Komatsu PC110-8M0 DBBUF001 & Up YEBM202300-00 (Preview)
PC110-8M0 Shop Manual
00 Index and foreword
CONTENTS
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 Specification
CONTENTS
Specifications
Specification dimension drawings
Working range diagram
Specifications
List of weights
List of lubricant and coolant to be filled
10 Structure, function and maintenance standard
CONTENTS
Engine and cooling system
Engine mount
PTO
Cooling system
Power train
Power train
Swing circle
Swing machinery
Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe
Hydraulic system
Hydraulic equipment layout drawing
Valve control
Hydraulic tank and filter
Hydraulic pump
Hydraulic control system
Control valve
CLSS
Functions and operation by valve
Work equipment, swing and travel system
PPC valve
Swing motor
Travel motor
Center swivel joint
Solenoid valve
Accumulator
Hydraulic cylinder
Work equipment
Work equipment
Dimensions of components
Electrical system
Electronic control system
Machine monitor system
KOMTRAX system
Sensor
20 Standard value table
CONTENTS
Standard service value table
Standard value table for engine related parts
Standard value table for chassis related parts
30 Testing and adjusting
CONTENTS
Precautions before work
Related Information on Testing and Adjusting
Tools for testing, adjusting, and troubleshooting
Sketches of special tools
Engine and Cooling System
Testing engine speed
Testing exhaust temperature
Checking exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Reduced cylinder mode operation
No-injection cranking
Handling fuel system parts
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return rate and fuel leakage
Bleeding air from fuel circuit
Checking fuel circuit for leakage
Testing and adjusting alternator belt tension
Checking and adjusting air conditioner compressor belt tension
Power Train
Testing swing circle bearing clearance
Undercarriage and Frame
Checking and adjusting track shoe tension
Hydraulic System
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing control circuit basic 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
Checking parts which cause hydraulic drift of work equipment
Testing and adjusting travel deviation
Releasing residual pressure from hydraulic circuit
Testing oil leakage
Bleeding air from each part
CAB Related Parts
Checking cab tipping stopper
Installation and adjustment of mirrors and camera
Inspection of air conditioner Recirc/Fresh air filter
Electrical System
Special functions of machine monitor
Handling voltage circuit of engine controller
Preparation work for troubleshooting of electrical system
Handle Battery Disconnect Switch
Procedure for testing diodes
Pm Clinic
Pm Clinic service
40 Troubleshooting
CONTENTS
Precautions before work
Failure code table and fuse locations
Failure code table
Fuse locations
Connection table of fuse box
Locations of fusible links
Location of fuse box and fuse Nos.
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Classification for troubleshooting
Procedure for troubleshooting
Information in troubleshooting table
Phenomena looking like troubles and troubleshooting Nos.
Connector list and layout
Connector list
Connector layout
Connection table for connector pin numbers
T- branch box and T- branch adapter tabl
Troubleshooting method for open circuit in wiring harness of pressure sensor system
Troubleshooting by Failure Code (Display of Code)
Failure code [879AKA]
Failure code [879AKB]
Failure code [879BKA]
Failure code [879BKB]
Failure code [879CKA]
Failure code [879CKB]
Failure code [879DKZ]
Failure code [879EMC]
Failure code [879FMC]
Failure code [879GKX]
Failure code [989L00]
Failure code [989M00]
Failure code [989N00]
Failure code [AA10NX]
Failure code [AB00KE]
Failure code [B@BAZG]
Failure code [B@BAZK]
Failure code [B@BCNS]
Failure code [B@BCZK]
Failure code [B@HANS]
Failure code [CA111]
Failure code [CA115]
Failure code [CA122]
Failure code [CA123]
Failure code [CA131]
Failure code [CA132]
Failure code [CA144]
Failure code [CA145]
Failure code [CA153]
Failure code [CA154]
Failure code [CA187]
Failure code [CA221]
Failure code [CA222]
Failure code [CA227]
Failure code [CA234]
Failure code [CA238]
Failure code [CA271]
Failure code [CA272]
Failure code [CA322]
Failure code [CA324]
Failure code [CA331]
Failure code [CA332]
Failure code [CA351]
Failure code [CA352]
Failure code [CA386]
Failure code [CA428]
Failure code [CA429]
Failure code [CA435]
Failure code [CA441]
Failure code [CA442]
Failure code [CA449]
Failure code [CA451]
Failure code [CA452]
Failure code [CA553]
Failure code [CA559]
Failure code [CA689]
Failure code [CA731]
Failure code [CA757]
Failure code [CA778]
Failure code [CA2185]
Failure code [CA2186]
Failure code [CA2249]
Failure code [CA2311]
Failure code [D110KB]
Failure code [D19JKZ]
Failure code [D811MC]
Failure code [D862KA]
Failure code [D8AQKR]
Failure code [DA22KK]
Failure code [DA25KP]
Failure code [DA29KQ]
Failure code [DA2QKR]
Failure code [DAF0MB]
Failure code [DAF0MC]
Failure code [DAF8KB]
Failure code [DAF9KQ]
Failure code [DAFGMC]
Failure code [DAFQKR]
Failure code [DAZ9KQ]
Failure code [DAZQKR]
Failure code [DB2QKR]
Failure code [DGH2KB]
Failure code [DHA4KA]
Failure code [DHPAMA]
Failure code [DHSFMA]
Failure code [DHSGMA]
Failure code [DHSHMA]
Failure code [DHSJMA]
Failure code [DV20KB]
Failure code [DW43KA]
Failure code [DW43KB]
Failure code [DW45KA]
Failure code [DW45KB]
Failure code [DW91KA]
Failure code [DW91KB]
Failure code [DWJ0KA]
Failure code [DWJ0KB]
Failure code [DWK0KA]
Failure code [DWK0KB]
Failure code [DXA8KA]
Failure code [DXA8KB]
Failure code [DXE4KA]
Failure code [DXE4KB]
Failure code [DY20KA]
Failure code [DY20MA]
Failure code [DY2CKB]
Failure code [DY2DKB]
Failure code [DY2EKB]
Troubleshooting of Electrical System (E-Mode)
Locations of fuses
Connection table in fuse box
Information in troubleshooting table
★ The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
E-1 Engine does not start (Engine does not crank)
E-2 Preheater does not operate
E-3 When starting switch is turned to ON, machine monitor displays nothing
E-4 When starting switch turned ON (before starting engine), basic check item lights up
E-5 Precaution lights up while engine is running
E-6 Emergency stop item lights up while engine is running
E-7 Fuel level gauge does not indicate normally
E-8 Engine coolant temperature gauge does not indicate normally
E-9 Hydraulic oil temperature gauge does not indicate normally
E-10 Contents of display by machine monitor are different from applicable machine
E-11 Machine monitor does not display some items
E-12 Function switch does not work
E-13 Automatic warm-up system does not operate (in cold season)
E-14 Auto-decelerator does not operate normally
E-15 Working mode does not change
E-16 Travel speed does not change
E-17 Alarm buzzer cannot be stopped
E-18 While starting switch is in OFF position, service meter is not displayed
E-19 Machine monitor cannot be set in service mode
E-20 All work equipment, swing, and travel mechanism do not move or cannot be locked
E-21 Swing holding brake does not operate normally
E-22 One-touch power maximizing function does not operate normally
E-23 Travel alarm does not sound or does not stop sounding
E-24 Horn does not sound or does not stop sounding
E-25 Windshield wiper and window washer do not operate
E-26 “Boom Lower” is Not Shown Correctly with Monitoring Function
E-27 “Arm OUT” is Not Shown Correctly with Monitoring Function
E-28 “Arm IN” is Not Shown Correctly with Monitoring Function
E-29 “Boom Raise” is Not Shown Correctly with Monitoring Function
E-30 “Bucket Curl” is Not Shown Correctly with Monitoring Function
E-31 “Bucket Dump” is Not Shown Correctly with Monitoring Function
E-32 “Swing” is Not Shown Correctly with Monitoring Function
E-33 “Travel” is Not Shown Correctly with Monitoring Function
E-34 Service is Not Shown Correctly with Monitoring Function
E-35 KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Information contained in troubleshooting table (H-mode)
System chart for hydraulic and mechanical systems
Failure mode and cause table
H-1 Speed or power of all work equipment, swing, and travel are low
H-2 Engine speed sharply drops or engine stalls
H-3 Work equipment, swing, and travel systems do not work
H-4 Abnormal noise is heard from around hydraulic pump
H-5 Fine control mode does not function
H-6 Speed or power of boom is low
H-7 Speed or power of arm is low
H-8 Speed or power of bucket is low
H-9 Work equipment does not move in its single operation
H-10 Hydraulic drift of work equipment is large
H-11 Time lag of work equipment is large
H-12 Power maximizing function does not operate normally
H-13 Work equipment loaded more is slower during compound operation
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE
H-15 Travel speed drops largely during compound operation of work equipment/swing + travel
H-16 Machine deviates during travel
H-17 Travel speed is low
H-18 Machine cannot be steered easily or steering power is low
H-19 Travel speed does not change or it is kept low or high
H-20 Track does not move (Only either side)
H-21 Machine does not swing
H-22 Swing acceleration or swing speed is low
H-23 Excessive overrun when stopping swing
H-24 When upper structure stops swinging, it makes large shock
H-25 When upper structure stops swinging, it makes large sound
H-26 Hydraulic drift of swing is large
H-27 Flow rate in attachment circuit cannot be adjusted
Troubleshooting of hydraulic and mechanical system (S-mode)
Method of using troubleshooting chart
Questions
Check items
Cause
Troubleshooting
S-1 Engine starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant or fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
CONTENTS
General information on disassembly and assembly
Precautions before work
How to read this manual
Coating materials list
Special tool list
Sketch of special tool
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of front oil seal
Removal and installation of rear oil seal
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of work equipment oil cooler assembly
Removal and installation of engine and work equipment pump assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of travel motor and final drive assembly
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Disassembly and assembly of track roller
Disassembly and assembly of idler assembly
Disassembly and assembly of recoil spring
Spreading and installation of track shoe assembly
Removal and installation of sprocket
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 work equipment pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
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
Electrical system
Removal and installation of air compressor assembly
Removal and installation of air conditioner condenser
Removal and installation of air conditioner unit assembly
Removal and installation of KOMTRAX communication modem assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly
Removal and installation of engine controller assembly
80 Appendix
CONTENTS
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 FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
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
Precautions for disconnecting and connecting air conditioner piping
Handling of compressor oil
Desiccant replacement procedure
90 Diagrams and drawings
CONTENTS
Hydraulic diagrams and drawings
Symbols in hydraulic circuit diagram
HYDRAULIC CIRCUIT DIAGRAM (1/2)
HYDRAULIC CIRCUIT DIAGRAM (2/2)
Electrical diagrams and drawings
Symbols in electric circuit diagram
ELECTRICAL CIRCUIT DIAGRAM (1/5)
ELECTRICAL CIRCUIT DIAGRAM (2/5)
ELECTRICAL CIRCUIT DIAGRAM (3/5)
ELECTRICAL CIRCUIT DIAGRAM (4/5)
ELECTRICAL CIRCUIT DIAGRAM (5/5)
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