W/E CON Solenoid Power Voltage Low Error
  • Failure code [DB95KP] W/E CON 5V Sensor 0 Power Volt Low Error
  • Failure code [DB96KP] W/E CON 5V Sensor 1 Power Volt Low Error
  • Failure code [DB99KQ] Model Selection Signal Mismatch (W/E Con)
  • Failure code [DB9LKA] Operating Lamp Open Circuit (W/E CON)
  • Failure code [DB9LKB] Operating Lamp Hot Short Circuit (W/E CON)
  • Failure code [DB9QKR] CAN2 Defective Communication (W/E CON)
  • Failure code [DB9RKR] CAN1 Defective Communication (W/E CON)
  • Failure code [DBR0KT] ICT Sensor Controller Internal Failure
  • Failure code [DBR0MC] ICT Sensor Controller Reset
  • Failure code [DBR2KK] ICT/S CON Solenoid Power Low Error
  • Failure code [DBR5KP] ICT/S CON 5V Sensor 0 Power Abnormality
  • Failure code [DBR6KP] ICT/S CON 5V Sensor 1 Power Abnormality
  • Failure code [DBR9KQ] Model Selection Signal Mismatch (ICT Sens)
  • Failure code [DBRLKA] Operating Lamp Open Circuit (ICT/S CON)
  • Failure code [DBRLKB] Operating Lamp Short Circuit (ICT/S CON)
  • Failure code [DBRQKR] CAN2 Discon (ICT/S CON)
  • Failure code [DBRRKR] CAN 1 Discon (ICT/S CON)
  • Failure code [DBRSKB] ICT/S Con Battery Relay Drive Short Cir
  • Failure code [DBUSKR] Ethernet 0 Discon (GNSS Receiver)
  • Failure code [DD20MA] Auto/Manual Selector Switch Error
  • Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
  • Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
  • Failure code [DHPAMA] F Pump Press Sensor Abnormality
  • Failure code [DHPBMA] R Pump Press Sensor Abnormality
  • Failure code [DHS3MA] Arm IN PPC Press Sens Defective Function
  • Failure code [DHS4MA] Bucket CURL PPC Press Sensor Def Function
  • Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function
Failure code [DHSAMA] Swing RH PPC Press Sens Def Function
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSCMA] Arm Dump PPC Press Sens Def Function
Failure code [DHSDMA] Bucket Dump PPC Press Sens Def Function
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality
Failure code [DK80KM] IMU Calibration Not Complete
Failure code [DK80KR] IMU Defective Communication
Failure code [DK80KT] IMU Error
Failure code [DKG1KM] Bucket Cylinder Calibration Not Complete
Failure code [DKG1L8] Bucket Cyl Stroke Sensor Inrange Error
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality
Failure code [DKT0KM] Boom Cylinder Calibration Not Complete
Failure code [DKT0L8] Boom Cyl Stroke Sensor Inrange Error
Failure code [DKT1KA] Boom Cyl Stroke Sensor A Open Circuit
Failure code [DKT1KB] Boom Cyl Stroke Sensor A Short Circuit
Failure code [DKT2KA] Boom Cyl Stroke Sensor B Open Circuit
Failure code [DKT2KB] Boom Cyl Stroke Sensor B Short Circuit
Failure code [DKT4KM] Arm Cylinder Calibration Not Complete
Failure code [DKT4L8] Arm Cylinder Stroke Sensor Inrange Error
Failure code [DKT5KA] Arm Cyl Stroke Sensor A Open Circuit
Failure code [DKT5KB] Arm Cyl Stroke Sensor A Short Circuit
Failure code [DKT6KA] Arm Cyl Stroke Sensor B Open Circuit
Failure code [DKT6KB] Arm Cyl Stroke Sensor B Short Circuit
Failure code [DKT8KA] Bucket Cyl Stroke Sensor A Open Circuit
Failure code [DKT8KB] Bucket Cyl Stroke Sensor A Short Circuit
Failure code [DKT9KA] Bucket Cyl Stroke Sensor B Open Circuit
Failure code [DKT9KB] Bucket Cyl Stroke Sensor B Short Circuit
Failure code [DKTAKA] Bucket Cyl Stroke Reset Sens Open Circuit
Failure code [DKTAKB] Bucket Cyl Stroke Reset Sens Short Circuit
Failure code [DKTAMB] Bucket Cyl Stroke Reset Sens Inrange Error
Failure code [DKTBKX] Boom Cyl Stroke Reset Enc A,B Abnormality
Failure code [DKTBMC] Boom Cylinder Stroke Reset Encoder Error
Failure code [DKTEMB] Boom Cyl Stroke Reset Enc Z Abnormality
Failure code [DKTFKX] Boom Cyl Stroke Reset Enc A,B Abnormality
Failure code [DKTFMC] Arm Cyl Stroke Reset Enc Error
Failure code [DKTJMB] Arm Cyl Stroke Reset Enc Z Abnormality
Failure code [DKU1MA] Boom Spool Stroke Sensor In Range Error
Failure code [DKU2MA] Arm Spool Storke Sensor In Range Error
Failure code [DKUGKA] Arm IN PPC Reduce Press EPC Open Circuit
Failure code [DKUGKB] Arm IN PPC Reduce Press EPC Ground Fault
Failure code [DKUGKY] Arm IN PPC Reduce Pressure EPC Hot Short
Failure code [DKUHKA] Arm OUT PPC Reduce Press EPC Open Circuit
Failure code [DKUHKB] Arm OUT PPC Reduce Press EPC Ground Fault
Failure code [DKUHKY] Arm OUT PPC Reduce Pressure EPC Hot Short
Failure code [DKV0KA] Boom Spool Stroke Sensor 1 Open Circuit
Failure code [DKV0KY] Boom Spool Stroke Sensor 1 Hot Short Cir
Failure code [DKV1KA] Arm Spool Stroke Sensor 1 Open Circuit
Failure code [DKV1KY] Arm Spool Stroke Sensor 1 Hot Short Cir
Failure code [DKV2KA] Boom Spool Stroke Sensor 2 Open Circuit
Failure code [DKV2KY] Boom Spool Stroke Sensor 2 Hot Short Cir
Failure code [DKV3KA] Arm Spool Stroke Sensor 2 Open Circuit
Failure code [DKV3KY] Arm Spool Stroke Sensor 2 Hot Short Cir
Failure code [DKV4MA] Boom RAISE PPC Press Sensor 2 Def Function
Failure code [DKV5MA] Boom LOWER PPC Press Sensor 2 Def Function58 topics
  • Failure code [DKV6MA] Arm OUT PPC Press Sensor 2 Def Function
  • Failure code [DKV7MA] Arm IN PPC Press Sens 2 Defective Function
  • Failure code [DKV8MA] Bucket DUMP PPC Press Sens 2 Def Function
  • Failure code [DKV9MA] Bucket CURL PPC Press Sens 2 Def Function
  • Failure code [DKVAMA] PPC Source Press Sensor Error
  • Failure code [DKVBKA] Bucket CURL PPC Reduce Press EPC Open Cir
  • Failure code [DKVBKB] Bucket CURL PPC Reduce Press EPC Grd Fault
  • Failure code [DKVBKY] Bucket CURL PPC Reduce Press EPC Hot Short
  • Failure code [DKVCKA] Boom RAISE PPC Intervention EPC Open Cir
  • Failure code [DKVCKB] Boom RAISE PPC Intervention EPC Grnd Fault
  • Failure code [DKVCKY] Boom RAISE PPC Intervention EPC Hot Short
  • Failure code [DKVDKA] Boom RAISE EPC Cut Relay Open Circuit
  • Failure code [DKVDKB] Boom RAISE EPC Cut Relay Ground Fault
  • Failure code [DKVDKY] Boom RAISE EPC Cut Relay Hot Short Circuit
  • Failure code [DKVDMA] Boom RAISE EPC Cut Relay Error
  • Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
  • Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
  • Failure code [DV20KB] Travel Alarm Short Circuit
  • Failure code [DW43KA] Travel Speed Sol Open Circuit
  • Failure code [DW43KB] Travel Speed Sol Short Circuit
  • Failure code [DW45KA] Swing holding brake Sol Open Circuit
  • Failure code [DW45KB] Swing holding brake Sol Short Circuit
  • Failure code [DW4FKA] Boom LOWER PPC Reduce Press EPC Open Cir
  • Failure code [DW4FKB] Boom LOWER PPC Reduce Press EPC Grnd Fault
  • Failure code [DW4FKY] Boom LOWER PPC Reduce Press EPC Hot Short
  • Failure code [DW4GKA] Boom RAISE PPC Reduce Press EPC Open Cir
  • Failure code [DW4GKB] Boom RAISE PPC Reduce Press EPC Grnd Fault
  • Failure code [DW4GKY] Boom RAISE PPC Reduce Press EPC Hot Short
  • Failure code [DW4SKA] Bucket DUMP PPC Reduce Press EPC Open Cir
  • Failure code [DW4SKB] Bucket DUMP PPC Reduce Press EPC Grd Fault
  • Failure code [DW4SKY] Bucket DUMP PPC Reduce Press EPC Hot Short
  • Failure code [DW91KA] Travel Junction Sol Open Circuit
  • Failure code [DW91KB] Travel Junction Sol Short Circuit
  • Failure code [DWA2KA] Attachment Sol Open Circuit
  • Failure code [DWA2KB] Attachment Sol Short Circuit
  • Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit
  • Failure code [DWK0KB] 2-stage Relief Sol Short Circuit
  • Failure code [DWK2KA] Variable Back Press Sol Open Circuit
  • Failure code [DWK2KB] Variable Back Press Sol Short Circuit
  • Failure code [DWK8KA] Swing Press C/O Sol Open Circuit
  • Failure code [DWK8KB] Swing Press C/O Sol Short Circuit
  • Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
  • Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
  • Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
  • Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
  • Failure code [DXE0KA] LS-EPC Sol Open Circuit
  • Failure code [DXE0KB] LS-EPC Sol Short Circuit
  • Failure code [DXE4KA] Attachment Flow EPC Open Circuit
  • Failure code [DXE4KB] Attachment Flow EPC Short Circuit
  • Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
  • Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
  • Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
  • Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
  • Failure code [DY20KA] Wiper Working Abnormality
  • Failure code [DY20MA] Wiper Parking Abnormality
  • Failure code [DY2CKB] Washer Drive Short Circuit
  • Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
  • Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Troubleshooting of electrical system (E-mode)
Engine does not start (Engine does not crank)
Manual preheating system does not work
Automatic preheating system does not work
Preheating monitor does not light up when preheater is operated
When starting switch is turned to ON position, machine monitor displays nothing
Coolant temperature monitor lights up in white while engine is running
Hydraulic oil temperature monitor lights up in white while engine is running
Charge level monitor lights up while engine is running
Fuel level monitor lights up in red while engine is running
Air cleaner clogging monitor lights up in yellow while engine is running
Water separator monitor lights up while engine is running
Coolant temperature monitor lights up in red while engine is running
Hydraulic oil temperature monitor lights up in red while engine is running
Engine oil pressure monitor lights up in red while engine is running
Fuel gauge indicates either full or empty and does not move
Fuel gauge indicates incorrect amount (indicates neither full nor empty)
Coolant temperature gauge indicates either Min. or Max. and does not move
Content of display on machine monitor is different from that of actual machine
Machine monitor does not display some items
Function switch does not work
Automatic preheating system does not work (In cold season)
Auto-deceleration is not actuated or canceled when lever is operated
Travel speed monitor does not change when travel speed switch is operated
Travel speed does not change while travel speed selection is changed
Alarm buzzer does not stop sounding
When starting switch is turned to OFF position, service meter is not displayed
Service mode cannot be selected
Any of work equipment, swing and travel does not work
Any of work equipment, swing and travel cannot be locked
Machine cannot swing while swing brake cancel switch is canceled
Swing brake does not operate while swing brake cancel switch is locked
One-touch power maximizing function does not work or monitor is not displayed
One-touch power maximizing function cannot be canceled
Travel alarm does not sound when machine travels
Alarm does not stop sounding while machine is stopped
Horn does not sound
Horn does not stop sounding
Wiper monitor does not light up or go out when wiper switch is operated
Wiper does not operate when wiper switch is operated
Window washer does not operate when window washer switch is operated
BOOM LOWER indication is not displayed properly with monitoring function
ARM DUMP indication is not displayed properly with monitoring function
ARM IN indication is not displayed properly with monitoring function28 topics
  • BOOM RAISE indication is not displayed properly with monitoring function
  • BUCKET CURL indication is not displayed properly with monitoring function
  • BUCKET DUMP indication is not displayed properly with monitoring function
  • SWING indication is not displayed properly with monitoring function
  • TRAVEL indication is not displayed properly with monitoring function
  • Service is not displayed properly with monitoring function
  • Attachment hydraulic circuit cannot be changed
  • KOMTRAX system does not operate normally
  • Control box displays the message [GPS receiver not connected!]
  • Control box displays the message [Waiting for radio link
  • Control box displays the message [Tilt Bucket Sensor Offline!]
  • Control box displays the message [Waiting for satellites
  • Control box displays the message [Komatsu controller not connected!]
  • Control box displays the message [Sensors are invalid]
  • Control box displays the message [Waiting to initialize
  • Control box displays the message [Initializing
  • Control box displays the message [No GPS Localization
  • Control box displays the message [Low precisions
  • Control box displays [Out of design area
  • Control box displays [Avoidance Area Breach]
  • Control box can not be turned on
  • Control box does not display intelligent Machine Control screen
  • Control box does not display hydraulic excavator image
  • Control box does not display design surface
  • Control box touch panel does not respond
  • Control box touch panel is inaccurate
  • Opposite direction compass does not show the opposite direction
  • NG occurs very often in IMU calibration diagnosis
Troubleshooting of hydraulic and mechanical system (H-mode)16 topics
  • Information described in troubleshooting table (H-mode)
  • System chart for hydraulic system
  • Failure mode and cause table
  • All of work equipment, swing and travel operation lacks speed or power
  • Engine speed drops significantly or engine stalls
  • All work equipment, swing and travel does not work
  • Unusual sound is heard from around hydraulic pump
  • Fine control performance or response is poor
  • Boom speed or power is low
  • Arm speed or power is low
  • Bucket speed or power is low
  • Work equipment does not move in single operation
  • Hydraulic drift of boom is large
  • Hydraulic drift of arm is large
  • Hydraulic drift of bucket is large
  • Time lag of work equipment is large
One-touch power maximizing function does not operate
In combined operations of swing and boom RAISE, boom rising speed is low
In combined operations of swing and travel, travel speed drops largely
Machine does not travel straight
Travel speed is slow
Machine is hard to steer or travel power is low
Travel speed does not change, or travel speed is too slow or fast
One of tracks does not run
Upper structure does not swing to the right or left
Upper structure swing only to the right or left
Swing acceleration or swing speed is low in both directions (right and left)
Upper structure overruns excessively when it stops swinging (either right or left)
Shock is large when upper structure stops swinging
Large unusual noise is heard when upper structure stops swinging
Swing drift on a slope is large while swing holding brake is applied
Swing drift on a slope is large while swing holding brake is released
Attachment hydraulic circuit cannot be changed while attachment is installed
Oil flow in attachment circuit cannot be controlled
All work equipment do not operate
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
When starting switch is turned to START position, engine does not crank
Engine cranks but no exhaust smoke comes out
Engine startability is poor
Engine does not pick up smoothly
Engine stops during operation
Engine runs rough or is unstable
Engine lacks power
Exhaust smoke is black (KDPF clogs up early)
Engine oil consumption is excessive
Engine oil becomes contaminated early
Fuel consumption is excessive
Oil is in coolant (or coolant spurts or coolant level goes down)
Engine oil pressure drops
Fuel is contaminated in engine oil
Coolant is contaminated in engine oil (Oil becomes cloudy white)
Coolant temperature rises too high (overheating)
Unusual noise is heard
Vibration is excessive
Air cannot be bled from fuel circuit
Active regeneration is executed frequently
Active regeneration takes time
White smoke is exhausted during active regeneration
Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list53 topics
  • Sketches of special tools
  • Removal and installation of supply pump assembly
  • Removal and installation of injector assembly
  • Removal and installation of cylinder head assembly
  • Removal and installation of radiator assembly
  • Removal and installation of hydraulic oil cooler assembly
  • Removal and installation of aftercooler assembly
  • Removal and installation of engine and main pump assembly
  • Removal and installation of engine front oil seal
  • Removal and installation of engine rear oil seal
  • Removal and installation of fuel cooler assembly
  • Removal and installation of fuel tank assembly
  • Removal and installation of engine hood assembly
  • Removal and installation of KDPF assembly
  • Disassembly and assembly of KDPF assembly
  • Removal and installation of KCCV assembly
  • Removal and installation of air cleaner assembly
  • Removal and installation of travel motor and final drive assembly
  • Disassembly and assembly of final drive
  • Removal and installation of swing motor and swing machinery assembly
  • Disassembly and assembly of swing machinery
  • Removal and installation of swing circle assembly
  • Separation and connection of track shoe assembly
  • Removal and installation of sprocket
  • Removal and installation of idler and idler cushion assembly
  • Disassembly and assembly of idler assembly
  • Disassembly and assembly of idler cushion
  • Disassembly and assembly of track roller assembly
  • Disassembly and assembly of carrier roller
  • Removal and installation of revolving frame assembly
  • Removal and installation of counterweight assembly
  • Removal and installation of center swivel joint assembly
  • Disassembly and assembly of center swivel joint
  • Removal and installation of hydraulic tank assembly
  • Removal and installation of main pump assembly
  • Removal and installation of control valve assembly
  • Disassembly and assembly of control valve
  • Removal and installation of junction block assembly for Intelligent Machine Control
  • Removal and installation of pressure sensor for Intelligent Machine Control
  • Removal and installation of boom spool stroke sensor
  • Removal and installation of arm spool stroke sensor
  • Disassembly and assembly of work equipment PPC valve
  • Disassembly and assembly of travel PPC valve
  • Removal and installation of work equipment assembly
  • Disassembly and assembly of work equipment cylinder assembly
  • Removal and installation of operator's cab assembly
  • Removal and installation of operator cab glass (adhered glass)
  • Removal and installation of front window assembly
  • Removal and installation of floor frame assembly
  • Removal and installation of air conditioner unit assembly
  • Removal and installation of operator's seat
  • Removal and installation of seat belt
  • Removal and installation of front wiper assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of machine monitor assembly
Removal and installation of pump swash plate sensor
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal assembly
Removal and installation of ICTsensor controller assembly
Removal and installation of junction harness of control box
Removal and installation of control box harness
Removal and installation of work equipment controller assembly
Removal and installation of GNSS receiver
Removal and installation of radio device and site link
Removal and installation of GNSS antenna
Removal and installation of IMU sensor
Maintenance standard
Engine mount
Sprocket
Idler
Track roller
Carrier roller
Track shoe
Work equipment and swing PPC valve
Travel PPC valve
1st-line attachment PPC valve (with EPC valve)
2nd-line attachment PPC valve
Attachment circuit selector valve (for high-pressure circuit)
Attachment circuit selector valve (for low-pressure circuit)
Center swivel joint
Boom cylinder
Stroke sensing boom cylinder
Stroke sensing arm cylinder
Stroke sensing bucket cylinder
Appendix
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle22 topics
  • Outline of refrigeration cycle
  • Air conditioner unit
  • Dual pressure switch
  • Air conditioner controller
  • Compressor
  • Air conditioner condenser
  • Sunlight sensor
  • Outer temperature sensor (outside air temperature sensor)
  • Procedure for testing and troubleshooting
  • Circuit diagram and arrangement of connector pins
  • System diagram
  • Input and output signals of the air conditioner controller
  • Parts and connectors layout
  • Testing air leakage (duct)
  • Testing with self-diagnosis function
  • Testing vent (mode) changeover
  • Testing FRESH/RECIRC air changeover
  • Testing sunlight sensor
  • Testing (dual) pressure switch for refrigerant
  • Testing relays
  • Troubleshooting chart 1
  • Troubleshooting chart 2

Inside this manual

Real pages from this service manual (2,419 pages). Open the sample pages (PDF, 964 KB)

Sample pages from the Komatsu PC210i -10, PC210LCi-10 Hydraulic Excavator Service Manual: Specifications, Troubleshooting, Diagram, Color page, Color page, Foldout diagram
  • Specifications, page 876: 30 Testing and adjusting
  • Troubleshooting, page 1,542: Failure code [DKT1KB] Boom Cyl Stroke Sensor A Short Circuit
  • Diagram, page 1,986: 50 Disassembly and assembly
  • Color page, page 126: 10 Structure and function
  • Color page, page 328: 10 Structure and function
  • Foldout diagram, page 2,405: PC210I-10,PC210LCI-10

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This manual: Service Manual SEN06515-03$249.65
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Details

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 2,419 pages

Quantity one is the manual described above.

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Binder not included

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