Komatsu Mobile Excavator PW210 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Mobile Excavator PW210-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Mobile Excavator PW210-1 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 477 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM020K0102 - Komatsu Mobile Excavator PW210-1 Shop Manual.pdf
PW210-1 mounts S6D105-1 engine.
MAIN SECTIONS
COVER....1
CONTENTS....2
10 ENGINE....16
11 STRUCTURE AND FUNCTION....16
AUTO-DECELERATION SYSTEM....17
12 TESTING AND ADJUSTING....25
TABLE OF JUDGEMENT STANDARD VALUE....26
TESTING AND ADJUSTING TOOL LIST....27
ADJUSTING VALVE CLEARANCE....28
MEASURING COMPRESSION PRESSURE....29
ADJUSTING FUEL INJECTION TIMING....30
ADJUSTING DECELERATION CYLINDER....31
ADJUSTING FUEL CONTROL LEVER....32
13 DISASSEMBLY AND ASSEMBLY....34
STARTING MOTOR....35
REMOVAL AND INSTALLATION....35
ALTERNATOR....35
REMOVAL AND INSTALLATION....35
ENGINE OIL COOLER....35
REMOVAL AND INSTALLATION....35
FUEL INJECTION PUMP....37
REMOVAL AND INSTALLATION....37
AIR COMPRESSOR....39
REMOVAL AND INSTALLATION....39
WATER PUMP....39
REMOVAL AND INSTALLATION....39
NOZZLE HOLDER....41
REMOVAL AND INSTALLATION....41
TURBOCHARGER....41
REMOVAL AND INSTALLATION....41
CYLINDER HEAD....43
REMOVAL....43
INSTALLATION....45
HYDRAULIC OIL COOLER....47
REMOVAL AND INSTALLATION....47
RADIATOR....47
REMOVAL AND INSTALLATION....47
ENGINE,MAIN PUMP....49
REMOVAL....49
INSTALLATION....51
DAMPER....53
REMOVAL AND INSTALLATION....53
AUTO-DECELERATION CYLINDER....53
REMOVAL AND INSTALLATION....53
20 POWER TRAIN....55
21 STRUCTURE AND FUNCTION....55
POWER TRAIN....56
TRAVEL AND SWING HYDRAULIC SYSTEM....58
TRAVEL AND SWING HYDRAULIC CIRCUIT DIAGRAM....59
TRAVEL HYDRAULIC PIPING DIAGRAM....60
TRAVEL HYDRAULIC CIRCUIT DIAGRAM....61
CENTER SWIVEL JOINT(FOR HYDRAULIC AND PNEUMATIC)....62
TRAVEL MOTOR....63
TRAVEL SHUTTLE VALVE....70
TRANSMISSION....71
FORWARD-REVERSE SELECTOR LEVER....74
SOLENOID VALVE(FOR FORWARD-REVERSE SELECTION)....75
TRANSMISSION SELECTOR VALVE....76
TRAVEL PPC VALVE....78
SWING HYDRAULIC PIPING DIAGRAM....79
SWING CONTROL CIRCUIT....80
SWING PRIORITY VALVE....81
SWING MOTOR....82
SWING MECHANICAL BRAKE....86
SWING MACHINERY....90
SWING CIRCLE....92
23 DISASSEMBLY AND ASSEMBLY....94
CENTER SWIVEL JOINT....95
REMOVAL AND INSTALLATION....95
DISASSEMBLY AND ASSEMBLY....97
SWING CIRCLE....99
REMOVAL AND INSTALLATION....99
SWING MACHINERY....101
REMOVAL AND INSTALLATION....101
DISASSEMBLY....103
ASSEMBLY....107
TRANSMISSION....111
REMOVAL AND INSTALLATION....111
DISASSEMBLY....113
ASSEMBLY....119
SWING MOTOR....123
REMOVAL AND INSTALLATION....123
DISASSEMBLY....125
ASSEMBLY....129
TRAVEL MOTOR....133
REMOVAL AND INSTALLATION....133
TRAVEL BRAKE VALVE....133
REMOVAL AND INSTALLATION....133
PISTON MOTOR....135
DISASSEMBLY....135
ASSEMBLY....141
24 MAINTENANCE STANDARD....149
TRAVEL MOTOR....150
TRAVEL BRAKE VALVE....151
TRAVEL SUCTION VALVE....152
TRAVEL SHUTTLE VALVE....153
TRANSMISSION....154
SWING MOTOR....155
SWING MACHINERY....156
SWING CIRCLE....157
40 STEERING SYSTEM....158
41 STRUCTURE AND FUNCTION....158
STEERING SYSTEM....159
STEERING HYDRAULIC SCHEMATICS....160
STEERING HYDRAULIC CIRCUIT DIAGRAM....160
STEERING PUMP....161
STEERING VALVE....162
STEERING CYLINDER....167
AXLE....168
DRIVE SHAFT....171
WHEEL....171
BRAKE SYSTEM....172
BRAKE AIR AND HYDRAULIC SYSTEM....173
BRAKE AIR AND HYDRAULIC DIAGRAM....174
BRAKE VALVE....175
BRAKE LOCK SELECTOR VALVE(2-WAY CONTROL VALVE)....177
SHUTTLE VALVE(DOUBLE CHECK VALVE)....178
AIR MASTER....179
WHEEL BRAKE....181
PARKING BRAKE SYSTEM....182
SUSPENSION SYSTEM....188
SUSPENSION AIR AND HYDRAULIC SYSTEM....189
SUSPENSION AIR AND HYDRAULIC CIRCUIT DIAGRAM....190
SUSPENSION LOCK VALVE....191
SUSPENSION RELIEF VALVE....192
SUSPENSION LOCK CYLINDER....195
SUSPENSION LOCK SELECTOR VALVE....195
42 TESTING AND ADJUSTING....196
TESTING AND ADJUSTING TOE-IN....197
ADJUSTING MAXIMUM TURNING ANGLE OF FRONT WHEELS....198
ADJUSTING PARKING BRAKE....199
BLEEDING AIR FROM BRAKE CIRCUIT....200
43 DISASSEMBLY AND ASSEMBLY....201
STEERING CYLINDER....202
REMOVAL AND INSTALLATION....202
STEERING PUMP....202
REMOVAL AND INSTALLATION....202
FRONT AXLE....204
REMOVAL AND INSTALLATION....204
REAR AXLE....206
REMOVAL AND INSTALLATION....206
DIFFERENTIAL(FRONT)....206
REMOVAL AND INSTALLATION....206
DIFFERENTIAL(REAR)....208
REMOVAL AND INSTALLATION....208
DIFFERENTIAL....210
DISASSEMBLY....210
ASSEMBLY....212
AIR MASTER....216
REMOVAL AND INSTALLATION....216
FRONT CALIPER....218
REMOVAL AND INSTALLATION....218
REAR CALIPER....218
REMOVAL AND INSTALLATION....218
CALIPER....220
DISASSEMBLY AND ASSEMBLY....220
FRONT FINAL DRIVE....222
REMOVAL AND INSTALLATION....222
FINAL DRIVE....226
DISASSEMBLY....226
ASSEMBLY....228
PARKING BRAKE....232
REMOVAL AND INSTALLATION....232
SUSPENSION LOCK CYLINDER....232
REMOVAL AND INSTALLATION....232
DISASSEMBLY AND ASSEMBLY....234
44 MAINTENANCE STANDARD....236
STEERING PUMP....237
STEERING CYLINDER....238
FINAL DRIVE....239
DIFFERENTIAL....239
KING PIN,KNUCKLE AND TIE-ROD....241
WHEEL BRAKE....242
PARKING BRAKE....243
SUSPENSION LOCK CYLINDER....244
50 AIR SYSTEM....245
51 STRUCTURE AND FUNCTION....245
AIR PIPING DIAGRAM....246
AIR SCHEMATICS....248
AIR CIRCUIT DIAGRAM....249
AIR GOVERNOR....250
LOW PRESSURE INDICATOR SWITCH,PARKING CAUTION SWITCH AND SUSPENSION LOCK CAUTION SWITCH....251
STOP LAMP SWITCH AND BRAKE LOCK CAUTION SWITCH....252
60 HYDRAULIC SYSTEM....253
61 STRUCTURE AND FUNCTION....253
HYDRAULIC SYSTEM....254
HYDRAULIC CIRCUIT DIAGRAM....256
WORK EQUIPMENT CONTROL....257
ARM THROTTLE VALVE....261
PPC VALVE....262
PPC SHUTTLE VALVE....265
HYDRAULIC TANK....267
HYDRAULIC PUMP....268
CONTROL VALVE(4-SPOOL VALVE AND 5-SPOOL VALVE)....285
2-STAGE AND 3-STAGE MODE SELECTOR OLSS(OPEN CENTER LOAD SENSING SYSTEM)....290
ACCUMULATOR....307
HYDRAULIC CYLINDER....308
WORK EQUIPMENT....311
OUTRIGGER....311
DOUBLE CHECK VALVE....312
62 TESTING AND ADJUSTING....313
TABLE OF JUDGEMENT STANDARD VALUE....314
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE....324
TESTING AND ADJUSTING TOOL LIST....328
TESTING AND ADJUSTING MAIN RELIEF VALVE....329
TESTING PRESSURE OF CONTROL CIRCUIT....331
MEASURING DELIVERY OF MAIN PUMP....333
MEASURING OIL LEAKAGE OF SWING,TRAVEL MOTOR....334
AIR BLEEDING....335
ADJUSTING OUTRIGGER CONTROL LEVER....336
TROUBLESHOOTING....337
CIRCUIT DIAGRAM....338
CONNECTOR POSITION FOR TROUBLESHOOTING....340
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....350
TROUBLESHOOTING PROCEDURE....353
CHECKS BEFORE TROUBLESHOOTING....354
ABNORMALITY DISPLAYS BY SELF CHECKER....355
TROUBLESHOOTING(EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR)....356
TROUBLESHOOTING FOR ELECTRIC SYSTEM(E1-E6)....362
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEM(H1-H16)....381
63 DISASSEMBLY AND ASSEMBLY....399
CHARGING PUMP....400
REMOVAL AND INSTALLATION....400
MAIN PUMP....402
REMOVAL....402
INSTALLATION....404
MAIN PUMP INPUT SHAFT OIL SEAL....406
REMOVAL AND INSTALLATION....406
TVC VALVE....408
REMOVAL AND INSTALLATION....408
CONC VALVE....408
REMOVAL AND INSTALLATION....408
SERVO VALVE....410
REMOVAL AND INSTALLATION....410
MAIN PUMP....412
DISASSEMBLY....412
ASSEMBLY....416
CONTROL VALVE....426
REMOVAL....426
INSTALLATION....428
DISASSEMBLY AND ASSEMBLY....430
JET SENSOR RELIEF VALVE....434
REMOVAL AND INSTALLATION....434
RELIEF VALVE....434
REMOVAL AND INSTALLATION....434
MAIN RELIEF VALVE....436
REMOVAL AND INSTALLATION....436
BOOM CYLINDER....438
REMOVAL AND INSTALLATION....438
ARM CYLINDER....438
REMOVAL AND INSTALLATION....438
BUCKET CYLINDER....440
REMOVAL AND INSTALLATION....440
OUTRIGGER CYLINDER....440
REMOVAL AND INSTALLATION....440
HYDRAULIC CYLINDER....442
DISASSEMBLY....442
ASSEMBLY....446
WORK EQUIPMENT....450
REMOVAL AND INSTALLATION....450
BUCKET....452
REMOVAL AND INSTALLATION....452
ARM....452
REMOVAL AND INSTALLATION....452
BOOM....454
REMOVAL AND INSTALLATION....454
ARM AND BUCKET....454
REMOVAL AND INSTALLATION....454
64 MAINTENANCE STANDARD....456
CHARGING PUMP....457
CONTROL VALVE....458
PPC SHUTTLE VALVE....463
PPC VALVE....464
WORK EQUIPMENT....465
HYDRAULIC CYLINDER....467
80 ELECTRIC AND ELECTRONIC SYSTEM....468
81 STRUCTURE AND FUNCTION....468
ELECTRICAL CIRCUIT DIAGRAM....469
82 TESTING AND ADJUSTING....470
CIRCUIT DIAGRAM....471
TROUBLESHOOTING FOR MACHINE MONITOR....472
M-1 CAUTION LAMPS DO NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STOPPED(AIR PRESSURE:MAX.4.5kg/cm2)....472
A) ENGINE OIL PRESSURE LAMP DOES NOT LIGHT UP....472
B) CHARGING LAMP DOES NOT LIGHT UP....472
C) PARKING BRAKE LAMP DOES NOT LIGHT UP....473
D) SUSPENSION LOCK LAMP DOES NOT LIGHT UP....473
M-2 BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STOPPED(AIR PRESSURE:MAX.4.5kg/cm2)....474
M-3 CAUTION LAMPS DO NOT LIGHT UP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STARTED(AIR PRESSURE:MAX.5.5kg/cm2)....475
M-4 BUZZER DOES NOT STOP WHEN STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STARTED(AIR PRESSURE:MAX.5.5kg/cm2)....476
M-5 ENGINE WATER TEMPERATURE GAUGE DOES NOT WORK....476
M-6 FUEL GAUGE DOES NOT DISPLAY....477
