Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-10 – PDF DOWNLOAD
$40.95
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-10 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-10 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-10 – PDF DOWNLOAD
Language : English
Pages : 2488
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-10 – PDF DOWNLOAD
Cover................................................................................................................................... 1 00 Index and Foreword.............................................................................................................. 3 Index.......................................................................................................................... 4 Abbreviation List.............................................................................................................. 16 Foreword, Safety, Basic Information............................................................................................ 19 How to Read the Shop Manual................................................................................................ 19 Safety Notice for Operation................................................................................................ 21 Precautions to Prevent Fire................................................................................................ 29 Procedures If Fire Occurs.................................................................................................. 30 Precautions When You Dispose of Waste Materials............................................................................ 31 Precautions When You Handle Hydraulic Equipment............................................................................ 32 Precautions When You Disconnect and Connect Pipings........................................................................ 35 Precautions When You Handle Electrical Equipment........................................................................... 42 Precautions When You Handle Fuel System Equipment.......................................................................... 44 Precautions When You Handle Intake System Equipment........................................................................ 45 Practical Use of KOMTRAX................................................................................................... 46 Disconnect and Connect Push-Pull Type Coupler.............................................................................. 47 How to Disconnect and Connect Type 1 Push-Pull Type Coupler............................................................ 47 How to Disconnect and Connect Type 2 Push-Pull Type Coupler............................................................ 48 How to Disconnect and Connect Type 3 Push-Pull Type Coupler............................................................ 49 Precautions for Disconnection and Connection of Connectors................................................................. 51 How to Disconnect and Connect Deutsch Connector............................................................................ 55 How to Disconnect and Connect Slide Lock Type Connector.................................................................... 56 How to Disconnect and Connect Connector with Lock to Pull.................................................................. 58 How to Disconnect and Connect Connector with Lock to Push.................................................................. 59 How to Disconnect and Connect Connector with Housing to Rotate............................................................. 61 How to Read the Codes for Electric Cable................................................................................... 62 Explanation of Terms for Maintenance Standard.............................................................................. 66 Standard Tightening Torque Table........................................................................................... 69 Conversion Table........................................................................................................... 76 01 Specifications.................................................................................................................. 81 Table of Contents.............................................................................................................. 82 Specifications................................................................................................................. 83 Specification Drawing...................................................................................................... 83 Specification Drawing: PC210-10M0...................................................................................... 83 Specification Drawing: PC210LC-10M0.................................................................................... 84 Working Range Drawings..................................................................................................... 86 Working Range: PC210-10M0.............................................................................................. 86 Working Range Drawings PC210LC-10M0.................................................................................... 87 Specifications............................................................................................................. 89 Specifications PC210-10M0.............................................................................................. 89 Specifications PC210LC-10M0............................................................................................ 91 Weight Table............................................................................................................... 95 Weight Table: PC210-10M0............................................................................................... 95 Weight Table: PC210LC-10M0............................................................................................. 96 Fuel, Coolant and Lubricant to Meet Ambient Temperature.................................................................... 98 10 Structure and Function.......................................................................................................... 101 Table of Contents.............................................................................................................. 102 Boot-up System................................................................................................................. 105 Layout Drawing of Boot-up System........................................................................................... 105 System Operating Lamp System............................................................................................... 106 System Diagram of System Operating Lamp System......................................................................... 106 Function of Operation Lamp System...................................................................................... 106 Operation of System Operating Lamp..................................................................................... 106 Battery Disconnect Switch.................................................................................................. 107 Function of Battery Disconnect Switch.................................................................................. 107 Operation of Battery Disconnect Switch................................................................................. 107 Engine System.................................................................................................................. 108 Layout Drawing of Engine System............................................................................................ 108 Engine Control System...................................................................................................... 109 System Diagram of Engine Control....................................................................................... 109 Operation of Engine Control System..................................................................................... 109 Auto-Deceleration System................................................................................................... 111 System Diagram of Auto-Deceleration System............................................................................. 111 Function of Auto-Deceleration System................................................................................... 111 Operation of Auto-Deceleration System.................................................................................. 112 Engine Automatic Warm-up System............................................................................................ 113 System Diagram of Engine Automatic Warm-up System...................................................................... 113 Function of Engine Automatic Warm-up System............................................................................ 114 Operation of Engine Automatic Warm-up System........................................................................... 114 Overheat Prevention System................................................................................................. 115 Overheat Prevention System Diagram..................................................................................... 115 Function of Overheat Prevention System................................................................................. 116 Operation of Overheat Prevention System................................................................................ 116 Turbocharger Protection System............................................................................................. 118 Function of Turbocharger Protection System............................................................................. 118 Cooling System................................................................................................................. 119 Layout Drawing of Cooling System........................................................................................... 119 Specifications of Cooling System....................................................................................... 120 Control System................................................................................................................. 121 Layout Drawing of Control System........................................................................................... 121 Machine Monitor System..................................................................................................... 123 System Diagram of Machine Monitor System............................................................................... 123 Function of Machine Monitor System..................................................................................... 123 KOMTRAX System............................................................................................................. 125 System Diagram of KOMTRAX System....................................................................................... 125 Function of KOMTRAX System............................................................................................. 125 Component Parts of Control System.......................................................................................... 126 Machine Monitor........................................................................................................ 126 KOMTRAX Terminal....................................................................................................... 137 Pump Controller........................................................................................................ 140 Resistor for PC-EPC Valve.............................................................................................. 144 CAN Terminating Resistor............................................................................................... 144 Engine Controller...................................................................................................... 145 Fuel Control Dial...................................................................................................... 149 Hydraulic System............................................................................................................... 150 Layout Drawing of Hydraulic System......................................................................................... 150 CLSS....................................................................................................................... 153 System Diagram of CLSS................................................................................................. 153 Function of CLSS....................................................................................................... 154 Pressure Compensation Control.......................................................................................... 171 Engine and Pump Combined Control System.................................................................................... 172 Engine and Pump Combined Control System Diagram........................................................................ 172 Function of Engine and Pump Combined Control System.................................................................... 173 Pump and Valve Control System.............................................................................................. 177 Pump and Valve Control System Diagram.................................................................................. 177 Function of Pump and Valve Control System.............................................................................. 178 Component Parts of Hydraulic System........................................................................................ 180 Hydraulic Tank......................................................................................................... 180 Main Pump.............................................................................................................. 181 Control Valve.......................................................................................................... 202 Work Equipment System.......................................................................................................... 248 Layout Drawing of Work Equipment System.................................................................................... 248 One-Touch Power Maximizing System.......................................................................................... 252 System Diagram of One-Touch Power Maximizing System.................................................................... 252 Function of One-Touch Power Maximizing System.......................................................................... 253 PPC Lock System............................................................................................................ 254 System Diagram of PPC Lock............................................................................................. 254 Function of PPC Lock System............................................................................................ 255 Attachment Oil Flow Adjuster System........................................................................................ 256 Attachment Oil Flow Adjuster System Diagram............................................................................ 256 Function of Attachment Oil Flow Adjuster System........................................................................ 257 Component Parts of Work Equipment System................................................................................... 258 Work Equipment and Swing PPC Valve..................................................................................... 258 1st-Line Attachment PPC Valve (with EPC Valve)......................................................................... 262 2nd-Line Attachment PPC Valve.......................................................................................... 266 Solenoid Valve......................................................................................................... 269 Attachment Circuit Selector Valve (For High Pressure).................................................................. 272 Attachment Circuit Selector Valve (For Low Pressure)................................................................... 274 Pilot Circuit Accumulator.............................................................................................. 276 Attachment Circuit Accumulator......................................................................................... 276 Swing System................................................................................................................... 279 Layout Drawing of Swing System............................................................................................. 279 Swing Control System Diagram............................................................................................... 281 Function of Swing Control System....................................................................................... 281 Component Parts of Swing System............................................................................................ 285 Swing Motor............................................................................................................ 285 Swing Machinery........................................................................................................ 293 Swing Circle........................................................................................................... 296 Travel System.................................................................................................................. 297 Layout Drawing of Travel System............................................................................................ 297 System Diagram of Travel Control System.................................................................................... 299 Function of Travel Control System.......................................................................................... 300 Component Parts of Travel System........................................................................................... 301 Travel Motor........................................................................................................... 301 Final Drive............................................................................................................ 312 Travel PPC Valve....................................................................................................... 313 Center Swivel Joint.................................................................................................... 318 Function of Swing Circle....................................................................................................... 320 Undercarriage and Frame........................................................................................................ 321 Layout Drawing of Undercarriage............................................................................................ 321 Specifications of Undercarriage........................................................................................ 321 Work Equipment................................................................................................................. 323 Structure of Work Equipment................................................................................................ 323 Work Equipment Clearance Adjustment Shim................................................................................... 324 Function of Work Equipment Clearance Adjustment Shim................................................................... 324 Bucket Clearance Adjustment Shim........................................................................................... 325 Function of Bucket Clearance Adjustment Shim........................................................................... 325 CAB Related Parts.............................................................................................................. 326 ROPS CAB................................................................................................................... 326 Structure of ROPS CAB.................................................................................................. 326 Function of ROPS CAB................................................................................................... 326 CAB Mount.................................................................................................................. 327 Structure of CAB Mount................................................................................................. 327 Function of CAB Mount.................................................................................................. 328 CAB Tipping Stopper........................................................................................................ 329 Structure of CAB Tipping Stopper....................................................................................... 329 Function of CAB Tipping Stopper........................................................................................ 329 20 Standard Value Table............................................................................................................ 331 Table of Contents.............................................................................................................. 332 Standard Value Table for Engine................................................................................................ 333 Standard Value Table for Engine: PC210-10M0................................................................................ 333 Standard Value Table for Engine: PC210LC-10M0.............................................................................. 337 Standard Value Table for Machine: PC210-10M0............................................................................... 341 Standard Value Table for Machine: PC210LC-10M0............................................................................. 355 Machine Posture and Procedures to Measure Performance...................................................................... 369 30 Testing and Adjusting........................................................................................................... 373 Table of Contents.............................................................................................................. 374 Precautions Before Work........................................................................................................ 377 Related Information on Testing and Adjusting................................................................................... 378 Tools for Testing and Adjusting............................................................................................ 378 Sketch of Tools for Testing and Adjusting.................................................................................. 383 Engine and Cooling System...................................................................................................... 385 Examine Engine Speed....................................................................................................... 385 How to Examine Engine High Idle Speed.................................................................................. 385 How to Examine Engine Low Idle Speed................................................................................... 385 How to Examine Engine Speed at 2 Pump Relief........................................................................... 385 Test Engine Speed at 2 Pumps Relief and One-touch Power Maximizing..................................................... 386 How to Examine Engine Speed with Auto-Deceleration..................................................................... 386 Examine Boost Pressure..................................................................................................... 388 How to Examine Boost Pressure on Machine Monitor....................................................................... 388 How to Examine Boost Pressure by Testing Tool.......................................................................... 389 Examine Exhaust Gas Color.................................................................................................. 391 How to Examine Exhaust Gas Color with the Handy Smoke Checker.......................................................... 391 How to Examine Exhaust Gas Color with Smoke Meter...................................................................... 392 Examine Mass Air Flow and Temperature Sensor............................................................................... 394 How to Examine Mass Air Flow and Temperature Sensor.................................................................... 394 Examine and Adjust Valve Clearance......................................................................................... 396 How to Examine Valve Clearance......................................................................................... 396 How to Adjust Valve Clearance.......................................................................................... 397 Examine Compression Pressure............................................................................................... 399 How to Examine Compression Pressure.................................................................................... 399 Examine Blowby Pressure.................................................................................................... 402 How to Examine Blowby Pressure on Machine Monitor (Machine with Blowby Pressure Sensor (OPT)).......................... 402 How to Examine Blowby Pressure (Machine Without Blowby Pressure Sensor)................................................ 403 Examine Engine Oil Pressure................................................................................................ 405 How to Examine Engine Oil Pressure..................................................................................... 405 Examine Fuel Pressure...................................................................................................... 407 How to Examine Fuel Pressure........................................................................................... 408 Examine Fuel Discharge, Return and Leakage................................................................................. 414 How to Examine Fuel Discharge, Return, and Leakage..................................................................... 415 Bleed Air from Fuel System................................................................................................. 420 How to Bleed Air from Fuel System...................................................................................... 420 Examine Fuel Circuit for Leakage........................................................................................... 422 How to Examine Fuel System for Leakage................................................................................. 422 Handle Cylinder Cut-out Mode Operation..................................................................................... 424 Handle No-Injection Cranking Operation..................................................................................... 425 Examine and Adjust Air Conditioner Compressor Belt Tension................................................................. 426 How to Examine Air Conditioner Compressor Belt......................................................................... 426 How to Adjust Air Conditioner Compressor Belt.......................................................................... 426 Power Train.................................................................................................................... 428 Examine Swing Circle Bearing Clearance..................................................................................... 428 How to Examine Swing Circle Bearing Clearance.......................................................................... 428 Undercarriage and Frame........................................................................................................ 429 Examine and Adjust Track Tension........................................................................................... 429 How to Examine Track Tension........................................................................................... 429 How to Adjust Track Tension............................................................................................ 429 Hydraulic System............................................................................................................... 431 Release Remained Pressure in Hydraulic Circuit............................................................................. 431 How to Release Remained Pressure from Hydraulic Tank................................................................... 431 How to Release Remained Pressure in Hydraulic Cylinder Circuit......................................................... 431 How to Release Remained Pressure for Machines Without Anti-drop Valve.................................................. 431 How to Release Remained Pressure for Machines with Boom Anti-drop Valve................................................ 431 How to Release Remained Pressure from Swing Motor Circuit.............................................................. 433 How to Release Remained Pressure from Travel Motor Circuit............................................................. 433 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits.............................................. 434 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits.............................................. 434 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits............................................... 441 Examine Oil Pressure of Control Circuit.................................................................................... 444 How to Examine Oil Pressure in Control Circuit......................................................................... 444 Examine and adjust oil pressure in pump PC control circuit................................................................. 446 How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure).................................................. 446 How to Examine PC-EPC Valve Outlet Pressure............................................................................ 447 How to Adjust Oil Pressure in Pump PC Control Circuit.................................................................. 448 Examine and Adjust Oil Pressure in Pump LS Control Circuit................................................................. 450 How to Examine LS Differential Pressure with Machine Monitor........................................................... 450 How to Examine LS Differential Pressure by Testing Tool................................................................ 452 How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure).................................................. 454 How to Examine LS-EPC Valve Outlet Pressure............................................................................ 455 How to Adjust LS Valve................................................................................................. 456 Examine Outlet Pressure of Solenoid Valve.................................................................................. 458 How to Examine Outlet Pressure of Solenoid Valve....................................................................... 458 Operating Condition of Solenoid Valve.................................................................................. 460 Examine PPC Valve Outlet Pressure.......................................................................................... 462 How to Examine PPC Valve Outlet Pressure on Machine Monitor............................................................ 462 How to Examine PPC Valve Outlet Pressure by Testing Tool............................................................... 463 Adjust Play of Work Equipment and Swing PPC Valve.......................................................................... 465 How to Adjust play of work equipment and swing PPC valve............................................................... 465 Examine Pump Swash Plate Sensor............................................................................................ 466 How to Examine pump swash plate sensor................................................................................. 466 Examine parts which cause hydraulic drift of work equipment................................................................ 467 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder.................................. 467 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder................................................... 467 How to Examine Parts Which Cause Hydraulic Drift of Boom Hydraulic Drift Prevention Valve.............................. 468 How to Examine Parts Which Cause Hydraulic Drift of PPC Valve.......................................................... 468 Examine Oil Leakage........................................................................................................ 469 How to Examine Oil Leakage from Boom Cylinder.......................................................................... 469 How to Examine Oil Leakage from Arm Cylinder........................................................................... 470 How to Examine Oil Leakage from Bucket Cylinder........................................................................ 471 How to Examine Oil Leakage from Swing Motor............................................................................ 471 How to Examine Oil Leakage from Travel Motor........................................................................... 472 Bleed Air from Hydraulic System............................................................................................ 474 How to Bleed Air from Main Pump........................................................................................ 475 How to Bleed Air from Cylinder......................................................................................... 476 How to Bleed Air from Swing Motor...................................................................................... 477 How to Bleed Air from Travel Motor..................................................................................... 477 CAB Related Parts.............................................................................................................. 479 Examine CAB Tipping Stopper................................................................................................ 479 How to Examine Cab Tipping Stopper..................................................................................... 479 How to Adjust Mirrors...................................................................................................... 480 How to Adjust Machine Left Front Mirror (A)............................................................................ 480 Adjust regular position of machine left front mirror (A)............................................................... 481 How to Adjust Machine Right Front Mirror (B)........................................................................... 482 How to Adjust Regular Position of Machine Right Front Mirror (B)....................................................... 482 How to Adjust Machine Right Side Mirror (C)............................................................................ 483 Electrical System.............................................................................................................. 485 Set and Operate Machine Monitor............................................................................................ 485 Operator Mode.......................................................................................................... 489 Function to Show Technician Identification Status Screen............................................................... 489 Function to Show Operator Identification Input Screen.................................................................. 489 Examine Function by LCD (Liquid Crystal Display)....................................................................... 490 Examine Function of Service Meter...................................................................................... 490 How to Set Usage Limitation and Change Maintenance Password............................................................ 490 Service Mode........................................................................................................... 493 How to Operate Service Mode............................................................................................ 493 How to See Pre-defined Monitoring Information.......................................................................... 494 How to Examine Monitoring Information.................................................................................. 498 Abnormality Record Menu................................................................................................ 506 How to See Maintenance Record.......................................................................................... 509 Maintenance Mode Setting............................................................................................... 511 How to Set Phone Number Entry.......................................................................................... 515 Default Setting Menu................................................................................................... 516 Testing Menu........................................................................................................... 524 Adjustment Menu........................................................................................................ 526 No-Injection Cranking Operation........................................................................................ 543 KOMTRAX Settings Menu.................................................................................................. 546 How to Show Service Message............................................................................................ 548 How to Start Up KOMTRAX Terminal........................................................................................... 549 Adjust Rearview Camera Angle............................................................................................... 553 How to Adjust Rearview Camera Angle.................................................................................... 553 Handle Voltage Circuit of Engine Controller................................................................................ 555 Examine Diodes............................................................................................................. 556 How to Examine Diodes by Digital Tester................................................................................ 556 How to Examine Diodes by Analog Tester................................................................................. 556 Pm Clinic...................................................................................................................... 557 Pm Clinic Service.......................................................................................................... 557 Pm Clinic Check Sheet: PC210-10M0...................................................................................... 560 Pm Clinic Check Sheet: PC210LC-10M0.................................................................................... 568 40 Troubleshooting................................................................................................................. 577 Table of Contents.............................................................................................................. 578 Precautions Before Work........................................................................................................ 584 Related Information to Troubleshooting......................................................................................... 585 Precautions for Troubleshooting............................................................................................ 585 Sequence of Events in Troubleshooting...................................................................................... 586 Checks Before Troubleshooting.............................................................................................. 588 Inspection Procedure Before Troubleshooting................................................................................ 590 Walk-Around Check...................................................................................................... 590 Examine Engine Related Parts........................................................................................... 591 Examine Work Equipment and Undercarriage............................................................................... 593 Examine Electric Equipment............................................................................................. 594 How to Connect Adapter for Troubleshooting Controller...................................................................... 599 How to Connect Adapter for Troubleshooting Machine Monitor............................................................. 599 How to Connect Adapter to Troubleshoot Pump Controller................................................................. 601 How to Connect Adapter to Troubleshoot KOMTRAX Terminal................................................................ 605 How to Connect Adapter for Troubleshooting Engine Controller........................................................... 607 How to Connect Adapter to Troubleshoot Engine Intermediate Connector................................................... 608 Disconnect and Connect Connector with Lock to Push......................................................................... 610 How to Disconnect and Connect Deutsch Connector........................................................................ 610 How to Disconnect and Connect BOSCH Connector.......................................................................... 610 How to Disconnect and Connect AMP Connector............................................................................ 611 How to Disconnect and Connect SUMITOMO Connector....................................................................... 612 How to Disconnect and Connect Connector with Lock to Pull.................................................................. 613 How to Disconnect and Connect DELPHI Connector and PACKARD Connector................................................... 613 How to Disconnect and Connect Slide Type Connector......................................................................... 614 How to Disconnect and Connect Framatome Connector...................................................................... 614 How to Disconnect and Connect TYCO Connector........................................................................... 615 How to Disconnect and Connect Connector with Housing to Rotate............................................................. 616 Procedure for Troubleshooting.............................................................................................. 617 Information Shown in Troubleshooting....................................................................................... 618 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness............................................ 621 Connector and Wiring Harness Identification Table.......................................................................... 624 Connector Layout........................................................................................................... 698 Connector Contact Connection Table......................................................................................... 704 T-Branch Box and T-Branch Adapter Table.................................................................................... 746 Fuse Location and Connection Table......................................................................................... 752 Drawing of Short Circuit Electrical Connector for Troubleshooting.......................................................... 755 Failure Code Table......................................................................................................... 757 Troubleshooting by Failure Code (Display of Code).............................................................................. 765 Failure Code [602KNX]...................................................................................................... 765 Failure Code [6AZ0ZG]...................................................................................................... 768 Failure Code [879AKA]...................................................................................................... 772 Failure Code [879AKB]...................................................................................................... 774 Failure Code [879BKA]...................................................................................................... 776 Failure Code [879BKB]...................................................................................................... 779 Failure Code [879CKA]...................................................................................................... 782 Failure Code [879CKB]...................................................................................................... 784 Failure Code [879DKZ]...................................................................................................... 786 Failure Code [879EMC]...................................................................................................... 790 Failure Code [879FMC]...................................................................................................... 792 Failure Code [879GKX]...................................................................................................... 794 Failure Code [989L00]...................................................................................................... 797 Failure Code [989M00]...................................................................................................... 799 Failure Code [989N00]...................................................................................................... 801 Failure Code [AA10NX]...................................................................................................... 802 Failure Code [AB00KE]...................................................................................................... 805 Failure Code [B@BAZG]...................................................................................................... 809 Failure Code [B@BAZK]...................................................................................................... 813 Failure Code [B@BCZK]...................................................................................................... 816 Failure Code [B@BCNS]...................................................................................................... 818 Failure Code [B@BCQA]...................................................................................................... 822 Failure Code [B@HANS]...................................................................................................... 824 Failure Code [CA111]....................................................................................................... 827 Failure Code [CA115]....................................................................................................... 832 Engine NE (Crankshaft) Speed Sensor.................................................................................... 838 Failure Code [CA122]....................................................................................................... 840 Failure Code [CA123]....................................................................................................... 843 Failure Code [CA131]....................................................................................................... 847 Failure Code [CA132]....................................................................................................... 850 Failure Code [CA144]....................................................................................................... 854 Failure Code [CA145]....................................................................................................... 858 Failure Code [CA153]....................................................................................................... 862 Failure Code [CA154]....................................................................................................... 866 Failure Code [CA155]....................................................................................................... 870 Failure Code [CA187]....................................................................................................... 872 Failure Code [CA221]....................................................................................................... 875 Failure Code [CA222]....................................................................................................... 878 Failure Code [CA227]....................................................................................................... 881 Failure Code [CA234]....................................................................................................... 884 Failure Code [CA238]....................................................................................................... 886 Failure Code [CA271]....................................................................................................... 889 Failure Code [CA272]....................................................................................................... 892 Failure Code [CA322]....................................................................................................... 894 Failure Code [CA323]....................................................................................................... 898 Failure Code [CA324]....................................................................................................... 902 Failure Code [CA325]....................................................................................................... 906 Failure Code [CA331]....................................................................................................... 910 Failure Code [CA332]....................................................................................................... 914 Failure Code [CA342]....................................................................................................... 918 Failure Code [CA351]....................................................................................................... 923 Failure Code [CA352]....................................................................................................... 928 Failure Code [CA386]....................................................................................................... 931 Failure Code [CA435]....................................................................................................... 933 Failure Code [CA441]....................................................................................................... 936 Failure Code [CA442]....................................................................................................... 941 Failure Code [CA449]....................................................................................................... 945 Failure Code [CA451]....................................................................................................... 951 Failure Code [CA452]....................................................................................................... 954 Failure Code [CA488]....................................................................................................... 957 Failure Code [CA553]....................................................................................................... 960 Failure Code [CA559]....................................................................................................... 965 Examine Low Pressure Fuel Circuit Devices.............................................................................. 971 Failure Code [CA689]....................................................................................................... 973 Failure Code [CA731]....................................................................................................... 978 Installation Points of Crankshaft and Camshaft Speed Sensors........................................................... 981 Failure Code [CA757]....................................................................................................... 983 Failure Code [CA778]....................................................................................................... 988 Engine NE (Crankshaft) Speed Sensor.................................................................................... 993 Failure Code [CA2185]...................................................................................................... 995 Failure Code [CA2186]...................................................................................................... 997 Failure Code [CA2249]......................................................................................................1000 Examine Low Pressure Fuel Circuit Devices..............................................................................1006 Failure Code [CA2311]......................................................................................................1008 Failure Code [CA2555]......................................................................................................1015 Failure Code [CA2556]......................................................................................................1018 Failure Code [D110KB]......................................................................................................1022 Failure Code [D19JKZ]......................................................................................................1025 Failure Code [D1N0KA]......................................................................................................1030 Failure Code [D1N0KB]......................................................................................................1033 Failure Code [D1N0KY]......................................................................................................1036 Failure Code [D811MC]......................................................................................................1038 Failure Code [D862KA]......................................................................................................1039 Failure Code [D8AQKR]......................................................................................................1041 Failure Code [D8ALKA]......................................................................................................1049 Failure Code [D8ALKB]......................................................................................................1053 Failure Code [DA20MC]......................................................................................................1056 Failure Code [DA22KK]......................................................................................................1057 Failure Code [DA25KP]......................................................................................................1062 Failure Code [DA26KP]......................................................................................................1066 Failure Code [DA29KQ]......................................................................................................1072 Failure Code [DA2LKA]......................................................................................................1077 Failure Code [DA2LKB]......................................................................................................1081 Failure Code [DA2QKR]......................................................................................................1084 Failure Code [DA2RKR]......................................................................................................1093 Failure Code [DAF0MB]......................................................................................................1101 Failure Code [DAF0MC]......................................................................................................1102 Failure Code [DAF9KQ]......................................................................................................1103 Failure Code [DAFGMC]......................................................................................................1105 Failure Code [DAFLKA]......................................................................................................1106 Failure Code [DAFLKB]......................................................................................................1110 Failure Code [DAFQKR]......................................................................................................1113 Failure Code [DAZ9KQ]......................................................................................................1122 Failure Code [DAZQKR]......................................................................................................1124 Failure Code [DB2QKR]......................................................................................................1132 Failure Code [DDPAKA]......................................................................................................1141 Failure Code [DGH2KA]......................................................................................................1144 Failure Code [DGH2KB]......................................................................................................1147 Failure Code [DHA4KA]......................................................................................................1150 Failure Code [DHE5MA]......................................................................................................1153 Failure Code [DHPAMA]......................................................................................................1157 Failure Code [DHPBMA]......................................................................................................1161 Failure Code [DHS3MA]......................................................................................................1165 Failure Code [DHS4MA]......................................................................................................1169 Failure Code [DHS8MA]......................................................................................................1173 Failure Code [DHS9MA]......................................................................................................1177 Failure Code [DHSAMA]......................................................................................................1181 Failure Code [DHSBMA]......................................................................................................1185 Failure Code [DHSCMA]......................................................................................................1189 Failure Code [DHSDMA]......................................................................................................1193 Failure Code [DHSFMA]......................................................................................................1197 Failure Code [DHSGMA]......................................................................................................1201 Failure Code [DHSHMA]......................................................................................................1205 Failure Code [DHSJMA]......................................................................................................1209 Failure Code [DJG1KX]......................................................................................................1213 Failure Code [DKR0MA]......................................................................................................1217 Failure Code [DKR1MA]......................................................................................................1221 Failure Code [DKR2MA]......................................................................................................1225 Failure Code [DKR2NX]......................................................................................................1229 Failure Code [DLM5KA]......................................................................................................1231 Failure Code [DLM5MB]......................................................................................................1235 Failure Code [DR21KX]......................................................................................................1239 Failure Code [DR31KX]......................................................................................................1242 Failure Code [DV20KB]......................................................................................................1243 Failure Code [DW43KA]......................................................................................................1246 Failure Code [DW43KB]......................................................................................................1249 Failure Code [DW43KY]......................................................................................................1252 Failure Code [DW45KA]......................................................................................................1254 Failure Code [DW45KB]......................................................................................................1258 Failure Code [DW45KY]......................................................................................................1262 Failure Code [DW91KA]......................................................................................................1265 Failure Code [DW91KB]......................................................................................................1267 Failure Code [DW91KY]......................................................................................................1270 Failure Code [DW97KA]......................................................................................................1272 Failure Code [DW97KB]......................................................................................................1274 Failure Code [DW97KY]......................................................................................................1277 Failure Code [DWA2KA]......................................................................................................1279 Failure Code [DWA2KB]......................................................................................................1281 Failure Code [DWA2KY]......................................................................................................1284 Failure Code [DWK0KA]......................................................................................................1286 Failure Code [DWK0KB]......................................................................................................1288 Failure Code [DWK0KY]......................................................................................................1291 Failure Code [DWK2KA]......................................................................................................1293 Failure Code [DWK2KB]......................................................................................................1295 Failure Code [DWK2KY]......................................................................................................1298 Failure Code [DWK8KA]......................................................................................................1300 Failure Code [DWK8KB]......................................................................................................1302 Failure Code [DWK8KY]......................................................................................................1305 Failure Code [DWN5KA]......................................................................................................1307 Failure Code [DWN5KB]......................................................................................................1310 Failure Code [DWN5KY]......................................................................................................1314 Failure Code [DXA8KA]......................................................................................................1316 Failure Code [DXA8KB]......................................................................................................1319 Failure Code [DXA9KA]......................................................................................................1323 Failure Code [DXA9KB]......................................................................................................1326 Failure Code [DXE0KA]......................................................................................................1330 Failure Code [DXE0KB]......................................................................................................1332 Failure Code [DXE4KA]......................................................................................................1335 Failure Code [DXE4KB]......................................................................................................1337 Failure Code [DXE4KY]......................................................................................................1340 Failure Code [DXE5KA]......................................................................................................1342 Failure Code [DXE5KB]......................................................................................................1344 Failure Code [DXE6KA]......................................................................................................1347 Failure Code [DXE6KB]......................................................................................................1349 Failure Code [DY20KA]......................................................................................................1352 Failure Code [DY20MA]......................................................................................................1356 Failure Code [DY2CKB]......................................................................................................1360 Failure Code [DY2DKB]......................................................................................................1365 Failure Code [DY2EKB]......................................................................................................1368 Failure Code [F@BBZL]......................................................................................................1371 Troubleshooting of Electrical System (E-Mode)..................................................................................1374 Engine Does Not Start (Engine Does Not Crank)..............................................................................1374 Manual Preheating System Does Not Operate..................................................................................1384 Automatic Preheating System Does Not Operate...............................................................................1388 While Preheating is in Operation, Preheating Monitor Does Not Come On......................................................1392 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing...............................................1397 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow..........1402 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow....1404 Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation..........................................1406 Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation...........................................1408 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation...............................................1410 Charge Level Monitor Comes On in Red While Engine is in Operation..........................................................1412 Fuel Level Monitor Comes On in Red While Engine is in Operation............................................................1416 Water Separator Monitor Comes On in Red While Engine is in Operation.......................................................1417 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation............................................1418 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation...................................................1420 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation.............................................1421 Fuel Gauge Does Not Move from Minimum or Maximum...........................................................................1423 Display of Fuel Gauge is Different from Actual Fuel Level..................................................................1426 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum....................................................1428 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature..........................................1429 Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum......................................................1431 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature........................................1434 Machine Monitor Shows Incorrect Model......................................................................................1436 Some Areas of Machine Monitor Screen are Not Shown.........................................................................1437 Function Switch Does Not Operate...........................................................................................1438 Automatic Warm-up System Does Not Operate (in Cold Weather)................................................................1439 Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated............................1441 Auto-Decelerator is Not Operated or Canceled with Lever....................................................................1442 Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated..................................................1445 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed..........................................1446 Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated.................................................1447 Travel Speed Does Not Change Even When You Change Travel Speed.............................................................1448 Alarm Buzzer Does Not Stop.................................................................................................1450 Service Meter is Not Shown While Starting Switch is in OFF Position........................................................1451 Service Mode Cannot be Selected............................................................................................1452 All Work Equipment, Swing, Travel Do Not Operate...........................................................................1453 All Work Equipment, Swing, Travel Cannot be Locked.........................................................................1457 Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position.................................1459 While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated.........................................1463 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor is Not Shown.....................................1466 One-Touch Power Maximizing Function is Not Cancelled.......................................................................1470 Travel Alarm Does Not Operate During Travel................................................................................1472 Travel Alarm Does Not Stop When Machine Stops..............................................................................1475 Horn Does Not Sound........................................................................................................1477 Horn Does Not Stop.........................................................................................................1481 Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated....................................................1483 Windshield Wiper Does Not Operate When Wiper Switch is Operated............................................................1484 When Window Washer Switch is Operated, Window Washer Does Not Operate......................................................1487 Boom Raise is Not Shown Normally with Monitoring Function..................................................................1490 Boom Lower is Not Shown Normally with Monitoring Function..................................................................1491 Arm OUT is Not Shown Correctly with Monitoring Function....................................................................1492 Arm IN is Not Shown Normally with Monitoring Function......................................................................1493 Bucket DUMP is Not Shown Correctly with Monitoring Function................................................................1494 Bucket CURL is Not Shown Correctly with Monitoring Function................................................................1495 Swing is Not Shown Normally with Monitoring Function.......................................................................1496 Travel is Not Shown Normally with Monitoring Function......................................................................1497 Service is Not Shown Correctly with Monitoring Function....................................................................1498 Attachment Hydraulic Circuit Cannot be Changed.............................................................................1501 KOMTRAX System Does Not Operate Correctly..................................................................................1503 Quick Coupler Does Not Work................................................................................................1505 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)..................................................................1510 Information Shown in Troubleshooting Table (H-Mode)........................................................................1510 All Work Equipment, Swing and Travel Do Not Work...........................................................................1511 All Work Equipment, Swing, and Travel Lack Speed or Power..................................................................1513 Fine Control Performance or Response is Unsatisfactory.....................................................................1524 Unusual Noise is Heard from Around Hydraulic Pump..........................................................................1529 Engine Speed Drops Largely or Engine Stops.................................................................................1531 Boom Speed or Power is Low.................................................................................................1540 Arm Speed or Power is Low..................................................................................................1552 Bucket Speed or Power is Low...............................................................................................1563 Work Equipment Does Not Move in Single Operation...........................................................................1573 Hydraulic Drift of Boom is Large...........................................................................................1577 Hydraulic Drift of Arm is Large............................................................................................1579 Hydraulic Drift of Bucket is Large.........................................................................................1583 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves...........................................1586 Time Lag of Work Equipment is Large........................................................................................1588 One-Touch Power Maximizing Function Does Not Operate.......................................................................1595 Attachment Circuit Cannot be Changed.......................................................................................1598 Oil Flow in Attachment Circuit Cannot be Changed...........................................................................1600 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower........................................1602 In Mixed Operation of Swing and Travel, Travel Speed Falls Largely.........................................................1604 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low........................................................1605 Machine Does Not Travel Straight...........................................................................................1606 Machine is Not Steered Well or Steering Power is Low.......................................................................1617 Travel Speed is Low........................................................................................................1632 One of Tracks Does Not Run.................................................................................................1643 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast..........................................................1652 Upper Structure Does Not Swing in Two Directions of Right and Left.........................................................1655 Machine Swings Only in One Direction.......................................................................................1660 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left...............................................1663 Swing Acceleration or Swing Speed is Low in Only One Direction.............................................................1670 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)...........................................1674 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction).......................................1676 Shock is Large When Upper Structure Stops Swing Operation..................................................................1680 Large Unusual Noise is Heard When Upper Structure Stops....................................................................1682 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied).....................................................1685 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)....................................................1687 Fan Speed is Abnormal (Too High or Low, or Does Not Move)..................................................................1691 Unusual Noise is Heard from Around Fan.....................................................................................1693 50 Disassembly and Assembly........................................................................................................1695 Table of Contents..............................................................................................................1696 Precautions Before Work........................................................................................................1700 Related Information on Disassembly and Assembly................................................................................1701 How to Read This Manual....................................................................................................1701 Coating Materials List.....................................................................................................1702 Special Tool List..........................................................................................................1707 Sketches of Special Tools..................................................................................................1716 Prepare........................................................................................................................1722 Drain and Add Coolant......................................................................................................1722 How to Drain Coolant...................................................................................................1722 How to Add Coolant.....................................................................................................1723 Drain and Add Hydraulic Oil................................................................................................1725 How to Drain Hydraulic Oil.............................................................................................1725 How to Add Hydraulic Oil...............................................................................................1727 Drain and Add Fuel.........................................................................................................1729 How to Drain Fuel......................................................................................................1729 How to Add Fuel........................................................................................................1730 Collect and Refill Refrigerant.............................................................................................1733 How to Collect Refrigerant.............................................................................................1733 How to Refill Refrigerant..............................................................................................1733 Engine and Cooling System......................................................................................................1734 Remove and Install Supply Pump Assembly....................................................................................1734 How to Remove Supply Pump Assembly.....................................................................................1735 How to Install Supply Pump Assembly....................................................................................1739 Remove and Install Injector Assembly.......................................................................................1743 How to Remove Injector Assembly........................................................................................1744 How to Install Injector Assembly.......................................................................................1747 Remove and Install Cylinder Head Assembly..................................................................................1754 How to Remove Cylinder Head Assembly...................................................................................1755 How to Install Cylinder Head Assembly..................................................................................1766 Remove and Install Starter Assembly........................................................................................1781 How to Remove Starting Motor Assembly..................................................................................1781 How to Install Starting Motor Assembly.................................................................................1783 Remove and Install Alternator Belt.........................................................................................1786 How to Remove Alternator Belt..........................................................................................1786 How to Install Alternator Belt.........................................................................................1790 Remove and Install Radiator Assembly.......................................................................................1793 How to Remove Radiator Assembly........................................................................................1793 How to Install Radiator Assembly.......................................................................................1796 Remove and Install Hydraulic Oil Cooler Assembly...........................................................................1799 How to Remove Hydraulic Oil Cooler Assembly............................................................................1800 How to Install Hydraulic Oil Cooler Assembly...........................................................................1803 Remove and Install Aftercooler Assembly....................................................................................1806 How to Remove Aftercooler Assembly.....................................................................................1806 How to Install Aftercooler Assembly....................................................................................1808 Remove and Install Fan Clutch Assembly.....................................................................................1812 How to Remove Fan Clutch Assembly......................................................................................1813 How to Install Fan Clutch Assembly.....................................................................................1817 Remove and Install Fan.....................................................................................................1823 How to Remove Fan......................................................................................................1823 How to Install Fan.....................................................................................................1823 Remove and Install Engine and Main Pump Assembly...........................................................................1824 How to Remove Engine and Main Pump Assembly............................................................................1825 How to Install Engine and Main Pump Assembly...........................................................................1841 Remove and Install Engine Front Oil Seal...................................................................................1858 How to Remove Engine Front Oil Seal....................................................................................1858 How to Install Engine Front Oil Seal...................................................................................1861 Remove and Install Engine Rear Oil Seal....................................................................................1864 How to Remove Engine Rear Oil Seal.....................................................................................1864 How to Install Engine Rear Oil Seal....................................................................................1866 Remove and Install Fuel Cooler Assembly....................................................................................1870 How to Remove Fuel Cooler Assembly.....................................................................................1870 How to Install Fuel Cooler Assembly....................................................................................1871 Remove and Install Engine Hood Assembly....................................................................................1873 How to Remove Engine Hood Assembly.....................................................................................1873 How to Install Engine Hood Assembly....................................................................................1875 Remove and Install Fuel Tank Assembly......................................................................................1877 How to Remove Fuel Tank Assembly.......................................................................................1878 How to Install Fuel Tank Assembly......................................................................................1882 Remove and Install Air Cleaner Assembly....................................................................................1888 How to Remove Air Cleaner Assembly.....................................................................................1888 How to Install Air Cleaner Assembly....................................................................................1890 Remove and Install Air Conditioner Compressor Assembly.....................................................................1892 How to Remove Air Conditioner Compressor Assembly......................................................................1892 How to Install Air Conditioner Compressor Assembly.....................................................................1895 Remove and Install Air Conditioner Condenser Assembly......................................................................1898 How to Remove Air Conditioner Condenser Assembly.......................................................................1898 How to Install Air Conditioner Condenser Assembly......................................................................1900 Power Train....................................................................................................................1902 Remove and Install Travel Motor and Final Drive Assembly...................................................................1902 How to Remove Travel Motor and Final Drive Assembly....................................................................1902 How to Install Travel Motor and Final Drive Assembly...................................................................1904 Disassemble and Assemble Final Drive Assembly..............................................................................1906 How to Disassemble Final Drive Assembly................................................................................1907 How to Assemble Final Drive Assembly...................................................................................1912 Remove and Install Swing Motor and Swing Machinery Assembly................................................................1924 How to Remove Swing Motor and Swing Machinery Assembly.................................................................1925 How to Install Swing Motor and Swing Machinery Assembly................................................................1927 Disassemble and Assemble Swing Machinery Assembly..........................................................................1931 How to Disassemble Swing Machinery Assembly............................................................................1932 How to Assemble Swing Machinery Assembly...............................................................................1938 Remove and Install Swing Circle Assembly...................................................................................1947 How to Remove Swing Circle Assembly....................................................................................1947 How to Install Swing Circle Assembly...................................................................................1947 Undercarriage and Frame........................................................................................................1949 Separate and Connect Track Assembly........................................................................................1949 How to Separate Track Assembly.........................................................................................1949 How to Install Track Assembly..........................................................................................1951 Remove and Install Sprocket................................................................................................1955 How to Remove Sprocket.................................................................................................1955 How to Install Sprocket................................................................................................1955 Remove and Install Idler and Idler Cushion Assembly........................................................................1957 How to Remove Idler and Idler Cushion Assembly.........................................................................1957 How to Install Idler and Idler Cushion Assembly........................................................................1958 Disassemble and Assemble Idler Assembly....................................................................................1959 How to Disassemble Idler Assembly......................................................................................1959 How to Assemble Idler Assembly.........................................................................................1961 Disassemble and Assemble Idler Cushion Assembly............................................................................1968 How to Disassemble Idler Cushion Assembly..............................................................................1969 How to Assemble Idler Cushion Assembly.................................................................................1970 Disassemble and Assemble Track Roller Assembly.............................................................................1972 How to Disassemble Track Roller Assembly...............................................................................1972 How to Assemble Track Roller Assembly..................................................................................1973 Disassemble and Assemble Carrier Roller Assembly...........................................................................1975 How to Disassemble Carrier Roller Assembly.............................................................................1975 How to Assemble Carrier Roller Assembly................................................................................1977 Remove and Install Revolving Frame Assembly................................................................................1980 How to Remove Revolving Frame Assembly.................................................................................1981 How to Install Revolving Frame Assembly................................................................................1984 Remove and Install Counterweight Assembly..................................................................................1987 How to Remove Counterweight Assembly...................................................................................1987 How to Install Counterweight Assembly..................................................................................1988 Hydraulic System...............................................................................................................1990 Remove and Install Center Swivel Joint Assembly............................................................................1990 How to Remove Center Swivel Joint Assembly.............................................................................1991 How to Install Center Swivel Joint Assembly............................................................................1994 Disassemble and Assemble Center Swivel Joint Assembly......................................................................1998 How to Disassemble Center Swivel Joint Assembly........................................................................1998 How to Assemble Center Swivel Joint Assembly...........................................................................1999 Remove and Install Hydraulic Tank Assembly.................................................................................2002 How to Remove Hydraulic Tank Assembly..................................................................................2003 How to Install Hydraulic Tank Assembly.................................................................................2007 Remove and Install Main Pump Assembly......................................................................................2014 How to Remove Main Pump Assembly.......................................................................................2015 How to Install Main Pump Assembly......................................................................................2022 Remove and Install Control Valve Assembly..................................................................................2030 How to Remove Control Valve Assembly...................................................................................2031 How to Install Control Valve Assembly..................................................................................2043 Disassemble and Assemble Control Valve Assembly............................................................................2056 How to Replace Pressure Compensation Valve Seal Ring...................................................................2056 Disassemble and Assemble Work Equipment PPC Valve Assembly.................................................................2059 How to Disassemble Work Equipment PPC Valve Assembly...................................................................2059 How to Assemble Work Equipment PPC Valve Assembly......................................................................2059 Disassemble and Assemble Travel PPC Valve Assembly.........................................................................2062 How to Disassemble Travel PPC Valve Assembly...........................................................................2062 How to Assemble Travel PPC Valve Assembly..............................................................................2063 Work Equipment.................................................................................................................2065 Remove and Install Work Equipment Assembly.................................................................................2065 How to Remove Work Equipment Assembly..................................................................................2066 How to Install Work Equipment Assembly.................................................................................2069 Disassemble and Assemble Work Equipment Cylinder Assembly..................................................................2072 How to Disassemble Work Equipment Cylinder Assembly....................................................................2073 How to Assemble Work Equipment Cylinder Assembly.......................................................................2078 CAB Related Parts..............................................................................................................2087 Remove and Install Operator Cab Assembly...................................................................................2087 How to Remove Operator Cab Assembly....................................................................................2088 How to Install Operator Cab Assembly...................................................................................2098 Remove and Install Operator Cab Glass (Adhered Glass)......................................................................2108 How to Remove Operator Cab Glass (Adhered Glass).......................................................................2110 How to Install Operator Cab Glass (Adhered Glass)......................................................................2110 Remove and Install Front Window Assembly...................................................................................2121 How to Remove Front Window Assembly....................................................................................2121 How to Install Front Window Assembly...................................................................................2124 Remove and Install Floor Frame Assembly....................................................................................2130 How to Remove Floor Frame Assembly.....................................................................................2131 How to Install Floor Frame Assembly....................................................................................2137 Remove and Install Air Conditioner Unit Assembly...........................................................................2145 How to Remove Air Conditioner Unit Assembly............................................................................2146 How to Install Air Conditioner Unit Assembly...........................................................................2154 Remove and Install Operator Seat...........................................................................................2162 How to Remove Operator Seat............................................................................................2162 How to Install Operator Seat...........................................................................................2163 How to Remove and Install Seat Belt........................................................................................2165 How to Remove Seat Belt................................................................................................2165 How to Install Seatbelt................................................................................................2166 Remove and Install Work Equipment Control Lever Assembly...................................................................2167 How to Remove Work Equipment Control Lever Assembly....................................................................2167 How to Install Work Equipment Control Lever Assembly...................................................................2172 Remove and Install Front Wiper Assembly....................................................................................2180 How to Remove Front Wiper Assembly.....................................................................................2180 How to Install Front Wiper Assembly....................................................................................2185 Electrical System..............................................................................................................2193 Remove and Install Engine Controller Assembly..............................................................................2193 How to Remove Engine Controller Assembly...............................................................................2193 How to Install Engine Controller Assembly..............................................................................2195 Remove and Install Pump Controller Assembly................................................................................2197 How to Remove Pump Controller Assembly.................................................................................2197 How to Install Pump Controller Assembly................................................................................2199 Remove and Install Machine Monitor Assembly................................................................................2203 How to Remove Machine Monitor Assembly.................................................................................2203 How to Install Machine Monitor Assembly................................................................................2206 Remove and Install Pump Swash Plate Sensor.................................................................................2210 How to Remove Pump Swash Plate Sensor..................................................................................2210 How to Install Pump Swash Plate Sensor.................................................................................2212 Remove and Install KOMTRAX Terminal Assembly...............................................................................2215 How to Remove KOMTRAX Terminal Assembly................................................................................2215 How to Install KOMTRAX Terminal Assembly...............................................................................2218 60 Maintenance Standard............................................................................................................2221 Table of Contents..............................................................................................................2222 Explanation of Terms for Maintenance Standard..................................................................................2223 Engine and Cooling System......................................................................................................2225 Maintenance Standard for Engine Mount......................................................................................2225 Maintenance Standard for Cooling System....................................................................................2226 Power Train....................................................................................................................2228 Maintenance Standard for Swing Circle......................................................................................2228 Maintenance Standard for Swing Machinery...................................................................................2229 Maintenance Standard for Final Drive.......................................................................................2232 Maintenance Standard for Sprocket..........................................................................................2234 Sprocket Tooth Profile Full-Scale Drawing..................................................................................2235 Undercarriage and Frame........................................................................................................2236 Maintenance Standard for Track Frame and Idler Cushion.....................................................................2236 Maintenance Standard for Idler.............................................................................................2237 Maintenance Standard for Track Roller......................................................................................2239 Maintenance Standard for Carrier Roller....................................................................................2241 Maintenance Standard for Track Shoes.......................................................................................2242 Maintenance Standard for Triple Shoes......................................................................................2245 Maintenance Standard for Swamp Shoes.......................................................................................2246 Maintenance Standard for Road Liner........................................................................................2247 Hydraulic System...............................................................................................................2248 Maintenance Standard for Hydraulic Tank....................................................................................2248 Maintenance Standard for Main Pump.........................................................................................2249 Maintenance Standard for LS-EPC Valve......................................................................................2251 Maintenance Standard for PC-EPC Valve......................................................................................2252 Maintenance Standard for Swing Motor.......................................................................................2253 Maintenance Standard for Travel Motor......................................................................................2255 Maintenance Standard for Control Valve.....................................................................................2258 Maintenance Standard for PPC Valve (Work Equipment and Swing Operation)....................................................2268 Maintenance Standard for Travel PPC Valve..................................................................................2271 Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)....................................................2274 Maintenance Standard for Attachment Oil Flow Adjuster EPC Valve............................................................2275 Maintenance Standard for 2nd-Line Attachment PPC Valve.....................................................................2276 Maintenance Standard for Solenoid Valve....................................................................................2277 Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure).............................................2279 Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)..............................................2280 Maintenance Standard for Center Swivel Joint...............................................................................2281 Work Equipment.................................................................................................................2282 Maintenance Standard for Work Equipment Linkage............................................................................2282 Dimensions of Arm..........................................................................................................2288 Dimensions of Bucket.......................................................................................................2290 Maintenance Standard for Boom Cylinder.....................................................................................2292 Maintenance Standard for Arm Cylinder......................................................................................2293 Maintenance Standard for Bucket Cylinder...................................................................................2294 80 Others..........................................................................................................................2295 Table of Contents..............................................................................................................2296 Precautions Before Work........................................................................................................2298 Air Conditioner System.........................................................................................................2299 Precautions for Refrigerant................................................................................................2299 Layout Drawing of Air Conditioner System...................................................................................2300 Specifications of Air Conditioner..........................................................................................2302 Structure of Refrigeration Cycle...........................................................................................2303 Function of Refrigeration Cycle............................................................................................2304 System Diagram of Air Conditioner..............................................................................................2305 Component Parts of Air Conditioner System......................................................................................2306 Air Conditioner Unit.......................................................................................................2306 Structure of Air Conditioner Unit......................................................................................2307 Function of Air Conditioner Unit.......................................................................................2308 Component Parts of Air Conditioner Unit................................................................................2309 Air Conditioner Controller.................................................................................................2313 Structure of Air Conditioner Controller................................................................................2313 Function of Air Conditioner Controller.................................................................................2313 Input and Output Signals of Air Conditioner Controller.................................................................2313 Compressor.................................................................................................................2315 Structure of Compressor................................................................................................2315 Specifications of Compressor...........................................................................................2315 Function of Compressor.................................................................................................2315 Operation of Compressor................................................................................................2315 Condenser..................................................................................................................2316 Structure of Condenser.................................................................................................2316 Specifications of Condenser............................................................................................2316 Function of Condenser..................................................................................................2316 Air Conditioner Related Sensors............................................................................................2318 Structure of Sunlight Sensor...........................................................................................2318 Function of Sunlight Sensor............................................................................................2318 Structure of Outside Temperature Sensor................................................................................2318 Function of Outside Air Temperature Sensor.............................................................................2318 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.........................................................2319 Locations of Air Conditioner Parts and Layout of Connectors....................................................................2321 Examine Air Leakage (Duct Connection)..........................................................................................2325 How to Examine Air Leakage (Duct Connection)...............................................................................2325 Examine Air Conditioner with Self-Diagnosis Function...........................................................................2328 Examine Vent (Mode) Changeover.................................................................................................2329 How to Examine Vent (Mode) Changeover......................................................................................2329 Examine Fresh/Recirc Air Changeover............................................................................................2331 How to Examine Fresh/Recirc Air Changeover.................................................................................2331 Examine Sunlight Sensor........................................................................................................2332 How to Examine Sunlight Sensor.............................................................................................2332 Examine Dual Pressure Switch...................................................................................................2333 How to Examine Dual Pressure Switch........................................................................................2333 Examine Relay..................................................................................................................2334 How to Examine Relay.......................................................................................................2334 Simple Check of Refrigerant Level Through Sight Glass..........................................................................2336 Procedure for Troubleshooting of Air Conditioner...............................................................................2337 Information Shown in Troubleshooting Table.....................................................................................2338 Failure Code [879AKA]..........................................................................................................2341 Failure Code [879AKB]..........................................................................................................2343 Failure Code [879BKA]..........................................................................................................2345 Failure Code [879BKB]..........................................................................................................2348 Failure Code [879CKA]..........................................................................................................2351 Failure Code [879CKB]..........................................................................................................2353 Failure Code [879DKZ]..........................................................................................................2355 Failure Code [879EMC]..........................................................................................................2359 Failure Code [879FMC]..........................................................................................................2361 Failure Code [879GKX]..........................................................................................................2363 Air Conditioner Does Not Operate...............................................................................................2366 Defective Cooling..............................................................................................................2369 Heater Does Not Operate........................................................................................................2378 Cool Air Does Not Come Out.....................................................................................................2382 No Air Comes Out or Air Flow is Abnormal.......................................................................................2389 Fresh/Recirc Air Changeover Does Not Work......................................................................................2393 Connect Service Tool...........................................................................................................2397 How to Connect Service Tool................................................................................................2398 Precautions for Disconnection and Connection of Air Conditioner Piping.........................................................2399 Handle Compressor Oil..........................................................................................................2401 How to Replace Desiccant.......................................................................................................2403 90 Circuit Diagrams................................................................................................................2405 Table of Contents..............................................................................................................2406 How to Read the Codes for Electric Cable.......................................................................................2407 Hydraulic Circuit Diagram......................................................................................................2411 Symbols Used in Hydraulic Circuit Diagram..................................................................................2411 Hydraulic Circuit Diagram..................................................................................................2415 Electrical Circuit Diagram.....................................................................................................2417 Symbols Used in Electric Circuit Diagram...................................................................................2417 Electrical Circuit Diagram (Applicable Machine: 600001 to 601173) (1/7)....................................................2421 Electrical Circuit Diagram (Applicable Machine: 600001 to 601173) (2/7)....................................................2423 Electrical Circuit Diagram (Applicable Machine: 600001 to 601173) (3/7)....................................................2425 Electrical Circuit Diagram (Applicable Machine: 600001 to 601173) (4/7)....................................................2427 Electrical Circuit Diagram (Applicable Machine: 600001 to 601173) (5/7)....................................................2429 Electrical Circuit Diagram (Applicable Machine: 600001 to 601173) (6/7)....................................................2431 Electrical Circuit Diagram (Applicable Machine: 600001 to 601173) (7/7)....................................................2433 Electrical Circuit Diagram (Applicable Machine: 601174 and Up) (1/7).......................................................2435 Electrical Circuit Diagram (Applicable Machine: 601174 and Up) (2/7).......................................................2437 Electrical Circuit Diagram (Applicable Machine: 601174 and Up) (3/7).......................................................2439 Electrical Circuit Diagram (Applicable Machine: 601174 and Up) (4/7).......................................................2441 Electrical Circuit Diagram (Applicable Machine: 601174 and Up) (5/7).......................................................2443 Electrical Circuit Diagram (Applicable Machine: 601174 and Up) (6/7).......................................................2445 Electrical Circuit Diagram (Applicable Machine: 601174 and Up) (7/7).......................................................2447 Connector and Wiring Harness Chart.............................................................................................2449 Wiring Harness Diagram (1/11)..............................................................................................2451 Wiring Harness Diagram (2/11)..............................................................................................2453 Wiring Harness Diagram (3/11)..............................................................................................2455 Wiring Harness Diagram (4/11)..............................................................................................2457 Wiring Harness Diagram (5/11)..............................................................................................2459 Wiring Harness Diagram (6/11)..............................................................................................2461 Wiring Harness Diagram (7/11)..............................................................................................2463 Wiring Harness Diagram (8/11)..............................................................................................2465 Wiring Harness Diagram (9/11)..............................................................................................2467 Wiring Harness Diagram (10/11).............................................................................................2469 Wiring Harness Diagram (11/11).............................................................................................2471 Index...............................................................................................................................2473
DESCRIPTION:
KOMATSU PC210-10M0 PC210LC-10M0 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06701-10 – PDF DOWNLOAD
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure. Descriptions of troubleshooting are sorted by failure mode.
50 Disassembly and Assembly
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 27/12/24
