Komatsu PC210-10M0 PC210LC-10M0 PC225LC-10M0 Shop Manual SEN06701-CA

Data Size: 131.55 MB
File Type: PDF
Language: English
Manufacturer: Komatsu
Applicable Machine: Hydraulic Excavator
Document: Shop Manual, Error Code, Electrical Schematic, Hydraulic Schematic
Machine Model: Komatsu PC210-10M0 (C00001 and up), PC210LC-10M0 (C00001 and up), PC225LC-10M0 (C90001 and up)
Book Number: SEN06701-CA
Page: 2498 Pages

List Contents:

00 Index and Foreword
Abbreviation List
Foreword, Safety, Basic Information
How to Read the Shop Manual
Safety Notice for Operation
Precautions to Prevent Fire
Procedures If Fire Occurs
Precautions When You Dispose of Waste Materials
Precautions When You Handle Hydraulic Equipment
Precautions When You Disconnect and Connect Pipings
Precautions When You Handle Electrical Equipment
Precautions When You Handle Fuel System Equipment
Precautions When You Handle Intake System Equipment
Practical Use of KOMTRAX
Disconnect and Connect Push-Pull Type Coupler
Precautions for Disconnection and Connection of Connectors
How to Disconnect and Connect Deutsch Connector
How to Disconnect and Connect Slide Lock Type Connector
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Housing to Rotate
How to Read the Codes for Electric Cable
Explanation of Terms for Maintenance Standard
Standard Tightening Torque Table
Conversion Table
01 Specifications
Table of Contents
Specifications
Specification Drawing
Working Range Drawings
Specifications
Weight Table
Fuel, Coolant and Lubricant to Meet Ambient Temperature
10 Structure and Function
Table of Contents
Boot-up System
Layout Drawing of Boot-up System
System Operating Lamp System
Battery Disconnect Switch
Engine System
Layout Drawing of Engine System
Engine Control System
Auto-Deceleration System
Engine Automatic Warm-up System
Overheat Prevention System
Turbocharger Protection System
Cooling System
Layout Drawing of Cooling System
Control System
Layout Drawing of Control System
Machine Monitor System
KOMTRAX System
Component Parts of Control System
Hydraulic System
Layout Drawing of Hydraulic System
CLSS
Engine and Pump Combined Control System
Pump and Valve Control System
Component Parts of Hydraulic System
Work Equipment System
Layout Drawing of Work Equipment System
One-Touch Power Maximizing System
PPC Lock System
Attachment Oil Flow Adjuster System
Component Parts of Work Equipment System
Swing System
Layout Drawing of Swing System
Swing Control System Diagram
Component Parts of Swing System
Travel System
Layout Drawing of Travel System
System Diagram of Travel Control System
Function of Travel Control System
Component Parts of Travel System
Function of Swing Circle
Undercarriage and Frame
Layout Drawing of Undercarriage
Work Equipment
Structure of Work Equipment
Work Equipment Clearance Adjustment Shim
Bucket Clearance Adjustment Shim
CAB Related Parts
ROPS CAB
CAB Mount
CAB Tipping Stopper
20 Standard Value Table
Table of Contents
Standard Value Table for Engine
Standard Value Table for Engine: PC210-10M0
Standard Value Table for Engine: PC210LC-10M0/PC225LC-10M0
Standard Value Table for Machine: PC210-10M0
Standard Value Table for Machine: PC210LC-10M0/PC225LC-10M0
Machine Posture and Procedures to Measure Performance
30 Testing and Adjusting
Table of Contents
Precautions Before Work
Examine and Adjust Air Conditioner Compressor Belt Tension
Power Train
Examine Swing Circle Bearing Clearance
Undercarriage and Frame
Examine and Adjust Track Tension
Hydraulic System
Release Remained Pressure in Hydraulic Circuit
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits
Examine Oil Pressure of Control Circuit
Examine and adjust oil pressure in pump PC control circuit
Examine and Adjust Oil Pressure in Pump LS Control Circuit
Examine Outlet Pressure of Solenoid Valve
Examine PPC Valve Outlet Pressure
Adjust Play of Work Equipment and Swing PPC Valve
Examine Pump Swash Plate Sensor
Examine parts which cause hydraulic drift of work equipment
Examine Oil Leakage
Bleed Air from Hydraulic System
CAB Related Parts
Examine CAB Tipping Stopper
How to Adjust Mirrors
Electrical System
Set and Operate Machine Monitor
How to Start Up KOMTRAX Terminal
Adjust Rearview Camera Angle
Handle Voltage Circuit of Engine Controller
Examine Diodes
Pm Clinic
Pm Clinic Service
40 Troubleshooting
Table of Contents
Precautions Before Work
Related Information to Troubleshooting
Precautions for Troubleshooting
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Inspection Procedure Before Troubleshooting
How to Connect Adapter for Troubleshooting Controller
Disconnect and Connect Connector with Lock to Push
How to Disconnect and Connect Connector with Lock to Pull
How to Disconnect and Connect Slide Type Connector
How to Disconnect and Connect Connector with Housing to Rotate
Procedure for Troubleshooting
Information Shown in Troubleshooting
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness
Connector and Wiring Harness Identification Table
Connector Layout
Connector Contact Connection Table
T-Branch Box and T-Branch Adapter Table
Fuse Location and Connection Table
Drawing of Short Circuit Electrical Connector for Troubleshooting
Failure Code Table
Troubleshooting by Failure Code (Display of Code)
Failure Code [602KNX]
Failure Code [6AZ0ZG]
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
Failure Code [989L00]
Failure Code [989M00]
Failure Code [989N00]
Failure Code [AA10NX]
Failure Code [AB00KE]
Failure Code [B@BAZG]
Failure Code [B@BAZK]
Failure Code [B@BCZK]
Failure Code [B@BCNS]
Failure Code [B@BCQA]
Failure Code [B@HANS]
Failure Code [CA111]
Failure Code [CA115]
Failure Code [CA122]
Failure Code [CA123]
Failure Code [CA131]
Failure Code [CA132]
Failure Code [CA144]
Failure Code [CA145]
Failure Code [CA153]
Failure Code [CA154]
Failure Code [CA155]
Failure Code [CA187]
Failure Code [CA221]
Failure Code [CA222]
Failure Code [CA227]
Failure Code [CA234]
Failure Code [CA238]
Failure Code [CA271]
Failure Code [CA272]
Failure Code [CA322]
Failure Code [CA323]
Failure Code [CA324]
Failure Code [CA757]
Failure Code [CA778]
Failure Code [CA2185]
Failure Code [CA2186]
Failure Code [CA2249]
Failure Code [CA2311]
Failure Code [CA2555]
Failure Code [CA2556]
Failure Code [D110KB]
Failure Code [D19JKZ]
Failure Code [D1N0KA]
Failure Code [D1N0KB]
Failure Code [D1N0KY]
Failure Code [D811MC]
Failure Code [D862KA]
Failure Code [D8AQKR]
Failure Code [D8ALKA]
Failure Code [D8ALKB]
Failure Code [DA20MC]
Failure Code [DA22KK]
Failure Code [DA25KP]
Failure Code [DA26KP]
Failure Code [DA29KQ]
Failure Code [DA2LKA]
Failure Code [DA2LKB]
Failure Code [DA2QKR]
Failure Code [DA2RKR]
Failure Code [DAF0MB]
Failure Code [DAF0MC]
Failure Code [DAF9KQ]
Failure Code [DAFGMC]
Failure Code [DAFLKA]
Failure Code [DAFLKB]
Failure Code [DAFQKR]
Failure Code [DAZ9KQ]
Failure Code [DAZQKR]
Failure Code [DB2QKR]
Failure Code [DDPAKA]
Failure Code [DGH2KA]
Failure Code [DGH2KB]
Failure Code [DHA4KA]
Failure Code [DHE5MA]
Failure Code [DHPAMA]
Failure Code [DHPBMA]
Failure Code [DHS3MA]
Failure Code [DHS4MA]
Failure Code [DHS8MA]
Failure Code [DHS9MA]
Failure Code [DHSAMA]
Failure Code [DHSBMA]
Failure Code [DHSCMA]
Failure Code [DHSDMA]
Failure Code [DHSFMA]
Failure Code [DHSGMA]
Failure Code [DHSHMA]
Failure Code [DHSJMA]
Failure Code [DJG1KX]
Failure Code [DKR0MA]
Failure Code [DKR1MA]
Failure Code [DKR2MA]
Failure Code [DKR2NX]
Failure Code [DLM5KA]
Failure Code [DLM5MB]
Failure Code [DR21KX]
Failure Code [DR31KX]
Failure Code [DV20KB]
Failure Code [DW43KA]
Failure Code [DW43KB]
Failure Code [DW43KY]
Failure Code [DW45KA]
Failure Code [DW45KB]
Failure Code [DW45KY]
Failure Code [DW91KA]
Failure Code [DW91KB]
Failure Code [DW91KY]
Failure Code [DW97KA]
Failure Code [DW97KB]
Failure Code [DW97KY]
Failure Code [DWA2KA]
Failure Code [DWA2KB]
Failure Code [DWA2KY]
Failure Code [DWK0KA]
Failure Code [DWK0KB]
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor
Comes On in Yellow
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level
Monitor Comes On in Yellow
E-8 Engine Coolant Temperature Monitor Comes On in White While Engine is in Operation
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine is in Operation
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation
E-12 Fuel Level Monitor Comes On in Red While Engine is in Operation
E-13 Water Separator Monitor Comes On in Red While Engine is in Operation
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation
E-15 Engine Oil Pressure Monitor Comes On in Red While Engine is in Operation
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation
E-17 Fuel Gauge Does Not Move from Minimum or Maximum
E-18 Display of Fuel Gauge is Different from Actual Fuel Level
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature
E-21 Hydraulic Oil Temperature Gauge Does Not Move from Minimum or Maximum
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature
E-23 Machine Monitor Shows Incorrect Model
E-24 Some Areas of Machine Monitor Screen are Not Shown
E-25 Function Switch Does Not Operate
E-26 Automatic Warm-up System Does Not Operate (in Cold Weather)
E-27 Auto-Deceleration Monitor Does Not Come On or Go Out While Auto-Deceleration Switch is Operated
E-28 Auto-Decelerator is Not Operated or Canceled with Lever
E-29 Work Mode Selector Screen is Not Shown While Work Mode Switch is Operated
E-30 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed
E-31 Travel Speed Monitor Does Not Change While Travel Speed Switch is Operated
E-32 Travel Speed Does Not Change Even When You Change Travel Speed
E-33 Alarm Buzzer Does Not Stop
E-34 Service Meter is Not Shown While Starting Switch is in OFF Position
E-35 Service Mode Cannot be Selected
E-36 All Work Equipment, Swing, Travel Do Not Operate
E-37 All Work Equipment, Swing, Travel Cannot be Locked
E-38 Machine Does Not Swing While Swing Parking Brake Release Switch is Set to Release Position
E-39 While Swing Parking Brake Release Switch is Turned on, Swing Brake is Not Operated
E-40 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor is Not Shown
E-41 One-Touch Power Maximizing Function is Not Cancelled
E-42 Travel Alarm Does Not Operate During Travel
E-43 Travel Alarm Does Not Stop When Machine Stops
E-44 Horn Does Not Sound
E-45 Horn Does Not Stop
E-46 Wiper Monitor Does Not Come On or Go Out While Wiper Switch is Operated
E-47 Windshield Wiper Does Not Operate When Wiper Switch is Operated
E-48 When Window Washer Switch is Operated, Window Washer Does Not Operate
E-49 Boom Raise is Not Shown Normally with Monitoring Function
E-50 Boom Lower is Not Shown Normally with Monitoring Function
E-51 Arm OUT is Not Shown Correctly with Monitoring Function
E-52 Arm IN is Not Shown Normally with Monitoring Function
E-53 Bucket DUMP is Not Shown Correctly with Monitoring Function
E-54 Bucket CURL is Not Shown Correctly with Monitoring Function
E-55 Swing is Not Shown Normally with Monitoring Function
E-56 Travel is Not Shown Normally with Monitoring Function
Remove and Install Pump Controller Assembly
Remove and Install Machine Monitor Assembly
Remove and Install Pump Swash Plate Sensor
Remove and Install KOMTRAX Terminal Assembly
60 Maintenance Standard
Table of Contents
Explanation of Terms for Maintenance Standard
Engine and Cooling System
Maintenance Standard for Engine Mount
Maintenance Standard for Cooling System
Power Train
Maintenance Standard for Swing Circle
Maintenance Standard for Swing Machinery
Maintenance Standard for Final Drive
Maintenance Standard for Sprocket
Sprocket Tooth Profile Full-Scale Drawing
Undercarriage and Frame
Maintenance Standard for Track Frame and Idler Cushion
Maintenance Standard for Idler
Maintenance Standard for Track Roller
Maintenance Standard for Carrier Roller
Maintenance Standard for Track Shoes
Maintenance Standard for Triple Shoes
Maintenance Standard for Swamp Shoes
Maintenance Standard for Road Liner
Hydraulic System
Maintenance Standard for Hydraulic Tank
Maintenance Standard for Main Pump
Maintenance Standard for LS-EPC Valve
Maintenance Standard for PC-EPC Valve
Maintenance Standard for Swing Motor
Maintenance Standard for Travel Motor
Maintenance Standard for Control Valve
Maintenance Standard for PPC Valve (Work Equipment and Swing Operation)
Maintenance Standard for Travel PPC Valve
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)
Maintenance Standard for Attachment Oil Flow Adjuster EPC Valve
Maintenance Standard for 2nd-Line Attachment PPC Valve
Maintenance Standard for Solenoid Valve
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure)
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)
Maintenance Standard for Center Swivel Joint
Work Equipment
Maintenance Standard for Work Equipment Linkage
Dimensions of Arm
Dimensions of Bucket
Maintenance Standard for Boom Cylinder
Maintenance Standard for Arm Cylinder
Maintenance Standard for Bucket Cylinder
80 Others
Table of Contents
Precautions Before Work
Air Conditioner System
Precautions for Refrigerant
Layout Drawing of Air Conditioner System
Specifications of Air Conditioner
Structure of Refrigeration Cycle
Function of Refrigeration Cycle
System Diagram of Air Conditioner
Component Parts of Air Conditioner System
Air Conditioner Unit
Air Conditioner Controller
Compressor
Condenser
Air Conditioner Related Sensors
Circuit Diagram and Configuration of Connector Pins of Air Conditioner
Locations of Air Conditioner Parts and Layout of Connectors
Examine Air Leakage (Duct Connection)
How to Examine Air Leakage (Duct Connection)
Examine Air Conditioner with Self-Diagnosis Function
Examine Vent (Mode) Changeover
How to Examine Vent (Mode) Changeover
Examine Fresh/Recirc Air Changeover
How to Examine Fresh/Recirc Air Changeover
Examine Sunlight Sensor
How to Examine Sunlight Sensor
Examine Dual Pressure Switch
How to Examine Dual Pressure Switch
Examine Relay
How to Examine Relay
Simple Check of Refrigerant Level Through Sight Glass
Procedure for Troubleshooting of Air Conditioner
Information Shown in Troubleshooting Table
Failure Code [879AKA]
Failure Code [879AKB]
Failure Code [879BKA]
Failure Code [879BKB]
Failure Code [879CKA]
Failure Code [879CKB]
Failure Code [879DKZ]
Failure Code [879EMC]
Failure Code [879FMC]
Failure Code [879GKX]
A-1 Air Conditioner Does Not Operate
A-2 Defective Cooling
A-3 Heater Does Not Operate
A-4 Cool Air Does Not Come Out
A-5 No Air Comes Out or Air Flow is Abnormal
A-6 Fresh/Recirc Air Changeover Does Not Work
Connect Service Tool
How to Connect Service Tool
Precautions for Disconnection and Connection of Air Conditioner Piping
Handle Compressor Oil
How to Replace Desiccant
90 Circuit Diagrams
Table of Contents
How to Read the Codes for Electric Cable
Hydraulic Circuit Diagram
Symbols Used in Hydraulic Circuit Diagram
Hydraulic Circuit Diagram
Electrical Circuit Diagram
Symbols Used in Electric Circuit Diagram
Electrical Circuit Diagram (Applicable Machine: C00001-C03057 ) (1/7)
Electrical Circuit Diagram (Applicable Machine: C00001-C03057 ) (2/7)
Electrical Circuit Diagram (Applicable Machine: C00001-C03057 ) (3/7)
Electrical Circuit Diagram (Applicable Machine: C00001-C03057 ) (4/7)
Electrical Circuit Diagram (Applicable Machine: C00001-C03057 ) (5/7)
Electrical Circuit Diagram (Applicable Machine: C00001-C03057 ) (6/7)
Electrical Circuit Diagram (Applicable Machine: C00001-C03057 ) (7/7)
Electrical Circuit Diagram (Applicable Machine: C03058/C90001 and Up)
Electrical Circuit Diagram (Applicable Machine: C03058/C90001 and Up) (2/7)
Electrical Circuit Diagram (Applicable Machine: C03058/C90001 and Up) (3/7)
Electrical Circuit Diagram (Applicable Machine: C03058/C90001 and Up (4/7)
Electrical Circuit Diagram (Applicable Machine: C03058/C90001 and Up) (5/7
Electrical Circuit Diagram (Applicable Machine: C03058/C90001 and Up) (6/7)
Electrical Circuit Diagram (Applicable Machine: C03058/C90001 and Up) (7/7)
Connector and Wiring Harness Chart
Wiring Harness Diagram (1/11)
Wiring Harness Diagram (2/11)
Wiring Harness Diagram (3/11)
Wiring Harness Diagram (4/11)
Wiring Harness Diagram (5/11)
Wiring Harness Diagram (6/11)
Wiring Harness Diagram (7/11)
Wiring Harness Diagram (8/11)
Wiring Harness Diagram (9/11)
Wiring Harness Diagram (10/11)
Wiring Harness Diagram (11/11)
Index