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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-00-NI-01 – PDF DOWNLOAD
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KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-00-NI-01 – PDF DOWNLOAD
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Description
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-00-NI-01 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-00-NI-01 – PDF DOWNLOAD
Language : English
Pages : 1055
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS 60001 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-00-NI-01 – PDF DOWNLOAD
COVER ....................................................................................................................................................... 1 00 Index and foreword........................................................................................................................................ 0 100 Index................................................................................................................................................ 3 Composition of shop manual........................................................................................................................... 4 Table of contents.................................................................................................................................... 6 200 Foreword and general information..................................................................................................................... 15 Safety notice........................................................................................................................................ 16 How to read the shop manual.......................................................................................................................... 21 Explanation of terms for maintenance standard........................................................................................................ 23 Handling of electric equipment and hydraulic component............................................................................................... 25 Handling of connectors newly used for engines........................................................................................................ 34 How to read electric wire code....................................................................................................................... 37 Precautions when carrying out operation.............................................................................................................. 40 Method of disassembling and connecting push-pull type coupler........................................................................................ 43 Standard tightening torque table..................................................................................................................... 46 Conversion table..................................................................................................................................... 50 01 General................................................................................................................................................... 0 100 Specification and technical data..................................................................................................................... 57 Specification dimensional drawing.................................................................................................................... 58 Specifications....................................................................................................................................... 60 Weight table......................................................................................................................................... 68 Table of fuel, coolant and lubricants................................................................................................................ 72 10 Structure, function and maintenance standard.............................................................................................................. 0 100 Engine and cooling system............................................................................................................................ 75 Engine system parts.................................................................................................................................. 76 Cooling system....................................................................................................................................... 77 Cooling fan pump..................................................................................................................................... 78 Cooling fan motor.................................................................................................................................... 79 Oil cooler bypass valve.............................................................................................................................. 84 200 Power train.......................................................................................................................................... 89 Power train.......................................................................................................................................... 90 Power train system................................................................................................................................... 91 Damper............................................................................................................................................... 92 HST hydraulic equipment arrangement diagram.......................................................................................................... 93 Steering and brake control........................................................................................................................... 94 Solenoid valve....................................................................................................................................... 96 Final drive.......................................................................................................................................... 103 HST pump............................................................................................................................................. 106 HST motor............................................................................................................................................ 118 Charge pump.......................................................................................................................................... 128 300 Undercarriage and frame.............................................................................................................................. 131 Main frame........................................................................................................................................... 132 Track frame and idler cushion........................................................................................................................ 134 Idler................................................................................................................................................ 136 Track roller......................................................................................................................................... 138 Carrier roller....................................................................................................................................... 140 Sprocket............................................................................................................................................. 142 Track shoe........................................................................................................................................... 144 410 Hydraulic system, Part 1............................................................................................................................. 149 Arrangement of hydraulic equipment for work equipment................................................................................................ 150 Work equipment control............................................................................................................................... 152 Hydraulic tank and filter............................................................................................................................ 154 Work equipment and fan pump.......................................................................................................................... 156 Control valve........................................................................................................................................ 164 CLSS................................................................................................................................................. 176 Functions and operation of each valve................................................................................................................ 179 420 Hydraulic system, Part 2............................................................................................................................. 189 Blade PPC valve...................................................................................................................................... 190 Accumulator.......................................................................................................................................... 199 500 Work equipment....................................................................................................................................... 201 Work equipment....................................................................................................................................... 202 Cutting edge and end bit............................................................................................................................. 206 Ripper............................................................................................................................................... 207 Work equipment cylinder.............................................................................................................................. 208 Piston valve......................................................................................................................................... 211 600 Cab and its attachments.............................................................................................................................. 213 ROPS cab............................................................................................................................................. 214 Cab mount............................................................................................................................................ 215 Canopy mount......................................................................................................................................... 216 Air conditioner...................................................................................................................................... 217 700 Electrical system.................................................................................................................................... 221 Monitor system....................................................................................................................................... 222 Engine control....................................................................................................................................... 224 Engine control system................................................................................................................................ 225 Cooling control system............................................................................................................................... 226 HST control system................................................................................................................................... 228 Parking brake control system......................................................................................................................... 234 KOMTRAX system....................................................................................................................................... 236 Component equipment of system........................................................................................................................ 238 PCCS lever (for steering)............................................................................................................................ 247 Sensor............................................................................................................................................... 250 20 Standard value table...................................................................................................................................... 0 100 Standard service value table......................................................................................................................... 263 Standard service value table for engine.............................................................................................................. 264 Standard service value table for chassis............................................................................................................. 266 30 Testing and adjusting..................................................................................................................................... 0 110 Testing and adjusting, Part 1........................................................................................................................ 277 Tools for testing, adjusting, and troubleshooting.................................................................................................... 279 Measuring engine speed............................................................................................................................... 283 Measuring intake air pressure (boost pressure)....................................................................................................... 284 Testing exhaust temperature.......................................................................................................................... 286 Measuring exhaust gas color (boost pressure)......................................................................................................... 287 Adjusting valve clearance............................................................................................................................ 288 Testing compression pressure......................................................................................................................... 290 Measuring blow-by pressure........................................................................................................................... 292 Testing oil pressure................................................................................................................................. 294 Handling fuel system equipment....................................................................................................................... 295 Releasing residual pressure in fuel system........................................................................................................... 295 Bleeding air from fuel circuit....................................................................................................................... 296 Testing fuel pressure................................................................................................................................ 299 Testing leakage from pressure limiter and return rate from injector.................................................................................. 300 Testing leakage in fuel system....................................................................................................................... 303 Measuring fan circuit pressure and fan speed......................................................................................................... 304 Adjustment of fan speed sensor....................................................................................................................... 305 Handling reduced cylinder mode operation............................................................................................................. 306 Handling no-injection cranking operation............................................................................................................. 306 Check of muffler and muffler stack for looseness and damage.......................................................................................... 307 Check of muffler function............................................................................................................................ 307 Check of installed condition of cylinder head and manifolds.......................................................................................... 308 Check of engine piping for damage and looseness...................................................................................................... 308 Testing and adjusting alternator belt tension........................................................................................................ 309 Testing and adjusting air conditioner compressor belt tension........................................................................................ 310 120 Testing and adjusting, Part 2........................................................................................................................ 313 Adjusting decelerator pedal.......................................................................................................................... 314 Testing and adjusting HST oil pressure............................................................................................................... 316 Measuring solenoid valve output oil pressure......................................................................................................... 321 Testing travel deviation............................................................................................................................. 324 Adjusting parking brake lever........................................................................................................................ 325 Simple brake performance test procedure.............................................................................................................. 327 Adjusting brake pedal................................................................................................................................ 328 Method of releasing parking brake (Procedure for emergency escape)................................................................................... 330 Testing and adjusting idler clearance................................................................................................................ 332 Testing and adjusting track shoe tension............................................................................................................. 333 Testing work equipment oil pressure.................................................................................................................. 334 Testing work equipment PPC valve output oil pressure................................................................................................. 336 Adjusting play of work equipment PPC valve........................................................................................................... 338 Adjusting work equipment lock lever.................................................................................................................. 339 Testing internal leakage of work equipment cylinder.................................................................................................. 340 Releasing residual pressure in hydraulic circuit..................................................................................................... 342 Bleeding air from hydraulic circuit.................................................................................................................. 343 Adjusting play of blade center ball.................................................................................................................. 344 Procedure for testing diodes......................................................................................................................... 345 Preparation work for troubleshooting for electrical system........................................................................................... 346 How to start operation of KOMTRAX terminal........................................................................................................... 350 Lamp display of KOMTRAX terminal..................................................................................................................... 353 130 Testing and adjusting, Part 3........................................................................................................................ 357 Special functions of monitor panel (EMMS)............................................................................................................ 358 Items to be adjusted when electric/hydraulic devices are adjusted/replaced........................................................................... 418 Adjustment procedure after replacement of HST controller............................................................................................. 419 Adjustment procedure after replacement of monitor panel.............................................................................................. 421 Pm-clinic service (D31EX-22, D31PX-22)............................................................................................................... 423 Pm-clinic service (D37EX-22, D37PX-22)............................................................................................................... 431 40 Troubleshooting........................................................................................................................................... 0 100 Failure code table and fuse locations................................................................................................................ 441 Failure code table................................................................................................................................... 442 Before carrying out troubleshooting for electrical system (E-mode)................................................................................... 448 200 General information on troubleshooting............................................................................................................... 453 Points to remember when troubleshooting.............................................................................................................. 454 Sequence of events in troubleshooting................................................................................................................ 455 Testing before troubleshooting....................................................................................................................... 456 Classification and procedures of troubleshooting..................................................................................................... 457 Information contained in troubleshooting table....................................................................................................... 460 Connection table for connector pin numbers........................................................................................................... 462 T- branch box and T- branch adapter table............................................................................................................ 498 310 Troubleshooting by failure code (Display of code), Part 1............................................................................................ 503 Failure code [6091NX] HST charge filter element: Clogging............................................................................................ 505 Failure code [AA10NX] Air cleaner: Clogging.......................................................................................................... 506 Failure code [AB00MA] Alternator: Malfunction........................................................................................................ 508 Failure code [B@BAZG] Engine oil: Lowering of oil pressure........................................................................................... 509 Failure code [B@BCNS] Coolant: Overheat.............................................................................................................. 510 Failure code [B@CRNS] HST oil: Overheating........................................................................................................... 511 Failure code [B@CRZG] HST oil: Lowering of oil pressure.............................................................................................. 512 Failure code [CA111] Engine controller: Abnormality in controller.................................................................................... 513 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal......................................................... 516 Failure code [CA122] Charge pressure sensor tool high: Excessively high voltage detected............................................................. 517 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected................................................................ 519 Failure code [CA131] Decelerator pedal sensor tool high: Excessively high voltage detected........................................................... 520 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.............................................................. 522 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected.......................................................... 524 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected............................................................ 526 Failure code [CA153] Charge air temperature sensor too high: Excessively high voltage detected....................................................... 528 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected............................................................. 530 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected................................................................. 531 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected......................................................... 532 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected........................................................... 534 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected............................................................... 536 Failure code [CA234] Engine over speed: Excessively high speed....................................................................................... 538 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected..................................................... 540 Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................................... 542 Failure code [CA272] IMV/PCV1 disconnection: Disconnection........................................................................................... 544 320 Troubleshooting by failure code (Display of code), Part 2............................................................................................ 547 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit.............................................. 550 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit.............................................. 552 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit.............................................. 554 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit.............................................. 556 Failure code [CA351] Injector drive circuit abnormality: Abnormal circuit............................................................................ 558 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected................................................................. 560 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected............................................................... 562 Failure code [CA428] Water in fuel sensor too high: Excessively high voltage detected................................................................ 564 Failure code [CA429] Water in fuel sensor too low: Excessively low voltage detected.................................................................. 566 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................................................... 568 Failure code [CA441] Power source voltage too low: Excessively low voltage detected.................................................................. 569 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit..................... 570 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred................................................... 571 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected......................................................... 572 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected........................................................... 574 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected........................................................... 575 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected...................................................... 576 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................................................ 580 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase......................................................................... 582 Failure code [CA757] Loss of all engine controller data: Loss of all data............................................................................ 583 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................................................................... 584 Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................................................ 586 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected.............................................. 588 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected................................................ 590 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected..................................................... 591 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance..................................................................................... 592 Failure code [CA2555] Air intake heater relay disconnection: Disconnection........................................................................... 594 Failure code [CA2556] Air intake heater relay short circuit: Short circuit1.......................................................................... 596 330 Troubleshooting by failure code (Display of code), Part 3............................................................................................ 599 Failure code [D130KA] Neutral safety relay: Disconnection............................................................................................ 602 Failure code [D130KB] Neutral safety relay: Short circuit............................................................................................ 604 Failure code [DAFRKR] CAN communication (Monitor panel - HST controller): Defective communication (Abnormality in objective component system)........ 606 Failure code [DAFRMC] CAN communication (Monitor panel - ENGINE controller): Defective communication (Abnormality in objective component system)..... 609 Failure code [DAJ000] HST controller: Memory error................................................................................................... 612 Failure code [DAJ0KK] HST controller: Lowing of source voltage....................................................................................... 614 Failure code [DAJ0KQ] HST controller: Machine code error............................................................................................. 616 Failure code [DAJ0KT] HST controller: Memory error................................................................................................... 617 Failure code [DAJ5KK] HST controller sensor 5 V power supply No.1: Lowing of source voltage/Input.................................................... 618 Failure code [DAJ6KK] HST controller sensor 5 V power supply No.2: Lowing of source voltage/Input.................................................... 620 Failure code [DAJRKR] CAN communication (HST controller - Monitor panel): Defective communication (Abnormality in objective component system)........ 622 Failure code [DB2RKR] CAN communication (HST controller - Engine controller): Defective communication (Abnormality in objective component system).... 625 Failure code [DD12KA] Shift up switch: Disconnection................................................................................................. 628 Failure code [DD12KB] Shift up switch: Short circuit................................................................................................. 630 Failure code [DD13KA] Shift down switch: Disconnection............................................................................................... 632 Failure code [DD13KB] Shift down switch: Short circuit............................................................................................... 634 Failure code [DD14KB] Travel lock limit switch 1: Short circuit...................................................................................... 636 Failure code [DD1NL4] Fan rotation selector switch: Disagreement of ON, OFF Signals.................................................................. 638 Failure code [DDDCKB] Reverse travel speed switch: Short circuit..................................................................................... 640 Failure code [DDP6KA] Brake oil pressure sensor: Disconnection....................................................................................... 642 Failure code [DDP6KB] Brake oil pressure sensor: Short circuit....................................................................................... 644 Failure code [DDP6MA] Brake oil pressure sensor: Malfunction......................................................................................... 646 Failure code [DDQ2KA] Travel lock limit switch 1: Disconnection...................................................................................... 648 Failure code [DDT0L4] Shift mode switch: Disagreement of ON/ OFF Signals............................................................................. 650 Failure code [DDU1FS] Travel lock limit switches 1 and 2: Fixing..................................................................................... 652 Failure code [DDU1KA] Travel lock limit switch 2: Disconnection...................................................................................... 654 Failure code [DDU1KY] Travel lock limit switch 2: Short circuit with power supply line............................................................... 656 Failure code [DGS1KA] HST oil temperature sensor: Disconnection...................................................................................... 658 Failure code [DGS1KX] HST oil temperature sensor: Out of Input signal range.......................................................................... 660 340 Troubleshooting by failure code (Display of code), Part 4............................................................................................ 663 Failure code [DHH5KA] Left HST pump pressure sensor: Disconnection................................................................................... 666 Failure code [DHH5KB] Left HST pump pressure sensor: Short circuit................................................................................... 668 Failure code [DHH6KA] Right HST pump pressure sensor: Disconnection.................................................................................. 670 Failure code [DHH6KB] Right HST pump pressure sensor: Short circuit.................................................................................. 672 Failure code [DK10KA] Fuel dial sensor: Disconnection................................................................................................ 674 Failure code [DK10KB] Fuel dial sensor: Short circuit................................................................................................ 676 Failure code [DK30KA] Steering angle sensor 1: Disconnection......................................................................................... 678 Failure code [DK30KB] Steering angle sensor 1: Short circuit......................................................................................... 680 Failure code [DK30KX] Steering angle sensor: Out of input signal range............................................................................... 682 Failure code [DK30KZ] Steering angle sensor: Disconnection or short circuit.......................................................................... 683 Failure code [DK30L8] Steering angle sensor: Disagreement of analog signals.......................................................................... 684 Failure code [DK31KA] Steering angle sensor 2: Disconnection......................................................................................... 686 Failure code [DK31KB] Steering angle sensor 2: Short circuit......................................................................................... 688 Failure code [DK40KA] Brake pedal sensor: Disconnection.............................................................................................. 690 Failure code [DK40KB] Brake pedal sensor: Short circuit.............................................................................................. 692 Failure code [DK55KX] Directional potentiometer: Out of input signal range........................................................................... 694 Failure code [DK55KZ] Directional potentiometer: Disconnection or short circuit...................................................................... 695 Failure code [DK55L8] Directional potentiometer: Disagreement of analog signals...................................................................... 696 Failure code [DK56KA] Directional potentiometer 1: Disconnection..................................................................................... 698 Failure code [DK56KB] Directional potentiometer 1: Short circuit..................................................................................... 700 Failure code [DK57KA] Directional potentiometer 2: Disconnection..................................................................................... 702 Failure code [DK57KB] Directional potentiometer 2: Short circuit..................................................................................... 704 Failure code [DLM0KX] HST motor speed sensors: Out of input signal range............................................................................. 706 Failure code [DLM1KA] Left HST motor speed sensor: Disconnection..................................................................................... 708 Failure code [DLM1KB] Left HST motor speed sensor: Short circuit..................................................................................... 710 Failure code [DLM1MA] Left HST motor speed sensor: Malfunction....................................................................................... 712 Failure code [DLM2KA] Right HST motor speed sensor: Disconnection.................................................................................... 714 Failure code [DLM2KB] Right HST motor speed sensor: Short circuit.................................................................................... 716 Failure code [DLM2MA] Right HST motor speed sensor: Malfunction...................................................................................... 718 Failure code [DLM3KA] Fan speed sensor: Disconnection................................................................................................ 720 Failure code [DLM3KB] Fan speed sensor: Short circuit................................................................................................ 722 350 Troubleshooting by failure code (Display of code), Part 5............................................................................................ 725 Failure code [DN21FS] Brake pedal and proximity switch: Fixing....................................................................................... 728 Failure code [DV00KB] Caution buzzer: Short circuit.................................................................................................. 730 Failure code [DV20KB] Back alarm buzzer: Short circuit............................................................................................... 731 Failure code [DW4BKA] Parking brake solenoid valve: Disconnection.................................................................................... 732 Failure code [DW4BKB] Parking brake solenoid valve: Short circuit.................................................................................... 734 Failure code [DW4BKY] Parking brake solenoid valve: Short circuit with power supply line............................................................. 736 Failure code [DW7BKA] Fan reverse solenoid valve: Disconnection...................................................................................... 738 Failure code [DW7BKB] Fan reverse solenoid valve: Short circuit...................................................................................... 740 Failure code [DW7BKY] Fan reverse solenoid valve: Short circuit with power supply line............................................................... 741 Failure code [DW7EKA] Slow brake solenoid valve: Disconnection....................................................................................... 742 Failure code [DW7EKB] Slow brake solenoid valve: Short circuit....................................................................................... 746 Failure code [DW7EKY] Slow brake solenoid valve: Short circuit with power supply line................................................................ 748 Failure code [DWN5KA] Fan EPC solenoid valve: Disconnection.......................................................................................... 750 Failure code [DWN5KB] Fan EPC solenoid valve: Short circuit.......................................................................................... 752 Failure code [DWN5KY] Fan EPC solenoid valve: Short circuit with power supply line................................................................... 754 Failure code [DXA4KA] LF HST pump EPC solenoid valve: Disconnection.................................................................................. 756 Failure code [DXA4KB] LF HST pump EPC solenoid valve: Short circuit.................................................................................. 758 Failure code [DXA4KY] LF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 760 Failure code [DXA5KA] LR HST pump EPC solenoid valve: Disconnection.................................................................................. 762 Failure code [DXA5KB] LR HST pump EPC solenoid valve: Short circuit.................................................................................. 764 Failure code [DXA5KY] LR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 766 Failure code [DXA6KA] RF HST pump EPC solenoid valve: Disconnection.................................................................................. 768 Failure code [DXA6KB] RF HST pump EPC solenoid valve: Short circuit.................................................................................. 770 Failure code [DXA6KY] RF HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 771 Failure code [DXA7KA] RR HST pump EPC solenoid valve: Disconnection.................................................................................. 772 Failure code [DXA7KB] RR HST pump EPC solenoid valve: Short circuit.................................................................................. 774 Failure code [DXA7KY] RR HST pump EPC solenoid valve: Short circuit with power supply line........................................................... 776 Failure code [DXK1KA] Left HST motor EPC solenoid valve: Disconnection............................................................................... 777 Failure code [DXK1KB] Left HST motor EPC solenoid valve: Short circuit............................................................................... 778 Failure code [DXK1KY] Left HST motor EPC solenoid valve: Short circuit with power supply line........................................................ 779 Failure code [DXK2KA] Right HST motor EPC solenoid valve: Disconnection.............................................................................. 780 Failure code [DXK2KB] Right HST motor EPC solenoid valve: Short circuit.............................................................................. 781 Failure code [DXK2KY] Right HST motor EPC solenoid valve: Short circuit with power supply line....................................................... 782 400 Troubleshooting of electrical system (E-mode)........................................................................................................ 785 E-1 Engine does not start (Starting motor does not rotate) .......................................................................................... 788 E-2 Engine is not preheated.......................................................................................................................... 791 E-3 When starting switch is turned ON, any item does not light up.................................................................................... 794 E-4 Charge level caution flashes while engine is running............................................................................................. 796 E-5 Emergency warning items flash while engine is running............................................................................................ 798 E-6 Preheating pilot lamp does not light up during preheating operation.............................................................................. 804 E-7 The coolant temperature gauge does not indicate correctly........................................................................................ 806 E-8 The HST oil temperature gauge does not indicate correctly........................................................................................ 807 E-9 Fuel level gauge does not indicate properly...................................................................................................... 808 E-10 Gear speed, set travel speed, and shift mode indicator does not display normally................................................................ 810 E-12 Caution lamp does not flash or does not go off.................................................................................................. 811 E-13 Caution buzzer does not sound or does not stop.................................................................................................. 812 E-14 Reverse travel speed setting switch does not function........................................................................................... 814 E-15 Shift mode switch does not function............................................................................................................. 816 E-16 Buzzer cancel switch does not function.......................................................................................................... 818 E-17 Information switch does not function............................................................................................................ 820 E-18 The fan cleaning does not operate or cannot be reset............................................................................................ 822 E-19 Backup alarm does not sound..................................................................................................................... 824 E-20 The horn does not sound or does not stop........................................................................................................ 825 E-21 Work equipment does not move.................................................................................................................... 826 E-22 Headlamp or rear lamp does not light up......................................................................................................... 828 E-23 Foot heater does not operate.................................................................................................................... 831 E-24 Air conditioner does not operate................................................................................................................ 834 E-25 Windshield wiper and window washer do not operate............................................................................................... 839 E-26 KOMTRAX system does not operate normally........................................................................................................ 852 500 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................... 857 Information in troubleshooting table................................................................................................................. 859 H-1 Right and left travel systems do not operate forward and in reverse (No travel systems operate).................................................. 860 H-2 Right or left travel system does not operate forward and in reverse (Only right or left travel system does not operate).......................... 862 H-3 Right or left travel system does not operate forward or in reverse (Only 1 system does not operate).............................................. 863 H-4 Speed or power of travel is low.................................................................................................................. 864 H-5 Gear is not shifted.............................................................................................................................. 865 H-6 Large shocks are made when machine starts and stops travel....................................................................................... 866 H-7 Machine deviates largely during travel........................................................................................................... 867 H-8 Hydraulic drift of travel is large............................................................................................................... 868 H-9 Engine stalls or engine speed lowers extremely during travel..................................................................................... 869 H-10 Abnormal sound comes out from around HST pump and motor......................................................................................... 870 H-11 Work equipment dose not operate at all.......................................................................................................... 871 H-12 Speed or power of whole work equipment is low................................................................................................... 872 H-13 Speed or power of lifting blade is low.......................................................................................................... 873 H-14 Speed or power of tilting blade is low.......................................................................................................... 874 H-15 Speed or power of angling blade is low.......................................................................................................... 875 H-16 Time lag in lifting blade is large.............................................................................................................. 876 H-17 Hydraulic drift of lifting blade is large....................................................................................................... 876 H-18 Hydraulic drift of tilting blade is large....................................................................................................... 876 H-19 Abnormal sound comes out from around work equipment pump and control valve...................................................................... 877 H-20 HST oil temperature (Hydraulic oil temperature) rises too high.................................................................................. 878 H-21 Fan speed is abnormal (High, low, or 0 rpm)..................................................................................................... 880 H-22 Abnormal sound is heard from around fan......................................................................................................... 881 600 Troubleshooting of engine (S-mode)................................................................................................................... 883 Troubleshooting of engine (S-mode)................................................................................................................... 885 S-1 Starting performance is poor..................................................................................................................... 888 S-2 Engine does not start............................................................................................................................ 889 S-3 Engine does not pick up smoothly................................................................................................................. 892 S-4 Engine stops during operations................................................................................................................... 893 S-5 Engine does not rotate smoothly.................................................................................................................. 894 S-6 Engine lacks output (or lacks power)............................................................................................................. 895 S-7 Exhaust smoke is black (incomplete combustion)................................................................................................... 896 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................................... 897 S-9 Oil becomes contaminated quickly................................................................................................................. 898 S-10 Fuel consumption is excessive................................................................................................................... 899 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)........................................................................... 900 S-12 Oil pressure drops.............................................................................................................................. 901 S-13 Oil level rises (Entry of coolant or fuel)...................................................................................................... 902 S-14 Coolant temperature becomes too high (overheating).............................................................................................. 903 S-15 Abnormal noise is made.......................................................................................................................... 904 S-16 Vibration is excessive.......................................................................................................................... 905 50 Disassembly and assembly.................................................................................................................................. 0 100 General information on disassembly and assembly...................................................................................................... 907 How to read this manual.............................................................................................................................. 908 Coating materials list............................................................................................................................... 910 Special tools list................................................................................................................................... 913 Sketches of special tools............................................................................................................................ 916 200 Engine and cooling system............................................................................................................................ 921 Removal and installation of fuel supply pump assembly................................................................................................ 922 Removal and installation of fuel injector assembly................................................................................................... 925 Removal and installation of front seal assembly...................................................................................................... 928 Removal and installation of rear seal assembly....................................................................................................... 930 Removal and installation of cylinder head assembly................................................................................................... 933 Removal and installation of engine and HST pump assembly............................................................................................. 940 Removal and installation of front guard assembly..................................................................................................... 944 Removal and installation of radiator assembly........................................................................................................ 946 Removal and installation of hydraulic oil cooler assembly............................................................................................ 948 Removal and installation of aftercooler assembly..................................................................................................... 950 Removal and installation of cooling fan and motor assembly........................................................................................... 952 Removal and installation of cooling fan drive motor assembly......................................................................................... 954 Removal and installation of fuel tank assembly....................................................................................................... 956 300 Power train.......................................................................................................................................... 959 Removal and installation of HST pump assembly........................................................................................................ 960 Removal and installation of HST motor and final drive assembly....................................................................................... 962 Disassembly and assembly of final drive assembly..................................................................................................... 964 400 Undercarriage and frame.............................................................................................................................. 975 Spreading and installation of track shoe assembly.................................................................................................... 976 Removal and installation of idler and recoil spring assembly......................................................................................... 978 Disassembly and assembly of idler assembly........................................................................................................... 979 Disassembly and assembly of recoil spring assembly................................................................................................... 982 Disassembly and assembly of track roller assembly.................................................................................................... 986 Disassembly and assembly of carrier roller assembly.................................................................................................. 990 500 Hydraulic system..................................................................................................................................... 995 Removal and installation of hydraulic tank assembly.................................................................................................. 996 Removal and installation of control valve assembly................................................................................................... 998 Disassembly and assembly of control valve assembly................................................................................................... 999 Disassembly and assembly of hydraulic cylinder assembly..............................................................................................1001 600 Work equipment.......................................................................................................................................1007 Removal and installation of work equipment assembly..................................................................................................1008 700 Cab and its attachments..............................................................................................................................1013 Removal and installation of ROPS canopy and operator seat frame assembly.............................................................................1014 Removal and installation of ROPS cab and operator seat frame assembly................................................................................1017 Removal and installation of operator’s cab glass (Stuck glass).......................................................................................1021 800 Electrical system....................................................................................................................................1029 Removal and installation of HST controller assembly..................................................................................................1030 Removal and installation of KOMTRAX terminal assembly................................................................................................1031 90 Diagrams and drawings..................................................................................................................................... 0 100 Hydraulic diagrams and drawings......................................................................................................................1033 Work equipment hydraulic circuit diagram.............................................................................................................1035 200 Electrical diagrams and drawings.....................................................................................................................1040 Electrical circuit diagram...........................................................................................................................1042 Cab electrical circuit diagram.......................................................................................................................1049 Air conditioner circuit diagram......................................................................................................................1052 Connector list and stereogram........................................................................................................................1053
DESCRIPTION:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-00-NI-01 – PDF DOWNLOAD
Composition of shop manual
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly. The marks shown to the right of Form No. denote the following: Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
* Place a divider on the top of each section in the file after matching the Tub No. with No. indicated next to each Section Name shown in the table below:
* File overview and other materials in sections in the order shown below and utilize them accordingly
S.S 28/12/24
