Komatsu Excavator PC210-8M0 PC210LC-8M0 service & repaIr manual

Description Komatsu Excavator PC210-8M0 PC210LC-8M0 service & repaIr manual

Komatsu Hydraulic Excavator PC210-8M0, PC210LC-8M0 pdf workshop service manual

Serial numbers:
N710001 and up

Technical documentation, specifications, troubleshooting, adjusting, testing, diagrams, circuits, maintenance, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Foreword and general information
Foreword, safety and general information
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connectingof push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

Specification
Specification and technical data
Specification dimension drawings
Working range diagram
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Engine related parts
Radiator, oil cooler, aftercooler and fuel cooler
Power train
Final drive
Swing machinery
Swing circle
Undercarriage and frame
Track frame and recoil spring
Idler
Carrier roller
Track roller
Track shoe
Hydraulic system, Part 1
Hydraulic equipment layout drawing
Hydraulic tank and filter
Hydraulic pump
Pilot oil filter
Hydraulic system, Part 2
Control valve
CLSS
Functions and operation by valve
Hydraulic system, Part 3
Swing motor
Center swivel joint
Travel motor
PPC valve
Valve control
Solenoid valve
PPC accumulator
Return oil filter
Attachment circuit selector valve
Hydraulic cylinder
Work equipment
Dimensions of arm
Dimensions of bucket
Electrical system
Engine control
Electrical control system
Machine monitor system
Sensor
KOMTRAX system

Standard value table
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Sketch of special tool
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling fuel system parts
Releasing residual pressure from fuel system
Testing fuel pressure
Handling reduced cylinder mode operation
Handling no-injection cranking operation
Testing fuel discharge, return and leak amount
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling controller high voltage circuit
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Testing swing circle bearing clearance
Testing and adjusting track tension
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing control circuit source pressure
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing solenoid valve output pressure
Testing PPC valve output pressure
Adjusting play of work equipment and swing PPC valves
Testing parts which cause hydraulic drift of work equipment
Releasing remaining pressure from hydraulic circuit
Testing oil leakage
Bleeding air from each part
Testing cab tipping stopper
Adjusting mirrors
Installation and adjustment of mirrors
Angle adjustment of rear view camera
Testing and adjusting, Part 2
Special functions of machine monitor
Testing and adjusting, Part 3
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Procedure for testing diodes
Pm Clinic service

Troubleshooting
Failure code table and fuse locations
Failure codes table
Fuse locations
General Information on troubleshooting
Symptom and troubleshooting numbers
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Symptom and troubleshooting numbers
Information in troubleshooting table
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Troubleshooting by failure code
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of fuel cooler assembly
Removal and installation of engine and hydraulic pump assembly
Power train
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing motor and swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Disassembly and assembly of carrier roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler
Disassembly and assembly of idler cushion
Removal and installation of sprocket
Separation and connection of track shoe assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve
Removal and installation of hydraulic pump assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve
Disassembly and assembly of work equipment cylinder
Work equipment
Removal and installation of work equipment assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator cab glass (stuck glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of machine monitor assembly
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of KOMTRAX terminal assembly

Appendix
Air conditioner
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Air conditioner controller
Compressor
Condenser and Modulator
Sensor
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Inner sensor Open Circuit
Failure code [879AKB] A/C Inner sensor Short Circuit
Failure code [879BKA] A/C Outer sensor Open Circuit
Failure code [879BKB] A/C Outer sensor Short Circuit
Failure code [879CKA] Ventilating sensor Open Circuit
Failure code [879CKB] Ventilating sensor Short Circuit
Failure code [879DKZ] Sunlight sensor Open or Short Circuit
Failure code [879EMC] Ventilating Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
Troubleshooting for compressor and refrigerant system (Air is not cooled)
Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil
Desiccant replacement procedure

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