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KOMATSU PC210LCE-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06970-02 – PDF DOWNLOAD
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KOMATSU PC210LCE-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06970-02 – PDF DOWNLOAD
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KOMATSU PC210LCE-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06970-02 – PDF DOWNLOAD
Language : English
Pages : 1344
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC210LCE-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06970-02 – PDF DOWNLOAD
Cover................................................................................................................. 1 00 Index and Foreword............................................................................................ 3 Index........................................................................................................ 4 Abbreviation List............................................................................................ 10 Foreword, Safety, Basic Information.......................................................................... 13 How to Read the Shop Manual.............................................................................. 13 Safety Notice for Operation.............................................................................. 15 Precautions for Battery-Powered Hydraulic Excavator...................................................... 23 Precautions to Prevent Fire.............................................................................. 24 Procedures If Fire Occurs............................................................................ 24 Prevent Fire......................................................................................... 24 Precautions When You Discard Waste Materials............................................................. 28 Precautions When You Handle Hydraulic Equipment.......................................................... 29 Precautions When You Disconnect and Connect Pipings...................................................... 32 Precautions When You Handle Electrical Equipment......................................................... 38 Precautions for Maintenance of Power Electronics Components.............................................. 40 Handle Power Electronics Components...................................................................... 41 Precautions for Normal Inspection and Maintenance........................................................ 42 Precautions When Machine Falls over and Power Electronics Components Have Damage......................... 43 Precautions for Machine Not to be Put in Water........................................................... 44 Related Regulations...................................................................................... 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: PC210LCE-11................................................................... 83 Working Range Drawings................................................................................... 84 Working Range Drawings: PC210LCE-11.................................................................. 84 Specifications........................................................................................... 85 Specifications: PC210LCE-11.......................................................................... 85 Weight Table............................................................................................. 88 Weight Table: PC210LCE-11............................................................................ 88 Coolant, Lubricant....................................................................................... 90 How to Use Coolant and Lubricants by Ambient Temperature............................................. 90 10 Structure and Function........................................................................................ 93 Table of Contents............................................................................................ 94 Boot-up System............................................................................................... 98 Layout Drawing of Boot-up System......................................................................... 98 System Operating Lamp System............................................................................. 99 System Diagram of System Operating Lamp System....................................................... 99 Function of Operation Lamp System.................................................................... 99 Operation of System Operating Lamp System............................................................ 99 Auxiliary Battery Disconnect Switch...................................................................... 100 Function of Auxiliary Battery Disconnect Switch...................................................... 100 Function of Electric Motor Shutdown Secondary Switch..................................................... 101 Function of Electric Motor Shutdown Secondary Switch................................................. 101 Operation of Electric Motor Shutdown Secondary Switch................................................ 101 Electric Drive System........................................................................................ 102 Layout Drawing of Electric Drive System.................................................................. 102 System Diagram of Electric Drive System.................................................................. 103 Structure of Electric Drive System....................................................................... 104 Worker Protection System When You Disassemble Power Electronics Components............................... 105 Function of Worker Protection System When You Disassemble Power Electronics Components............... 105 High Voltage Wiring (Power Cable)........................................................................ 106 Layout Drawing of High Voltage Wiring (Power Cable).................................................. 106 Structure of High Voltage Wiring (Power Cable)....................................................... 106 Function of High Voltage Wiring (Power Cable)........................................................ 106 Component Parts of Electric Drive System................................................................. 107 Main Battery Assembly................................................................................ 107 BTMS (Battery Thermal Management System)............................................................. 109 Inverter............................................................................................. 111 DC-DC Converter...................................................................................... 113 HVJB (High Voltage Junction Box)..................................................................... 114 Power Distribution Unit.............................................................................. 116 Electric Motor....................................................................................... 119 Charging Port........................................................................................ 121 Electric Motor System........................................................................................ 123 Layout Drawing of Electric Motor System.................................................................. 123 Electric Motor Control System............................................................................ 124 System Diagram of Electric Motor Control System...................................................... 124 Operation of Electric Motor Control System........................................................... 124 Auto-Deceleration System................................................................................. 126 System Diagram of Auto-Deceleration System........................................................... 126 Function of Auto-Deceleration System................................................................. 126 Operation of Auto-Deceleration System................................................................ 127 Overheat Prevention System............................................................................... 128 Overheat Prevention System Diagram................................................................... 128 Function of Overheat Prevention System............................................................... 129 Component Parts of Electric Motor System................................................................. 131 Coupling............................................................................................. 131 Cooling System............................................................................................... 132 Layout Drawing of Cooling System......................................................................... 132 Specifications of Cooling System..................................................................... 134 Fan Speed Control System of Electric Fan................................................................. 135 Function of Fan Speed Control System of Electric Fan................................................. 135 Component Parts of Cooling System........................................................................ 136 Electric Fan......................................................................................... 136 Control System............................................................................................... 137 Layout Drawing of Control System......................................................................... 137 Machine Monitor System................................................................................... 138 System Diagram of Machine Monitor System............................................................. 138 Function of Machine Monitor System................................................................... 139 KomVision System......................................................................................... 140 Layout Drawing of KomVision System................................................................... 140 System Diagram of KomVision System................................................................... 142 Function of KomVision System......................................................................... 142 KOMTRAX System........................................................................................... 144 System Diagram of KOMTRAX System..................................................................... 144 Function of KOMTRAX System........................................................................... 144 Component Parts of Control System........................................................................ 145 Machine Monitor...................................................................................... 145 KomVision Controller................................................................................. 160 KomVision Camera..................................................................................... 164 Gateway Function Controller.......................................................................... 165 Communication Terminal............................................................................... 168 Pump Controller...................................................................................... 169 Resistor for PC-EPC Valve............................................................................ 173 CAN Terminating Resistor............................................................................. 173 Power Management Controller.......................................................................... 174 Battery Integration Controller....................................................................... 178 Telemetry (Battery Information Communication Terminal)............................................... 182 Electric Fan Controller.............................................................................. 183 Motor Speed Adjustment Dial.......................................................................... 185 Quick Coupler Low Pressure Alarm Switch.............................................................. 187 Hydraulic System............................................................................................. 188 Layout Drawing of Hydraulic System....................................................................... 188 CLSS..................................................................................................... 192 Structure of CLSS.................................................................................... 192 Operation of Unload Valve and LS Pressure............................................................ 194 Pump Swash Plate Angle (Oil Flow) Control............................................................ 195 Pressure Compensation Control........................................................................ 211 Electric Motor and Pump Combined Control System.......................................................... 214 System Diagram of Electric Motor and Pump Combined Control System.................................... 214 Function of Electric Motor and Pump Combined Control System.......................................... 215 Pump and Valve Control System............................................................................ 220 Pump and Valve Control System Diagram................................................................ 220 Function of Pump and Valve Control System............................................................ 221 Component Parts of Hydraulic System...................................................................... 223 Hydraulic Tank....................................................................................... 223 Main Pump............................................................................................ 225 Control Valve........................................................................................ 251 Work Equipment System........................................................................................ 311 Layout Drawing of Work Equipment System.................................................................. 311 Structure of Valve Control............................................................................... 316 One-Touch Power Maximizing System........................................................................ 318 System Diagram of One-Touch Power Maximizing System.................................................. 318 Function of One-Touch Power Maximizing System........................................................ 319 PPC Lock System.......................................................................................... 320 System Diagram of PPC Lock........................................................................... 320 Function of PPC Lock System.......................................................................... 320 Work Equipment and Travel Automatic Lock System.......................................................... 321 System Diagram of Lock Lever Automatic Lock System................................................... 321 Function of Work Equipment and Travel Automatic Lock System.......................................... 321 Operation of Lock Lever Automatic Lock System........................................................ 322 Attachment Oil Flow Adjuster System...................................................................... 323 Attachment Oil Flow Adjuster System Diagram.......................................................... 323 Function of Attachment Oil Flow Adjuster System...................................................... 324 Bucket DUMP Control Lock System.......................................................................... 325 Bucket DUMP Control Lock System Diagram.............................................................. 325 Function of Bucket DUMP Control Lock System.......................................................... 325 Tool Control System...................................................................................... 326 Tool Control System Diagram.......................................................................... 326 Component Parts of Work Equipment System................................................................. 328 Work Equipment and Swing PPC Valve................................................................... 328 1st-Line Attachment PPC Valve (with EPC Valve)....................................................... 335 2nd-Line Attachment PPC Valve........................................................................ 343 Solenoid Valve....................................................................................... 345 Bucket DUMP Control Lock Solenoid Valve.............................................................. 349 Boom Anti-drop Valve................................................................................. 351 Arm Anti-Drop Valve.................................................................................. 356 Attachment Circuit Selector Valve (For High Pressure)................................................ 361 Attachment Circuit Selector Valve (For Low Pressure)................................................. 363 1st-Line Attachment Variable Relief Valve............................................................ 365 Attachment Bypass Solenoid Valve..................................................................... 368 Pilot Circuit Accumulator............................................................................ 370 Attachment Circuit Accumulator....................................................................... 371 Swing System................................................................................................. 372 Layout Drawing of Swing System........................................................................... 372 Swing Control System Diagram............................................................................. 376 Function of Swing Control System..................................................................... 376 Component Parts of Swing System.......................................................................... 380 Swing Motor.......................................................................................... 380 Swing Machinery...................................................................................... 392 Swing Circle......................................................................................... 394 Travel System................................................................................................ 395 Layout Drawing of Travel System.......................................................................... 395 System Diagram of Travel Control System.................................................................. 399 Function of Travel Control System.................................................................... 399 Component Parts of Travel System......................................................................... 401 Travel Motor......................................................................................... 401 Final Drive.......................................................................................... 415 Travel PPC Valve..................................................................................... 417 Center Swivel Joint.................................................................................. 421 Undercarriage and Frame...................................................................................... 423 Layout Drawing of Undercarriage.......................................................................... 423 Specifications of Undercarriage...................................................................... 424 Work Equipment............................................................................................... 425 Structure of Work Equipment.............................................................................. 425 Function of Work Equipment............................................................................... 425 Work Equipment Clearance Adjustment Shim................................................................. 426 Function of Work Equipment Clearance Adjustment Shim................................................. 426 Bucket Clearance Adjustment Shim......................................................................... 426 Function of Bucket Clearance Adjustment Shim......................................................... 426 CAB Related Parts............................................................................................ 427 ROPS CAB................................................................................................. 427 Structure of ROPS CAB................................................................................ 427 Function of ROPS CAB................................................................................. 427 CAB Mount................................................................................................ 428 Structure of CAB Mount............................................................................... 428 Function of CAB Mount................................................................................ 428 CAB Tipping Stopper...................................................................................... 429 Structure of CAB Tipping Stopper..................................................................... 429 Function of CAB Tipping Stopper...................................................................... 429 Quick Coupler System......................................................................................... 430 Structure of Hydraulic Slider Type Quick Coupler Assembly................................................ 430 Operation of Hydraulic Slider Type Quick Coupler Assembly (Unlock)....................................... 432 Operation of Hydraulic Slider Type Quick Coupler Assembly (Lock)......................................... 432 Structure of Hydraulic Full-Automatic Type Quick Coupler................................................. 433 Operation of Hydraulic Full-Automatic Type Quick Coupler (Unlock)........................................ 434 Operation of Hydraulic Full-Automatic Type Quick Coupler (Lock).......................................... 434 20 Standard Value Table.......................................................................................... 435 Table of Contents............................................................................................ 436 Standard Value Table for Electric Motor...................................................................... 437 Standard Value Table for Electric Motor: PC210LCE-11..................................................... 437 Standard Value Table for Machine............................................................................. 438 Standard Value Table for Machine: PC210LCE-11............................................................ 438 Machine Posture and Procedures to Measure Performance.................................................... 449 30 Testing and Adjusting......................................................................................... 453 Table of Contents............................................................................................ 454 Precautions Before Work...................................................................................... 457 Related Information on Testing and Adjusting................................................................. 458 Tools for Testing and Adjusting.......................................................................... 458 Sketch of Tools for Testing and Adjusting................................................................ 464 Motor and Cooling System..................................................................................... 465 Examine Electric Motor Speed............................................................................. 465 How to Examine Electric Motor High Idle Speed........................................................ 465 How to Examine Electric Motor Low Idle Speed......................................................... 465 How to Examine Electric Motor Speed at 2 Pump Relief................................................. 465 How to Examine Electric Motor Speed at 2 Pump Relief and One-Touch Power Maximizing.................. 466 How to Examine Electric Motor Speed with Auto-Deceleration........................................... 466 Examine Air Conditioner Compressor Belt Tension.......................................................... 468 How to Examine Air Conditioner Compressor Belt....................................................... 468 Examine Automatic Tensioner.............................................................................. 469 How to Examine Automatic Tensioner................................................................... 469 Electric Drive System........................................................................................ 470 Precautions for Electric Drive System.................................................................... 470 Examine Tightening Torque of Electric Motor High Voltage Wiring Terminal................................. 471 How to Examine Tightening Torque of Electric Motor High Voltage Wiring Terminal...................... 471 Replace Desiccant for Main Battery....................................................................... 473 How to Replace Desiccant for Main Battery............................................................ 473 Examine Water Level of Hot Water Heater and Add Water.................................................... 476 How to Examine Water Level of Hot Water Heater and Add Water......................................... 476 Power Train.................................................................................................. 477 Examine Swing Circle Bearing Clearance................................................................... 477 How to Examine Swing Circle Bearing Clearance........................................................ 477 Undercarriage and Frame...................................................................................... 478 Examine and Adjust Track Tension......................................................................... 478 How to Examine Track Tension......................................................................... 478 How to Adjust Track Tension.......................................................................... 478 Hydraulic System............................................................................................. 480 Release Remained Pressure in Hydraulic Circuit........................................................... 480 How to Release Remained Pressure from Hydraulic Tank................................................. 480 How to Release Remained Pressure in Hydraulic Cylinder Circuit....................................... 480 How to Release Remained Pressure from Swing Motor Circuit............................................ 485 How to Release Remained Pressure from Travel Motor Circuit........................................... 485 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits............................ 487 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits............................ 488 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits............................. 494 Examine Oil Pressure of Control Circuit.................................................................. 497 How to Examine Oil Pressure in Control Circuit....................................................... 497 Examine and Adjust Oil Pressure in Pump PC Control Circuit............................................... 499 Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)....................................... 499 Examine PC-EPC Valve Outlet Pressure................................................................. 500 How to Adjust Oil Pressure in Pump PC Control Circuit................................................ 501 Examine and Adjust Oil Pressure in Pump LS Control Circuit............................................... 503 Examine LS Differential Pressure with Machine Monitor................................................ 503 How to Examine LS Differential Pressure by Testing Tool.............................................. 504 How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure)................................ 507 How to Examine LS-EPC Valve Outlet Pressure.......................................................... 508 How to Adjust LS Valve............................................................................... 509 Examine Outlet Pressure of Solenoid Valve................................................................ 510 How to Examine Outlet Pressure of Solenoid Valve..................................................... 510 Operating Condition of Solenoid Valve................................................................ 511 Examine PPC Valve Outlet Pressure........................................................................ 514 How to Examine PPC Valve Outlet Pressure............................................................. 514 Examine Attachment Circuit Oil Pressure.................................................................. 516 How to Examine Attachment Circuit Oil Pressure....................................................... 516 Adjust Play of Work Equipment and Swing PPC Valves....................................................... 517 How to Adjust Play of Work Equipment and Swing PPC Valves............................................ 517 Examine Pump Swash Plate Sensor.......................................................................... 518 How to Examine Pump Swash Plate Sensor............................................................... 518 Examine Parts Which Cause Hydraulic Drift of Work Equipment.............................................. 519 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder................ 519 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder................................. 519 How to Examine Parts that Cause Hydraulic Drift of PPC Valve......................................... 520 Examine Oil Leakage...................................................................................... 521 How to Examine Oil Leakage from Boom Cylinder........................................................ 521 How to Examine Oil Leakage from Arm Cylinder......................................................... 521 How to Examine Oil Leakage from Bucket Cylinder...................................................... 522 How to Examine Oil Leakage from Swing Motor.......................................................... 523 How to Examine Oil Leakage from Travel Motor......................................................... 523 Bleed Air from Hydraulic System.......................................................................... 525 How to Bleed Air from Hydraulic System............................................................... 526 Examine Oil Pressure of Pressure Reducing Valve.......................................................... 528 How to Examine Pressure Reducing Valve Oil Pressure.................................................. 529 Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side).... 532 How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side).... 532 Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)................. 536 How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)................. 536 Replace Accumulator Bladder on High Pressure Side for Attachment Piping.................................. 540 How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping....................... 540 Work Equipment............................................................................................... 547 Examine Oil Pressure Auto Coupler........................................................................ 547 Examine Guide Plate for Damage....................................................................... 547 Examine Clearance Between Locking Pin and Bushing.................................................... 547 How to Examine Lubrication and Antirust Application in Housing....................................... 547 Examine Tightness of Linkage......................................................................... 548 Replace S-Block Valve.................................................................................... 550 How to Replace S-Block Valve......................................................................... 550 How to Replace S-Block Valve O-Ring (Outer).......................................................... 551 How to Replace S-Block Valve O-Ring (Contact Surface)................................................ 552 Replace A-Block Valve.................................................................................... 554 How to Replace A-Block Valve......................................................................... 554 How to Replace A-Block Valve O-Ring (Outer).......................................................... 555 How to Replace A-Block Valve O-Ring (Inner).......................................................... 555 Replace Buffer Element and Socket........................................................................ 558 How to Replace Buffer Element and Socket............................................................. 558 CAB Related Parts............................................................................................ 560 Examine CAB Tipping Stopper.............................................................................. 560 How to Examine Cab Tipping Stopper................................................................... 560 How to Adjust Mirrors.................................................................................... 561 Procedure to Adjust Left Front Mirror (A)............................................................ 562 Procedure to Adjust Regular Position of Machine Left Front Mirror (A)................................ 563 Procedure to Adjust Right Front Mirror (B)........................................................... 565 Procedure to Adjust Regular Position of Machine Right Front Mirror (B)............................... 565 Procedure to Adjust Right Front Mirror (C)........................................................... 568 Electrical System............................................................................................ 569 Set and Operate Machine Monitor.......................................................................... 569 Operator Mode........................................................................................ 573 Function to Show Technician Identification Status Screen............................................. 573 Function to Show Operator Identification Input Screen................................................ 573 Examine Function by LCD (Liquid Crystal Display)..................................................... 574 Examine Function of Service Meter.................................................................... 574 Usage Limitation and Maintenance Password Change Function............................................ 574 Service Mode......................................................................................... 577 How to Operate Service Mode.......................................................................... 577 How to See Pre-defined Monitoring Information........................................................ 579 How to Examine Monitoring Information................................................................ 584 Abnormality Record Menu.............................................................................. 595 How to See Maintenance Record........................................................................ 599 Maintenance Mode Setting............................................................................. 600 How to Set Phone Number Entry........................................................................ 604 Default Setting Menu................................................................................. 606 Testing Menu......................................................................................... 618 Adjustment Menu...................................................................................... 619 KOMTRAX Settings Menu................................................................................ 650 How to Show Service Message.......................................................................... 652 Start Up KOMTRAX System.................................................................................. 654 Stop Use of KOMTRAX System............................................................................... 660 Adjust KomVision Camera Angle............................................................................ 662 How to Adjust KomVision Camera Angle................................................................. 663 Adjust KomVision Related Function........................................................................ 666 Setting of KomVision (Main Setting).................................................................. 667 Setting of KomVision (Camera Setting)................................................................ 669 Setting of KomVision (Camera Calibration)............................................................ 671 KomVision Screen - 12m Visibility Check.............................................................. 684 Set Region of Bluetooth(R) Compatible Radio.............................................................. 687 How to Set Region of Bluetooth(R) Compatible Radio................................................... 687 Handle MSD of High Voltage Junction Box.................................................................. 689 Handle MSD of Main Battery............................................................................... 690 Handle Voltage Circuit of Power Management Controller.................................................... 691 Handle Auxiliary Battery Disconnect Switch............................................................... 692 Examine Diodes........................................................................................... 693 How to Examine Diodes by Digital Tester.............................................................. 693 How to Examine Diodes by Analog Tester............................................................... 693 Pm Clinic.................................................................................................... 694 Pm Clinic Service........................................................................................ 694 Pm Clinic Check Sheet: PC210LCE-11................................................................... 696 40 Troubleshooting............................................................................................... 705 Table of Contents............................................................................................ 706 Precautions Before Work...................................................................................... 707 Related Information to Troubleshooting....................................................................... 708 Failure Code Table....................................................................................... 708 50 Disassembly and Assembly...................................................................................... 737 Table of Contents............................................................................................ 738 Precautions Before Work...................................................................................... 742 Related Information on Disassembly and Assembly.............................................................. 743 How to Read This Manual.................................................................................. 743 Coating Materials List................................................................................... 745 Special Tool List........................................................................................ 750 Sketches of Special Tools................................................................................ 760 Prepare...................................................................................................... 765 Drain and Add Coolant.................................................................................... 765 How to Drain Coolant................................................................................. 765 How to Add Coolant................................................................................... 768 Drain and Add Hydraulic Oil.............................................................................. 770 How to Drain Hydraulic Oil........................................................................... 770 How to Add Hydraulic Oil............................................................................. 771 Collect and Refill Refrigerant........................................................................... 772 How to Collect Refrigerant........................................................................... 772 How to Refill Refrigerant............................................................................ 772 Motor and Cooling System..................................................................................... 774 Remove and Install Air Conditioner Compressor Belt....................................................... 774 How to Remove Air Conditioner Compressor Belt........................................................ 774 How to Install Air Conditioner Compressor Belt....................................................... 775 Remove and Install Radiator Assembly..................................................................... 778 How to Remove Radiator Assembly...................................................................... 778 How to Install Radiator Assembly..................................................................... 784 Remove and Install Hydraulic Oil Cooler Assembly......................................................... 790 How to Remove Hydraulic Oil Cooler Assembly.......................................................... 790 How to Install Hydraulic Oil Cooler Assembly......................................................... 793 Remove and Install Electric Fan Assembly................................................................. 796 How to Remove Electric Fan Assembly.................................................................. 796 How to Install Electric Fan Assembly................................................................. 797 Remove and Install Electric Motor and Main Pump Assembly................................................. 799 How to Remove Electric Motor and Main Pump Assembly.................................................. 799 How to Install Electric Motor and Main Pump Assembly................................................. 811 Remove and Install Hood Assembly......................................................................... 823 How to Remove Hood Assembly.......................................................................... 823 How to Install Hood Assembly......................................................................... 825 Remove and Install Air Conditioner Compressor Assembly................................................... 828 How to Remove Air Conditioner Compressor Assembly.................................................... 828 How to Install Air Conditioner Compressor Assembly................................................... 829 Remove and Install Air Conditioner Condenser Assembly.................................................... 832 How to Remove Air Conditioner Condenser Assembly..................................................... 832 How to Install Air Conditioner Condenser Assembly.................................................... 833 Power Train.................................................................................................. 835 Remove and Install Travel Motor and Final Drive Assembly................................................. 835 How to Remove Travel Motor and Final Drive Assembly.................................................. 835 Install Travel Motor and Final Drive Assembly........................................................ 836 Disassemble and Assemble Final Drive Assembly............................................................ 837 How to Disassemble Final Drive Assembly.............................................................. 837 How to Assemble Final Drive Assembly................................................................. 841 Remove and Install Swing Motor and Swing Machinery Assembly.............................................. 850 Remove Swing Motor and Swing Machinery Assembly...................................................... 850 How to Install Swing Motor and Swing Machinery Assembly.............................................. 852 Disassemble and Assemble Swing Machinery Assembly........................................................ 855 How to Disassemble Swing Machinery Assembly.......................................................... 855 How to Assemble Swing Machinery Assembly............................................................. 859 Undercarriage and Frame...................................................................................... 866 Separate and Connect Track Assembly...................................................................... 866 How to Separate Track Assembly....................................................................... 866 How to Install Track Assembly........................................................................ 868 Remove and Install Sprocket.............................................................................. 871 How to Remove Sprocket............................................................................... 871 How to Install Sprocket.............................................................................. 871 Remove and Install Idler and Idler Cushion Assembly...................................................... 873 How to Remove Idler and Idler Cushion Assembly....................................................... 873 How to Install Idler and Idler Cushion Assembly...................................................... 874 Disassemble and Assemble Idler Assembly.................................................................. 875 How to Disassemble Idler Assembly.................................................................... 875 How to Assemble Idler Assembly....................................................................... 876 Disassemble and Assemble Idler Cushion Assembly.......................................................... 880 How to Disassemble Idler Cushion Assembly............................................................ 881 How to Assemble Idler Cushion Assembly............................................................... 881 Disassemble and Assemble Track Roller Assembly........................................................... 883 How to Disassemble Track Roller Assembly............................................................. 883 How to Assemble Track Roller Assembly................................................................ 884 Disassemble and Assemble Carrier Roller Assembly......................................................... 886 How to Disassemble Carrier Roller Assembly........................................................... 886 How to Assemble Carrier Roller Assembly.............................................................. 887 Remove and Install Counterweight Assembly................................................................ 890 How to Remove Counterweight Assembly................................................................. 890 How to Install Counterweight Assembly................................................................ 894 Hydraulic System............................................................................................. 898 Remove and Install Center Swivel Joint Assembly.......................................................... 898 How to Remove Center Swivel Joint Assembly........................................................... 898 Install Center Swivel Joint Assembly................................................................. 900 Disassemble and Assemble Center Swivel Joint Assembly.................................................... 903 How to Disassemble Center Swivel Joint Assembly...................................................... 903 How to Assemble Center Swivel Joint Assembly......................................................... 904 Remove and Install Hydraulic Tank Assembly............................................................... 906 How to Remove Hydraulic Tank Assembly................................................................ 906 How to Install Hydraulic Tank Assembly............................................................... 913 Remove and Install Main Pump Assembly.................................................................... 920 How to Remove Main Pump Assembly..................................................................... 920 How to Install Main Pump Assembly.................................................................... 930 Remove and Install Control Valve Assembly................................................................ 939 How to Remove Control Valve Assembly................................................................. 939 How to Install Control Valve Assembly................................................................ 944 Disassemble and Assemble Control Valve Assembly.......................................................... 950 How to Replace Pressure Compensation Valve Seal Ring................................................. 950 How to Assemble Control Valve Assembly............................................................... 951 Disassemble and Assemble Work Equipment PPC Valve Assembly............................................... 955 How to Disassemble Work Equipment PPC Valve Assembly................................................. 955 How to Assemble Work Equipment PPC Valve Assembly.................................................... 955 Disassemble and Assemble Travel PPC Valve Assembly....................................................... 957 How to Disassemble Travel PPC Valve Assembly......................................................... 957 How to Assemble Travel PPC Valve Assembly............................................................ 958 Work Equipment............................................................................................... 960 Remove and Install Work Equipment Assembly............................................................... 960 How to Remove Work Equipment Assembly................................................................ 960 How to Install Work Equipment Assembly............................................................... 963 Remove and Install Boom Anti-Drop Valve Assembly......................................................... 967 Remove Boom Anti-drop Valve Assembly................................................................. 967 Install Boom Anti-drop Valve Assembly................................................................ 969 Remove and Install Arm Anti-Drop Valve Assembly.......................................................... 970 Remove Arm Anti-Drop Valve Assembly.................................................................. 970 Install Arm Anti-Drop Valve Assembly................................................................. 972 Disassemble and Assemble Anti-Drop Valve Assembly........................................................ 973 How to Disassemble Anti-Drop Valve Assembly.......................................................... 973 How to Assemble Anti-Drop Valve Assembly............................................................. 973 Disassemble and Assemble Work Equipment Cylinder Assembly................................................ 974 How to Disassemble Work Equipment Cylinder Assembly.................................................. 974 How to Assemble Work Equipment Cylinder Assembly..................................................... 977 Remove and Install Hydraulic Full Automatic Type Quick Coupler Assembly.................................. 983 How to Remove Hydraulic Full Automatic Type Quick Coupler Assembly................................... 983 How to Install Hydraulic Full Automatic Type Quick Coupler Assembly.................................. 984 Disassemble and Assemble Hydraulic Full Automatic Type Quick Coupler Assembly............................ 988 How to Disassemble Hydraulic Full Automatic Type Quick Coupler Assembly.............................. 988 How to Assemble Hydraulic Full Automatic Type Quick Coupler Assembly................................. 998 Remove and Install Hydraulic Slider Type Quick Coupler Assembly..........................................1008 How to Remove Hydraulic Slider Type Quick Coupler Assembly...........................................1008 How to Install Hydraulic Slider Type Quick Coupler Assembly..........................................1009 Disassemble and Assemble Hydraulic Slider Type Quick Coupler Assembly....................................1011 How to Disassemble Hydraulic Slider Type Quick Coupler Assembly......................................1011 How to Assemble Hydraulic Slider Type Quick Coupler Assembly.........................................1014 Disassemble and Assemble Arm Crane Hook Storage Pin for Quick Coupler....................................1016 How to Disassemble Arm Crane Hook Storage Pin for Quick Coupler......................................1016 How to Assemble Arm Crane Hook Storage Pin for Quick Coupler.........................................1017 Disassemble and Assemble Arm Crane Hook Storage Pin......................................................1019 How to Disassemble Arm Crane Hook Storage Pin........................................................1019 How to Assemble Arm Crane Hook Storage Pin...........................................................1020 Emergently Remove Hydraulic Slider Type Quick Coupler Attachment.........................................1021 How to Emergently Remove Hydraulic Slider Type Quick Coupler Attachment..............................1022 CAB Related Parts............................................................................................1024 Remove and Install Operator Cab Assembly.................................................................1024 How to Remove Operator Cab Assembly..................................................................1024 How to Install Operator Cab Assembly.................................................................1032 Remove and Install Operator Cab Glass (Adhered Glass)....................................................1041 How to Remove Operator Cab Glass (Adhered Glass).....................................................1043 How to Install Operator Cab Glass (Adhered Glass)....................................................1043 Remove and Install Front Window Assembly.................................................................1053 How to Remove Front Window Assembly..................................................................1053 How to Install Front Window Assembly.................................................................1056 Remove and Install Floor Frame Assembly..................................................................1062 How to Remove Floor Frame Assembly...................................................................1062 How to Install Floor Frame Assembly..................................................................1068 Remove and Install Air Conditioner Unit Assembly.........................................................1076 How to Remove Air Conditioner Unit Assembly..........................................................1076 How to Install Air Conditioner Unit Assembly.........................................................1083 Remove and Install Hot Water Heater Assembly.............................................................1092 How to Remove Hot Water Heater Assembly..............................................................1092 How to Install Hot Water Heater Assembly.............................................................1094 Remove and Install Operator Seat.........................................................................1096 How to Remove Operator Seat..........................................................................1096 How to Install Operator Seat.........................................................................1098 How to Remove and Install Seat Belt......................................................................1101 How to Remove Seat Belt..............................................................................1101 How to Install Seatbelt..............................................................................1101 Remove and Install Work Equipment Control Lever Assembly.................................................1103 How to Remove Work Equipment Control Lever Assembly..................................................1103 How to Install Work Equipment Control Lever Assembly.................................................1109 Remove and Install Front Wiper Assembly..................................................................1117 How to Remove Front Wiper Assembly...................................................................1117 How to Install Front Wiper Assembly..................................................................1122 Electrical System............................................................................................1131 Remove and Install Electric Motor Assembly...............................................................1131 How to Remove Electric Motor Assembly................................................................1131 How to Install Electric Motor Assembly...............................................................1132 Remove and Install Inverter..............................................................................1133 How to Remove Inverter...............................................................................1133 How to Install Inverter..............................................................................1135 Remove and Install Power Management Controller Assembly..................................................1138 How to Remove Power Management Controller Assembly...................................................1138 How to Install Power Management Controller Assembly..................................................1140 Remove and Install Pump Controller Assembly..............................................................1143 How to Remove Pump Controller Assembly...............................................................1143 How to Install Pump Controller Assembly..............................................................1150 Remove and Install KomVision Controller Assembly.........................................................1158 How to Remove KomVision Controller Assembly..........................................................1158 How to Install KomVision Controller Assembly.........................................................1159 Remove and Install Machine Monitor Assembly..............................................................1160 How to Remove Machine Monitor Assembly...............................................................1160 How to Install Machine Monitor Assembly..............................................................1163 Remove and Install Pump Swash Plate Sensor...............................................................1166 How to Remove Pump Swash Plate Sensor................................................................1166 How to Install Pump Swash Plate Sensor...............................................................1167 Remove and Install KomVision Camera......................................................................1168 How to Remove KomVision Camera.......................................................................1168 How to Install KomVision Camera......................................................................1169 Remove and Install Gateway Function Controller Assembly..................................................1171 How to Remove Gateway Function Controller Assembly...................................................1171 How to Install Gateway Function Controller Assembly..................................................1178 Remove and Install Communication Terminal Wiring Harness.................................................1186 How to Remove Communication Terminal Wiring Harness..................................................1186 How to Install Communication Terminal Wiring Harness.................................................1193 Remove and Install Communication Terminal................................................................1202 How to Remove Communication Terminal.................................................................1202 How to Install Communication Terminal................................................................1204 Remove and Install Main Battery Service Plug.............................................................1206 How to Remove Main Battery Service Plug..............................................................1206 How to Install Main Battery Service Plug.............................................................1206 60 Maintenance Standard..........................................................................................1209 Table of Contents............................................................................................1210 Electric Motor and Cooling System............................................................................1211 Maintenance Standard for Electric Motor..................................................................1211 Maintenance Standard for Electric Motor Terminal.........................................................1212 Maintenance Standard for Cooling System..................................................................1214 Maintenance Standard for Main Battery....................................................................1215 Maintenance Standard for BTMS............................................................................1216 Power Train..................................................................................................1217 Maintenance Standard for Swing Circle....................................................................1217 Maintenance Standard for Swing Machinery.................................................................1218 Maintenance Standard for Final Drive.....................................................................1220 Maintenance Standard for Sprocket........................................................................1222 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing.......................................1223 Undercarriage and Frame......................................................................................1224 Maintenance Standard for Track Frame and Idler Cushion...................................................1224 Maintenance Standard for Idler...........................................................................1226 Maintenance Standard for Track Roller....................................................................1228 Maintenance Standard for Carrier Roller..................................................................1229 Maintenance Standard for Track Shoes.....................................................................1230 Maintenance Standard for Triple Shoes....................................................................1233 Maintenance Standard for Swamp Shoes.....................................................................1234 Maintenance Standard for Road Liner......................................................................1235 Hydraulic System.............................................................................................1236 Maintenance Standard for Hydraulic Tank..................................................................1236 Maintenance Standard for Main Pump.......................................................................1237 Maintenance Standard for LS-EPC Valve....................................................................1238 Maintenance Standard for PC-EPC Valve....................................................................1239 Maintenance Standard for Swing Motor.....................................................................1240 Maintenance Standard for Travel Motor....................................................................1243 Maintenance Standard for Control Valve...................................................................1246 Maintenance Standard for Boom Anti-Drop Valve............................................................1256 Maintenance Standard for Arm Anti-Drop Valve.............................................................1258 Maintenance Standard for Work Equipment and Swing PPC Valve..............................................1260 Maintenance Standard for Travel PPC Valve................................................................1263 Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)..................................1266 Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve..................................1267 Maintenance Standard for 2nd-Line Attachment PPC Valve...................................................1269 Maintenance Standard for Solenoid Valve..................................................................1271 Maintenance Standard for Bucket DUMP Operation Lock Solenoid Valve.......................................1272 Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)...........................1273 Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)............................1274 Maintenance Standard for Center Swivel Joint.............................................................1275 Work Equipment...............................................................................................1276 Maintenance Standard for Work Equipment Linkage..........................................................1276 Dimensions of Arm....................................................................................1281 Dimensions of Bucket.................................................................................1283 Maintenance Standard for Boom Cylinder...................................................................1285 Maintenance Standard for Arm Cylinder....................................................................1286 Maintenance Standard for Bucket Cylinder.................................................................1287 90 Circuit Diagrams..............................................................................................1289 Table of Contents............................................................................................1290 How to Read the Codes for Electric Cable.....................................................................1291 Hydraulic Circuit Diagram....................................................................................1295 Symbols Used in Hydraulic Circuit Diagram................................................................1295 Hydraulic Circuit Diagram (1/2)..........................................................................1299 Hydraulic Circuit Diagram (2/2)..........................................................................1301 Electrical Circuit Diagram...................................................................................1303 Symbols Used in Electric Circuit Diagram.................................................................1303 Electrical Circuit Diagram (1/12)........................................................................1307 Electrical Circuit Diagram (2/12)........................................................................1309 Electrical Circuit Diagram (3/12)........................................................................1311 Electrical Circuit Diagram (4/12)........................................................................1313 Electrical Circuit Diagram (5/12)........................................................................1315 Electrical Circuit Diagram (6/12)........................................................................1317 Electrical Circuit Diagram (7/12)........................................................................1319 Electrical Circuit Diagram (8/12)........................................................................1321 Electrical Circuit Diagram (9/12)........................................................................1323 Electrical Circuit Diagram (10/12).......................................................................1325 Electrical Circuit Diagram (11/12).......................................................................1327 Electrical Circuit Diagram (12/12).......................................................................1329 Index.............................................................................................................1331
DESCRIPTION:
KOMATSU PC210LCE-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06970-02 – 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
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