Komatsu PC210LC-11 Maintenance Checklist
Daily pre-start checks · Service schedule by operating hours · Warning alert actions for the Komatsu PC210LC-11 with SAA6D107E-3 EPA Tier 4 Final engine, KDPF + SCR aftertreatment and KOMTRAX Level 5.0 telematics.
Daily Pre-Start Checklist
Complete these checks before every shift. They take about 10–15 minutes and help prevent damage, downtime and safety incidents on the Tier 4 Final SAA6D107E-3 machine.
Engine Oil Level
Pull the dipstick on the left side of the engine — wipe clean, reinsert and read the oil mark.
Act if: oil is at or below the MIN mark — add Komatsu EO15W-40DH before starting.
Engine Coolant Level
Check the coolant reservoir on the right side against the MIN/MAX markings.
Act if: level is below MIN — add coolant before starting; never open the cap when hot.
Fuel Level
Check the fuel gauge on the monitor panel and the fuel tank sight glass (400 L tank).
Act if: fuel is very low — refuel; do not let the tank run dry (air-lock risk).
DEF (Urea) Level
Check the DEF level gauge on the LCD monitor main screen (DEF tank 23.1 L).
Act if: a DEF LEVEL LOW warning appears — refill the DEF tank before the shift.
Hydraulic Oil Level
Check the sight gauge on the hydraulic tank with the machine on flat ground and all cylinders retracted.
Act if: oil is below the MIN mark — add Komatsu hydraulic oil ISO VG46.
Hydraulic Hoses & Cylinders
Walk around the machine and visually inspect all hoses, fittings and cylinder rods.
Act if: any visible oil leak, damaged hose or weeping cylinder seal — do not operate.
Fuel & Oil Leaks
Visually inspect under the engine bay, the hydraulic pump area and all visible connections.
Act if: any dripping or pooling of oil or fuel — stop and identify the source.
Track Tension & Condition
Check track sag (10–30 mm depending on ground conditions); inspect shoes for damage (49 shoes/side).
Act if: excessive slack or broken/missing shoes — tension the tracks or report to the workshop.
Undercarriage
Walk around the undercarriage — inspect rollers, carrier rollers, track frame, sprocket and idler.
Act if: cracked frame, missing roller bolts or seized rollers — do not operate.
Grease Pin Joints
Grease all pin joints daily: boom foot, boom tip, arm-to-boom, arm tip, bucket pins and linkage.
Act if: pins are dry, hot or squeaking — grease before operating.
Air Cleaner Restriction
Check the restriction indicator on the air cleaner — a visible red band means service is required.
Act if: red indicator visible — service the air cleaner element before operating.
Radiator & Cooler Screens
Inspect and clean dust and debris from the radiator, oil cooler and fuel cooler screens.
Act if: screens heavily blocked — clean before operating to prevent overheating.
Cab & Controls
Test the horn, travel alarm, all warning lamps and the lock-lever function before moving.
Act if: a warning lamp stays on after start-up or a control malfunctions — stop and investigate.
Walk-Around Structural
Visually inspect the boom, arm, bucket, counterweight mounting bolts and cab structure.
Act if: visible cracks in boom/arm welds or loose counterweight bolts — do not operate.
Rearview Camera & Monitor
Verify the rear camera image displays on the monitor at start-up.
Act if: camera not displaying — check connections; do not swing/travel without rear visibility.
Service Schedule by Hourmeter
Use the hourmeter reading for service timing — do not delay if service is due. Read cumulatively: carry forward all lower-interval tasks at each higher milestone. CHANGE / REPLACE / INSPECT / GREASE / CHECK / CLEAN.
Engine oil & coolant level
Check levels — top up as required (oil 23.1 L | coolant 30.7 L)
Air cleaner restriction
Check restriction indicator; clean radiator/cooler screens
Hydraulic oil level
Check sight gauge (system 234 L | tank 132 L, ISO VG46)
Hoses, cylinders & fittings
Inspect for leaks, damage or weeping seals
Fuel level & water separator
Check gauge (400 L); drain fuel-tank water separator
DEF (urea) level
Check DEF gauge on monitor (23.1 L); refill if low
All pin joints
Grease boom, arm, bucket and linkage pins — EP-2 lithium
Track tension, welds & shoes
Check track tension; inspect structural welds and track shoes
Air cleaner outer element
Inspect outer element — service if restriction shows
Fan & alternator belts
Inspect belt tension and condition
Radiator & cooler screens
Check and clear dust/debris
Swing circle
Grease swing bearing / ring-gear points
Track tension
Check sag mid-span; adjust hydraulic track adjuster
All pin joints
Full lubrication of boom, arm, bucket and linkage pins
Track & carrier rollers
Grease roller seals
Track shoes
Inspect wear and bolt tightness
Engine oil + filter
Drain & refill 23.1 L Komatsu EO15W-40DH; replace oil filter
Fuel pre-filter + fuel filter
Replace 10-micron pre-filter and high-efficiency element; bleed system
Air cleaner outer element
Replace outer element
Hydraulic oil filter
Replace ecology-white element
Swing drive oil *
Initial-fill change only — drain & refill 6.5 L
Final drive oil — each side *
Initial-fill change only — 5.0 L each side
Radiator & cooler screens
Clean radiator, oil cooler and fuel cooler
Counterweight & boom-foot bolts
Torque-check; inspect structural welds
Engine oil + all filters
Change oil (23.1 L); replace oil, fuel pre-filter and fuel filter
Air cleaner inner + outer
Replace both elements; replace fan/alternator belts
Engine coolant
Drain & refill 30.7 L
Hydraulic oil filter
Replace ecology-white element
Hydraulic pump
Pressure & flow check
Travel motor (axial piston)
Inspect for leaks and performance
Swing circle
Grease bearing / ring gear
Welds & bolts
Inspect boom/arm/bucket welds; torque-check counterweight & boom-foot bolts
Engine oil + all filters
Change oil (23.1 L); replace oil, fuel and air (inner+outer) filters; replace belts
Engine coolant
Drain & refill 30.7 L
Hydraulic oil — full change
Drain & refill — system 234 L, tank 132 L (ISO VG46)
Hydraulic oil filter & pump
Replace ecology-white filter; pressure & flow check
DEF pump filter
Replace DEF pump filter
Swing & final drive oil
Change swing drive 6.5 L and final drive 5.0 L each side; inspect travel motor
Track shoes
Measure wear & bolt tightness — replace as required
Counterweight & boom-foot bolts
Torque-check per Komatsu spec
Warning Alerts & Immediate Actions
All alerts are logged in EMMS and reported via KOMTRAX to the Aether IoT fleet platform. Always note the fault code before acknowledging or clearing any alert.
Engine Overheat
Engine coolant temperature critically high — overheating in progress.
Immediate action: stop all work. Idle the engine 2 min, then shut down. Do NOT open the radiator cap when hot. Call service.
Risk if ignored: warped cylinder head, blown head gasket, seized engine.
Engine Oil Pressure Low
Engine oil pressure below the minimum safe threshold.
Immediate action: shut down the engine IMMEDIATELY. Do NOT restart. Check oil level. Call Komatsu service.
Risk if ignored: catastrophic engine seizure within seconds to minutes.
Hydraulic Overtemp
Hydraulic oil temperature critically high — risk of fire or seal failure.
Immediate action: stop all work cycles. Idle the machine. Allow the temperature to normalise. Inspect the cooler.
Risk if ignored: hydraulic pump failure, seal damage, fire risk.
DEF / SCR System Fault
DEF quality issue or SCR aftertreatment critical fault — EPA de-rate active.
Immediate action: stop operation. Check DEF quality and level. Fault code logged in EMMS — contact Komatsu service.
Risk if ignored: forced engine power de-rate, regulatory non-compliance.
Battery / Charging Fault
Alternator not charging — battery charge critically low.
Immediate action: park safely at the next opportunity. Inspect the alternator belt and battery terminals. Do not restart if the fault persists — call Komatsu service.
Risk if ignored: complete machine shutdown, loss of KOMTRAX data.
Low Engine Coolant
Coolant level below minimum — overheating risk building.
Immediate action: finish the current work cycle. Stop the machine and allow it to cool. Top up coolant. Check for leaks.
Risk if ignored: engine overheating and head-gasket failure.
Low Fuel Level
Fuel tank approaching empty — risk of air ingestion.
Immediate action: stop work and refuel. Do not allow the tank to run dry — an air lock will require bleeding the fuel system.
Risk if ignored: air lock in fuel system, engine shutdown, difficult restart.
Low DEF Level
DEF tank level low — SCR system approaching shutdown threshold.
Immediate action: top up DEF at the next opportunity. Do not delay more than 2–4 operating hours.
Risk if ignored: progressive engine power de-rate by the ECM.
Hydraulic Filter Clog
Hydraulic oil filter restriction indicator active — element near bypass.
Immediate action: schedule filter replacement at the end of the current shift. Do not delay more than 8 hours.
Risk if ignored: contaminated oil bypassing the filter — pump and valve wear.
Air Cleaner Restriction
Air cleaner restriction indicator triggered — element blocked.
Immediate action: stop the machine at the end of the current task. Service the air cleaner immediately — clean or replace the element.
Risk if ignored: reduced power, black smoke, increased fuel consumption, engine damage.
KOMTRAX Fault / Offline
Telematics or GPS tracking offline — machine not reporting to the Aether platform.
Immediate action: note the machine hours. Check the antenna connection. Report to the fleet manager. Service is non-urgent.
Risk if ignored: loss of GPS tracking, fuel monitoring and maintenance alerts.
Dig. Depth
Dump Height