Komatsu PC210-8 Manuals

Manuals and User Guides for Komatsu PC210-8. We have 2 Komatsu PC210-8 manuals available for free PDF download: Shop Manual, Operation & Maintenance Manual

Komatsu PC210-8 Shop Manual (1201 pages)

HYDRAULIC EXCAVATOR

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

Table of Contents
6
Table of Contents
17
Foreword and General Information
18
- Safety Notice
  18
- How to Read the Shop Manual
  22
  - Filing Method
    23
  - Symbols
    23
  - Units
    23
- Explanation of Terms for Maintenance Standard
  24
- Handling Electric Equipment and Hydraulic Component
  26
- 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
- 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
- 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
- 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
- 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
- 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

Komatsu PC210-8 Operation & Maintenance Manual (41 pages)

HYDRAULIC EXCAVATOR

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

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