PC210LC-11 Sen06695-01 Appendix

SEN06695-01
HYDRAULIC PC210LC -11

EXCAVATOR SERIAL NUMBERS 500001 and up
80 APPENDIX
PC210LC-11 80-1
CONTENTS 80 APPENDIX
CONTENTS
ABBREVIATION LIST .................................................................................................................................... 80-4
AIR CONDITIONER SYSTEM ..................................................................................................................... 80-10
PRECAUTIONS FOR REFRIGERANT ................................................................................................. 80-10
AIR CONDITIONER COMPONENT .......................................................................................................80-11
SPECIFICATIONS OF AIR CONDITIONER .......................................................................................... 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .................................................... 80-14
OUTLINE OF REFRIGERATION CYCLE .............................................................................................. 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM ........................................................................... 80-17
AIR CONDITIONER UNIT..................................................................................................................... 80-17
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT ........................................................ 80-17
FUNCTION OF AIR CONDITIONER UNIT..................................................................................... 80-19
COMPONENT PARTS OF AIR CONDITIONER UNIT........................................................................... 80-21
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT .............................. 80-22
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT ............................. 80-22
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPO-
NENT ......................................................................................................................................... 80-22
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT............................ 80-22
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .................. 80-23
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT ...................... 80-23
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT ............................. 80-23
FUNCTION OF DUAL PRESSURE SWITCH................................................................................. 80-24
AIR CONDITIONER CONTROLLER ..................................................................................................... 80-25
STRUCTURE OF AIR CONDITIONER CONTROLLER ................................................................. 80-25
COMPRESSOR .................................................................................................................................... 80-26
STRUCTURE OF COMPRESSOR ................................................................................................ 80-26
SPECIFICATIONS OF COMPRESSOR ......................................................................................... 80-26
FUNCTION OF COMPRESSOR .................................................................................................... 80-26
CONDENSER ....................................................................................................................................... 80-27
STRUCTURE OF CONDENSER ................................................................................................... 80-27
SPECIFICATIONS OF CONDENSER ............................................................................................ 80-27
FUNCTION OF CONDENSER ....................................................................................................... 80-27
SENSORS FOR AIR CONDITIONER SYSTEM.................................................................................... 80-29
STRUCTURE OF SUNLIGHT SENSOR ........................................................................................ 80-29
FUNCTION OF SUNLIGHT SENSOR............................................................................................ 80-29
STRUCTURE OF AMBIENT TEMPERATURE SENSOR ............................................................... 80-29
FUNCTION OF AMBIENT TEMPERATURE SENSOR .................................................................. 80-29
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER... 80-31
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ................ 80-33
AIR CONDITIONER SYSTEM DIAGRAM .................................................................................................... 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER ........................................... 80-36
FUNCTION OF AIR CONDITIONER CONTROLLER..................................................................... 80-37
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .........
................................................................................................................................................................. 80-38
TESTING AIR LEAKAGE (DUCT)................................................................................................................ 80-42
METHOD FOR TESTING AIR LEAKAGE (DUCT) ................................................................................ 80-42
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION....................................................... 80-44
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF
THE MACHINE MONITOR ....................................................................................................................... 80-45
TEST VENT (MODE) CHANGEOVER ......................................................................................................... 80-46
METHOD FOR TESTING VENT (MODE) CHANGEOVER ................................................................... 80-46
TESTING FRESH/RECIRC AIR CHANGEOVER......................................................................................... 80-48
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER ......................................................... 80-48
TEST SUNLIGHT SENSOR......................................................................................................................... 80-49
METHOD FOR TESTING SUNLIGHT SENSOR................................................................................... 80-49
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT......................................................................... 80-50
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT................................... 80-50
80-2 PC210LC-11
80 APPENDIX CONTENTS
TEST RELAYS ............................................................................................................................................. 80-51

METHOD FOR TESTING RELAYS ....................................................................................................... 80-51
AIR CONDITIONER TROUBLESHOOTING CHART 1 ................................................................................ 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 2 ................................................................................ 80-53
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................. 80-56
FAILURE CODE [879AKA]........................................................................................................................... 80-58
FAILURE CODE [879AKB]........................................................................................................................... 80-59
FAILURE CODE [879BKA]........................................................................................................................... 80-60
FAILURE CODE [879BKB]........................................................................................................................... 80-62
FAILURE CODE [879CKA]........................................................................................................................... 80-64
FAILURE CODE [879CKB]........................................................................................................................... 80-65
FAILURE CODE [879DKZ]........................................................................................................................... 80-66
FAILURE CODE [879EMC] .......................................................................................................................... 80-68
FAILURE CODE [879FMC] .......................................................................................................................... 80-69
FAILURE CODE [879GKX] .......................................................................................................................... 80-70
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) ........
................................................................................................................................................................. 80-72
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)..........
................................................................................................................................................................. 80-74
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS AB-
NORMAL)................................................................................................................................................. 80-77
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...................................................... 80-79
TROUBLESHOOTING USING GAUGE PRESSURE................................................................................... 80-81
CONNECTION OF SERVICE TOOL ............................................................................................................ 80-84
METHOD FOR CONNECTING SERVICE TOOL .................................................................................. 80-84
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER
PIPINGS................................................................................................................................................... 80-86
HANDLE COMPRESSOR OIL ..................................................................................................................... 80-88
METHOD FOR REPLACING DESICCANT .................................................................................................. 80-90
PC210LC-11 80-3
ABBREVIATION LIST 80 APPENDIX
ABBREVIATION LIST
• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, 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.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).
80-4 PC210LC-11
80 APPENDIX ABBREVIATION LIST

Abbrevia-
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.
PC210LC-11 80-5

Abbrevia-
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.
Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.
80-6 PC210LC-11

Abbrevia-
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.
PC210LC-11 80-7

Abbrevia-
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.
*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate 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
80-8 PC210LC-11
Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission
PC210LC-11 80-9
PRECAUTIONS FOR REFRIGERANT 80 APPENDIX
AIR CONDITIONER SYSTEM

PRECAUTIONS FOR REFRIGERANT
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working
clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
k When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnect-
ing the air conditioner hoses.
NOTICE
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas: R134a).
80-10 PC210LC-11
80 APPENDIX AIR CONDITIONER COMPONENT
AIR CONDITIONER COMPONENT
1: Compressor 4: Hot water piping

2: Condenser 5: Hot water return piping
3: Modulator(Containing desiccant) 6: Refrigerant piping
PC210LC-11 80-11
AIR CONDITIONER COMPONENT 80 APPENDIX
7: Dual pressure switch 11: Recirculation air filter

8: Sight glass 12: Fresh air filter
9: Air conditioner controller 13: Machine monitor
10: Air conditioner unit 14: Sunlight sensor
A: Front vents D: Defroster vents

B: Rear vents E: Recirculation air inlet
C: Foot vents F: Fresh air inlet
80-12 PC210LC-11
80 APPENDIX SPECIFICATIONS OF AIR CONDITIONER
SPECIFICATIONS OF AIR CONDITIONER

Refrigerant: R134a
Refrigerant quantity: : 930±50 g
PC210LC-11 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80 APPENDIX
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE

Cycle Compression Condensation Expansion Evaporation
(component) (compressor) (condenser) (Expansion valve) (Evaporator)
Location of Engine compartment Front part of radiator Inside of operator's cab Inside of operator's cab
component (built in air conditioner (built in air conditioner
unit) unit)
Function Circulates refrigerant Condenses refrigerant Decreases temperature Absorbs heat from air
and increases tem- to discharge heat ab- and pressure of refriger- around evaporator to
perature and pres- sorbed in evaporator. ant with throttle and con- cool that air by evapo-
sure of gas refriger- (condensation of re- vert it partially into gas so rating refrigerant.
ant so that it is lique- frigerant) that it is evaporated easi- (Evaporation of refriger-
fied easily in con- ly, and controls flow rate. ant)
denser. (Throttling of refrigerant)
(Compression of re-
frigerant)
State of refrig- Gas → gas Gas → liquid Liquid → liquid, gas Liquid, gas → gas
erant Adiabatic compres- Isobaric change Adiabatic expansion Isobaric change
sion
80-14 PC210LC-11
80 APPENDIX OUTLINE OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE

Regeneration cycles are composed of the following 4 processes. Refrigerant circulates around the system re-
peatedly changing its phase from liquid → gas → liquid.
Compression (Compressor)
• The compressor sucks in the refrigerant which is evaporated in the evaporator and compresses the refriger-
ant until it can be easily liquefied at the ambient temperature.
• The gas refrigerant sucked in the compressor cylinder is compressed to make the pressure higher. When
the refrigerant is cooled at the ambient temperature, it can be easily liquefied.
Condensation (Condenser)
• The condenser cools and liquefies the high-temperature and high-pressure gas refrigerant sent from the
compressor at the ambient temperature.
• The heat radiation from the condenser to the atmosphere is called the condensation heat.
• The amount of condensation heat is the sum total of the heat absorbed by the evaporator from the air in the
cab and the quantity of the work applied (the value converted into a heat quantity) by compression of the
compressor.
• The refrigerant liquefied in the condenser is dehydrated in the modulator and cooled further in the sub-cool
section to increase the cooling efficiency
• In the condensation process, gas refrigerant and liquid refrigerant are mixed.
• The temperature (condensation temperature) and the pressure (condensation pressure) at which the gas-
eous refrigerant is liquefied are proportional to each other.
Reference: The pressure varies depending on the condensation temperature of the refrigerant.
Expansion (Expansion valve)
• The expansion valve reduces the liquid refrigerant pressure to a level where liquid refrigerant can be easily
evaporated by the throttle action (*1).
• The action of reducing the pressure of the liquid refrigerant to a state where it easily evaporates before
sending it to the evaporator is called expansion.
• The expansion valve used for expansion reduces the refrigerant pressure and controls the refrigerant flow
simultaneously.
• The quantity of the liquid refrigerant that can be evaporated in the evaporator depends on the amount of
heat (refrigeration load) to be removed under the specific evaporation temperature (evaporation pressure).
• The expansion valve controls the refrigerant supply rate to prevent too much or too little supply of the liquid
refrigerant.
(*1) Throttle action
• If there is a narrow section in the passage through which liquid is flowing at a constant rate, a resistance to
the flow is generated.
When the liquid passes through a narrow section, cross-sectional area suddenly increases. The liquid ex-
pansion causes pressure and temperature to decrease.
• No heat is transferred between inside and outside by the throttle action.
Evaporation (Evaporator)
• The evaporator evaporates the liquid refrigerant (superheated vapor).
• The refrigerant evaporates, while absorbing an amount of heat necessary for evaporation (evaporation
heat) from the air around the cooling fins (air in the cab).
• The cooled air is sent into the cab by the blower fan, and it decreases the temperature in the cab.
• In the evaporator, the misty refrigerant sent from the expansion valve and the evaporated gas refrigerant
are mixed together.
• The temperature (evaporation temperature) and the pressure (evaporation pressure) at which the liquid re-
frigerant is evaporated are proportional to each other.
PC210LC-11 80-15
OUTLINE OF REFRIGERATION CYCLE 80 APPENDIX
• To evaporate the liquid refrigerant at lower temperature, the pressure in the evaporator must be kept as low
as possible. For this purpose, the compressor sucks in the evaporated refrigerant.
Relation between refrigerant and cooling trouble
• While repeating the refrigeration cycle, the refrigerant circulates in the refrigeration circuit and dissipates
the heat in the cab to the outside of the cab.
• If there is an insufficient quantity of refrigerant, all of it is evaporated while it is passing through the evapora-
tor. This causes evaporator efficiency to deteriorate, which will result in defective air conditioning.
• If there is excessive refrigerant, not all of it is evaporated and part of it will be sucked into the compressor in
liquid form, which causes the compressor to compress the liquid and may damage the components.
• If water is contained in the refrigerant circuit, it freezes in the small hole of the expansion valve and blocks
the refrigerant flow to cause a cooling trouble.
80-16 PC210LC-11
80 APPENDIX AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER SYSTEM

AIR CONDITIONER UNIT
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT
PC210LC-11 80-17
AIR CONDITIONER UNIT 80 APPENDIX
A: Refrigerant inlet (from condenser) E: Recirculation air inlet

B: Refrigerant outlet (to compressor) F: Fresh air inlet
C: Hot water inlet G: Front vents
D: Hot water outlet H: Rear vents
80-18 PC210LC-11
80 APPENDIX AIR CONDITIONER UNIT
J: Foot vents K: Defroster vents

1: Evaporator 9: Foot door
2: Heater core 10: Defroster door
3: Expansion valve 11: FRESH/RECIRC air changeover servomotor
4: Blower fan, blower motor 12: FRESH/RECIRC air changeover door
5: Air mix servomotor 13: Power transistor
6: Air mix door 14: Evaporator temperature sensor
7: Vent (mode) changeover servomotor 15: Recirculation air temperature sensor
8: Rear door
REMARK
"Door" may be expressed as "damper".
FUNCTION OF AIR CONDITIONER UNIT

The air conditioner unit consists of evaporator (1) and heater core (2) to heat or cool the air in the operator's
cab.
Temperature control
When the temperature control switch on the machine monitor is operated, the temperature setting data is sent to
the air conditioner controller at the rear of the operator's seat. The air conditioner controller controls air mix ser-
vomotor (5) and changes the angle of air mix door (6) to control the temperature.
Over-cooling (Freezing) prevention
• Evaporator temperature sensor (14) varies the resistance of its resistor corresponding to temperature.
• The air conditioner controller converts the change in resistance of evaporator temperature sensor (14) into
the change in voltage to determine the temperature of evaporator (1).
• The air conditioner controller operates the compressor clutch relay *1 to stop the compressor so that evapo-
rator (1) does not freeze.
*1: For the compressor clutch relay, see “INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND
ARRANGEMENT OF CONNECTORS”.
Air flow adjustment
Whenever an air flow control switch is operated on the machine monitor, air flow setting data is sent to the air
conditioner controller. The air conditioner controller controls blower motor (4) by using power transistor (13) in
order to adjust the air flow.
Vent (mode) changeover
The mode data is sent to the air conditioner controller according to the vent switch operation on the machine
monitor. The air conditioner controller controls vent (mode) changeover servomotor (7) to adjust the opening an-
gles of mode changeover doors (8) to (10) and change the vents.
FRESH/RECIRC air changeover
FRESH/RECIRC air changeover setting data is sent to the air conditioner controller according to the operation
of FRESH/RECIRC air changeover switch on the machine monitor. The air conditioner controller controls
FRESH/RECIRC air changeover servomotor (11) to open/close FRESH/RECIRC air changeover door (12).
Automatic mode of air conditioner
• Inside air temperature sensor (15) senses the inside temperature by the change in resistance. The air con-
ditioner controller converts the change in resistance of inside air temperature sensor (15) into change in
voltage and senses the inside temperature by the change in voltage.
• The air conditioner controller checks the voltage of inside air temperature sensor (15) and controls the in-
side temperature to the temperature set by the machine monitor.
PC210LC-11 80-19
AIR CONDITIONER UNIT 80 APPENDIX
• Air conditioner considers the information of the sunlight sensor and outside air temperature sensor for con-
trol of the inside temperature.
Changeover pattern of vent (mode) changeover doors

Rear door (8) Foot door (9) Defroster door (10)
Position of Position of Position of
Angle Angle Angle
door door door
Front Close 0 Close 0 Close 0
Front, Rear Open 25 Close 0 Close 0
Air vent Front, Rear, Foot Open 25 Open 35 Close 0

mode Foot Open 25 Open 53 Close 0
Foot, Defroster Open 25 Open 23 Open 38
Defroster Open 25 Open 0 Open 38
Changeover pattern of air mix door (6)

Temperature setting Position of door Angle
Max. Cool Close 0
Max. Hot Open 80
80-20 PC210LC-11
80 APPENDIX COMPONENT PARTS OF AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER UNIT
PC210LC-11 80-21
COMPONENT PARTS OF AIR CONDITIONER UNIT 80 APPENDIX
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT

• Evaporator (1) is cooled by the low-pressure and low-temperature refrigerant gas sent from expansion
valve (3).
• Air sent from blower fan, blower motor (4) is cooled and dried when it passes through the fins of evaporator
(1).
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT

• Heater core (2) is heated with the hot water (engine coolant) sent from the engine.
• Air sent by blower fan, blower motor (4) is heated when it passes through the fins of heater core (2).
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER

UNIT COMPONENT
Evaporator temperature sensor (14) is installed to evaporator (1) by using the holder, and its resistance varies
with the temperature of evaporator (1). The air conditioner controller grasps the temperature of evaporator (1)
from the voltage change in evaporator temperature sensor (14), and preventing the freeze of evaporator (1).
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT

The servomotor is used for the air mix (temperature control)
and to switch the vents (modes).
NOTICE
Do not drive the servomotor by supplying power directly
between servomotor terminals (6) and (7) during inspec-
tion.
• When the switch on the machine monitor is operated, the
air conditioner controller supplies 24V power to servomotor
terminal B (6) and servomotor terminal A (7) of the servo-
motor. (The rotation direction changes according to the
supplied polarity.)
• The internal servomotor has a variable resistor, the resistance varies by the rotation of the motor.
Since the FRESH/RECIRC air changeover servomotor has no resistor of this type, it has no self-diagnosis
function.
• The air conditioner controller applies a voltage of 5 V to the variable resistor and determines the motor rota-
tion angle from the potential difference.
• When the door (damper) reaches the position specified by each switch, the air conditioner controller stops
the supply of current to the servomotor, then the corresponding door stops.
• If the potential difference does not reach the voltage set for control of the servomotor, air conditioner con-
troller notifies the machine monitor of the abnormality by a failure code of the air conditioner. On the electri-
cal system abnormality record screen of the machine monitor, “879EMC” or “879FMC” is displayed.
REMARK
FRESH/RECIRC air changeover servo motor does not feature a variable resistance, and therefore, does
not have a self-diagnosis function.
80-22 PC210LC-11
80 APPENDIX COMPONENT PARTS OF AIR CONDITIONER UNIT
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT

Route diagram
A: When evaporator outlet temperature is high C: From condenser (high-pressure refrigerant)

B: When evaporator outlet temperature is low D: To compressor (Low-pressure refrigerant)
1: Expansion valve 1b: Spring
1a: Needle valve 2: Refrigerant gas
1a-1: Diaphragm 3: Evaporator
1a-2: Thermoprobe
Structure
• Box-type expansion valve (1) consists of needle valve (1a), spring (1b), etc.
• The diaphragm chamber (hatched area) on the outside of diaphragm (1a-1) of needle valve (1a) is filled
with refrigerant gas (2).
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT

• Expansion valve (1) converts the high-pressure and high-temperature liquid refrigerant sent from the receiv-
er drier into low-pressure and low-temperature misty refrigerant by throttle action.
• It controls the refrigerant flow rate by changing the throttle degree according to the temperature in the oper-
ator's cab.
• The temperature of the air flowing out of the vents is controlled by the flow rate of the refrigerant into evapo-
rator (3).
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT

1. Thermoprobe (1a-2) senses the temperature of the refrigerant after it passes through evaporator (3).
The temperature of the refrigerant after it passes evaporator (3) is transmitted through thermoprobe (1a-2)
to refrigerant gas (2) in the diaphragm chamber (hatched portion).
PC210LC-11 80-23
COMPONENT PARTS OF AIR CONDITIONER UNIT 80 APPENDIX
2. When refrigerant gas (2) sealed in the diaphragm chamber (hatched portion) receives the temperature
change from thermoprobe (1a-2), its pressure varies, and accordingly force (Fg) to press needle valve (1a)
varies.
3. The position of needle valve (1a) is determined by the balance between the rightward reaction force of
spring (1b) and force (F g) of refrigerant gas (2) to push needle valve (1a) to the left through diaphragm
(1a-1).
4. The position of needle valve (1a) determines the flow rate of the refrigerant from the receiver drier to evapo-
rator (3).
When evaporator (3) outlet temperature is high
1. The pressure of refrigerant gas (2) in the diaphragm chamber (hatched portion) increases and the volume
increases.
2. Force (F g) of refrigerant gas (2) to push needle valve (1a) increases, and needle valve (1a) moves to the
left.
3. Needle valve (1a) opens wider to increase the refrigerant flow rate to evaporator (3), and the cooling per-
formance increases. (State (A) in the above figure)
When evaporator (3) outlet temperature is low
1. The pressure of refrigerant gas (2) in the diaphragm chamber (hatched portion) decreases, and accordingly
the volume decreases.
2. Force (F g) of refrigerant gas (2) to push needle valve (1a) decreases, and needle valve (1a) moves to the
right.
3. Needle valve (1a) opens smaller to decrease the refrigerant flow rate to evaporator (3), and the cooling ca-
pacity decreases. (State (B) in the above figure)
FUNCTION OF DUAL PRESSURE SWITCH

The dual pressure switch is installed to the air conditioner hose
under the floor.
Below LA: Abnormally low pressure
Above HA: Abnormally high pressure
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
• The dual pressure switch turns "OFF" when it detects abnormally low refrigerant pressure in low-pressure
line or abnormally high refrigerant pressure in high-pressure line.
• When the dual pressure switch turns "OFF", the air conditioner controller turns the compressor clutch relay
"OFF". As a result, the compressor's magnet clutch is released and air conditioner components are protect-
ed.
80-24 PC210LC-11
80 APPENDIX AIR CONDITIONER CONTROLLER
AIR CONDITIONER CONTROLLER

STRUCTURE OF AIR CONDITIONER CONTROLLER
General view
For input signals, see “System diagram”.
PC210LC-11 80-25
COMPRESSOR 80 APPENDIX
COMPRESSOR
STRUCTURE OF COMPRESSOR
General view
A: Refrigerant inlet (from air conditioner unit) B: Refrigerant outlet (to condenser)
1: Pulley 3: Relief valve
2: Magnetic clutch
SPECIFICATIONS OF COMPRESSOR
Number of cylinders - Cylinder bore x Stroke: : 10 - 32x20.8 mm
Delivery: : 157.3 cc/rev
Allowable max. speed: : 6000 rpm
Compressor oil: DENSO: ND-OIL8 (for R134a)
Compressor oil quantity: : 180 cc
FUNCTION OF COMPRESSOR
• The compressor circulates the refrigerant and compresses the gaseous refrigerant from the evaporator into
a misty refrigerant at high pressure and high temperature so that it is easily regenerated (liquefied) at the
normal temperature.
• The air conditioner controller operates magnetic clutch (2) inside the compressor, according to the evapora-
tor temperature and refrigerant pressure.
• When magnetic clutch (2) is engaged, the compressor shaft is turned together with pulley (1) by the engine
power, and the compressor is driven.
80-26 PC210LC-11
80 APPENDIX CONDENSER
CONDENSER
STRUCTURE OF CONDENSER
General view
A: Refrigerant inlet (from compressor) 4. Filter

B: Refrigerant outlet (to air conditioner unit) 5. Seal cap
1. Condenser 6. O-ring
2. Modulator 7. Snap ring
3. Desiccating agent
SPECIFICATIONS OF CONDENSER
Fin pitch: 4.0 mm
Total heat dissipation area: 3.58 m2
Max. using pressure: 3.53 MPa {36 kg/cm2}
Weight of desiccating agent: 290 g
FUNCTION OF CONDENSER
• Condensing part of condenser (1) cools and liquefies the high-temperature high-pressure misty refrigerant
sent from the compressor.
• Sub-cooling part of condenser(1) furthermore cools liquid refrigerant sent through modulator (2) to improve
cooling efficiency.
• Modulator (2) stores the high-pressure and high-temperature liquid refrigerant sent from the condenser.
Even if bubbles are mixed in the liquid refrigerant depending on heat radiation condition of the condenser,
the refrigerant is liquefied completely.
• Filter (4) and desiccating agent (3) which are built-in modulator (2) remove foreign material in the refrigerant
circulation circuit and moisture contained in the refrigerant.
PC210LC-11 80-27
CONDENSER 80 APPENDIX
NOTICE
If its cooling fins are crushed or clogged with dirt and dust, heat exchange efficiency lowers. According-
ly, the condenser cannot liquefy the refrigerant entirely. If the pressure in the refrigerant circulation cir-
cuit increases, unnecessary load applies on the engine and cooling efficiency decreases. Be careful not
to crush the fins in handling and daily maintenance of the condenser.
When replacing desiccating agent (3) in modulator (2), see “METHOD FOR REPLACING DESICCANT”
80-28 PC210LC-11
80 APPENDIX SENSORS FOR AIR CONDITIONER SYSTEM
SENSORS FOR AIR CONDITIONER SYSTEM

STRUCTURE OF SUNLIGHT SENSOR
The sunlight sensor is installed to the top of the machine monitor.
General view
1: Connector
2: Sensor
FUNCTION OF SUNLIGHT SENSOR

• The sunlight sensor senses the sunlight intensity and sends signals to the air conditioner controller.
• Only in the automatic air conditioner mode, the air conditioner controller controls the blower motor and air
mix servomotor to adjust the air temperature and flow rate by using the data of the sunlight sensor.
Output characteristics
STRUCTURE OF AMBIENT TEMPERATURE SENSOR

The outside air temperature sensor is installed to the cooling unit.
General view
1: Connector
2: Sensor
FUNCTION OF AMBIENT TEMPERATURE SENSOR

• The resistance of the sensor changes according to the temperature, and the sensor senses the outside air
temperature.
• The air conditioner controller converts the change in resistance of the outside air temperature sensor into
the change in voltage to determine the outside air temperature.
PC210LC-11 80-29
SENSORS FOR AIR CONDITIONER SYSTEM 80 APPENDIX
• Only in the automatic air conditioner mode, the air conditioner controller controls the blower motor and air
mix servomotor to adjust the air temperature and flow rate by using the data of the outside air temperature
sensor.
80-30 PC210LC-11
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLE-
80 APPENDIX SHOOTING OF AIR CONDITIONER
EXPLANATION OF PROCEDURE FOR TESTING AND

TROUBLESHOOTING OF AIR CONDITIONER
The air conditioner is provided with self-diagnosis function in order to test its main components. It can test the
operation of sensors and servomotors.
If a failed portion is identified, each part must be checked.
1. After performing the basic check, narrow the failed portion according to the symptoms of failure of the air
conditioner.
2. Narrow down the sections with the self-diagnosis function. (See “Explanation of inspection of air conditioner
by self-diagnosis function”.)
However, when the air conditioner unit does not operate at all, check if the power supply up to the air condi-
tioner controller is normal. Also, check whether the CAN communication between the machine monitor and
air conditioner controller is normal.
If any part of the air conditioner unit operates, the power supply up to the air conditioner controller and the
CAN communication between the machine monitor and air conditioner controller are normal.
3. After narrowing down the sections, check the related component parts to find out the failed part, and repair
it.
Basic flow chart of check and troubleshooting
*1: Error displayed on machine monitor and abnormality displayed on “Abnormality Record screen”.
*2: See “Simple check of refrigerant amount through sight glass”.
PC210LC-11 80-31
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLE-
SHOOTING OF AIR CONDITIONER 80 APPENDIX
*3: If refrigerant leakage is spotted, compressor oil circulating in the air conditioner circuit definitely leaks from
that point.
In such a case, retighten according to the tightening torque table in “Precautions for disconnecting and connect-
ing air conditioner piping”.
*4: Start the engine, turn the air conditioner switch ON, and check.
Simple check of refrigerant amount through sight glass
Start the engine and turn the air conditioner switch ON, and check after 5 minutes.
S: Condition viewed through sight glass LR: Liquid refrigerant

R: Condition in receiver drier
A: When bubbles are continuously seen, the quantity of refrigerant is insufficient
B: When bubbles are seen intermittently, the quantity of refrigerant is proper
C: When bubbles cannot be seen (i.e., the liquid is clear), the system has too much refrigerant or no refrigerant
The above is a generally known method. However, use it for reference only, since there are exceptions.
Referring to “Troubleshooting by gauge pressure”, judge by the gauge pressure.
80-32 PC210LC-11
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS
80 APPENDIX FOR AIR CONDITIONER
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNEC-

TOR PINS FOR AIR CONDITIONER
PC210LC-11 80-33
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS
FOR AIR CONDITIONER 80 APPENDIX
• The diffuser servomotor means the servomotor to change the vents (modes).
• The FRESH/RECIRC servomotor means the servomotor to change over the fresh air and recirculation air.
• The frost sensor means the evaporator temperature sensor.
80-34 PC210LC-11
80 APPENDIX AIR CONDITIONER SYSTEM DIAGRAM
AIR CONDITIONER SYSTEM DIAGRAM

This air conditioner is the automatic temperature control type.
PC210LC-11 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 80 APPENDIX
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER

Connector on controller side: AMP025 - 32PM
Connector on wiring harness side: ACECU
Input/output sig-
Pin No. Symbol Signal name
nal
1 +Bback Backup power supply Input
k Never connect these pins. Malfunctions or failures may oc-

2 - -
cur.
3 SS Sunlight sensor Input
4 THOUT Outside air temperature sensor Input
5 THF Evaporator temperature sensor Input
6 THI Inside air temperature sensor Input
7 POT5 Servomotor potentiometer power supply (5 V) Output
8 BWFB Blower feedback signal Input
9 PTRB Power transistor control signal Output
10 CAN_H CAN communication signal (H) Input/Output
11 CAN_L CAN communication signal (L) Input/Output

12 - -
cur.
13 MRFA FRESH/RECIRC air servomotor terminal A Output
14 MRFB FRESH/RECIRC air servomotor terminal B Output
15 MAMA Air mix servomotor terminal A Output
16 MAMB Air mix servomotor terminal B Output
17 +24V (24 V) Power supply Input

18 - -
cur.
19 SAM Air mix servomotor potentiometer signal Input
20 SV1 Vent (mode) changeover servomotor potentiometer signal Input
21 PRESS SW Dual pressure switch Input

22 - -
cur.
23 - -
cur.
24 - -
cur.
25 GNDS Sensor GND Input
26 GND GND Input

27 - -
cur.
28 - -
cur.
29 RLCC Compressor clutch relay Output
80-36 PC210LC-11
80 APPENDIX INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
Input/output sig-
Pin No. Symbol Signal name
nal

30 - -
cur.
31 MV1A Vent (mode) changeover servomotor terminal A Output
32 MV1B Vent (mode) changeover servomotor terminal B Output
FUNCTION OF AIR CONDITIONER CONTROLLER

• Performs CAN communication with the machine monitor and controls the air conditioner unit according to
the switch inputs related to the air conditioner.
• Controls 3 servomotors located inside the air conditioner unit in order to perform temperature control (AIR-
MIX), vent (mode) changeover, and FRESH/RECIRC air changeover.
• Controls ON/OFF condition of the compressor clutch relay (i.e., a switch for activating the compressor).
• Adjust the air flow with the power transistor.
REMARK
The power transistor has a fuse in it to prevent an overcurrent.
• Evaporator temperature sensor determines the evaporator temperature.
• Turn compressor clutch relay ON/OFF and control the compressor to prevent the evaporator from freezing.
REMARK
If dual pressure switch detects abnormal pressure (it is turned OFF), compressor clutch relay is turned OFF
and compressor stops.
• Adjust the inside temperature to set temperature and controls air flow according to data of sunlight sensor,
outside air temperature sensor, and inside air temperature sensor in automatic air conditioner mode.
• Self-diagnosis function is installed and it detects abnormality to machine monitor by CAN communication.
Then, failure code [879***] is displayed on electrical system abnormality record screen of machine monitor.
PC210LC-11 80-37
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND AR-
RANGEMENT OF CONNECTORS 80 APPENDIX
INSTALLATION LOCATIONS OF AIR CONDITIONER

PARTS AND ARRANGEMENT OF CONNECTORS
k Park the machine on a level ground, swing the upper structure 90 °, lower the work equipment per-
fectly to the ground in a stable posture, set the lock lever to LOCK position, and stop the engine.
k Turn the battery disconnect switch to OFF position, and remove the key.
• Write down the connector numbers and installed positions of the wiring harnesses and hoses before dis-
connecting them.
• When disconnecting the dual pressure switch connector, swing the upper structure 90 ° and remove the cab
undercover.
• The 3 fuses related to the air conditioner are located in the fuse box at the rear of the operator's seat.
• The air conditioner unit is mounted inside the rear cover at the rear of the operator's seat.
Locations of fuse boxes and connectors

Connector No. Remarks Location Reference
Rear right of operator's Air conditioner controller and connectors
AC01 Intermediate connector
seat layout
Rear right of operator's Air conditioner controller and connectors
AC02 Intermediate connector
seat layout
Air conditioner compressor connectors lay-
AC03 Air conditioner compressor Engine
out
Air conditioner controller and connectors
ACECU Air conditioner controller Rear of operator's seat
layout
CM01*1 Machine monitor Front of operator's seat Machine monitor connectors layout
CM02 Machine monitor Front of operator's seat Machine monitor connectors layout
Inside of fuse box at rear
F01 Fuse box Fuses layout in fuse box F01
right of operator's seat
P17 Dual pressure switch Under operator's seat Dual pressure switch connectors layout
Outside air temperature Outside air temperature sensor connectors
P18 Cooling unit
sensor layout
P31 Sunlight sensor Machine monitor Sunlight sensor connectors layout
Air conditioner controller and connectors
R21 Relay Rear of operator's seat
layout
[2] Power transistor Air conditioner unit Air conditioner unit and connectors layout
FRESH/RECIRC air
[5]*1 Air conditioner unit Air conditioner unit and connectors layout
changeover servomotor
Inside air temperature sen-
sor
Evaporator temperature
sensor (frost sensor)
*1: Connectors which do not appear in troubleshooting.

Fuses layout in fuse box F01
Open the cover of fuse box at the rear right of the operator's seat.
80-38 PC210LC-11
80 APPENDIX RANGEMENT OF CONNECTORS
No. 10: Fuse for power supply to blower (fan) and air condition-
er compressor (20 A)
No. 13: Fuse for air conditioner unit, air conditioner controller
and primary side power supply of electromagnetic clutch relay
of air conditioner compressor (5 A)
No. 19: Fuse for power supply (backup power supply) to air
conditioner controller (5 A)
Air conditioner controller and connectors layout

1: Air conditioner controller
AC01: Intermediate connector
AC02: Intermediate connector
ACECU: Air conditioner controller connector
R21: Air conditioner compressor solenoid clutch relay connec-
tor
Air conditioner unit and connectors layout

2: Power transistor connector [2]
3: FRESH/RECIRC air changeover servomotor connector [5]
4: Inside air temperature sensor connector [6]
5: Evaporator temperature sensor (frost sensor) connector [7]
REMARK
• The connectors cannot be disconnected while mounted on
the machine, except connector 2 at the rear side of the air
conditioner unit.
• [2], [5], [6], and [7] are unlabeled connectors.
PC210LC-11 80-39
RANGEMENT OF CONNECTORS 80 APPENDIX
Sunlight sensor connectors layout

P31: Sunlight sensor connector
Machine monitor connectors layout

CM01 to CM04: Machine monitor connectors
REMARK
• Connector CM03: (Unused)
• Connector CM04: (For connecting camera)
Dual pressure switch connectors layout

When disconnecting the dual pressure switch connector, swing the upper structure 90 ° and remove the cab un-
dercover.
P17: Dual pressure switch connectors
Air conditioner compressor connectors layout

Open the engine hood.
80-40 PC210LC-11
80 APPENDIX RANGEMENT OF CONNECTORS
AC03: Air conditioner compressor connector
Outside air temperature sensor connectors layout

P18: Outside air temperature sensor connector
PC210LC-11 80-41
METHOD FOR TESTING AIR LEAKAGE (DUCT) 80 APPENDIX
TESTING AIR LEAKAGE (DUCT)

k Park the machine on a level ground, lower the work equipment to the ground in a stable posture, set
the lock lever to LOCK position, and stop the engine.
Write down the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
METHOD FOR TESTING AIR LEAKAGE (DUCT)

1. Pull up front window assembly (1) to the ceiling, and lock
it.
2. Remove front lower window (2).
3. Remove floor mat (3).
4. Remove cover (4) first, and remove cover (5).
5. Remove cover (6).
6. Remove cap (7-1).

7. Remove cover (7).
8. Disconnect the sunlight sensor connector (P31) from the

backside of cover (7).
80-42 PC210LC-11
80 APPENDIX METHOD FOR TESTING AIR LEAKAGE (DUCT)
9. Remove drink box (8) (5 bolts).

10. Disconnect the hose at the bottom of drink box (8).
11. Remove magazine box (9) (3 bolts) while paying attention
to connectors (10) and (11) at the back of magazine box
(9).
Connector (10): 12 V power socket intermediate harness
(M13A)
(M13B)
12. Pull up and remove cover (12) (2 bolts) from being caught
in connectors or wiring harnesses at the back of cover
(12).
13. Remove cover (13) (7 bolts) while paying attention to con-

nector (14) at the back of cover (13).
Connector (14): Cigarette lighter (M04)
14. Check that the following ducts and pin are installed nor-
mally.
(15): Front duct
(16): Defroster duct
(17): Rear duct
(18): Fresh air inlet duct
(19): Pin
PC210LC-11 80-43
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 80 APPENDIX
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS

FUNCTION
• The air conditioner controller self-checks the refrigerant
pressure by using the inside air temperature sensor, out-
side air temperature sensor, evaporator temperature sen-
sor, temperature control switch, vent selector (mode)
switch, and pressure switch. If abnormally related to the
temperature control, vent (mode) selection, or refrigerant
among them occurs, the machine monitor changes to the
warning screen momentarily, and then continues display-
ing “Air conditioner system state monitor”.
• When the machine monitor fails in communication with the
air conditioner controller, it displays system state monitor
“!”.
• Once abnormality is detected, the abnormality in the self-diagnosis is not reset when the abnormal portion
becomes normal. It is reset when the starting switch to “OFF” position.
• FRESH/RECIRC air changeover servomotor has no self-diagnosis function.
• If the controller detect a failure by self-diagnosis, it displays the failure on “Electrical Sys Abnormality Re-
cord” screen in Service Mode of the machine monitor.
Failure code list related to air conditioner

Failure code Failure (Displayed on screen) Remarks
879AKA A/C Inner sensor Open Circuit While it is mounted, not only the connector check but also trouble-
shooting cannot be performed.
879AKB A/C Inner sensor Short Circuit The A/C Inner sensor means the inside air temperature sensor.
879BKA A/C Outer sensor Open Circuit
The A/C Outer sensor means the outside air temperature sensor.
879BKB A/C Outer sensor Short Circuit
879CKA Ventilating sensor Open Circuit While it is mounted, not only the connector check but also trouble-
879CKB Ventilating sensor Short Circuit The Ventilating sensor means the evaporator temperature sensor
(frost sensor).
Sunlight sensor Open or Short
879DKZ
Circuit
While it is mounted, not only the connector check but also trouble-
879EMC Ventilating Damper Abnormality
The Ventilating Damper means the vent (mode) changeover
damper (door).
While it is mounted, not only the connector check but also trouble-
879FMC Air Mix Damper Abnormality
The Air Mix Damper means the temperature control (air mix)
damper (door).
879GKX Refrigerant Abnormality
Air conditioner model selection Troubleshooting is not performed by the air conditioner unit but by
DAZ9KQ
abnormality the machine monitor.
DAZQKR CAN2 Discon (Air conditioner) See Chapter 40, “Troubleshooting by failure code”
80-44 PC210LC-11
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RE-
80 APPENDIX CORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALI-

TY RECORD SCREEN IN SERVICE MODE OF THE MA-
CHINE MONITOR
1. Press“1”, “2”, and “3” in this order on the standard screen
while pressing numeric key “4”.
2. Press F3 twice on the Service Menu screen, and select

“03 Abnormality Record”.
3. Press F6 to enter the selection.
4. Press F3 once on the Abnormality Record screen, and se-

lect “02 Electrical Systems”.
5. Press F6 to enter the selection.
PC210LC-11 80-45
METHOD FOR TESTING VENT (MODE) CHANGEOVER 80 APPENDIX
TEST VENT (MODE) CHANGEOVER

Write down the connector numbers and installed positions before disconnecting wiring harnesses and hoses.
METHOD FOR TESTING VENT (MODE) CHANGEOVER

1. Remove drink box (1) (5 bolts).
2. Disconnect the hose at the bottom of drink box (1).
3. Remove magazine box (2) (3 bolts) while paying attention
to connectors (3) and (4) at the back of magazine box (2).
(M13A)
(M13B)
4. Remove cover (5) (3 bolts).
5. Remove cover (6) (7 bolts) while paying attention to con-

nector (7) at the back of cover (6).
Connector (7): Cigarette lighter (M04)
6. Remove ducts (8) and (9).
80-46 PC210LC-11
80 APPENDIX METHOD FOR TESTING VENT (MODE) CHANGEOVER
7. Turn battery disconnect switch to “ON” position.

8. Start the engine and turn the power supply of the air condi-
tioner to “ON”.
9. Operate the vent selector switch.
10. Check the opening and closing operations of rear door (11)
and defroster door (12) of air conditioner unit (10).
After finishing testing, turn the starting switch to OFF position.
PC210LC-11 80-47
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 80 APPENDIX
TESTING FRESH/RECIRC AIR CHANGEOVER

• The FRESH/RECIRC air changeover servomotor is not checked by the self-diagnosis.
• The FRESH/RECIRC air changeover servomotor switches the fresh air and recirculation air by changing
the angle of the FRESH/RECIRC air changeover door (damper). Visually check opening and closing of this
door (damper).
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER

1. Open fresh air filter cover (1) and remove fresh air filter (2).
2. Start the engine and turn the power supply of the air condi-
tioner to “ON”.
3. Operate the FRESH/RECIRC air selector switch.
4. Check opening and closing operations of FRESH/RECIRC

air selector rear door (3) through the fresh air inlet on the
left side of the cab.
After finishing testing, turn the starting switch to OFF position.
80-48 PC210LC-11
80 APPENDIX METHOD FOR TESTING SUNLIGHT SENSOR
TEST SUNLIGHT SENSOR

k If the sunlight sensor is measured with a multimeter in the resistance range, it may be broken.
• Write down the connector numbers and installed positions before disconnecting wiring harnesses and ho-
ses.
• If [879DKZ] is displayed by the self-diagnosis (on "Air-conditioning System" screen of "Abnormality Record"
in the machine monitor), test sunlight sensor connector P31.
To reset the self-diagnosis system (detection of abnormality), turn the starting switch to OFF position.
METHOD FOR TESTING SUNLIGHT SENSOR

1. Remove the machine monitor cover. For details, see “Check method of air leakage (duct)”, steps 6 and 7.
2. Check connector P31 at the back of the sunlight sensor.
(Check that it is connected securely)
3. Disconnect connector P31, remove the sunlight sensor,
and measure the voltage between the terminals on the
sensor side with a multimeter in the voltage range.
Rough voltage of sunlight sensor unit
0.55 V: Direct sunlight
0.45 V: Cloudy
0.4 V: Indoor
PC210LC-11 80-49
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIG-
ERANT 80 APPENDIX
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT

k Since refrigerant is potentially hazardous to health and environment, collect it before replacing the
dual pressure switch.
See “PRECAUTIONS FOR REFRIGERANT” in chapter 80.
ses.
• If [879GKX] is displayed by the self-diagnosis (on "Air-conditioning System" screen of "Abnormality Record"
in the machine monitor), test dual pressure switch connector P17.
To reset the self-diagnosis system (detection of abnormality), turn the starting switch to OFF position.
• The dual pressure switch unit is ON when the refrigerant pressure is normal and OFF when the refrigerant
pressure is abnormal.
REMARK
When the ambient temperature decreases below 0 °C, the refrigerant pressure decreases, thus the dual
pressure switch may be turned OFF. In this case, the dual pressure switch is normal.
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT

1. Swing the upper structure 90 °.
2. Remove the cab undercover.
3. Disconnect the dual pressure switch connector P17.
4. Check if the resistance between the switch-side terminals

of connector P17 is shorted (ON). (If it is not shorted, the
dual pressure switch is OFF and detects abnormal refriger-
ant pressure.)
If the dual pressure switch is OFF, attach a pressure
gauge to the high-pressure line of the air conditioner com-
pressor and check the refrigerant pressure. If the refriger-
ant pressure is normal, the dual pressure switch is defec-
tive. See “Connection of service tool” and “Troubleshooting
by gauge pressure”.
(Dual) Pressure switch
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
If resistance between the switch-side terminals from connector P17 is shorted (ON), perform “Troubleshooting
for compressor and refrigerant system”.
80-50 PC210LC-11
80 APPENDIX METHOD FOR TESTING RELAYS
TEST RELAYS
ses.
• If the air conditioner compressor is normal (it cools air), skip this troubleshooting.
• Compressor clutch relay R21 turns air conditioner compressor (clutch) ON/OFF.
For the location, see “Air conditioner parts locations and connector layout”.
METHOD FOR TESTING RELAYS

1. Check connector R21 for poor contact. (Check that they
are connected securely)
2. Turn the starting switch to ON position (with the engine

stopped), turn the main switch of the air conditioner ON,
and turn the air conditioner switch ON. If the air conditioner
is normal, the compressor relay turns ON to make clicking
sound.
Do not turn ON the compressor clutch relay if the air condi-
tioner controller is in the following conditions.
• When the evaporator temperature is 3°C or below (by
the evaporator temperature sensor)
• When the pressure switch senses abnormality (pres-
sure switch OFF)
REMARK
The coil resistance between compressor clutch relay (CCRL) terminals (1) and (2) is 300 to 500 Ω.
PC210LC-11 80-51
AIR CONDITIONER TROUBLESHOOTING CHART 1 80 APPENDIX
AIR CONDITIONER TROUBLESHOOTING CHART 1

Cooling trouble
Heating trouble
80-52 PC210LC-11
80 APPENDIX AIR CONDITIONER TROUBLESHOOTING CHART 2
AIR CONDITIONER TROUBLESHOOTING CHART 2

Blower fan motor does not turn in cooling and heating modes, or its
speed is different from flow setting in cooling mode.
Probable cause Check method Remedy
Open circuit or defective connec- Check for disconnection of connector. Repair the open circuit.
tion in wiring See “Parts and connectors layout”. Connect it correctly.
Operate fan switches in order and check that fan
Defective blower fan motor turns. Replacement
See “Air conditioner unit”.
Operate fan switches in order and check that fan
Defective power transistor (PTR) Replacement
turns.
Blower fan motor is normal but air flow is insufficient in cooling mode.
Check for clogging of filter and for crushing and
Draft resistance is high. Repair
clogging of duct.
Air leakage through connection Check connection part of duct.

Repair
part of duct See “Testing air leakage (duct)”.
Obstacles on suction side of Clean it to remove obsta-
Check evaporator for dirt and obstruction.
evaporator cles.
Evaporator is frozen.
Defective evaporator temperature
Check sensor fixing clip, check sensor for dirt and
sensor, defective contact of evap-
dust. Replacement or repair
orator temperature sensor, or de-
fective expansion valve *1 Check if air conditioner hose near pressure switch
is frosted (when freezing occurs more)
*1: Evaporator temperature sensor and expansion valve are located inside air conditioner unit.
Pressure is abnormal in cooling mode (low/high pressure)
Repair leaking point and
Insufficient refrigerant Check refrigerant volume through sight glass during refill with proper volume of
normal operation. refrigerant.
For better accuracy, connect check gauge manifold Collect refrigerant, then re-
Over-filling with refrigerant and check it. fill with proper volume of
refrigerant.
Normal refrigerant pressure range
Low pressure: : Approximately 0.13 to 0.2 MPa {1.3
to 2.0 kg/cm2}
Judgment by pressure at outlet See "Troubleshooting by
and inlet of compressor High pressure: : Approximately 1.5 to 1.7 MPa {15 gauge pressure".
to 17 kg/cm2}
Temperature in operator's cab: : 30 to 35 °C, engine
speed: Approximately 1500 rpm
Compressor does not turn at all or does not turn normally in cooling
mode.
See “Troubleshooting of compressor system (Air is not cooled)”.
PC210LC-11 80-53
AIR CONDITIONER TROUBLESHOOTING CHART 2 80 APPENDIX
Failed part Probable cause Check method Remedy

Belt deflection is large.
See Shop Manual, 30, Test-
Compressor belt Loose belt ing and adjusting, “TEST Adjust tension
AND ADJUST AIR CON-
DITIONER COMPRES-
SOR BELT TENSION”.
Internal defect of compres-
Slip of belt Replacement or repair
sor
Compressor
Insufficient compressor oil See “HANDLE COMPRES-
Overheating of compressor
Seized compressor SOR OIL”.
Low battery voltage Slip during rotation Battery charge

Open circuit or short circuit Check with multimeter (10
Replacement
in coil to 20 Ω).
Magnetic clutch Check ground cable and
Open circuit in wiring or de- connection part
fective connection of See “Troubleshooting for Repair
ground cable compressor and refriger-
ant system”.
Defective compressor
Relay See “TEST RELAYS”. Replacement
clutch relay
Abnormal pressure (pres- See “Troubleshooting by See “Troubleshooting by
Refrigerant pressure
sure switch is actuated) gauge pressure”. gauge pressure”.
See “Troubleshooting for
compressor and refriger-
Defective dual pressure ant system”.
Dual pressure switch Replacement
switch
See “Testing refrigerant
(dual) pressure switch”.
Blower fan motor is normal but air flow is insufficient in heating mode.
Check for clogging of filter and for crushing and
Draft resistance is high. Repair
clogging of duct.
Air leakage through connection Check connection part of duct. See “TESTING AIR
Repair
part of duct LEAKAGE (DUCT)”.
Clogging of heater core fins Check for clogging of heater core fins. Cleaning
Abnormality of temperature or quantity of engine coolant in heating mode

Engine coolant temperature is Check engine coolant temperature after warm-up
Investigation of the cause
low. operation.
Engine coolant level is low. Check coolant level in radiator. Add coolant.
Circulation rate of engine coolant Check for clogging of engine coolant piping (hose,
Bleeding and repair of air.
is low. pipe, core).
Connection of heater hoses to IN
Check destinations of heater hoses. Repair
and OUT is inverted.
80-54 PC210LC-11
80 APPENDIX AIR CONDITIONER TROUBLESHOOTING CHART 2
Abnormality of fan speed in cooling mode

Check the alternator belt for wear or damage. Replacement
See shop manual chapter
40, TROUBLESHOOTING
Fan speed is low. See shop manual, chapter 30, TESTING AND AD- (H mode), “FAN SPEED IS
JUSTING, “TEST COOLING FAN SPEED”. ABNORMAL (TOO HIGH
OR LOW, OR STATION-
ARY)”
Other abnormalities in cooling or heating mode

Probable cause Check method Remarks
Temperature cannot be adjusted. Change temperature setting in manual mode.
Vents (modes) cannot be
See “TEST VENT (MODE) CHANGEOVER”. Common to cooling and
changed.
heating modes
Fresh air and recirculation air See “TESTING FRESH/RECIRC AIR CHANGE-
cannot be changed over. OVER”.
Too much compressor oil See “HANDLE COMPRESSOR OIL”.
Cooling mode only
Water leakage into operator's cab Clogging of drain hole
PC210LC-11 80-55
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 80 APPENDIX
INFORMATION DESCRIBED IN TROUBLESHOOTING TA-

BLE
The following types of information are described in the troubleshooting table and related circuit diagram. Fully
understand the description and perform troubleshooting.
Failure Problem on machine
Related information Information related to the occurred failure and its troubleshooting
No. Cause Procedure, measuring location, criteria, and remarks

1 Probable causes for [Details]
2 trouble • Procedure
• Measuring point
"Between A and B" denotes measuring values such as voltage and resist-
ance, etc. between A and B.
• Criteria to judge probable causes (standard value), remarks
[Precautions for troubleshooting]
(1) Connector number description sequence and tester lead handling
3 Defective --- For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wiring harness indicated in the front.
• Connect the negative (-) lead to a pin or wiring harness indicated in the rear.
(2) Example of troubleshooting by check of multiple items
• Normal in 1 but abnormal in 2
At that time, the description is made as "Defective ---" as shown on the left.
[Failures in wiring harness]

• Open circuit
Connection of connector is defective or wiring harness is broken.
• Ground fault
A wiring harness not to be connected to the GND (ground) circuit comes to contact with the GND (ground)
circuit or chassis.
• Hot short circuit
A wiring harness not to be connected to the power supply circuit comes to contact with the power supply
circuit.
• Short circuit
An independent wire in the wiring harness abnormally comes into contact with one of other wires. (Defec-
tive insulation in connector, etc.)
80-56 PC210LC-11
80 APPENDIX INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting
• Connector numbers and pin numbers are shown.
• Size of wire is shown. When there is a number in front of color, it shows size.
W: White, B: Black, R: Red, G: Green, Y: Yellow, L: Blue, V: Purple, P: Pink, O: Orange, Br: Brown, Gr:
Gray, Sb: Sky blue, Lg: Light green, Dg: Dark green, Ch: Dark brown
• When there are two colors
Example) WY: Yellow line on white background
• When there is a number in front of color, it shows size.
• NC: Normally closed (Normally ON)
• [1] and [2] are numbers of unlabeled connectors.
• Arrow (←→): Roughly indicates their mounting place on the machine.
PC210LC-11 80-57
FAILURE CODE [879AKA] 80 APPENDIX
FAILURE CODE [879AKA]

Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Open Circuit
Failure
- 879AKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in recirculation air temperature sensor.
failure
Air conditioner controller transmits open circuit information of recirculation air temperature sensor to
Action of
machine monitor by CAN communication.
controller
Stops air conditioner when in automatic air conditioner mode.
Since air conditioner recirculation air temperature sensor has open circuit, automatic air conditioner
Phenomenon
does not operate.
on machine
(Air conditioner can be operated in manual mode.)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in “SERV-
information ICE MODE” of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.
No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)
80-58 PC210LC-11
80 APPENDIX FAILURE CODE [879AKB]
FAILURE CODE [879AKB]

Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Short Circuit
Failure
- 879AKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in recirculation air temperature sensor.
failure
• Air conditioner controller transmits short circuit information of recirculation air temperature
Action of
sensor to machine monitor by CAN communication.
controller
• Stops air conditioner when in automatic air conditioner mode.
Phenomenon Since air conditioner recirculation air temperature sensor has short circuit, automatic air conditioner
does not operate.
on machine (Air conditioner can be operated in manual mode)
Related • Check if this failure code is displayed on electrical system failure record screen in SERV-
information ICE MODE of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.

controller
2
PC210LC-11 80-59
FAILURE CODE [879BKA] 80 APPENDIX
FAILURE CODE [879BKA]

Action level Failure code Air Conditioner Fresh Air Temperature Sensor Open Circuit
Failure
- 879BKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in outside air temperature sensor.
failure
Air conditioner controller transmits open circuit information of outside air temperature sensor to ma-
Action of chine monitor by CAN communication.
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has open circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
(Air conditioner is not affected in manual mode.)
• Check if this failure code is displayed on electrical system failure record screen in service
mode of machine monitor.
Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information
• Since air conditioner controller connector ACECU has no T-adapter and has small pins,
perform troubleshooting by using intermediate connector (although intermediate connector
has no T-adapter either, it has large pins).
• When replacing air conditioner harness between air conditioner controller connector ACE-
CU and intermediate connector, replace air conditioner unit.

1. Turn starting switch to OFF position.
Defective fresh air tem- 2. Disconnect connector P18.
1
perature sensor
Between P18 (male) (1) Approx.
Resistance 25 °C
and (2) 1.7 kΩ
Open or short circuit in 2. Disconnect connector AC01.
2
wiring harness
Between AC01 (female) Approx.
Resistance 25 °C
(7) and (8) 1.7 kΩ
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or
3 2. Disconnect connectors P18 and AC01.
defective contact of con-
nector) Between AC01 (female) (7) and P18 (female) (1) Max. 1 Ω
Resistance
Between AC01 (female) (8) and P18 (female) (2) Max. 1 Ω
If failure code is still displayed after above checks, air conditioner controller is de-
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
controller
Replace whole assembly.)
If failure code is still displayed after above checks, air conditioner unit may be de-
unit
80-60 PC210LC-11
80 APPENDIX FAILURE CODE [879BKA]
Circuit diagram related to air conditioner fresh air temperature sensor
PC210LC-11 80-61
FAILURE CODE [879BKB] 80 APPENDIX
FAILURE CODE [879BKB]

Action level Failure code Air Conditioner Fresh Air Temperature Sensor Short Circuit
Failure
- 879BKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in outside air temperature sensor.
failure
Air conditioner controller transmits short circuit information of outside air temperature sensor to ma-
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has short circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
(Air conditioner is not affected in manual mode.)
Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information

Defective fresh air tem- 2. Disconnect connector P18.
1
perature sensor
Between P18 (male) (1) Approx.
Resistance 25 °C
and (2) 1.7 kΩ
Open or short circuit in 2. Disconnect connector AC01.
2
wiring harness
Between AC01 (female) Approx.
Resistance 25 °C
(7) and (8) 1.7 kΩ
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Short circuit in wiring har- 1. Turn starting switch to OFF position.
3
ness 2. Disconnect connectors P18 and AC01.
Between AC01 (female) (7) and (8), or between P18

Resistance Min. 1 MΩ
(female) (1) and (2)
Ground fault in wiring 2. Disconnect connectors P18 and AC01.
4
harness
Between ground and AC01 (female) (8) or P18 (fe-
male) (2)
controller
80-62 PC210LC-11
80 APPENDIX FAILURE CODE [879BKB]

unit
Circuit diagram related to air conditioner fresh air temperature sensor
PC210LC-11 80-63
FAILURE CODE [879CKA] 80 APPENDIX
FAILURE CODE [879CKA]

Action level Failure code Ventilating sensor Open Circuit
Failure
- 879CKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in evaporator temperature (frost) sensor.
failure
• Air conditioner controller transmits open circuit information of evaporator temperature
Action of
(frost) sensor to machine monitor by CAN communication.
controller
• Stops air conditioner.
Phenomenon
Air conditioner does not operate because of open circuit in evaporator temperature (frost) sensor.
on machine
Related • Check if this failure code is displayed on electrical system failure record screen in SERV-
information ICE MODE of machine monitor.
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

controller
2
80-64 PC210LC-11
80 APPENDIX FAILURE CODE [879CKB]
FAILURE CODE [879CKB]

Action level Failure code Ventilating sensor Short Circuit
Failure
- 879CKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in evaporator temperature (frost) sensor.
failure
• Air conditioner controller transmits short circuit information of evaporator temperature
Action of
(frost) sensor to machine monitor by CAN communication.
controller
• Stops air conditioner.
Phenomenon
Air conditioner does not operate because of short circuit in evaporator temperature (frost) sensor.
on machine
Related • Check if this failure code is displayed on electrical system failure record screen in service
information mode of machine monitor.
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

controller
2
PC210LC-11 80-65
FAILURE CODE [879DKZ] 80 APPENDIX
FAILURE CODE [879DKZ]

Action level Failure code Sunlight Sensor Open Circuit or Short Circuit
Failure
- 879DKZ (Machine monitor system)
Details of
Air conditioner controller detects open or short circuit in sunlight sensor.
failure
• Air conditioner controller transmits open or short circuit information of sunlight sensor to
Action of machine monitor by CAN communication.
controller • Ignores data of sunlight sensor and continues control of air conditioner in automatic air
conditioner mode.
Phenomenon Since air conditioner sunlight sensor has open or short circuit, sunlight intensity is not considered in
on machine automatic air conditioner mode.(Air conditioner is not affected in manual mode.)
• For each connector, see 80 APPENDIX, “Installation locations of air conditioner parts and
Related arrangement of connectors”.
information • Since air conditioner controller connector ACECU has no T-adapter and has small pins,
• T-adapter is not provided for connectors of sunlight sensor.

See 80 APPENDIX, “Testing sunlight sensor”.
Approx.
Direct sunlight
0.55 V
1 Defective sunlight sensor Between sunlight sensor Approx.
Voltage Cloudy
terminals 0.45 V
Approx.
Indoor
0.4 V
See “Testing sunlight sensor”.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or 2. Disconnect connector P31 and AC01.
2
nector) Between P31 (female) (1) and AC01 (female) (10) Max. 1 Ω
Resistance
Between P31 (female) (2) and AC01 (female) (9) Max. 1 Ω
controller
unit
80-66 PC210LC-11
80 APPENDIX FAILURE CODE [879DKZ]
Circuit diagram related to sunlight sensor
PC210LC-11 80-67
FAILURE CODE [879EMC] 80 APPENDIX
FAILURE CODE [879EMC]

Action level Failure code Ventilation Damper Malfunction
Failure
L01 879EMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of vent selector (mode) damper servomotor, judging
failure from potentiometer voltage of servomotor.
Action of Air conditioner controller transmits abnormality of vent selector (mode) damper to machine monitor
controller by CAN communication.
Phenomenon
Vent (mode) cannot be selected, but air conditioner operates.
on machine
• Since connector of vent selector (mode) damper servomotor cannot be checked when it is
mounted on machine, troubleshooting cannot be performed.

controller
2
80-68 PC210LC-11
80 APPENDIX FAILURE CODE [879FMC]
FAILURE CODE [879FMC]

Action level Failure code Air Mix Damper Malfunction
Failure
L01 879FMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of air mix (temperature regulator) damper servomotor,
failure judging from potentiometer voltage of servomotor.
Action of Air conditioner controller transmits abnormality of air mix damper to machine monitor by CAN com-
controller munication.
Phenomenon
Air conditioner does not operate since temperature cannot be regulated.
on machine
• Since connector of air mix damper servomotor cannot be checked when it is mounted on
machine, troubleshooting cannot be performed.

controller
2
PC210LC-11 80-69
FAILURE CODE [879GKX] 80 APPENDIX
FAILURE CODE [879GKX]

Action level Failure code Refrigerant Pressure Input Signal Out of Range
Failure
L01 879GKX (Machine monitor system)
Details of
Air conditioner controller detected that dual pressure switch is OFF.
failure
• Air conditioner controller transmits abnormality information of refrigerant pressure to ma-
controller • Air conditioner controller turns OFF compressor clutch relay since refrigerant pressure is
abnormal.(Air conditioner compressor stops)
Phenomenon
Air conditioner does not function (in cooling mode).
on machine
• Check if this failure code is displayed on electrical system failure record screen in SERV-
ICE MODE of machine monitor.
• For each connector, see 80 APPENDIX, “Installation locations of air conditioner parts and
Related arrangement of connectors”.
information • Since air conditioner controller connector ACECU has no T-adapter and has small pins,
• T-adapter is not provided for connectors of dual pressure switch.

See 80 APPENDIX, “TEST (DUSL) PRESSURE SWITCH FOR REFRIGERANT”.
Defective refrigerant (du-
1
al) pressure switch k Before replacing dual pressure switch, collect refrigerant. See 80 AP-
PENDIX, “PRECAUTIONS FOR REFRIGERANT”.
Open circuit in wiring har-
2. Disconnect connectors AC01 and P17.
2
defective contact of con- Between P17 (female) (1) and AC01 (female) (6) Max. 1 Ω
nector) Resistance
Between P17 (female) (2) and ground Max. 1 Ω
controller
unit
80-70 PC210LC-11
80 APPENDIX FAILURE CODE [879GKX]
Circuit diagram related to refrigerant (dual) pressure switch
PC210LC-11 80-71
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CON-
DITIONER DOES NOT OPERATE) 80 APPENDIX
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM

(AIR CONDITIONER DOES NOT OPERATE)
Failure Air conditioner does not operate because of power supply system failure.
Phenomenon [DAZQKR] is displayed on operation screen of machine monitor.
on machine No air comes out (Blower motor does not turn).
• When failure code [DAZQKR] is displayed on machine monitor, perform this troubleshoot-
ing first.
• [DAZQKR] is displayed on operation screen of machine monitor in following cases. In this
section, 1 and 2 below are explained.
1. Air conditioner controller is receiving no power.
2. Air conditioner controller is broken.
3. No communication is possible between air conditioner controller and machine monitor
(see failure code [DAZQKR]).
• Turn starting switch to ON position, and check if [DAZQKR] is displayed on machine moni-
tor and CAN communication is abnormal. Abnormal state of CAN communication means
that CAN communication between air conditioner controller and machine monitor does not
Related function.
information • Ground cable of air conditioner is connected together with other electrical components in-
side machine wiring harness.
• For each connector, see “INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS
AND ARRANGEMENT OF CONNECTORS”.
• If fuse is broken when air conditioner switch is pressed, see “A-2 TROUBLESHOOTING
OF COMPRESSOR SYSTEM”.

1 Blown fuse 2. Referring to “Installation locations of air conditioner parts and arrangement
of connectors”, check fuse No.13 (5 A) in fuse box F01 for breakage.
Defective wiring harness 2. Turn battery disconnect switch OFF.
2
(ground cable) 3. Disconnect connector AC02.
Resistance Between AC02 (female) (1) and ground Max. 1 Ω
If fuse described in Related information is blown, replace it.
2. Turn battery disconnect switch OFF.
3 Defective wiring harness 3. Disconnect connector AC02.
4. Turn battery disconnect switch ON.
5. Turn starting switch to ON position.
Voltage Between AC02 (female) (4) and (1) (black) 20 to 30 V
80-72 PC210LC-11
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CON-
80 APPENDIX DITIONER DOES NOT OPERATE)

2. Turn battery disconnect switch OFF.
Open circuit in wiring har- 3.
4 Disconnect connector AC02.
ness
4. Remove fuse No. 13 of fuse box F01.
Resistance Between AC02 (female) (4) and F01-13. Max. 1 Ω
If fuse is blown again in above test, perform following procedure.
Ground fault in wiring 2. Turn battery disconnect switch OFF.
5 harness (contact with
3. Disconnect connector AC02.
ground circuit)
4. Remove fuse No. 13 from fuse box F01.
Resistance Between ground and AC02 (female) (4) or F01-13. Min. 1 MΩ
controller
unit
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
8
tor an internal defect, troubleshooting cannot be performed.)
Circuit diagram related to air conditioner power supply
PC210LC-11 80-73
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT
SYSTEM (AIR IS NOT COOLED) 80 APPENDIX
A-2 TROUBLESHOOTING FOR COMPRESSOR AND RE-

FRIGERANT SYSTEM (AIR IS NOT COOLED)
Failure Air is not cooled because of compressor or refrigerant system failure
When engine is started and air conditioner switch is pressed on air conditioner screen of machine
Phenomenon
monitor, air is not cooled as displayed on screen.
on machine
Air conditioner compressor does not operate.
• Referring to inspection by self-diagnosis function, display electrical system abnormality re-
cord screen, and check if refrigerant is abnormal by display of [879GKX]. If refrigerant is
abnormal, compressor is not turned ON, thus air is not cooled.
• Abnormal refrigerant pressure indicates that signal ((21) of connector ACECU) from the
dual pressure switch is not grounded.
• Air conditioner may not turn ON at 3 °C or below (normal).
• When air does not come out, see “Troubleshooting of blower motor system”.
Related • For each connector and fuse, see “Installation locations of air conditioner parts and ar-
information rangement of connectors”.
.
• Connectors, except AC03, have no T-adapter
Since air conditioner controller connector ACECU has no T-adapter and has small pins,

• Perform this procedure when failure code [879GKX] is displayed on electri-
cal system failure record screen of machine monitor.
See 80 APPENDIX, “TEST (DUSL) PRESSURE SWITCH FOR REFRIG-
ERANT”.
• In certain cases, the dual pressure switch may be operating normally and
Defective dual pressure
1 set to OFF position, therefore, if abnormality is indicated (i.e., switch OFF),
switch system
attach a pressure gauge to the air conditioner compressor and check the
refrigerant pressure.
(See “Troubleshooting with gauge pressure”.)
k Before replacing dual pressure switch, collect refrigerant. See 80 AP-
PENDIX, “PRECAUTIONS FOR REFRIGERANT”.
Check the connection of ground cable of the air conditioner compressor.
Defective air conditioner 2. Disconnect connector AC03 from the air conditioner compressor and con-
2
compressor nect T-adapter to the male side.
Between connector AC03 (male) (1) and ground Approx.
Resistance
(resistance of air conditioner compressor coil) 15 Ω
Defective compressor Referring to “METHOD FOR TESTING RELAYS”, check compressor clutch relay.
3 clutch relay (it is not
turned ON)
80-74 PC210LC-11
80 APPENDIX SYSTEM (AIR IS NOT COOLED)

Check that no failure is found by check on cause 2 (air conditioner compressor is
normal).
2. Disconnect connector R21, AC03.
3. Disconnect fuse No. 10 and 13 of fuse box F01.
Open circuit in wiring har- Between connector R21 (female) (5) and F01-10 Max. 1 Ω
4
ness
Between connector R21 (female) (3) and chassis
ground approx.
Resistance 15 Ω
(coil resistance of air conditioner compressor)
Between F01-13 and R21 (female) (1) Max. 1 Ω
Between R21 (female) (2) and AC01 (female) (4) Max. 1 Ω
If fuse is not blown, skip the following troubleshooting.
Ground fault in wiring
5 harness (contact with 2. Disconnect connectors AC03 and R21, and connect T-adapter to female
ground circuit) side of AC03.
Resistance Between AC03 (female) (1) and chassis ground Min. 1 MΩ
Check that no failure is found by check on cause 2 (air conditioner compressor is
normal).
2. Disconnect connectors AC01, AC02, and R21.
Short circuit in wiring har-
6 REMARK
ness
For details of pin 3 of AC02, see circuit diagram in “A-1 Troubleshooting for power
supply system (Air conditioner does not operate)”.
Between R21 (female) (2) and AC02 (female) (2), (3),
and (4)
2. Disconnect connector R21.
Defective air conditioner 3. Turn starting switch to ON position.
7
controller 4. Display air conditioner operation screen on machine monitor and press
A/C switch.
Voltage Between R21 (female) (2) and ground Max. 1 V
Defective machine moni- 2.
8 Display air conditioner operation screen on machine monitor.
tor (defective switch)
Press A/C switch. “A/C ON” is displayed.
unit
PC210LC-11 80-75
SYSTEM (AIR IS NOT COOLED) 80 APPENDIX
Circuit diagram related to compressor and refrigerant system
80-76 PC210LC-11
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR
80 APPENDIX COMES OUT OR AIR FLOW IS ABNORMAL)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM

(NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
Failure No air comes out or air flow is abnormal because of blower motor system failure.
Phenomenon LCDs of machine monitor light up normally on air conditioner operation screen, but no air flows out.
on machine Air flow does not match fan switch setting on air conditioner operation screen.
• This is not included in self-diagnosis function.
• During cooling, if air flow becomes abnormal after a certain time, the evaporator may be
frozen. This may be due to the following.
1. Defective compressor clutch relay (kept ON)
2. Coming-off of mounting bolt of evaporator temperature sensor (Replace air conditioner
unit)
3. Defective adjustment of expansion valve (Replace air conditioner unit)
• When air comes out, fuse and motor are normal, and defective wiring harness is unlikely.
• For each connector and power transistor, see “INSTALLATION LOCATIONS OF AIR
CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS”.
REMARK
Related Since power transistor is at rear of air conditioner unit, it cannot be checked while it is
information mounted on machine or by disconnecting connector [2].
• If air comes out but its flow is abnormal in heating mode, power transistor is defective. In
this case, replace air conditioner unit.
REMARK
To replace power transistor and blower motor, air conditioner unit must be removed tem-
porarily.
• T-adapter is not provided for connectors of blower motor [1], power transistor [2].

Defective fuse No.10 in If fuse is blown, circuit probably has ground fault.
1
fuse box F01
Defective power transis-
2 2. Replace power transistor.
tor
If air comes out and air flow is adjustable, original power transistor is defective.
Open circuit in wiring har- 2. Disconnect connector AC02.
3 ness (wire breakage or
defective connector)
Resistance Between AC02 (female) (2) and F01-10 Max. 1 Ω
Ground fault in wiring 2. Disconnect connectors AC02 and R21.
ground circuit)
Resistance Between ground and AC02 (female) (2) or F01-10 Min. 1 MΩ
PC210LC-11 80-77
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR
COMES OUT OR AIR FLOW IS ABNORMAL) 80 APPENDIX

controller
unit
Circuit diagram related to blower motor system
80-78 PC210LC-11
80 APPENDIX A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR

CHANGEOVER
Failure Fresh air and recirculation air cannot be changed over.
When FRESH/RECIRC air selector switch on machine monitor is operated, recirculated or fresh air
Phenomenon
does not change over.
on machine
(FRESH/RECIRC air changeover door (damper) does not rotate)
• FRESH/RECIRC air changeover system has no self-diagnosis function.
• Referring to “TESTING FRESH/RECIRC AIR CHANGEOVERr”, operate FRESH/RECIRC
selector switch and check operation of FRESH/RECIRC air changeover door (damper).
• For each connector, see “INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS
AND ARRANGEMENT OF CONNECTORS”.
• Connector AC02, ACECU, FRESH/RECIRC air changeover servomotor [5] are not equip-
ped with T-adapters.
Since air conditioner controller connector ACECU has no T-adapter and has small pins,
Related
information has no T-adapter either, it has large pins).
• Method of reproducing failure code: Turn starting switch to ON position.
• Check if this failure code is displayed on “Electrical Systems” failure record screen in
“Service Mode” of machine monitor.
• Since connector of servomotor cannot be checked when it is mounted on machine, trou-
bleshooting cannot be performed for it.

Defective fuse No.19 in If fuse is blown, circuit probably has ground fault.
1
fuse box F01
Since connector [5] is at rear of air conditioner unit, it cannot be disconnected while
it is mounted on machine.
Open circuit in wiring har- 1.
Turn starting switch to OFF position.
2 2. Disconnect connector AC02.
nector) 3. Remove fuse No. 19 of fuse box F01.
Resistance Between F01-19 and AC02 (female) (3) Max. 1 Ω

Ground fault in wiring 2. Disconnect connector AC02.
3. Remove fuse No. 19 of fuse box F01.
ground circuit)
Resistance Between ground and F01-19 or AC02 (female) (3) Max. 1 MΩ
controller
unit
Defective machine moni- 2. Display air conditioner operation screen on machine monitor.
6
tor (defective switch)
Press FRESH/RECIRC air selector Display of FRESH/RECIRC air changes.
switch.
PC210LC-11 80-79
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 80 APPENDIX
Circuit diagram related to fresh/recirc air changeover
80-80 PC210LC-11
80 APPENDIX TROUBLESHOOTING USING GAUGE PRESSURE
TROUBLESHOOTING USING GAUGE PRESSURE

Connect the service tool referring to “METHOD FOR CONNECTING SERVICE TOOL”, perform troubleshooting
by reading the gauge pressures of the high-pressure and low-pressure lines in the freezing cycle.
• For the cause, checking method, and remedy corresponding to the gauge pressure, see the indicated
gauge pressure table.
• The gauge pressure varies with the weather condition and operating condition of the machine. Check the
gauge pressure under the pressure measurement conditions.
• Pressure measurement condition
Outside air temperature: 25 to 50 °C
Engine speed: 1500 rpm
Air conditioner switch: ON
Fan switch: HI
Set temperature: COOL MAX
• Pressure measurement standard value
High in high-pressure side: Approx. 2.5 MPa {25 kg/cm2} and above
Low in high-pressure side: Approx. 1 MPa {10 kg/cm2} and below
High in low-pressure side: Approx. 0.3 MPa {3 kg/cm2} and above
Low in low-pressure side: Approx. 0.05 MPa {0.5 kg/cm2} and below
• Dual pressure switch turns "OFF" to protect the air conditioner circuit if the pressure of the high-pressure or
low-pressure line is abnormally high or low.
Dual pressure switch is normally turned "ON" and is turned
"OFF" when it detects abnormal pressure in compressor opera-
tion.
LA: 0.20 MPa {2 kg/cm2}
LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
Indicated gauge pressure table

Indicated gauge pressure Cause Check method Remedy
Air conditioner cycle is operating normally.
If there is any failure (defective cooling), there is another
cause.
Pressure is normal -
High-pressure: Approx. 1.5 to 1.7 MPa {15 to 17 kg/cm2}
Low-pressure: Approx. 0.13 to 0.2 MPa {1.3 to
2.0 kg/cm2}
PC210LC-11 80-81
TROUBLESHOOTING USING GAUGE PRESSURE 80 APPENDIX
Indicated gauge pressure Cause Check method Remedy

Collect refrigerant, then re-
Bubbles are seen through
Insufficient refrigerant fill with proper volume of re-
sight glass.*1 *3
frigerant again.*2
There is a temperature dif-
ference between inlet and
Clogging of receiver drier outlet pipes of receiver dri- Replace*2
er.
Tank is frosted.
Clogging of expansion
Expansion valve is frosted. Clean or replace*2
valve
Both pressures in high- Gas leakage at heat sens- Low-pressure gauge indi-
pressure and low-pressure Replace*2
ing tube of expansion valve cates negative pressure.
side are low
Evaporator is frozen.
(Low-pressure side be- Repair or replace
comes vacuum) Air flow is decreased by
Defective evaporator tem-
freezing. Replace receiver drier
perature sensor or defec-
tive contact of sensor (com- (If temperature is set to Collect refrigerant, then re-
ing off of fixing clip) COOL MAX and fan speed fill with proper volume of re-
is set to HI, air does not get frigerant again.*2
cold later.)
Piping between receiver dri-
er and compressor is clog-
ged or crushed.
Clogged or crushed piping Clean or replace*2
If it is clogged completely,
low-pressure gauge indi-
cates negative pressure.
Collect refrigerant, then re-
Overfilling of refrigerant Connect gauge manifold. fill with proper volume of re-
frigerant again.*2
Dirty condenser, clogging or Clean condenser, repair
Defective cooling of con-
crushing of fins, or defec- fins, or repair or replace
Both pressures in high- denser
tive rotation of cooling fan cooling fan*2
pressure and low-pressure
side are high Incorrect adjustment of ex-
Bubbles are seen through
pansion valve (valve is Replace*2
sight glass.*3
opened too wide)
Evacuate, then refill with
Air mixed in refrigerant cir- Bubbles are seen through
proper volume of refrigerant
cuit sight glass.*3
again.*2
There is a remarkable tem-
Pressure in high-pressure Clogged or crushed refrig-
perature difference around Clean inside of refrigerant
side is high, and that in low- erant circuit between com-
clogged part in refrigerant circuit or replace.*2
pressure side is low pressor and condenser
circuit.
Both pressures in high-
pressure side and low-pres-
Pressure in high-pressure Defective compressor (de- sure side becomes same
side is low, and that in low- fective compression of while compressor is in op- Replace*2
pressure side is high compressor) eration.
Compressor has seizure
and is extremely hot.
*1: If refrigerant leaks, compressor oil in the air conditioner circuit always leaks as well. Accordingly, perform the
check mainly on pipe joints and dirty parts with oil.
80-82 PC210LC-11
80 APPENDIX TROUBLESHOOTING USING GAUGE PRESSURE
*2: When replacing cooling cycle parts, see “PRECAUTIONS FOR REFRIGERANT” and collect refrigerant. Af-
ter replacing it, fill up the air conditioner circuit with refrigerant again.
*3: Sight glass is on the receiver drier.
PC210LC-11 80-83
METHOD FOR CONNECTING SERVICE TOOL 80 APPENDIX
CONNECTION OF SERVICE TOOL

Use the following service tool kit for R134a.
Symbol Part No. Part name
- 799-703-1200 Service tool kit
Service tool kit
A: From operator's cab B: to condenser

1: Gauge manifold 5: Small diameter quick joint (for low-pressure line)
2: Red high-pressure line charging hose 6: High-pressure line valve
3: Blue low-pressure line charging hose 7: Low-pressure line valve
4: Large diameter quick joint (for high-pressure line) 8,9: Service valve
k a: Note that the threads are coarse and the hoses are relatively easy to loosen.
METHOD FOR CONNECTING SERVICE TOOL

1. Close high-pressure line valve (6) and low-pressure line valve (7) of gauge manifold (1).
2. Connect red high-pressure line charging hose (2) to the gauge manifold (1) (HI side) .
80-84 PC210LC-11
80 APPENDIX METHOD FOR CONNECTING SERVICE TOOL
3. Connect blue low-pressure line charging hose (3) to the gauge manifold (1) (LO side).
4. Connect quick joints (4) and (5) to each hose.
5. Connect quick joint (4) to service valve (8) of high-pressure piping.
6. Connect quick joint (5) to service valve (9) of low-pressure piping.
PC210LC-11 80-85
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES
AND TUBES IN AIR CONDITIONER PIPINGS 80 APPENDIX
PRECAUTIONS FOR DISCONNECTING AND CONNECT-

ING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
Precautions for disconnection
k When replacing the air conditioner unit, air conditioner compressor or condenser, etc., collect the
refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air
conditioner hoses.
k If refrigerant gas (air conditioner gas: R134a) gets in your eyes, you may lose your sight. And if it
touches your skin, you may suffer from frostbite. Put on protective eyeglasses, gloves and working
clothes with long sleeves while collecting the refrigerant or filling the air conditioner circuit with the
refrigerant.
NOTICE
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner
gas: R134a).
1: Engine 4: Modulator
2: Compressor 5: Air conditioner unit
3: Condenser
• When loosening the air conditioner hose nut after collecting the refrigerant, be sure to use 2 wrenches. Use
one wrench to fix one nut and the other wrench to loosen the other nut.
• When working on the air conditioner piping, take measures to prevent the entry of dirt, dust, water, etc. into
the hoses.
80-86 PC210LC-11
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES
80 APPENDIX AND TUBES IN AIR CONDITIONER PIPINGS
Precautions for connection

• When connecting the piping, apply compressor oil (ND-
OIL8) for R134a to its O-rings. (See item 4 of “Handling of
compressor oil”)
Do not apply oil to the threaded part of a bolt, nut or union,
however.
REMARK
An O-ring is fitted to every joint of the air conditioner pip-
ing.
• Once an O-ring is used, it is deformed and deteriorated.
Accordingly, do not reuse it. When removing it, use a soft
tool (such as a toothpick) so that the piping will not be
damaged.
• When connecting a pipe, push it into the end and fully fin-
ger-tighten the bolt or nut.
• Be sure to use 2 wrenches to tighten each nut. Use one
wrench to fix one nut and the other wrench (torque
wrench) to tighten the other nut to the specified torque.
Table of tightening torque for refrigerant pipe joint.

Thread size Tightening torque
M6x1.0 Air conditioner unit, compressor: : 8 to 12 Nm {0.8 to 1.2 kgm}
PC210LC-11 80-87
HANDLE COMPRESSOR OIL 80 APPENDIX
HANDLE COMPRESSOR OIL

Management of compressor oil (DENSO: ND-OIL8 for R134a)
The compressor oil does not need to be checked or refilled as frequently as the engine oil. However, if its level
is low or too high, it can cause the following troubles. Accordingly, charge the compressor oil by the specified
quantity, similarly to the refrigerant.
Condition Content
Lack of oil Defective lubrication, seizure of compressor
Defective cooling (Excess oil sticks to each part and decreases heat ex-
Excess of oil
change efficiency)
Refilling with compressor oil

k Refrigerant is potentially hazardous to health and environment. Before disconnecting air conditioner
hoses, collect refrigerant according to “PRECAUTIONS FOR DISCONNECTING AND CONNECTING
HOSES AND TUBES IN AIR CONDITIONER PIPINGS”.
NOTICE
• If oil for CFC-12 (R-12) is used, lubrication trouble will occur and the compressor may be broken or
seized.
Be sure to use oil for R134a (DENSO: ND-OIL8).
• Oil for R134a is extremely hygroscopic, and therefore, cap the oil container immediately after use to
limit contact with air.
Store the oil container in a dry and well ventilated place.
• Do not allow oil for R134a to come into contact with acrylic plastic or polystyrene surfaces (except a
baked finish) as it may dissolve these plastics.
Check in the following cases, and add new oil as necessary.
• The large quantity of leakage of refrigerant occurs and re-
frigerant is discharged abruptly.
• The compressor is defective and replaced.
(See "The quantity of compressor oil when the compressor
is replaced".)
• Cycle parts such as the condenser, receiver drier, evapo-
rator unit, etc. are replaced.
• Quantity of oil added after cycle parts are replaced
Quantity to be add-
Air conditioner component
ed
Air conditioner unit, evaporator Approximately 40 cc
Condenser (including modulator) Approximately 60 cc
Modulator (desiccating agent) Approximately 20 cc
Hose (compressor to cab) Approximately 35 cc
Hose (condenser to compressor) Approximately 30 cc
Hose (condenser to cab) Approximately 10 cc
The quantity of compressor oil when the compressor is replaced

The following is the necessary quantity of oil when the compressor is broken because of seizure, etc. and in
other cases.
• When compressor is broken because of seizure, etc.
Metal chips circulate in the air conditioner circuit and contaminate the compressor oil remarkably.
In such case, clean the air conditioner circuit and replace the compressor and receiver drier.
80-88 PC210LC-11
80 APPENDIX HANDLE COMPRESSOR OIL
Since all of the compressor oil is drained from the air conditioner circuit by cleaning the circuit, install the
new compressor together with the filled oil of the specified quantity (180 cc).
• In other cases
New compressor contains compressor oil of 180 cc in it.
1. Prepare an oil container to receive the oil, and drain
the oil from the removed compressor.
2. Measure the quantity of the drained oil with a measur-
ing cylinder, and write it down.
3. Drain the oil from the new compressor by the following
quantity.
Quantity to be drained = 180 cc - Quantity written
down
Example: The quantity of the oil drained from the re-
moved compressor is 30 cc, the quantity of the oil to
be drained from the new compressor is 180 cc - 30 cc
= 150 cc.
Applying compressor oil to O-rings
Apply compressor oil (ND-OIL8) for R134a to the O-rings in or-
der to prevent refrigerant leakage when the pipings and hoses
are connected.
2 O-ring:
Compressor oil for R134a (ND-OIL8)
PC210LC-11 80-89
Removal of desiccating agent (D) 80 APPENDIX
METHOD FOR REPLACING DESICCANT

k When replacing the desiccating agent, always collect the refrigerant of air conditioner cycle first.
If you replace the desiccating agent without collecting the refrigerant, you may lose your sight due
to the refrigerant or you may be injured by cap (C) which jumps out by refrigerant pressure in the
cycle.
Prepare a replacement kit of desiccating agent.
B: Boss F: Filter
C: Cap OR: O-ring
D: Desiccating agent SR: Snap ring
1: Condenser 2: Modulator
REMARK
Desiccating agent is contained in modulator (2).
Removal of desiccating agent (D)

1. Remove snap ring (SR) from modulator (2).
2. Grab boss (B) of cap (C) with pliers, etc. and remove cap (C) from modulator (2).
REMARK
If cap (C) is tightened too hard to remove, take care not to damage or deform sealing surface of modulator
(2) while removing.
3. Remove filter (F) from modulator (2).
4. Remove desiccating agent (D) from modulator (2).
80-90 PC210LC-11
80 APPENDIX Installation of new desiccating agent (D)
Installation of new desiccating agent (D)

Replace snap ring (SR), O-ring (OR), filter (F), and desiccating agent (D) with new one which are included in the
replacement kit of desiccating agent.
1. Apply compressor oil (ND-OIL8) to the circumference of O-ring (OR) of cap (C).
2 O-ring (OR):
Compressor oil for R134a (ND-OIL8)
2. Install filter (F) to cap (C).
3. Install desiccating agent (D) to modulator (2).
4. Install cap (C) with filter (F) to modulator (2).
5. Install snap ring (SR) to modulator (2) to fix cap (C).
NOTICE
If snap ring (SR) is not securely installed to the groove of modulator (2), cap (C) may come off.
PC210LC-11 80-91

PC210LC-11 Sen06695-01 Appendix

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SEN06695-01

HYDRAULIC PC210LC -11

TEST RELAYS ............................................................................................................................................. 80-51

Purpose of use (major ap-

Purpose of use (major ap-

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

Purpose of use (major ap-

Purpose of use (major ap-

*1: Code for applicable machine model

Abbreviation Actual word spelled out

AIR CONDITIONER SYSTEM

AIR CONDITIONER COMPONENT

1: Compressor 4: Hot water piping

7: Dual pressure switch 11: Recirculation air filter

A: Front vents D: Defroster vents

SPECIFICATIONS OF AIR CONDITIONER

CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE

OUTLINE OF REFRIGERATION CYCLE

COMPONENT PARTS OF AIR CONDITIONER SYSTEM

A: Refrigerant inlet (from condenser) E: Recirculation air inlet

J: Foot vents K: Defroster vents

FUNCTION OF AIR CONDITIONER UNIT

Changeover pattern of vent (mode) changeover doors

Air vent Front, Rear, Foot Open 25 Open 35 Close 0

Changeover pattern of air mix door (6)

COMPONENT PARTS OF AIR CONDITIONER UNIT

FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT

FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT

FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER

FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT

STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT

A: When evaporator outlet temperature is high C: From condenser (high-pressure refrigerant)

FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT

OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT

FUNCTION OF DUAL PRESSURE SWITCH

AIR CONDITIONER CONTROLLER

For input signals, see “System diagram”.

A: Refrigerant inlet (from compressor) 4. Filter

SENSORS FOR AIR CONDITIONER SYSTEM

FUNCTION OF SUNLIGHT SENSOR

STRUCTURE OF AMBIENT TEMPERATURE SENSOR

FUNCTION OF AMBIENT TEMPERATURE SENSOR

EXPLANATION OF PROCEDURE FOR TESTING AND

S: Condition viewed through sight glass LR: Liquid refrigerant

CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNEC-

AIR CONDITIONER SYSTEM DIAGRAM

INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER

k Never connect these pins. Malfunctions or failures may oc-

k Never connect these pins. Malfunctions or failures may oc-

k Never connect these pins. Malfunctions or failures may oc-

k Never connect these pins. Malfunctions or failures may oc-

k Never connect these pins. Malfunctions or failures may oc-

k Never connect these pins. Malfunctions or failures may oc-

FUNCTION OF AIR CONDITIONER CONTROLLER

INSTALLATION LOCATIONS OF AIR CONDITIONER

Locations of fuse boxes and connectors

*1: Connectors which do not appear in troubleshooting.

Air conditioner controller and connectors layout