Комацу 210 руководство по эксплуатации

Brand: Komatsu
|
Category: Excavators
|
Size: 69.18 MB

• Table of Contents

  6

• Table of Contents

  17

• Foreword and General Information

  18

  • Safety Notice

    18

    • General Precautions

      18

    • Preparations for Work

      18

    • Precautions for Sling Work and Making Signs

      20

    • Precautions for Using Mobile Crane

      21

    • Precautions for Using Overhead Hoist Crane

      21

    • Selecting Wire Ropes

      21

    • Wire Ropes

      21

  • How to Read the Shop Manual

    22

    • Filing Method

      23

    • Symbols

      23

    • Units

      23

  • Explanation of Terms for Maintenance Standard

    24

    • Standard Size and Tolerance

      24

    • Standard Clearance and Standard Value

      25

    • Standard Interference

      25

    • Repair Limit and Allowable Value

      25

    • Clearance Limit

      25

  • Handling Electric Equipment and Hydraulic Component

    26

    • Main Failures Occurring in Wiring Harness

      26

    • Disconnections in Wiring

      27

    • High-Pressure Water Entering Connector

      27

    • Oil or Dirt Stuck to Connector

      27

    • Disconnecting Connectors

      28

    • When Removing from Clips

      28

    • Connecting Connectors

      29

    • Connecting DT Connectors

      29

    • Drying Wiring Harness

      30

    • Handling Controller

      31

    • Points to Remember When Troubleshooting Electric Circuits

      31

    • Points to Remember When Handling Hydraulic Equipment

      32

    • Flushing Operations

      33

    • Cleaning Operations

      33

  • How to Read Electric Wire Code

    34

    • Type, Symbol, and Material

      34

    • Dimensions

      35

    • Colour Codes Table

      36

    • Types of Circuits and Colour Codes

      36

  • Method of Disassembling and Connecting Push-Pull Type Coupler

    37

  • Standard Tightening Torque Table

    40

    • Table of Tightening Torques for Bolts and Nuts

      40

    • Table of Tightening Torques for Split Flange Bolts

      41

    • Table of Tightening Torques for O-Ring Boss Piping Joints

      41

    • Table of Tightening Torques for O-Ring Boss Plugs

      41

    • Table of Tightening Torques for Hoses

      42

    • Table of Tightening Torques for 102, 107 and 114 Engine Series

      42

  • Conversion Table

    44

    • Millimetres to Inches

      44

    • Kilogram to Pound

      45

    • Litres to U.S. Gallons

      45

    • Litres to U.K. Gallons

      46

    • Temperature

      48

    • Hydraulic Excavator

      51

    • Specification and Technical Data

      51

  • Specification Dimension Drawings

    52

  • Specification and Technical Data

    52

  • Working Range Diagram

    53

  • Weight Table

    58

  • Table of Fuel, Coolant and Lubricants

    62

  • Structure, Function and Maintenance Standard

    65

  • Engine and Cooling System

    66

  • Engine Related Parts

    66

  • Structure, Function and

    66

  • Radiator, Oil Cooler, Aftercooler and Fuel Cooler

    67

  • Diesel Particulate Filter

    68

  • Diesel Particulate Filter — Component Parts

    69

  • System Description

    70

  • Regeneration

    70

  • Power Train

    73

  • Structure, Function and

    74

  • Power Train

    74

  • Final Drive

    76

  • Swing Machinery

    78

  • Swing Circle

    82

  • Undercarriage and Frame

    85

  • Track Frame and Recoil Spring

    86

  • Structure, Function and

    86

  • Undercarriage and Frame

    86

  • Standard Shoe

    87

  • Idler

    88

  • Carrier Roller

    90

  • Track Roller

    91

  • Track Shoe

    92

    • Triple Grouser Shoe

      96

    • Swamp Shoe

      96

    • Road Liner

      96

    • Hydraulic System

      99

  • Hydraulic Equipment Layout Drawing

    100

  • Structure, Function and

    100

  • Hydraulic System, Part 1

    100

  • Hydraulic Tank and Filter

    102

  • Hydraulic Pump

    103

    • Operation of Pump

      109

    • Control of Delivery

      110

    • LS Valve

      111

    • When the Control Valve Is Situated at Neutral

      112

    • Action for the Direction of Maximizing the Pump Delivery

      113

    • Action for the Direction of Minimizing the Pump Delivery

      114

    • When Servo Piston Is Balanced

      115

    • PC Valve

      116

    • When Pump Controller Is Normal

      117

    • Action of PC-EPC Valve Solenoid

      117

    • Action of Spring

      118

    • When the Main Pump Is under Heavy Load

      123

    • LS (PC)-EPC Valve

      124

    • When Signal Current Is 0

      125

    • When Signal Current Is very Small

      126

    • When Signal Current Is Maximum

      126

  • Pilot Oil Filter

    127

    • Control Valve

      130

    • General View

      131

    • Sectional View

      134

    • Arm Valve

      139

    • R.H. Travel Valve

      139

    • Swing Valve

      139

    • Boom Valve

      141

    • Bucket Valve

      141

    • L.H. Travel Valve

      141

    • Outline of CLSS

      143

    • Basic Principle

      144

    • Pump Swash Plate Angle Control

      144

    • LS Differential Pressure

      144

    • Pressure Compensation Control

      145

    • Functions and Operation by Valve

      148

    • Hydraulic Circuit Diagram and the Name of Valves

      148

    • Unload Valve

      150

    • When the Unload Valve Is Actuating

      150

    • Operation of Relief Valve

      151

    • Introduction of LS Pressure

      152

    • LS Bypass Valve

      153

    • Pressure Compensation Valve

      154

    • Integrated Pressure Compensation Valve

      154

    • When Compensated

      155

    • Pressure Compensation Valve Area Ratio

      156

    • Pressure Compensation Valve Inner Shuttle Valve

      157

    • In the Case of Travel

      158

    • Boom Regeneration Circuit

      159

    • Arm Regeneration Circuit

      161

    • If the Cylinder Head Pressure Is Lower than the Bottom Pressure

      162

    • Merge-Divider Valve

      163

    • LS Select Valve

      165

    • Self Pressure Reducing Valve

      166

    • During Neutral and When Load Pressur (P2) Is Low

      167

    • When Load Pressure (P2) Is High

      167

    • When Abnormally High Pressure Is Generated

      168

    • Travel Junction Valve

      169

    • When Pilot Pressure Is Turned on

      169

    • When Pilot Pressure Is Turned off

      170

    • Travel PPC Shuttle Valve

      171

    • Hydraulic Drift Prevention Valve

      174

    • When the Piping Is Free of Burst

      176

    • If the Piping Is Bursted

      176

    • Quick Return Valve

      179

    • When Arm out

      179

    • When the Arm Is in Neutral

      180

    • Lift Check Valve

      181

    • While Engine Is Stopped

      181

    • While Engine Is Running

      181

    • Main Relief Valve

      182

    • 2-Stage Safety-Suction Valve

      183

    • If Pilot Pressure Is on

      184

  • Swing Motor

    189

  • Hydraulic System, Part 3

    189

    • Swing Holding Brake

      192

    • Relief Valve Portion

      193

    • Reverse Prevention Valve

      194

    • Explanatory Drawing of Effects

      195

  • Centre Swivel Joint

    198

  • Travel Motor

    201

    • Operation of Motor

      204

    • At Slow Speed

      204

    • At High Speed

      205

    • Operation of Parking Brake

      206

    • Brake Valve

      208

    • Counterbalance Valve and Check Valve

      208

    • Operation When Pressurized Oil Is Supplied

      208

    • Operation of Brake During Travelling Downhill

      209

    • Safety Valve

      210

    • The Pump Pressure Rises, Providing a Large

      211

  • PPC Valve

    212

  • Work Equipment and Swing PPC Valve

    212

  • Travel PPC Valve

    216

    • Pressure Reducing Valve Function

      219

    • Travel Signal

      220

    • Steering Signal

      220

  • Service PPC Valve (with EPC Valve)

    225

  • EPC Valve

    227

  • Service PPC Valve

    230

  • Valve Control

    232

  • ATT EPC Valve Assembly

    234

  • Solenoid Valve

    236

  • PPC Accumulator

    238

  • Return Oil Filter

    239

  • Attachment Circuit Selector Valve

    240

  • Quick Coupler Control Valve

    242

  • K50001~K50303

    242

  • Function

    245

  • Hydraulic Cylinder

    246

    • Boom Cylinder

      248

    • Arm Cylinder

      248

    • Bucket Cylinder

      248

    • Work Equipment

      251

    • Dimensions of Components

      252

    • Dimension of Arm

      254

    • Dimension of Bucket

      256

    • Cab and Its Attachments

      259

    • Air Conditioner Piping

      260

    • Electrical System

      263

  • Engine Control

    264

  • Starting Engine

    264

  • Electrical System

    264

    • Fuel Control Dial

      265

    • Engine Controller

      267

    • Coolant Temperature Sensor

      269

    • Oil Pressure Switch

      269

    • Rotation Sensor

      270

    • Boost Pressure and Temperature Sensor

      270

    • WIF (Water-In-Fuel Detection) Sensor

      271

    • Engine Oil Level Sensor

      271

  • Electrical Control System

    272

    • Machine Control System Diagram

      274

    • Engine and Pump Composite Control Function

      276

    • Pump and Valve Control Function

      280

    • LS Control Function

      281

    • 2-Stage Relief Function

      281

    • Cut-Off Function

      281

    • Power Maximizing Function

      282

    • Auto-Deceleration Function

      283

    • Auto-Warm-Up and Overheat Prevention Function

      284

    • Auto-Warm-Up Function

      285

    • Overheat Prevention Function

      285

    • Swing Control Function

      286

    • Swing Lock and Swing Holding Brake Function

      287

    • Travel Control Function

      288

    • Function to Control Pump During Travel

      289

    • Travel Speed Change Function

      289

    • System Component Parts

      293

    • PPC Oil Pressure Switch

      293

    • Oil Pressure Sensor

      294

    • Pump Pressure Sensor

      295

    • Quick Coupler Low Pressure Warning Switch

      296

    • Auto Grease Pressure Switch

      297

  • Monitor System

    298

    • Machine Monitor

      299

    • Input and Output Signals

      300

    • Monitor Control, Display Portion

      303

    • Monitor Items and Display

      305

    • Switches

      309

    • Buzzer Cancel Switch

      309

    • Auto-Deceleration Switch

      309

    • Guidance Icon and Function Switch

      309

    • Working Mode Selector Switch

      311

    • Travel Speed Selector Switch

      311

    • Window Washer Switch

      311

    • Air Conditioner Control Switch

      311

    • Camera Screen Display Function

      312

    • Maintenance Function

      315

    • User Mode

      317

    • Breaker/Attachment 1 Setting

      317

    • Changing Breaker Mode Setting

      318

    • Changing Attachment Mode 1 Setting

      319

    • Attachment Setting Selection Screen

      320

    • Attachment Flow Rate Setting Screen

      320

    • Changing Attachment Mode 2 Setting

      321

    • Message Display

      323

    • Clock Adjustment

      324

    • Time Setting

      324

    • 12/24 Display Mode

      324

    • Language Setting

      325

    • Economy Mode Adjustment

      325

    • Summer Time

      325

    • Idle Stop Guidance Function

      326

    • Service Meter Check Function

      327

    • Display LCD Check Function

      327

    • User Code/Failure Code Display

      328

  • Sensor

    329

    • Hydraulic Oil Level Sensor

      329

    • Fuel Level Sensor

      330

    • Air Cleaner Clogging Sensor

      330

    • Coolant Level Sensor

      331

  • PPC Levers

    332

    • LH PPC Lever

      332

    • RH PPC Lever

      333

  • KOMTRAX Terminal System

    334

    • KOMTRAX Communication Modem

      335

    • Auto Grease System

      337

  • Outline of Auto Grease System

    338

    • The Relief Valve

      339

    • The Minimum-Level Switch

      339

    • The Test Push-Button

      339

  • Assembly

    339

  • Components

    339

    • Distribution Blocks and Metering Units

      340

    • Grease Pressure Switch

      341

    • The Display

      341

  • The Greasing Cycle

    342

    • The Pumping Phase

      342

    • The Re-Grease Phase

      342

    • The Pressure Decrease Phase

      342

    • Greasing Cycle B

      343

    • Pump Unit

      343

    • Pump Unit Assembly

      343

    • Magnetic Valve

      344

    • Metering Units

      345

    • Principle of Operation of the Metering Unit — First Phase

      345

    • Principle of Operation of the Metering Unit — Second Phase

      345

    • Principle of Operation of the Metering Unit — Third Phase

      346

    • Principle of Operation of the Metering Unit — Fourth Phase

      346

  • Introduction

    348

    • The Length of the Greasing Cycles

      349

    • Maximum Length of the Pumping Phase

      349

    • Length of the Re-Grease and Pressure Decrease Phases

      349

    • Reaction of the System to Grease Pressure Malfunctions

      350

    • Display

      350

    • Standard Service Value Table

      353

    • Standard Value Table for Engine Related Parts

      354

    • Standard Value Table for Chassis Related Parts

      356

    • Hydraulic Drift of Travel

      371

    • Boom Speed

      371

    • Bucket Speed

      371

    • Boom Time Lag

      371

    • Arm Time Lag

      372

    • Bucket Time Lag

      372

    • Testing and Adjusting

      375

  • Tools for Testing, Adjusting, and Troubleshooting

    377

  • 30 Testing and Adjusting

    377

  • Testing and Adjusting, Part 1

    377

  • Measuring Engine Speed

    380

    • Preparation Work

      380

    • Measuring Low Idle Speed

      380

    • Measuring High Idle Speed

      380

  • Measuring Intake Air Pressure (Boost Pressure)

    381

  • Checking Exhaust Gas Colour

    382

  • Checking Tools for Exhaust Gas Colour

    382

  • Adjusting Valve Clearance

    383

    • Measuring Tools for Valve Clearance

      383

    • Valve Arrangement Drawing

      383

  • Measuring Compression Pressure

    385

  • Measuring Blow-By Pressure

    387

  • Measuring Engine Oil Pressure

    388

  • Handling Fuel System Parts

    389

  • Releasing Residual Pressure from Fuel System

    389

  • Measuring Fuel Pressure

    390

  • Measuring Fuel Return Rate and Leakage

    392

  • Bleeding Air from Fuel Circuit

    394

  • Air Bleeding Route of Fuel Circuit

    395

  • Checking Fuel Circuit for Leakage

    396

  • Checking and Adjusting Air Conditioner Compressor Belt Tension

    397

  • Measuring Swing Circle Bearing Clearance

    398

  • Checking and Adjusting Track Shoe Tension

    399

    • Increasing Tension

      399

    • Decreasing Tension

      400

    • Measuring Swing Relief Pressure

      403

    • Travel Relief Pressure

      403

  • Measuring Control Circuit Basic Pressure

    405

  • Measuring and Adjusting Oil Pressure in Pump PC Control Circuit

    406

    • Measuring PC-EPC Valve Output Pressure

      407

    • Adjusting Pump PC Valve

      408

    • Loosen Locknut

      409

  • Measuring and Adjusting Oil Pressure in Pump LS Control Circuit

    410

  • Measuring LS Differential Pressure

    411

  • Measuring Solenoid Valve Output Pressure

    416

    • Operation Table of PPC Lock Solenoid Valve

      418

    • Operation Table of 2-Stage Relief Solenoid Valve

      418

    • Operation Table of Swing Holding Brake Solenoid Valve

      418

    • Operation Table of Travel Speed Shifting Solenoid Valve

      418

  • Measuring PPC Valve Output Pressure

    419

    • Connecting Points of PPC Piping

      419

    • Measuring Tools for PPC Valve Output Pressure

      420

  • Adjusting Play of Work Equipment and Swing PPC Valves

    421

  • Measuring and Adjusting Quick Coupler Control Valve Output Pressure

    422

  • Checking Parts Which Cause Hydraulic Drift of Work Equipment

    423

    • Checking Arm Cylinder

      423

    • Checking PPC Valve

      424

  • Releasing Residual Pressure from Hydraulic Circuit

    425

    • Releasing Residual Pressure from Swing Motor Circuit

      425

    • Releasing Residual Pressure from Travel Motor Circuit

      425

  • Measuring Oil Leakage

    426

    • Measuring Oil Leakage from Arm Cylinder

      426

    • Measuring Oil Leakage from Bucket Cylinder

      427

    • Measuring Oil Leakage from Swing Motor

      427

    • Measuring Oil Leakage from Travel Motor

      428

  • Bleeding Air from each Part

    429

    • Bleeding Air from Hydraulic Pump

      429

    • Starting

      430

    • Bleeding Air from Cylinder

      430

    • Bleeding Air from Swing Motor

      431

    • Bleeding Air from Travel Motor

      431

    • Checking Oil Level and Starting Work

      431

  • Checking Cab Tipping Stopper

    432

  • Adjusting Mirrors

    434

    • Installing Positions of Mirrors

      435

    • Adjusting Mirrors (A1) and (B1)

      435

    • Adjusting Mirrors (C1) and (D1)

      435

    • Special Functions of Machine Monitor

      440

    • Air Conditioner Specification

      440

    • Heater Specification

      441

    • Upper Section of Machine Monitor

      441

    • Lower Section of Machine Monitor

      441

    • Ordinary Functions and Special Functions of Machine Monitor

      442

    • Classification of Operator Mode

      443

    • Operator Mode (Outline)

      444

    • Display Pattern of Operator Mode

      444

    • Display of KOMATSU Logo

      444

    • Display of Inputting Password

      445

    • Display of Check before Starting

      445

    • Display of Check of Breaker Mode

      445

    • Display of Warning after Check before Starting

      446

    • Display of Ending of Maintenance Interval

      446

    • Display of Check of Working Mode and Travel Speed

      446

    • Display of Ordinary Screen

      446

    • Display of End Screen

      447

    • Selection of Working Mode

      447

    • Selection of Auto-Deceleration

      447

    • Selection of Travel Speed

      448

    • Precautions for Selecting Breaker Mode

      448

    • Operation to Stop Alarm Buzzer

      448

    • Operation of Windshield Wiper

      449

    • Operation of Air Conditioner/Heater

      449

    • Operation of Window Washer

      449

    • Operation to Display Camera Mode

      450

    • Operation to Display Clock and Service Meter

      450

    • Check of Maintenance Information

      451

    • Setting and Display of User Mode

      451

    • Display of Energy-Saving Guidance

      453

    • Display of Caution Monitor

      453

    • Display of Automatic Judgment of Breaker

      454

    • Display of User Code and Failure Code

      454

    • Function of Checking Display of LCD

      456

    • Function of Checking Service Meter

      456

    • Function of Changing Attachment/Maintenance Password

      457

    • Service Mode

      459

    • Selection of Service Menu

      459

    • Monitoring

      460

    • Selecting Menu

      460

    • Selecting Monitoring Items

      460

    • Deciding Monitoring Items

      460

    • Executing Monitoring

      461

    • Holding Monitoring Information

      461

    • Changing Machine Setting Mode

      461

    • Monitoring Items Table

      462

    • Abnormality Record

      465

    • Abnormality Record (Electrical Systems)

      466

    • Resetting Abnormality Record

      466

    • Failure Codes Table

      468

    • User Code

      472

    • Alarm Buzzer

      472

    • Component in Charge

      472

    • Category of Record

      472

    • Change of Maintenance Mode

      475

    • Contents of Setting of each Maintenance Item

      476

    • Function of Initializing All Items

      476

    • Default (Working Mode with Key ON)

      478

    • Default (Setting of Unit)

      479

    • Default (With/Without Attachment)

      480

    • Default (Setting of ECO Display)

      484

    • Default (Setting of Breaker Detect)

      485

    • Adjustment (Setting of Travel lo Speed)

      488

    • Cylinder Cut-Out Operation

      494

    • No Injection Cranking

      495

    • Starting no Injection Cranking

      496

    • Finishing no Injection Cranking

      496

    • Prohibiting no Injection Cranking

      496

    • Display of Fuel Consumption

      497

    • Starting Measurement

      497

    • Display and Function During Measurement

      497

    • Finishing Measurement

      497

    • Display of KOMTRAX Message

      502

  • Handling High-Voltage Circuit of Engine Controller

    506

  • 30 Testing and Adjusting

    506

  • Testing and Adjusting, Part 3

    506

  • Preparation Work for Troubleshooting of Electrical System

    507

  • Procedure for Testing Diodes

    511

    • When Using Analog Circuit Tester

      511

    • When Using Digital Circuit Tester

      511

  • Pm Clinic Service

    513

    • Items Related to Engine

      514

    • Items Related to Oil Pressure

      515

    • Check Sheet (PC210/LC/NLC-8/PC230NHD-8)

      516

    • General Information on Troubleshooting

      527

  • General Information on Troubleshooting

    528

  • Points to Remember When Troubleshooting

    528

  • Sequence of Events in Troubleshooting

    529

  • Check before Troubleshooting

    530

  • Classification and Procedures for Troubleshooting

    531

  • Phenomena Looking Like Troubles and Troubleshooting Nos.

    532

  • How to Read Electric Wire Code

    535

  • Connection Table for Connector Pin Numbers

    538

  • T-Boxes and T-Adapters Table

    569

    • Troubleshooting by Failure Code

      575

    • Locations of Fusible Links

      584

    • Location of Fuse Box and Fuse Nos.

      584

    • Troubles that Occur When Power Supply of Pump Controller Is Defective

      585

    • Information in Troubleshooting Table

      588

    • Failure Code [AB00KE] Charge Voltage Low

      592

    • Failure Code [B@BAZG] Eng Oil Press. Low

      594

    • Failure Code [B@BCNS] Eng Water Overheat

      595

    • Failure Code [B@HANS] Hydr Oil Overheat

      596

    • Failure Code [CA111] EMC Critical Internal Failure

      596

    • Failure Code [CA115] Eng Ne and Bkup Speed Sens Error

      597

    • Failure Code [CA122] Chg Air Press Sensor High Error

      598

    • Circuit Diagram Related to Boost Pressure/Temperature Sensor

      599

    • Failure Code [CA123] Chg Air Press Sensor Low Error

      600

    • Failure Code [CA131] Throttle Sensor High Error

      602

    • Failure Code [CA132] Throttle Sensor Low Error

      604

    • Failure Code [CA144] Coolant Temp Sens High Error

      606

    • Failure Code [CA145] Coolant Temp Sens Low Error

      608

    • Circuit Diagram Related to Coolant Temperature Sensor

      609

    • Failure Code [CA153] Chg Air Temp Sensor High Error

      610

    • Failure Code [CA154] Chg Air Temp Sensor Low Error

      612

    • Failure Code [CA155] Chg Air Temp High Speed Derate

      614

    • Failure Code [CA187] Sens Supply 2 Volt Low Error

      616

    • Failure Code [CA221] Ambient Press Sens High Error

      618

    • Failure Code [CA222] Ambient Press Sens Low Error

      620

    • Failure Code [CA227] Sens Supply 2 Volt High Error

      622

    • Failure Code [CA238] Ne Speed Sens Supply Volt Error

      624

    • Failure Code [CA271] IMV/PCV1 Short Error

      625

    • Failure Code [CA272] IMV/PCV1 Open Error

      626

    • Failure Code [CA322] Inj #1 (L#1) Open/Short Error

      628

    • Failure Code [CA323] Inj #5 (L#5) Open/Short Error

      630

    • Circuit Diagram Related to No. 5 Injector

      631

    • Failure Code [CA324] Inj #3 (L#3) Open/Short Error

      632

    • Circuit Diagram Related to No. 3 Injector

      633

    • Failure Code [CA325] Inj #6 (L#6) Open/Short Error

      634

    • Failure Code [CA331] Inj #2 (L#2) Open/Short Error

      636

    • Circuit Diagram Related to No. 2 Injector

      637

    • Failure Code [CA332] Inj #4 (L#4) Open/Short Error

      638

    • Circuit Diagram Related to No. 4 Injector

      639

    • Failure Code [CA342] Calibration Code Incompatibility

      643

    • Failure Code [CA351] Injectors Drive Circuit Error

      644

    • Circuit Diagram Related to Engine Controller

      645

    • Failure Code [CA352] Sens Supply 1 Volt Low Error

      646

    • Circuit Diagram Related to Sensor Power Supply 1

      647

    • Failure Code [CA386] Sens Supply 1 Volt High Error

      648

    • Failure Code [CA428] Water in Fuel Sensor High Error

      650

    • Circuit Diagram Related to Water-In-Fuel Sensor

      651

    • Failure Code [CA429] Water in Fuel Sensor Low Error

      652

    • Failure Code [CA435] Eng Oil Press Sw Error

      654

    • Failure Code [CA441] Battery Voltage Low Error

      655

    • Circuit Diagram Related to Engine Controller Power Supply

      657

    • Failure Code [CA442] Battery Voltage High Error

      658

    • Failure Code [CA449] Rail Press very High Error

      660

    • Failure Code [CA451] Rail Press Sensor High Error

      662

    • Circuit Diagram Related to Common Rail Pressure Sensor

      663

    • Failure Code [CA452] Rail Press Sensor Low Error

      664

    • Failure Code [CA488] Chg Air Temp High Torque Derate

      666

    • Failure Code [CA553] Rail Press High Error

      666

    • Failure Code [CA559] Rail Press Low Error

      667

    • Failure Code [CA689] Eng Ne Speed Sensor Error

      668

    • Circuit Diagram Related to Engine Ne Speed Sensor

      669

    • Failure Code [CA731] Eng Bkup Speed Sens Phase Error

      670

    • Failure Code [CA757] All Continuous Data Lost Error

      672

    • Failure Code [CA778] Eng Bkup Speed Sensor Error

      674

    • Circuit Diagram Related to Engine Bkup Speed Sensor

      675

    • Failure Code [CA1633] KOMNET Datalink Timeout Error

      676

    • Circuit Diagram Related to CAN Communication

      677

    • Failure Code [CA2185] Throt Sens Sup Volt High Error

      678

    • Failure Code [CA2186] Throt Sens Sup Volt Low Error

      679

    • Failure Code [CA2249] Rail Press very Low Error

      680

    • Failure Code [CA2311] IMV Solenoid Error

      682

    • Circuit Diagram Related to Supply Pump Actuator (Metering Unit)

      683

    • Failure Code [CA2555] Grid Htr Relay Volt High Error

      684

    • Failure Code [CA2556] Grid Htr Relay Volt Low Error

      686

    • Failure Code [D19JKZ] Personal Code Relay Abnormality

      688

    • Failure Code [D862KA] GPS Antenna Discon

      690

    • Failure Code [DA25KP] 5V Sensor 1 Power Abnormality

      691

    • Overload Alarm Monitor Non-Display Specification

      691

    • Overload Alarm Monitor Display Specification

      695

    • Failure Code [DA29KQ] Model Selection Abnormality

      698

    • Circuit Diagram Related to Model Selection Connector (PC210, 210LC-8)

      699

    • Circuit Diagram Related to Model Selection Connector (PC240LC-8)

      701

    • Failure Code [DA2RMC] CAN Discon (Pump con Detected)

      706

    • Failure Code [DAFGMC] GPS Module Error

      708

    • Failure Code [DAFRMC] CAN Discon (Monitor Detected)

      710

    • Failure Code [DGH2KB] Hydr Oil Sensor Short

      712

    • Failure Code [DHPAMA] F Pump Press Sensor Abnormality

      714

    • Circuit Diagram Related to F Pump Pressure Sensor

      715

    • Failure Code [DHPBMA] R Pump Press Sensor Abnormality

      716

    • Circuit Diagram Related to R Pump Pressure Sensor

      717

    • Failure Code [DHS3MA] Arm Curl PPC Press Sensor Abnormality

      718

    • Circuit Diagram Related to Arm Curl PPC Pressure Sensor

      719

    • Failure Code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality

      720

    • Circuit Diagram Related to Bucket Curl PPC Pressure Sensor

      721

    • Failure Code [DHS8MA] Boom Raise PPC Press Sensor Abnormality

      722

    • Circuit Diagram Related to Boom Raise PPC Pressure Sensor

      723

    • Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality

      724

    • Circuit Diagram Related to Swing Right PPC Pressure Sensor

      725

    • Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality

      726

    • Circuit Diagram Related to Swing Left PPC Pressure Sensor

      727

    • Failure Code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality

      728

    • Circuit Diagram Related to Bucket Dump PPC Pressure Sensor

      729

    • Failure Code [DHX1MA] Overload Sensor Abnormality (Analog)

      730

    • Circuit Diagram Related to Overload Alarm Pressure Sensor

      731

    • Failure Code [DW43KA] Travel Speed Sol Discon

      732

    • Circuit Diagram Related to Travel Speed Shifting Solenoid

      733

    • Failure Code [DW43KB] Travel Speed Sol Short

      734

    • Failure Code [DW45KA] Swing Brake Sol Discon

      736

    • Circuit Diagram Related to Swing Holding Brake Solenoid

      737

    • Failure Code [DW45KB] Swing Brake Sol Short

      738

    • Failure Code [DW91KA] Travel Junction Sol Discon

      740

    • Circuit Diagram Related to Travel Junction Solenoid

      741

    • Failure Code [DW91KB] Travel Junction Sol Short

      742

    • Failure Code [DWA2KA] Service Sol Discon

      744

    • Failure Code [DWA2KB] Service Sol Short

      745

    • Failure Code [DWK0KA] 2-Stage Relief Sol Discon

      746

    • Failure Code [DWK0KB] 2-Stage Relief Sol Short

      748

    • Circuit Diagram Related to 2-Stage Relief Solenoid

      749

    • Failure Code [DXA8KA] PC-EPC (F) Sol Discon

      753

    • Circuit Diagram Related to PC-EPC (F) Solenoid and PC-EPC (R) Solenoid

      754

    • Failure Code [DXA8KB] PC-EPC (F) Sol Short

      755

    • Failure Code [DXA9KA] PC-EPC (R) Sol Discon

      757

    • Failure Code [DXA9KB] PC-EPC (R) Sol Short

      759

    • Failure Code [DXE0KA] LS-EPC Sol Discon

      761

    • Failure Code [DXE0KB] LS-EPC Sol Short

      763

    • Failure Code [DXE4KA] Service Current EPC Discon

      765

    • Failure Code [DXE4KB] Service Current EPC Short

      767

    • Failure Code [DXE5KA] Merge-Divider Main Sol Discon

      769

    • Circuit Diagram Related to Merge-Divider Main EPC Solenoid

      770

    • Failure Code [DXE5KB] Merge-Divider Main Sol Short

      771

    • Failure Code [DXE6KA] Merge-Divider LS Sol Discon

      773

    • Failure Code [DXE6KB] Merge-Divider LS Sol Short

      775

    • Failure Code [DY20KA] Wiper Working Abnormality

      777

    • Circuit Diagram Related to Windshield Wiper and Window Washer

      778

    • Failure Code [DY20MA] Wiper Parking Abnormality

      779

    • Failure Code [DY2CKA] Washer Drive Discon

      781

    • Failure Code [DY2CKB] Washer Drive Short

      783

    • Failure Code [DY2DKB] Wiper Drive (For) Short

      785

    • Failure Code [DY2EKB] Wiper Drive (Rev) Short

      787

    • Failure Code [DXEAKA] Service Current EPC1 Discon

      789

    • Failure Code [DXEAKB] Service Current EPC1 Short

      790

    • Failure Code [DXE7KA] Service Current EPC2 Discon

      791

    • Failure Code [DXE7KB] Service Current EPC2 Short

      792

    • Failure Code [DXE8KA] Service Current EPC3 Discon

      793

    • Failure Code [DXE8KB] Service Current EPC3 Short

      794

    • Failure Code [DXE9KA] Service Current EPC4 Discon

      795

    • Failure Code [DXE9KB] Service Current EPC4 Short

      796

    • Failure Code [DFB1KZ] Service Lever Potentio 1 Abnormality

      799

    • Failure Code [DFB2KZ] Service Lever Potentio 2 Abnormality

      801

    • Failure Code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality

      803

    • Failure Code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality

      805

    • Failure Code [DFB3L8] Service Lever 1 Potentio Error

      807

    • Failure Code [DFB4L8] Service Lever 2 Potentio Error

      808

    • Troubleshooting of Electrical System

      813

    • Before Carrying out Troubleshooting of Electrical System

      815

    • Connection Table of Fuse Box

      816

    • E-1 When Starting Switch Turned ON, Machine Monitor Displays

      820

    • Circuit Diagram Related to Machine Monitor Power Supply

      821

    • When Starting Switch Turned on

      822

    • Circuit Diagram Related to Radiator Coolant Level Switch

      823

    • Engine Does Not Start (Engine Does Not Turn)

      825

    • Preheater Does Not Operate

      828

    • Automatic Warm-Up System Does Not Operate

      830

    • Precaution Lights up While Engine Is Running

      834

    • Circuit Diagram Related to Air Cleaner Clogging Switch

      837

    • Emergency Stop Item Lights up While Engine Is Running

      839

    • Engine Coolant Temperature Gauge Does Not Indicate Normally

      840

    • Hydraulic Oil Temperature Gauge Does Not Indicate Normally

      841

    • Circuit Diagram Related to Hydraulic Oil Temperature Sensor

      841

    • Fuel Level Gauge Does Not Indicate Normally

      843

    • Circuit Diagram Related to Fuel Level Sensor

      843

    • Fuel Level Gauge and Fuel Level Monitor

      844

    • Machine Monitor Does Not Display some Items

      845

    • Function Switch Does Not Work

      845

    • Auto-Decelerator Does Not Operate Normally

      846

    • Working Mode Does Not Change

      847

    • Travel Speed Does Not Change

      848

    • Alarm Buzzer Cannot be Stopped

      849

    • Circuit Diagram for Quick Coupler System

      851

    • Windshield Wiper and Window Washer Do Not Operate

      852

    • Power Maximising Function Does Not Operate Normally

      854

    • Circuit Diagram Related to Left Knob Switch

      854

    • Swing Holding Brake Does Not Operate Normally

      858

    • Travel Alarm Does Not Sound or Does Not Stop Sounding

      860

    • Air Conditioner Does Not Operate Normally

      862

    • Circuit Diagram Related to Air Conditioner

      873

    • Machine Monitor Cannot be Set in Service Mode

      874

    • Circuit Diagram Related to Travel PPC Pressure Switch and Travel Alarm

      879

    • KOMTRAX System Does Not Operate Normally

      884

    • Troubleshooting of Hydraulic and Mechanical System (H-Mode)

      887

    • System Diagram of Hydraulic and Mechanical System

      890

    • Engine Speed Lowers Extremely or Engine Stalls

      895

    • Work Equipment, Swing, and Travel Systems Do Not Work

      896

    • Abnormal Sound Comes out from Around Hydraulic Pump

      896

    • Auto-Decelerator Does Not Operate

      897

    • Fine Control Performance or Response Is Low

      897

    • Speed or Power of Boom Is Low

      898

    • Speed or Power of Arm Is Low

      899

    • Speed or Power of Bucket Is Low

      900

    • Work Equipment Does Not Move Singly

      900

    • Hydraulic Drift of Work Equipment Is Large

      901

    • Time Lag of Work Equipment Is Large

      903

    • Power Maximizing Function Does Not Work

      904

    • Machine Deviates During Travel

      906

    • Travel Speed Is Low

      907

    • Machine Is Not Steered Well or Steering Power Is Low

      908

    • Travel Speed Does Not Change or Travel Speed Is Low/High

      909

    • Travel System Does Not Move (Only One Side)

      910

    • Upper Structure Does Not Swing

      911

    • Swing Acceleration or Swing Speed Is Low

      913

    • Upper Structure Overruns Remarkably When It Stops Swinging

      914

    • Large Shock Is Made When Upper Structure Stops Swinging

      915

    • Large Sound Is Made When Upper Structure Stops Swinging

      915

    • Hydraulic Drift of Swing Is Large

      916

    • Attachment Circuit Is Not Changed

      917

    • Oil Flow in Attachment Circuit Cannot be Controlled

      917

    • Attachment Installation Specification

      917

    • Quick Coupler

      918

    • Troubleshooting of Engine (S-Mode)

      925

    • Method of Using Troubleshooting Chart

      927

    • Exhaust Gas Is Black

      928

    • Starting Performance Is Poor

      930

    • Engine Does Not Start

      931

    • Engine Does Not Turn

      931

    • Exhaust Smoke Comes but Engine Does Not Start

      933

    • Engine Does Not Pick up Smoothly

      934

    • General Causes Why Engine Does Not Pick up Smoothly

      934

    • Engine Stops During Operations

      935

    • General Causes Why Engine Stops During Operations

      935

    • Engine Does Not Rotate Smoothly

      936

    • General Causes Why Engine Does Not Rotate Smoothly

      936

    • Engine Lack Output (or Lacks Power)

      937

    • General Causes Why Engine Lacks Output

      937

    • Exhaust Smoke Is Black (Incomplete Combustion)

      939

    • General Causes Why Exhaust Smoke Is Black

      939

    • Oil Consumption Is Excessive (or Exhaust Smoke Is Blue)

      940

    • General Causes Why Oil Consumption Is Excessive

      940

    • Oil Becomes Contaminated Quickly

      941

    • Fuel Consumption Is Excessive

      942

    • Oil Is in Coolant

      943

    • General Causes Why Oil Is in Coolant

      943

    • Oil Pressure Drops

      944

    • General Causes Why Oil Pressure Drops

      944

    • Oil Level Rises (Entry of Coolant/Fuel)

      945

    • General Causes Why Oil Level Rises

      945

    • Coolant Temperature Becomes too High (Overheating)

      946

    • General Causes Why Coolant Temperature Becomes too High

      946

    • Abnormal Noise Is Made

      947

    • General Causes Why Abnormal Noise Is Made

      947

    • Vibration Is Excessive

      948

    • General Causes Why Vibration Is Excessive

      948

    • Diesel Particulate Filter System

      949

    • Troubleshooting of Auto Grease System

      951

    • Recognising Malfunctions

      952

    • Malfunction Reports of the Display

      952

    • Malfunction Finding Procedures

      955

    • Disassembly and Assembly Related Information

      959

    • Removal and Installation of Assemblies

      960

    • List of Adhesives

      962

    • Special Tool List

      965

    • Sketches of Special Tools

      970

    • A8 Plate

      970

    • F1 Push Tool

      970

    • F3 Plate

      971

    • J2 Push Tool

      971

    • J6 Push Tool

      972

    • S Push Tool

      972

    • Engine Cooling Related

      975

    • Removal and Installation of Fuel Supply Pump Assembly

      976

    • Removal and Installation of Fuel Injector Assembly

      978

    • Fuel Injector Assembly

      982

    • Rocker Arm and Crosshead Assembly

      983

    • High-Pressure Pipes and Common Rail

      984

    • Removal and Installation of Engine Front Seal

      985

    • Vibration Damper

      987

    • Removal and Installation of Engine Rear Seal

      988

    • Removal and Installation of Cylinder Head Assembly

      991

    • Cylinder Head Assembly

      997

    • Removal and Installation of Radiator Assembly

      1003

    • Removal and Installation of Aftercooler Assembly

      1008

    • Removal and Installation of Fuel Cooler Assembly

      1010

    • Disassembly and Assembly of Final Drive Assembly

      1026

  • 427-1510 Push Tool

    1026

  • Block T

    1026

  • Rod T

    1026

  • Puller (30 Ton) T

    1026

  • Pump T

    1026

    • Hub Assembly

      1028

    • Nut

      1030

    • No.2 Carrier Assembly

      1031

  • Wrench T

    1034

  • Installer T

    1034

  • 427-1220 Push Tool T

    1034

  • Block T

    1034

  • Washer T

    1034

  • Jack T

    1034

  • Hydraulic Pump T

    1034

    • Under Carriage and Frame

      1057

    • Disassembly and Assembly of Carrier Roller

      1058

  • Installer T

    1058

  • Disassembly and Assembly of Track Roller Assembly

    1061

  • Installer T

    1061

  • Disassembly and Assembly of Idler Assembly

    1063

  • Installer T

    1063

  • Disassembly and Assembly of Recoil Spring

    1066

  • Compressor (A) T

    1066

  • Compressor (B) T

    1066

  • Spacer Extension T

    1066

  • Cylinder

    1066

  • (686Kn{70Ton})

    1066

  • Guide Bolt T

    1066

  • Push Tool Kit (B) Q

    1066

  • Bolt

    1066

  • Push Tool Kit

    1066

    • Removal and Installation of Sprocket

      1068

    • Expansion and Installation of Track Shoe Assembly

      1069

    • Development of Track Shoe

      1069

    • Installation of Track Shoe

      1070

    • Removal and Installation of Revolving Frame Assembly

      1071

    • Removal and Installation of Center Swivel Joint Assembly

      1076

    • Disassembly and Assembly of Center Swivel Joint Assembly

      1078

    • Removal and Installation of Hydraulic Tank Assembly

      1079

    • Removal and Installation of Control Valve Assembly

      1082

    • Disassembly and Assembly of Control Valve Assembly

      1087

    • Assembly of Control Valve Assembly

      1089

    • Removal and Installation of Hydraulic Pump Assembly

      1091

    • Removal and Installation of Oil Seal in Hydraulic Pump Input Shaft

      1096

    • Disassembly and Assembly of Travel PPC Valve Assembly

      1098

    • Disassembly and Assembly of Hydraulic Cylinder Assembly

      1099

    • Disassembly of Cylinder Head Assembly

      1101

    • Disassembly of Piston Assembly

      1101

    • Piston Rod Assembly

      1102

    • Disassembly and Assembly of Quick Coupler Valve

      1105

    • Removal of Pressure Regulating Valve

      1105

    • Removal of Solenoid and Directional Control Valve

      1105

    • Removal and Installation of the Work Equipment Assembly

      1108

    • Cab Related

      1113

    • Removal and Installation of Operator’s Cab Assembly

      1114

    • Removal and Installation of Operator Cab Glass (Stuck Glass)

      1117

    • Removal and Installation of Front Window Assembly

      1127

    • Electric Components

      1139

    • Removal and Installation of Air Conditioner Unit Assembly

      1140

    • Removal and Installation of Monitor Assembly

      1144

    • Removal and Installation of Pump Controller Assembly

      1146

    • Removal and Installation of Engine Controller Assembly

      1147

    • Hydraulic Diagrams and Drawings

      1151

    • Hydraulic Circuit Diagram

      1153

    • Electrical Diagrams and Drawings

      1163

    • Electrical Circuit Diagram

      1165

Brand: Komatsu
|
Category: Excavators
|
Size: 1.15 MB

• Safety Information

  5

• Directions of Machine

  11

• Breaking-In the New Machine

  12

• Product Information

  13

• Service Meter Location

  14

• Machine Serial Plates

  15

• Location of Safety Labels

  32