Komatsu PC210i-10,PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-09 PDF

Description

Komatsu PC210i-10,PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-09  – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC210i-10,PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-09  – PDF DOWNLOAD

Language : English
Pages : 2518
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC210i-10,PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-09  – PDF DOWNLOAD

• SERIAL NUMBERS 451080 and up

SEN06515–08 3
00 Index and foreword . 3
Index . 4
Foreword, safety and general information 18
Important safety notice . 18
How to read the shop manual . 25
Explanation of terms for maintenance standard . 27
Handling equipment of fuel system devices . 29
Handling of intake system parts . 30
Handling of hydraulic equipment . 31
Method of disconnecting and connecting of push-pull type coupler 33
Handling of electrical equipment 36
How to read electric wire code 44
Precautions when performing operation . 47
Practical use of KOMTRAX 52
Standard tightening torque table 53
List of abbreviation 59
Conversion table 64
01 Specification 69
Table of contents . 70
Specifications 71
Specification drawing . 71
Working range drawings 73
Specifications 75
Weight table 81
Table of fuel, coolant, and lubricants 85
10 Structure and function . 87
Table of contents . 88
Engine and cooling system . 89
Engine related parts 89
KVGT 91
EGR system piping drawing . 98
EGR system circuit diagram 100
EGR valve . 102
EGR cooler 104
KCCV layout drawing . 106
KCCV ventilator . 108
KDPF 110
Cooling system 114
Power train . 116
Power train system 116
Swing circle 118
Swing machinery . 119
Final drive . 121
Undercarriage and frame . 123
Track frame and idler cushion . 123
Hydraulic system 125
Hydraulic component layout 125
Valve control . 127
Hydraulic tank 129
CLSS 131
Main pump . 136
Control valve . 162
Swing motor . 219
Travel motor 231
PPC valve . 244
Solenoid valve 267
Attachment circuit selector valve (for high pressure circuit) . 270
Attachment circuit selector valve (for low pressure circuit) 272
Center swivel joint . 275
Accumulator . 277
EPC valve for intelligent Machine Control . 278
Work equipment 283
Work equipment 283
Work equipment shim . 284
Bucket play adjustment shim . 285
Cab and its attachments . 286
Cab mount and cab tipping stopper . 286
ROPS cab 287
Electrical system . 288
Electrical control system . 288
Machine monitor system 378
KOMTRAX system 401
Sensor 404
20 Standard value tables 443
Table of contents . 444
Standard service value table 445
Standard value table for engine . 445
Standard value table for machine 447
Standard value table for electrical system 465
30 Testing and adjusting 475
Table of contents . 476
Related information on testing and adjusting 477
Tools for testing and adjusting . 477
Sketch of tools for testing and adjusting . 485
Engine and cooling system . 486
Testing engine speed 486
Testing boost pressure 487
Testing exhaust gas color . 489
Testing mass air flow and temperature sensor . 492
Testing and adjusting valve clearance . 495
Testing compression pressure 498
Testing blowby pressure . 502
Testing engine oil pressure . 503
Testing EGR valve and KVGT oil pressures 504
Measuring fuel pressure . 505
Measuring fuel delivery, return and leakage . 511
Bleeding air from fuel system . 516
Testing fuel circuit for leakage 518
Handling cylinder cutout mode operation . 519
Handling no-injection cranking operation 520
Testing and adjusting air conditioner compressor belt tension . 521
Replacing fan belt 523
Power train . 524
Testing swing circle bearing clearance 524
Undercarriage and frame . 525
Testing and adjusting track tension . 525
Hydraulic system 526
Releasing remaining pressure from hydraulic circuit . 526
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 531
Testing oil pressure of control circuit . 535
Testing and adjusting oil pressure in pump PC control circuit . 538
Testing and adjusting oil pressure in pump LS control circuit . 541
Testing output pressure of solenoid valve . 546
Testing PPC valve output pressure . 550
Adjusting play of work equipment and swing PPC valves . 552
Testing pump swash plate sensor . 553
Isolating the parts causing hydraulic drift in work equipment . 554
Testing oil leakage . 556
Bleeding air from hydraulic circuit . 559
Testing and charging accumulator (manufactured by NOK) nitrogen gas pressure for attachment (low pressure side) 561
Testing and charging accumulator nitrogen gas pressure for attachment (high pressure side) . 563
Replacing accumulator bladder on high pressure side for accumulator piping . 565
Cab and its attachments . 571
Testing cab tipping stopper . 571
Adjusting mirrors . 572
Electrical system . 574
Special functions of machine monitor 574
Special function of control box . 861
KOMTRAX terminal start-up procedure . 992
Adjusting rearview camera angle . 995
Handling voltage circuit of engine controller . 997
Handling battery disconnect switch 998
Testing diodes 999
Pm clinic .1000
Pm Clinic service .1000
40 Troubleshooting 1011
Table of contents .1012
Related information on troubleshooting 1021
Troubleshooting points 1021
Sequence of events in troubleshooting .1023
Testing before troubleshooting 1025
Inspection procedure before troubleshooting .1027
Preparation for troubleshooting of electrical system 1046
Classification and procedure for troubleshooting 1054
Symptom and troubleshooting numbers .1057
Information in troubleshooting table 1060
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 1062
Connector list and layout .1064
Connector contact identification 1077
T-branch box and T-branch adapter table .1116
Fuse location table .1121
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement .1124
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) .1127
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) .1128
Failure codes table .1129
Troubleshooting by failure code (Display of code) .1141
Failure code [879AKA] A/C Inner Sensor Open Circuit .1141
Failure code [879AKB] A/C Inner Sensor Short Circuit 1142
Failure code [879BKA] A/C Outer Sensor Open Circuit .1143
Failure code [879BKB] A/C Outer Sensor Short Circuit 1144
Failure code [879CKA] Ventilating Sensor Open Circuit .1145
Failure code [879CKB] Ventilating Sensor Short Circuit 1146
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit .1147
Failure code [879EMC] Ventilation Damper Abnormality 1148
Failure code [879FMC] Air Mix Damper Abnormality 1149
Failure code [879GKX] Refrigerant Abnormality .1150
Failure code [989L00] Engine Controller Lock Caution1 .1151
Failure code [989M00] Engine Controller Lock Caution2 .1152
Failure code [989N00] Engine Controller Lock Caution3 .1153
Failure code [A1U0N3] HC Desorb Request 1 .1154
Failure code [A1U0N4] HC Desorb Request 2 .1156
Failure code [AA10NX] Air Cleaner Clogging 1158
Failure code [AB00KE] Charge Voltage Low 1160
Failure code [B@BAZG] Engine Oil Pressure Low .1162
Failure code [B@BAZK] Eng Oil Level Low .1163
Failure code [B@BCNS] Engine Coolant Overheat .1164
Failure code [B@BCZK] Radiator Coolant Level Low 1165
Failure code [B@HANS] Hyd Oil Overheat 1167
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .1168
Failure code [CA122] Chg Air Press Sensor High Error 1169
Failure code [CA123] Chg Air Press Sensor Low Error .1171
Failure code [CA131] Throttle Sensor High Error .1173
Failure code [CA132] Throttle Sensor Low Error 1175
Failure code [CA144] Coolant Temp Sens High Error .1177
Failure code [CA145] Coolant Temp Sens Low Error 1179
Failure code [CA153] Chg Air Temp Sensor High Error .1181
Failure code [CA154] Chg Air Temp Sensor Low Error 1183
Failure code [CA187] Sensor 2 Supply Volt Low Error .1185
Failure code [CA221] Ambient Press Sensor High Error 1187
Failure code [CA222] Ambient Press Sensor Low Error .1189
Failure code [CA227] Sensor 2 Supply Volt High Error 1191
Failure code [CA234] Eng Overspeed 1192
Failure code [CA238] Ne Speed Sensor Supply Volt Error 1193
Failure code [CA239] Ne Speed Sens Supply Volt High Error .1194
Failure code [CA271] IMV/PCV1 Short Error .1195
Failure code [CA272] IMV/PCV1 Open Error 1197
Failure code [CA295] Ambient Press Sens In Range Error 1199
Failure code [CA322] Inj #1(L#1) Open/Short Error .1200
Failure code [CA323] Inj #5(L#5) Open/Short Error .1202
Failure code [CA324] Inj #3(L#3) Open/Short Error .1204
Failure code [CA325] Inj #6(L#6) Open/Short Error .1206
Failure code [CA331] Inj #2(L#2) Open/Short Error .1208
Failure code [CA332] Inj #4(L#4) Open/Short Error .1210
Failure code [CA343] ECM Critical Internal Failure 1212
Failure code [CA351] Injectors Drive Circuit Error 1213
Failure code [CA352] Sensor 1 Supply Volt Low Error .1214
Failure code [CA356] Mass Air Flow Sensor High Error 1216
Failure code [CA357] Mass Air Flow Sensor Low Error .1218
Failure code [CA386] Sensor 1 Supply Volt High Error 1220
Failure code [CA428] Water in Fuel Sensor High Error 1221
Failure code [CA429] Water in Fuel Sensor Low Error .1223
Failure code [CA435] Eng Oil Press Sw Error .1225
Failure code [CA441] Battery Voltage Low Error 1226
Failure code [CA442] Battery Voltage High Error .1228
Failure code [CA449] Rail Press Very High Error .1229
Failure code [CA451] Rail Press Sensor High Error .1230
Failure code [CA452] Rail Press Sensor Low Error 1232
Failure code [CA488] Chg Air Temp High Torque Derate 1234
Failure code [CA515] Rail Press Sens Sup Volt High Error 1235
Failure code [CA516] Rail Press Sens Sup Volt Low Error .1237
Failure code [CA553] Rail Press High Error 1239
Failure code [CA555] Crankcase Press High Error 1 .1240
Failure code [CA556] Crankcase Press High Error 2 .1241
Failure code [CA559] Rail Press Low Error .1242
Failure code [CA595] Turbo Speed High Error 2 .1244
Failure code [CA687] Turbo Speed Low Error 1245
Failure code [CA689] Eng Ne Speed Sensor Error 1247
Failure code [CA691] Intake Air Temp Sens High Error 1249
Failure code [CA692] Intake Air Temp Sens Low Error .1251
Failure code [CA697] ECM Int Temp Sensor High Error .1253
Failure code [CA698] ECM Int Temp Sensor Low Error 1254
Failure code [CA731] Eng Bkup Speed Sens Phase Error 1255
Failure code [CA778] Eng Bkup Speed Sensor Error 1257
Failure code [CA1117] Persistent Data Lost Error 1262
Failure code [CA1664] KDOC Malfunction 1263
Failure code [CA1691] Regeneration Ineffective 1265
Failure code [CA1695] Sensor 5 Supply Volt High Error .1268
Failure code [CA1696] Sensor 5 Supply Volt Low Error 1269
Failure code [CA1843] Crankcase Press Sens High Error .1270
Failure code [CA1844] Crankcase Press Sens Low Error 1272
Failure code [CA1879] KDPF Delta P Sensor High Error 1274
Failure code [CA1881] KDPF Delta P Sensor Low Error .1276
Failure code [CA1883] KDPF Delta P Sens In Range Error 1278
Failure code [CA1921] KDPF Soot Load High Error 1 .1281
Failure code [CA1922] KDPF Soot Load High Error 2 .1284
Failure code [CA1942] Crankcase Press Sens In Range Error .1289
Failure code [CA1993] KDPF Delta Pressure Low Error .1290
Failure code [CA2185] Throt Sensor Sup Volt High Error 1293
Failure code [CA2186] Throt Sensor Sup Volt Low Error .1295
Failure code [CA2249] Rail Press Very Low Error .1297
Failure code [CA2271] EGR Valve Pos Sens High Error .1298
Failure code [CA2272] EGR Valve Pos Sens Low Error 1300
Failure code [CA2288] Turbo Speed High Error 1 1303
Failure code [CA2311] IMV Solenoid Error 1304
Failure code [CA2349] EGR Valve Solenoid Open Error .1305
Failure code [CA2353] EGR Valve Solenoid Short Error 1307
Failure code [CA2357] EGR Valve Servo Error .1309
Failure code [CA2373] Exhaust Manifold Press Sens High error 1310
Failure code [CA2374] Exhaust Manifold Press Sens Low error .1312
Failure code [CA2375] EGR Orifice Temp Sens High Error 1314
Failure code [CA2376] EGR Orifice Temp Sens Low Error .1316
Failure code [CA2381] KVGT Pos Sens High Error 1318
Failure code [CA2382] KVGT Pos Sens Low Error .1320
Failure code [CA2383] KVGT Solenoid Open Error 1323
Failure code [CA2386] KVGT Solenoid Short Error .1325
Failure code [CA2387] VGT Servo Error .1327
Failure code [CA2554] Exh Manifold Press Sens In Range Error 1330
Failure code [CA2555] Grid Htr Relay Volt Low Error .1331
Failure code [CA2556] Grid Htr Relay Volt High Error 1333
Failure code [CA2637] KDOC Face Plugging 1335
Failure code [CA2639] Manual Stationary Regeneration Request 1337
Failure code [CA2961] EGR Orifice Temp High Error 1 .1340
Failure code [CA2973] Chg Air Press Sensor In Range Error .1341
Failure code [CA3133] KDPF Outlet Press Sens High Error .1342
Failure code [CA3134] KDPF Outlet Press Sens Low Error 1344
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .1346
Failure code [CA3251] KDOC Inlet Temp High Error 1350
Failure code [CA3253] KDOC Temp Error – Non Regeneration 1353
Failure code [CA3254] KDOC Outlet Temp High Error 1 .1356
Failure code [CA3255] KDPF Temp Error – Non Regeneration 1359
Failure code [CA3256] KDPF Outlet Temp High Error 1 .1362
Failure code [CA3311] KDOC Outlet Temp High Error 2 .1365
Failure code [CA3312] KDPF Outlet Temp High Error 2 .1368
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 1371
Failure code [CA3314] KDOC Inlet Temp Sens High Error .1374
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error .1378
Failure code [CA3316] KDOC Outlet Temp Sens Low Error .1382
Failure code [CA3317] KDOC Outlet Temp Sens High Error 1385
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error 1389
Failure code [CA3319] KDPF Outlet Temp Sens High Error 1393
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .1397
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 1400
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 1404
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error .1406
Failure code [CA3741] Rail Press Valve Trip Error .1408
Failure code [D110KB] Battery Relay Output Voltage 1409
Failure code [D19JKZ] Personal Code Relay Abnormality .1411
Failure code [D811MC] KOMTRAX Error .1414
Failure code [D862KA] GPS Antenna Open Circuit 1415
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .1416
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 1418
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .1419
Failure code [DA20MC] Pump Controller .1424
Failure code [DA22KK] Pump Solenoid Power Low Error .1425
Failure code [DA25KP] 5V Sensor 1 Power Abnormality .1427
Failure code [DA29KQ] Model Selection Abnormality .1429
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 1431
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) .1433
Failure code [DA2QKR] CAN2 Discon (Pump Con) 1434
Failure code [DA2RKR] CAN1 Discon (Pump Con) 1440
Failure code [DAF0MB] Monitor ROM Abnormality .1447
Failure code [DAF0MC] Monitor Error .1448
Failure code [DAF8KB] Camera Power Supply Short Circuit .1449
Failure code [DAF9KQ] Model Selection Abnormality .1451
Failure code [DAFGMC] GPS Module Error 1452
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) .1453
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 1455
Failure code [DAFQKR] CAN2 Discon (Monitor) .1456
Failure code [DAZ9KQ] A/C Model Selection Abnormality .1461
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 1462
Failure code [DB2QKR] CAN2 Discon (Engine Con) 1467
Failure code [DB2RKR] CAN1 Discon (Engine Con) 1473
Failure code [DB90KT] W/E Controller Internal Failure .1482
Failure code [DB90MC] W/E Controller Reset 1483
Failure code [DB92KK] W/E CON Solenoid Power Voltage Low Error 1484
Failure code [DB95KP] W/E CON 5V Sensor 0 Power Volt Low Error 1486
Failure code [DB96KP] W/E CON 5V Sensor 1 Power Volt Low Error 1489
Failure code [DB99KQ] Model Selection Signal Mismatch (W/E Con) .1493
Failure code [DB9LKA] Operating Lamp Open Circuit (W/E CON) .1496
Failure code [DB9LKB] Operating Lamp Hot Short Circuit (W/E CON) 1498
Failure code [DB9QKR] CAN2 Defective Communication (W/E CON) 1500
Failure code [DB9RKR] CAN1 Defective Communication (W/E CON) 1506
Failure code [DBR0KT] ICT Sensor Controller Internal Failure 1514
Failure code [DBR0MC] ICT Sensor Controller Reset .1515
Failure code [DBR2KK] ICT/S CON Solenoid Power Low Error 1516
Failure code [DBR5KP] ICT/S CON 5V Sensor 0 Power Abnormality .1518
Failure code [DBR6KP] ICT/S CON 5V Sensor 1 Power Abnormality .1520
Failure code [DBR9KQ] Model Selection Signal Mismatch (ICT Sens) 1522
Failure code [DBRLKA] Operating Lamp Open Circuit (ICT/S CON) .1525
Failure code [DBRLKB] Operating Lamp Short Circuit (ICT/S CON) 1527
Failure code [DBRQKR] CAN2 Discon (ICT/S CON) .1529
Failure code [DBRRKR] CAN 1 Discon (ICT/S CON) 1536
Failure code [DBRSKB] ICT/S Con Battery Relay Drive Short Cir. 1543
Failure code [DBRTKB] Control Box Activation Output Short Circuit (ICT Sensor Controller) .1545
Failure code [DBUSKR] Ethernet 0 Discon (GNSS Receiver) .1546
Failure code [DD20MA] Auto/Manual Selector Switch Error .1549
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 1551
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1553
Failure code [DHPAMA] F Pump Press Sensor Abnormality .1554
Failure code [DHPBMA] R Pump Press Sensor Abnormality .1557
Failure code [DHS3MA] Arm IN PPC Press Sens Defective Function 1560
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Def Function .1562
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function 1564
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function 1566
Failure code [DHSAMA] Swing RH PPC Press Sens Def Function 1568
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .1570
Failure code [DHSCMA] Arm Dump PPC Press Sens Def Function 1572
Failure code [DHSDMA] Bucket Dump PPC Press Sens Def Function .1574
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 1576
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 1579
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 1582
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 1585
Failure code [DK80KM] IMU Calibration Not Complete 1588
Failure code [DK80KR] IMU Defective Communication .1589
Failure code [DK80KT] IMU Error .1596
Failure code [DKG1KM] Bucket Cylinder Calibration Not Complete 1597
Failure code [DKG1L8] Bucket Cyl Stroke Sensor Inrange Error 1598
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality .1599
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality .1601
Failure code [DKT0KM] Boom Cylinder Calibration Not Complete 1603
Failure code [DKT0L8] Boom Cyl Stroke Sensor Inrange Error 1604
Failure code [DKT1KA] Boom Cyl Stroke Sensor A Open Circuit .1605
Failure code [DKT1KB] Boom Cyl Stroke Sensor A Short Circuit 1607
Failure code [DKT2KA] Boom Cyl Stroke Sensor B Open Circuit .1608
Failure code [DKT2KB] Boom Cyl Stroke Sensor B Short Circuit 1610
Failure code [DKT4KM] Arm Cylinder Calibration Not Complete .1611
Failure code [DKT4L8] Arm Cylinder Stroke Sensor Inrange Error 1612
Failure code [DKT5KA] Arm Cyl Stroke Sensor A Open Circuit 1613
Failure code [DKT5KB] Arm Cyl Stroke Sensor A Short Circuit .1615
Failure code [DKT6KA] Arm Cyl Stroke Sensor B Open Circuit 1617
Failure code [DKT6KB] Arm Cyl Stroke Sensor B Short Circuit .1619
Failure code [DKT8KA] Bucket Cyl Stroke Sensor A Open Circuit .1621
Failure code [DKT8KB] Bucket Cyl Stroke Sensor A Short Circuit 1623
Failure code [DKT9KA] Bucket Cyl Stroke Sensor B Open Circuit .1625
Failure code [DKT9KB] Bucket Cyl Stroke Sensor B Short Circuit 1627
Failure code [DKTAKA] Bucket Cyl Stroke Reset Sens Open Circuit .1629
Failure code [DKTAKB] Bucket Cyl Stroke Reset Sens Short Circuit 1631
Failure code [DKTAMB] Bucket Cyl Stroke Reset Sens Inrange Error 1633
Failure code [DKTBKX] Boom Cyl Stroke Reset Enc A,B Abnormality .1634
Failure code [DKTBMC] Boom Cylinder Stroke Reset Encoder Error 1636
Failure code [DKTEMB] Boom Cyl Stroke Reset Enc Z Abnormality .1637
Failure code [DKTFKX] Boom Cyl Stroke Reset Enc A,B Abnormality .1639
Failure code [DKTFMC] Arm Cyl Stroke Reset Enc Error 1641
Failure code [DKTJMB] Arm Cyl Stroke Reset Enc Z Abnormality 1642
Failure code [DKU1MA] Boom Spool Stroke Sensor In Range Error .1644
Failure code [DKU2MA] Arm Spool Storke Sensor In Range Error 1645
Failure code [DKUGKA] Arm IN PPC Reduce Press EPC Open Circuit 1646
Failure code [DKUGKB] Arm IN PPC Reduce Press EPC Ground Fault 1648
Failure code [DKUGKY] Arm IN PPC Reduce Pressure EPC Hot Short 1649
Failure code [DKUHKA] Arm OUT PPC Reduce Press EPC Open Circuit .1651
Failure code [DKUHKB] Arm OUT PPC Reduce Press EPC Ground Fault .1653
Failure code [DKUHKY] Arm OUT PPC Reduce Pressure EPC Hot Short .1654
Failure code [DKV0KA] Boom Spool Stroke Sensor 1 Open Circuit .1656
Failure code [DKV0KY] Boom Spool Stroke Sensor 1 Hot Short Cir 1658
Failure code [DKV1KA] Arm Spool Stroke Sensor 1 Open Circuit 1660
Failure code [DKV1KY] Arm Spool Stroke Sensor 1 Hot Short Cir .1662
Failure code [DKV2KA] Boom Spool Stroke Sensor 2 Open Circuit .1664
Failure code [DKV2KY] Boom Spool Stroke Sensor 2 Hot Short Cir 1666
Failure code [DKV3KA] Arm Spool Stroke Sensor 2 Open Circuit 1668
Failure code [DKV3KY] Arm Spool Stroke Sensor 2 Hot Short Cir .1670
Failure code [DKV4MA] Boom RAISE PPC Press Sensor 2 Def Function 1672
Failure code [DKV5MA] Boom LOWER PPC Press Sensor 2 Def Function 1674
Failure code [DKV6MA] Arm OUT PPC Press Sensor 2 Def Function .1677
Failure code [DKV7MA] Arm IN PPC Press Sens 2 Defective Function 1680
Failure code [DKV8MA] Bucket DUMP PPC Press Sens 2 Def Function .1683
Failure code [DKV9MA] Bucket CURL PPC Press Sens 2 Def Function .1685
Failure code [DKVAMA] PPC Source Press Sensor Error .1687
Failure code [DKVBKA] Bucket CURL PPC Reduce Press EPC Open Cir .1689
Failure code [DKVBKB] Bucket CURL PPC Reduce Press EPC Grd Fault 1691
Failure code [DKVBKY] Bucket CURL PPC Reduce Press EPC Hot Short 1692
Failure code [DKVCKA] Boom RAISE PPC Intervention EPC Open Cir 1694
Failure code [DKVCKB] Boom RAISE PPC Intervention EPC Grnd Fault 1696
Failure code [DKVCKY] Boom RAISE PPC Intervention EPC Hot Short .1698
Failure code [DKVDKA] Boom RAISE EPC Cut Relay Open Circuit .1701
Failure code [DKVDKB] Boom RAISE EPC Cut Relay Ground Fault .1702
Failure code [DKVDKY] Boom RAISE EPC Cut Relay Hot Short Circuit 1704
Failure code [DKVDMA] Boom RAISE EPC Cut Relay Error 1705
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .1706
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .1708
Failure code [DV20KB] Travel Alarm Short Circuit 1710
Failure code [DW43KA] Travel Speed Sol Open Circuit .1712
Failure code [DW43KB] Travel Speed Sol Short Circuit 1714
Failure code [DW45KA] Swing holding brake Sol Open Circuit 1716
Failure code [DW45KB] Swing holding brake Sol Short Circuit .1719
Failure code [DW4FKA] Boom LOWER PPC Reduce Press EPC Open Cir 1721
Failure code [DW4FKB] Boom LOWER PPC Reduce Press EPC Grnd Fault 1723
Failure code [DW4FKY] Boom LOWER PPC Reduce Press EPC Hot Short .1725
Failure code [DW4GKA] Boom RAISE PPC Reduce Press EPC Open Cir. .1727
Failure code [DW4GKB] Boom RAISE PPC Reduce Press EPC Grnd Fault 1729
Failure code [DW4GKY] Boom RAISE PPC Reduce Press EPC Hot Short .1731
Failure code [DW4SKA] Bucket DUMP PPC Reduce Press EPC Open Cir .1733
Failure code [DW4SKB] Bucket DUMP PPC Reduce Press EPC Grd Fault 1735
Failure code [DW4SKY] Bucket DUMP PPC Reduce Press EPC Hot Short 1736
Failure code [DW91KA] Travel Junction Sol Open Circuit 1738
Failure code [DW91KB] Travel Junction Sol Short Circuit .1740
Failure code [DWA2KA] Attachment Sol Open Circuit .1742
Failure code [DWA2KB] Attachment Sol Short Circuit 1744
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .1746
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 1748
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 1750
Failure code [DWK2KB] Variable Back Press Sol Short Circuit .1752
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 1754
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit .1756
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .1758
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1760
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .1762
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1764
Failure code [DXE0KA] LS-EPC Sol Open Circuit .1766
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1768
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 1770
Failure code [DXE4KB] Attachment Flow EPC Short Circuit .1772
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 1774
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .1776
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 1778
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit .1780
Failure code [DY20KA] Wiper Working Abnormality .1782
Failure code [DY20MA] Wiper Parking Abnormality .1784
Failure code [DY2CKB] Washer Drive Short Circuit 1786
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .1788
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .1790
Failure code [H16SL8] Boom cylinder stroke sensor rotor stuck 1792
Failure code [H17SL8] Arm cylinder stroke sensor rotor stuck .1793
Troubleshooting of electrical system (E-mode) .1794
E-1 Engine does not start (Engine does not crank) .1794
E-2 Manual preheating system does not work 1800
E-3 Automatic preheating system does not work .1803
E-4 Preheating monitor does not light up when preheater is operated .1805
E-5 When starting switch is turned to ON position, machine monitor displays nothing .1807
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow 1810
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow 1811
E-8 Coolant temperature monitor lights up in white while engine is running 1812
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1813
E-10 Charge level monitor lights up while engine is running .1814
E-11 Fuel level monitor lights up in red while engine is running 1815
E-12 Air cleaner clogging monitor lights up in yellow while engine is running .1816
E-13 Water separator monitor lights up while engine is running 1817
E-14 Coolant temperature monitor lights up in red while engine is running .1818
E-15 Hydraulic oil temperature monitor lights up in red while engine is running .1819
E-16 Engine oil pressure monitor lights up in red while engine is running .1820
E-17 Fuel gauge indicates either full or empty and does not move 1821
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .1822
E-19 Coolant temperature gauge indicates either Min. or Max. and does not move 1823
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) 1824
E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not move 1825
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) 1827
E-23 Content of display on machine monitor is different from that of actual machine .1828
E-24 Machine monitor does not display some items 1829
E-25 Function switch does not work 1830
E-26 Automatic preheating system does not work (In cold season) .1831
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated .1832
E-28 Auto-deceleration is not actuated or canceled when lever is operated .1833
E-29 Working mode selection screen is not diplayed when working mode switch is operated .1834
E-30 Engine or hydraulic pump setting does not change when working mode is changed 1835
E-31 Travel speed monitor does not change when travel speed switch is operated 1836
E-32 Travel speed does not change while travel speed selection is changed .1837
E-33 Alarm buzzer does not stop sounding 1838
E-34 When starting switch is turned to OFF position, service meter is not displayed .1839
E-35 Service mode cannot be selected 1840
E-36 Any of work equipment, swing and travel does not work 1841
E-37 Any of work equipment, swing and travel cannot be locked .1843
E-38 Machine cannot swing while swing brake cancel switch is canceled .1844
E-39 Swing brake does not operate while swing brake cancel switch is locked .1846
E-40 One-touch power maximizing function does not work or monitor is not displayed 1848
E-41 One-touch power maximizing function cannot be canceled .1850
E-42 Travel alarm does not sound when machine travels .1851
E-43 Alarm does not stop sounding while machine is stopped 1852
E-44 Horn does not sound 1853
E-45 Horn does not stop sounding 1855
E-46 Wiper monitor does not light up or go out when wiper switch is operated 1856
E-47 Wiper does not operate when wiper switch is operated .1857
E-48 Window washer does not operate when window washer switch is operated .1859
E-49 BOOM LOWER indication is not displayed properly with monitoring function .1860
E-50 ARM DUMP indication is not displayed properly with monitoring function .1861
E-51 ARM IN indication is not displayed properly with monitoring function .1862
E-52 BOOM RAISE indication is not displayed properly with monitoring function .1863
E-53 BUCKET CURL indication is not displayed properly with monitoring function 1864
E-54 BUCKET DUMP indication is not displayed properly with monitoring function 1865
E-55 SWING indication is not displayed properly with monitoring function 1866
E-56 TRAVEL indication is not displayed properly with monitoring function .1867
E-57 Service is not displayed properly with monitoring function .1868
E-58 Attachment hydraulic circuit cannot be changed .1871
E-59 KOMTRAX system does not operate normally .1872
E-60 Control box shuts down after displaying the messages [GPS receiver not connected!] and [Slope sensor not connected!] .1874
E-61 Control box displays the message [GPS receiver not connected!] .1879
E-62 Control box displays the message [Waiting for radio link .] .1882
E-63 Control box displays the message [Tilt Bucket Sensor Offline!] .1883
E-64 Control box displays the message [Waiting for satellites .] .1884
E-65 Control box displays the message [Komatsu controller not connected!] .1885
E-66 Control box displays the message [Sensors are invalid] .1888
E-67 Control box displays the message [Waiting to initialize .] 1890
E-68 Control box displays the message [Initializing .] .1891
E-69 Control box displays the message [No GPS Localization .] 1892
E-70 Control box displays the message [Low precisions .] .1893
E-71 Control box displays [Out of design area .] .1894
E-72 Control box displays [Avoidance Area Breach] .1895
E-73 Control box can not be turned on .1896
E-74 Control box does not display intelligent Machine Control screen 1897
E-75 Control box does not display hydraulic excavator image .1898
E-76 Control box does not display design surface 1899
E-77 Control box touch panel does not respond .1900
E-78 Control box touch panel is inaccurate 1901
E-79 When checking and adjusting the bucket edge position, the value is different from actual machine .1902
E-80 When pressing auto/manual switch, Semi-auto limited digging mode is not displayed. .1904
E-81 Automatic leveling assist function does not work while Semi-auto limited digging mode is displayed .1905
E-82 Automatic stop control function does not work while Semi-auto limited digging mode is displayed 1906
E-83 Blade edge position on design surface is not accurate when automatic leveling assist function is on. .1907
E-84 Blade edge stop position is not accurate for design surface when automatic stop control function is on .1909
E-85 Opposite direction compass does not show the opposite direction 1911
E-86 NG occurs very often in IMU calibration diagnosis 1912
E- 87 Boom RAISE end cushion does not work at all or worksinsufficiently .1913
E-88 Arm IN end cushion does not work at all or works insufficiently .1914
Troubleshooting of hydraulic and mechanical system (H-mode) .1917
Information described in troubleshooting table (H-mode) .1917
System chart for hydraulic system .1918
Failure mode and cause table 1920
H-1 All of work equipment, swing and travel operation lacks speed or power 1928
H-2 Engine speed drops significantly or engine stalls .1931
H-3 All work equipment, swing and travel does not work 1934
H-4 Unusual sound is heard from around hydraulic pump .1935
H-5 Fine control performance or response is poor 1936
H-6 Boom speed or power is low 1938
H-7 Arm speed or power is low .1942
H-8 Bucket speed or power is low 1947
H-9 Work equipment does not move in single operation 1950
H-10 Hydraulic drift of boom is large .1951
H-11 Hydraulic drift of arm is large 1952
H-12 Hydraulic drift of bucket is large .1953
H-13 Time lag of work equipment is large 1954
H-14 When part of work equipment is relieved singly, other parts of work equipment move .1956
H-15 One-touch power maximizing function does not operate .1957
H-16 In combined operation of work equipment, equipment having heavier load moves slower 1958
H-17 In combined operations of swing and boom RAISE, boom rising speed is low .1959
H-18 In combined operations of swing and travel, travel speed drops largely .1960
H-19 Machine does not travel straight .1961
H-20 Travel speed is slow .1964
H-21 Machine is hard to steer or travel power is low 1966
H-22 Travel speed does not change, or travel speed is too slow or fast 1969
H-23 One of tracks does not run .1970
H-24 Upper structure does not swing to the right or left 1972
H-25 Upper structure swing only to the right or left 1973
H-26 Swing acceleration or swing speed is low in both directions (right and left) .1974
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction 1975
H-28 Upper structure overruns excessively when it stops swinging (both right and left) 1976
H-29 Upper structure overruns excessively when it stops swinging (either right or left) .1977
H-30 Shock is large when upper structure stops swinging .1978
H-31 Large unusual noise is heard when upper structure stops swinging .1979
H-32 Swing drift on a slope is large while swing holding brake is applied .1980
H-33 Swing drift on a slope is large while swing holding brake is released 1981
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed .1982
H-35 Oil flow in attachment circuit cannot be controlled 1983
H-36 All work equipment do not operate 1984
Troubleshooting of engine (S-mode) 1985
Information mentioned in troubleshooting table (S mode) .1985
S-1 When starting switch is turned to START position, engine does not crank .1986
S-2 Engine cranks but no exhaust smoke comes out 1987
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 1988
S-4 Engine startability is poor .1989
S-5 Engine does not pick up smoothly 1991
S-6 Engine stops during operation .1993
S-7 Engine runs rough or is unstable 1995
S-8 Engine lacks power 1996
S-9 Exhaust smoke is black (KDPF clogs up early) 1998
S-10 Engine oil consumption is excessive 2000
S-11 Engine oil becomes contaminated early 2001
S-12 Fuel consumption is excessive 2002
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .2003
S-14 Engine oil pressure drops 2004
S-15 Fuel is contaminated in engine oil .2005
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .2006
S-17 Coolant temperature rises too high (overheating) .2007
S-18 Unusual noise is heard .2008
S-19 Vibration is excessive .2009
S-20 Air cannot be bled from fuel circuit .2010
S-21 Active regeneration is executed frequently .2011
S-22 Active regeneration takes time .2012
S-23 White smoke is exhausted during active regeneration 2013
50 Disassembly and assembly .2015
Table of contents .2016
Related information on disassembly and assembly .2018
How to read this manual .2018
Coating materials list 2020
Special tools list 2024
Sketches of special tools .2029
Engine and cooling system .2033
Removal and installation of supply pump assembly 2033
Removal and installation of injector assembly .2038
Removal and installation of cylinder head assembly 2047
Removal and installation of radiator assembly .2067
Removal and installation of hydraulic oil cooler assembly .2069
Removal and installation of aftercooler assembly 2072
Removal and installation of engine and main pump assembly .2074
Removal and installation of engine front oil seal .2086
Removal and installation of engine rear oil seal 2090
Removal and installation of fuel cooler assembly 2093
Removal and installation of fuel tank assembly 2094
Removal and installation of engine hood assembly 2097
Removal and installation of KDPF assembly .2100
Disassembly and assembly of KDPF assembly .2108
Removal and installation of KCCV assembly .2116
Removal and installation of air cleaner assembly 2120
Power train .2123
Removal and installation of travel motor and final drive assembly .2123
Disassembly and assembly of final drive .2124
Removal and installation of swing motor and swing machinery assembly 2132
Disassembly and assembly of swing machinery .2135
Removal and installation of swing circle assembly .2142
Undercarriage and frame .2143
Separation and connection of track shoe assembly 2143
Removal and installation of sprocket 2146
Removal and installation of idler and idler cushion assembly 2147
Disassembly and assembly of idler assembly 2148
Disassembly and assembly of idler cushion .2151
Disassembly and assembly of track roller assembly .2153
Disassembly and assembly of carrier roller 2155
Removal and installation of revolving frame assembly 2158
Removal and installation of counterweight assembly 2160
Hydraulic system 2163
Removal and installation of center swivel joint assembly 2163
Disassembly and assembly of center swivel joint .2166
Removal and installation of hydraulic tank assembly .2167
Removal and installation of main pump assembly 2171
Removal and installation of control valve assembly 2175
Disassembly and assembly of control valve .2182
Removal and installation of junction block assembly for Intelligent Machine Control .2187
Removal and installation of pressure sensor for Intelligent Machine Control .2190
Removal and installation of boom spool stroke sensor 2192
Removal and installation of arm spool stroke sensor .2193
Disassembly and assembly of work equipment PPC valve 2194
Disassembly and assembly of travel PPC valve 2196
Work equipment 2199
Removal and installation of work equipment assembly .2199
Disassembly and assembly of work equipment cylinder assembly 2203
Cab and its attachments .2219
Removal and installation of operator’s cab assembly .2219
Removal and installation of operator cab glass (adhered glass) 2225
Removal and installation of front window assembly .2235
Removal and installation of floor frame assembly 2241
Removal and installation of air conditioner unit assembly .2247
Removal and installation of operator’s seat .2253
Removal and installation of seat belt .2256
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLEVER ASSEMBLY 2259
Removal and installation of front wiper assembly 2272
Electrical system .2279
Removal and installation of air conditioner compressor assembly .2279
Removal and installation of air conditioner condenser assembly 2282
Removal and installation of engine controller assembly 2284
Removal and installation of pump controller assembly 2286
Removal and installation of machine monitor assembly 2290
Removal and installation of pump swash plate sensor .2293
Removal and installation of mass air flow and temperature sensor 2294
Removal and installation of KOMTRAX terminal assembly .2295
Removal and installation of ICT sensor controller assembly 2297
Removal and installation of junction harness of control box .2299
Removal and installation of control box harness .2301
Removal and installation of work equipment controller assembly 2302
Removal and installation of GNSS receiver .2304
Removal and installation of radio device and site link 2306
Removal and installation of GNSS antenna 2308
Removal and installation of IMU sensor 2310
60 Maintenance standard .2311
Table of contents .2312
Engine and cooling system .2313
Engine mount 2313
Cooling system 2314
Power train .2315
Swing circle 2315
Swing machinery .2316
Final drive .2318
Sprocket 2320
Undercarriage and frame .2322
Track frame and idler cushion .2322
Idler .2324
Track roller 2326
Carrier roller 2327
Track shoe 2328
Hydraulic system 2334
Hydraulic tank 2334
Main pump .2335
Control valve .2336
Swing motor .2346
Travel motor 2348
Work equipment and swing PPC valve 2351
Travel PPC valve 2354
1st-line attachment PPC valve (with EPC valve) 2356
2nd-line attachment PPC valve .2359
Solenoid valve 2361
Attachment circuit selector valve (for high-pressure circuit) .2362
Attachment circuit selector valve (for low-pressure circuit) 2363
Center swivel joint .2364
Work equipment 2365
Work equipment 2365
Boom cylinder .2374
Stroke sensing boom cylinder 2375
Stroke sensing arm cylinder .2376
Stroke sensing bucket cylinder 2377
80 Appendix .2381
Table of contents .2382
Air conditioner components 2383
Precautions for refrigerant .2383
Air conditioner component .2384
Configuration and function of refrigeration cycle .2387
Outline of refrigeration cycle 2388
Air conditioner unit 2390
Dual pressure switch 2397
Air conditioner controller 2398
Compressor 2399
Air conditioner condenser .2400
Sunlight sensor .2402
Outer temperature sensor (outside air temperature sensor) .2403
Procedure for testing and troubleshooting .2404
Circuit diagram and arrangement of connector pins .2406
System diagram 2408
Input and output signals of the air conditioner controller 2409
Parts and connectors layout .2411
Testing air leakage (duct) 2415
Testing with self-diagnosis function 2419
Testing vent (mode) changeover 2422
Testing FRESH/RECIRC air changeover .2425
Testing sunlight sensor .2426
Testing (dual) pressure switch for refrigerant 2427
Testing relays 2428
Troubleshooting chart 1 .2429
Troubleshooting chart 2 .2430
Information in troubleshooting table 2433
Failure code list related to air conditioner 2434
Failure code [879AKA] A/C Inner Sensor Open Circuit .2435
Failure code [879AKB] A/C Inner Sensor Short Circuit 2436
Failure code [879BKA] A/C Outer sensor Open Circuit .2437
Failure code [879BKB] A/C Outer sensor Short Circuit 2439
Failure code [879CKA] Ventilating Sensor Open Circuit .2441
Failure code [879CKB] Ventilating Sensor Short Circuit 2442
Failure code [879DKZ] Sunlight sensor Open or Short Circuit .2443
Failure code [879EMC] Ventilation Damper Abnormality 2445
Failure code [879FMC] Air Mix Damper Abnormality 2446
Failure code [879GKX] Refrigerant Abnormality .2447
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 2448
A-2 Troubleshooting of compressor system (Air is not cooled) 2450
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 2453
A-4 Troubleshooting for FRESH/RECIRC air changeover .2455
Troubleshooting with gauge pressure .2457
Connection of service tool 2460
Precautions for disconnecting and connecting air conditioner piping .2462
Handling of compressor oil 2464
Desiccant replacement .2466
90 Diagrams and drawings 2469
Table of contents .2470
Hydraulic circuit diagram .2471
Symbols in hydraulic circuit diagram 2471
Hydraulic circuit diagram .2475
Electric circuit diagram 2479
Symbols in electric circuit diagram .2479
Electrical circuit diagram 2483
Electric circuit diagram of air conditioner unit 2505
INDEX 2507

DESCRIPTION:

Komatsu PC210i-10,PC210LCi-10 Hydraulic Excavator Shop Manual SEN06515-09  – PDF DOWNLOAD

• SERIAL NUMBERS 451080 and up

G.B 28/12/24