Komatsu PC210LCI-11 Shop Manual Download

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HYDRAULIC
EXCAVATOR

SEN06616-03

PC210LCI

-11

SERIAL NUMBERS

500470

and up

Summary of Contents for PC210LCI-11

Page 1: ...HYDRAULIC EXCAVATOR SEN06616 03 PC210LCI 11 SERIAL NUMBERS 500470 and up...

Page 2: ...Find manuals at https best manuals com...

Page 3: ...00 INDEX AND FOREWORD PC210LCI 11 00 1 Find manuals at https best manuals com...

Page 4: ...OD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 71 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 73 HOW TO READ ELECTRICAL WIRE CODE 00 74 EXPLANATION...

Page 5: ...NENT PARTS OF WORK EQUIPMENT SYSTEM 10 280 ICT SYSTEM 10 305 LAYOUT DRAWING OF ICT SYSTEM 10 305 ICT CONTROL SYSTEM DIAGRAM 10 309 BUCKET EDGE POSITION DETECTION SYSTEM 10 310 THE INTELLIGENT MACHINE...

Page 6: ...SPEED 30 62 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 30 63 TEST SCR RELATED FUNCTIONS 30 64 CLEAN AdBlue DEF TANK 30 91 BLEED AIR FROM COOLANT CIRCUIT OF AdBlue DEF TANK 30 95 PO...

Page 7: ...RCUIT IN WIRING HARNESS OF PRESSURE SEN SOR SYSTEM 40 79 CONNECTOR LIST AND LAYOUT 40 82 CONNECTOR CONTACT IDENTIFICATION 40 105 T BRANCH BOX AND T BRANCH ADAPTER TABLE 40 145 FUSE LOCATION TABLE 40 1...

Page 8: ...CA234 40 257 FAILURE CODE CA238 40 258 FAILURE CODE CA239 40 260 FAILURE CODE CA249 40 262 FAILURE CODE CA256 40 264 FAILURE CODE CA271 40 266 FAILURE CODE CA272 40 268 FAILURE CODE CA322 40 270 FAILU...

Page 9: ...AILURE CODE CA1714 40 364 FAILURE CODE CA1715 40 365 FAILURE CODE CA1776 40 366 FAILURE CODE CA1777 40 369 FAILURE CODE CA1843 40 372 FAILURE CODE CA1844 40 374 FAILURE CODE CA1879 40 377 FAILURE CODE...

Page 10: ...500 FAILURE CODE CA3255 40 503 FAILURE CODE CA3256 40 507 FAILURE CODE CA3311 40 509 FAILURE CODE CA3312 40 511 FAILURE CODE CA3313 40 514 FAILURE CODE CA3314 40 516 FAILURE CODE CA3315 40 517 FAILURE...

Page 11: ...LURE CODE CA4151 40 639 FAILURE CODE CA4152 40 643 FAILURE CODE CA4155 40 647 FAILURE CODE CA4156 40 650 FAILURE CODE CA4157 40 653 FAILURE CODE CA4158 40 655 FAILURE CODE CA4159 40 656 FAILURE CODE C...

Page 12: ...URE CODE DAFLKB 40 767 FAILURE CODE DAFQKR 40 769 FAILURE CODE DAZ9KQ 40 770 FAILURE CODE DAZQKR 40 771 FAILURE CODE DB2QKR 40 776 FAILURE CODE DB2RKR 40 781 FAILURE CODE DB90MC 40 786 FAILURE CODE DB...

Page 13: ...URE CODE DHSJMA 40 928 FAILURE CODE DHUXMA 40 931 FAILURE CODE DHUYMA 40 933 FAILURE CODE DK80KM 40 935 FAILURE CODE DK80KR 40 936 FAILURE CODE DK80KT 40 942 FAILURE CODE DKG1KM 40 943 FAILURE CODE DK...

Page 14: ...E DKV3KY 40 1034 FAILURE CODE DKV4MA 40 1036 FAILURE CODE DKV5MA 40 1039 FAILURE CODE DKV6MA 40 1042 FAILURE CODE DKV7MA 40 1045 FAILURE CODE DKV8MA 40 1048 FAILURE CODE DKV9MA 40 1051 FAILURE CODE DK...

Page 15: ...CODE DWN5KB 40 1162 FAILURE CODE DWN5KY 40 1164 FAILURE CODE DXA8KA 40 1166 FAILURE CODE DXA8KB 40 1168 FAILURE CODE DXA9KA 40 1170 FAILURE CODE DXA9KB 40 1172 FAILURE CODE DXE0KA 40 1174 FAILURE COD...

Page 16: ...FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 40 1255 E 19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40 1256 E 20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS F...

Page 17: ...TRAX SYSTEM DOES NOT OPERATE NORMALLY 40 1312 E 60 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES GPS receiver not con nected AND Slope sensor not connected 40 1313 E 61 CONTROL BOX DISPLAYS THE...

Page 18: ...OVES 40 1400 H 15 TIME LAG OF WORK EQUIPMENT IS LARGE 40 1401 H 16 ONE TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 40 1402 H 17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 40 1403 H 18 OIL FLOW IN ATTAC...

Page 19: ...UTED FREQUENTLY 40 1457 S 22 ACTIVE REGENERATION TAKES TIME 40 1459 S 23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 40 1460 S 24 AdBlue DEF CONSUMPTION IS EXCESSIVE 40 1461 S 25 THERE IS UNUS...

Page 20: ...ASSEMBLE IDLER ASSEMBLY 50 347 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 50 352 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 50 355 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 50 359 RE...

Page 21: ...MODEM ANTENNA 50 655 REMOVE AND INSTALL GNSS ANTENNA 50 657 REMOVE AND INSTALL IMU SENSOR 50 659 60 MAINTENANCE STANDARD 60 1 CONTENTS 60 2 ABBREVIATION LIST 60 3 ENGINE AND COOLING SYSTEM 60 9 MAINT...

Page 22: ...S OF AIR CONDITIONER SYSTEM 80 17 AIR CONDITIONER UNIT 80 17 COMPONENT PARTS OF AIR CONDITIONER UNIT 80 21 AIR CONDITIONER CONTROLLER 80 25 COMPRESSOR 80 26 CONDENSER 80 27 SENSORS FOR AIR CONDITIONER...

Page 23: ...IRCUIT DIAGRAM 90 9 HYDRAULIC CIRCUIT DIAGRAM 1 2 90 13 HYDRAULIC CIRCUIT DIAGRAM 2 2 90 15 HYDRAULIC CIRCUIT DIAGRAM 1 2 90 17 HYDRAULIC CIRCUIT DIAGRAM 2 2 90 19 ELECTRICAL CIRCUIT DIAGRAM 90 21 SYM...

Page 24: ...ELECTRICAL CIRCUIT DIAGRAM 12 13 90 71 ELECTRICAL CIRCUIT DIAGRAM 13 13 90 73 INDEX 1 INDEX 00 INDEX AND FOREWORD 00 22 PC210LCI 11...

Page 25: ...n auto matically applies the retarder with a constant braking force HD HM ARSC Automatic Retarder Speed Control Travel and brake When the accelerator pedal is released while the machine is traveling d...

Page 26: ...draulic system This mechanism allows actuators to be operated in proportion to the current supplied FOPS Falling Object Protective Structure Cab and canopy This structure protects the operator s head...

Page 27: ...at the same time activates the in ter axle differential lock when the wheels idle while the machine travels on the soft ground road HM LCD Liquid Crystal Display Machine monitor Image display equipme...

Page 28: ...equipment This function performs hydraulic control of the tilt and pitch of the bulldozer blade D ROPS Roll Over Protective Structure Cab and canopy Sturcture protects the operator who wear the seatb...

Page 29: ...viations used in the circuit diagrams Abbreviation Actual word spelled out A C Air Conditioner A D Analogue to Digital A M Air Mix Damper ACC Accessory ADD Additional AUX Auxiliary BR Battery Relay CW...

Page 30: ...Abbreviation Actual word spelled out T C Torque Converter T M Transmission ABBREVIATION LIST 00 INDEX AND FOREWORD 00 28 PC210LCI 11...

Page 31: ...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 describe...

Page 32: ...ng posture for slinging work Tightening torque This signal indicates the tightening torque for portions which requires spe cial care in assembling work Coat This signal indicates a place to be coated...

Page 33: ...n good physical condition and good preparation Always be alert and careful General precautions k If the machine is handled incorrectly it is dangerous Read and understand what is described in the oper...

Page 34: ...levers and hang UNDER REPAIR warning tag on them When performing the disassembling or assembling work support the machine securely with blocks jacks or stands before starting the work Remove all mud a...

Page 35: ...aught in ro tating parts or moving parts When raising a heavy component heavier than 25 kg use a hoist or crane Before starting work check that the slings wire ropes webbing slings chains and hooks ar...

Page 36: ...orkers must communicate with each other fre quently The appointed signaler must make specified signals clearly at a place where he is well seen from the operator s seat and where he can see the workin...

Page 37: ...k is maximum at its central part Never use a wire rope which has breaks in strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Precautions fo...

Page 38: ...o work and passage After operating the hoist do not swing the control switch Remember the position of the main switch so that you can turn off the power immediately in an emer gency If the hoist stops...

Page 39: ...o use 2 wrenches use one wrench to fix and use the other one to loosen the nut Precautions for air conditioner piping When installing the air conditioner piping be careful so that dirt dusts and water...

Page 40: ...An O ring is fitted to every joint of the air conditioner piping For tightening torques see THE OTHER INFORMATION Pre cautions for disconnection and connection of air conditioner piping SAFETY NOTICE...

Page 41: ...attached to or around the engine exhaust manifold muffler or battery or on the undercovers To prevent fires from being caught remove any flammable materials such as dry leaves chips pieces of paper c...

Page 42: ...ee the Operation and Maintenance Manual for the setting procedure Explosion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting equipment with anti e...

Page 43: ...en they are inhaled Do not breathe the fumes After a fire there may be harmful compounds left If they touch your skin they may have a bad influence on your body Be sure to wear rubber gloves when hand...

Page 44: ...or lakes Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters batteries and DEF Avoid exposure to burning rubber or plastics which produce a...

Page 45: ...Association of Germany DEF is the abbreviation for Diesel Exhaust Fluid Commercial DEF that is API approved and meets all the requirements defined in ISO 22241 1 This solution will be represented as D...

Page 46: ...When opening the container perform it where there is good ventilation For storage see STORE AdBlue DEF Store AdBlue DEF avoiding direct sunlight Always use the original container at the time of purch...

Page 47: ...e remaining pressure from the hydraulic circuit always before performing the work In the field there is a risk of dust entering the component during disassembling or maintenance work and perform ance...

Page 48: ...RK Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir cuit Avoid reusing the hydraulic oil and lubricating oil Avoid reusing the hydraulic...

Page 49: ...can remove the ultra fine approxi mately 3 m particles that the filter built in the hydraulic equip ment cannot remove So it is very effective device 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYD...

Page 50: ...ckness and number of shims when storing shims When hoisting the components prepare the slings with sufficient strength When using forcing screws to remove any component tighten the forcing screws unif...

Page 51: ...of the split flange type hoses and tubes Nomi nal No Bolt pitch mm Hose side Tube side O ring 4 Bolt 5 Washer 6 a b Flange 1 Split flange 2 Sleeve head 3 04 38 1 17 5 07379 00400 07371 30400 07378 10...

Page 52: ...643 51232 30 106 4 62 07379 03010 07371 13010 07378 13000 07000 12085 07372 51650 01643 51645 34 120 6 69 8 07379 03411 07371 13411 07378 13400 07000 12100 07372 51650 01643 51645 40 130 2 77 8 07379...

Page 53: ...ps of adhesive to the threaded portion When applying liquid gasket clean and degrease the surface and apply it uniformly after making sure that the surface is free from dust or damage Clean all of the...

Page 54: ...specified amount of grease to the work equipment parts When the coolant is drained be sure that the drain valve is securely tightened then refill the coolant reser voir with the coolant Komatsu recomm...

Page 55: ...s installation portion If there is any damage replace the part Check that there is no looseness on the exhaust equipment and mounting bolts nuts and clamps on the instal lation portion If there is any...

Page 56: ...ecessary to be extremely careful when handling and maintenance of the wiring harnesses If AdBlue DEF is spilled over wiring harness and connectors it may cause corrosion and defective contact Be caref...

Page 57: ...city Entry of water dirt or dust when disconnecting a con nector If any water mud or dust is stuck to the outside surface of a connector it can enter inside the connector when the connector is disconn...

Page 58: ...pollute the environ ment Do not discard the oil inconsiderately Ask the customer for disposal or bring it back to dispose it appropriately How to clean parts when dirt is stuck If any dirt or dust st...

Page 59: ...n servicing the intake system Select an appropriate workplace Avoid the work of adding hydraulic oil replacing filters or repairing the machine in rainy or windy weather or in dusty environment Sealin...

Page 60: ...ndness of machine in addition to KOMTRAX function described above These data can be used on per sonal computer screens How to make a full use of KOMTRAX Making use of KOMTRAX enables the following act...

Page 61: ...onnection 1 Hold adapter 1 and push hose joint 2 into mating adapter 3 REMARK Push it in approximately 3 5 mm Do not hold rubber cap portion 4 2 While having adapter 3 inserted into hose side joint 2...

Page 62: ...isconnection 1 Hold the tightening adapter part and push body 2 straight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition...

Page 63: ...raight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of step 1 push cover 3 straight until it contacts contact surface...

Page 64: ...ning adapter part and push body 2 straight un til sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end DISCONNECT AND CONNECT PUSH PULL TYPE COUPLER 00 INDEX AND...

Page 65: ...th each other when the connec tor is connected When removing a connector from a clip pull the con nector in parallel with the clip as removing stoppers NOTICE If the connector is pried up and down or...

Page 66: ...protrusion of the boot and misalignment of the wiring harness If the connector is with the boot correct any extrusion of the boot In addition if the wiring harness is misaligned or the clamp is out of...

Page 67: ...from becoming too hot as this will cause deformation or damage to the connector 3 Perform a continuity test on the connector After drying leave the wiring harness disconnected con nect T adapter 1 an...

Page 68: ...fore disconnecting or connecting the connectors Before performing troubleshooting check all the related connectors for loose connection REMARK Check the related connectors for their performance by dis...

Page 69: ...Push in female connector 2 horizontally and insert it straight until it clicks Arrow x 2 In order to check whether locks a and b are completely inserted insert female connector 2 by rocking it vertica...

Page 70: ...and if connector 1 does not come out when it is pulled toward you push up portion A with a small flat head screwdriver while pressing lock L2 and then pull out connector 1 to ward you Method for conne...

Page 71: ...Lock L2 is located behind connector 1 in the figure Method for connecting slide lock type connector FRAMATOME 24 Insert it straight until it clicks 00 INDEX AND FOREWORD METHOD FOR DISCONNECTING AND C...

Page 72: ...ck to pull Disconnect the connector 2 by pulling lock B on the wiring harness side of connector 2 outward Method for connecting connector with lock to pull Insert the connector securely until it click...

Page 73: ...K If the lock is located on the underside use flat head screwdriver 1 since you cannot insert your fingers While pushing up lock C of the connector with flat head screwdriver 1 pull out connector 3 in...

Page 74: ...connector 5 in the direction of the arrow REMARK Pull up the connector straight Method for connecting connector with lock to push SUMITOMO 3 Insert it straight until it clicks Method for disconnectin...

Page 75: ...ft and pull it out REMARK Housing H1 is left on the wiring harness side Method for connecting connector with housing to rotate 1 Insert the connector to the end while aligning its groove to the other...

Page 76: ...AVS has a circular com pressed conductor It differs from AV and AVS in the outside diameter of conductor and thickness of the coating AEX is similar to AV in thickness and outside diameter of the coat...

Page 77: ...00 Conductor Number of strands 50 84 41 70 85 108 127 169 217 Diameter of strand 0 45 0 45 0 80 0 80 0 80 0 80 0 80 0 80 0 80 Cross sec tional area mm2 7 95 13 36 20 61 35 19 42 73 54 29 63 84 84 96 1...

Page 78: ...ck GB Green and Black RG Red and Green GL Green and Blue RL Red and Blue Gr Gray RW Red and White GR Green and Red RY Red and Yellow GW Green and White Sb Sky Blue GY Green and Yellow Y Yellow L Blue...

Page 79: ...cuit Charge R WG R Ground B B Start R R Light RW RB RY RG RL O Instrument Y YR YB YG YL YW Y Gr Signal G GW GR GY GB GL G Br Others L LW LR LY LB L Br BrW BrR BrY BrB Lg LgR LgY LgB LgW O Gr P Sb Dg C...

Page 80: ...dard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side Example Standard dimension Tolerance 120 0 022 0 126 The tolerance may be i...

Page 81: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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