Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Komatsu PC150-6K PC150LC-6K Repair Manual (UEBM000701) PDF Download
$32.95
KOMATSU PC150-6K PC150LC-6K SHOP MANUAL UEBM000701 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU PC150-6K PC150LC-6K SHOP MANUAL UEBM000701 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC150-6K PC150LC-6K SHOP MANUAL UEBM000701 – PDF DOWNLOAD
Language : English
Pages : 693
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC150-6K PC150LC-6K SHOP MANUAL UEBM000701 – PDF DOWNLOAD
MAIN MENU.......................................................................................................................................................................................... 0 COVER.............................................................................................................................................................................................. 1 CONTENTS........................................................................................................................................................................................... 2 SAFETY............................................................................................................................................................................................. 6 SAFETY NOTICE.................................................................................................................................................................................. 6 FOREWORD........................................................................................................................................................................................... 8 GENERAL........................................................................................................................................................................................ 8 HOW TO READ THE SHOP MANUAL.................................................................................................................................................................... 9 HOISTING INSTRUCTIONS.......................................................................................................................................................................... 10 COATING MATERIALS.............................................................................................................................................................................. 11 STANDARD TIGHTENING TORQUE..................................................................................................................................................................... 12 ELECTRIC WIRE CODE............................................................................................................................................................................. 14 CONVERSION TABLE............................................................................................................................................................................... 15 01 GENERAL......................................................................................................................................................................................... 22 SPECIFICATIONS................................................................................................................................................................................. 23 SPECIFICATON DRAWINGS.......................................................................................................................................................................... 26 WEIGHT TABLE................................................................................................................................................................................... 27 FUEL, COOLANT AND LUBRICANTS................................................................................................................................................................... 29 10 STRUCTURE AND FUNCTION.......................................................................................................................................................................... 32 ENGINE RELATED PARTS........................................................................................................................................................................... 33 RADIATOR • OIL COOLER.......................................................................................................................................................................... 34 POWER TRAIN.................................................................................................................................................................................... 35 FINAL DRIVE.................................................................................................................................................................................... 36 SWING CIRCLE................................................................................................................................................................................... 37 SWING MACHINERY................................................................................................................................................................................ 38 TRACK FRAME, RECOIL SPRING..................................................................................................................................................................... 40 TRACK SHOE..................................................................................................................................................................................... 41 HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................................................................... 44 HYDRAULIC TANK................................................................................................................................................................................. 45 HYDRAULIC PUMP................................................................................................................................................................................. 47 CONTROL VALVE.................................................................................................................................................................................. 54 CLSS........................................................................................................................................................................................... 60 SWING MOTOR.................................................................................................................................................................................... 97 CENTER SWIVEL JOINT............................................................................................................................................................................ 99 TRAVEL MOTOR...................................................................................................................................................................................100 VALVE CONTROL..................................................................................................................................................................................108 WORK EQUIPMENT - SWING PPC VALVE...............................................................................................................................................................109 TRAVEL PPC PEDAL...............................................................................................................................................................................113 TRAVEL PPC VALVE PEDAL.........................................................................................................................................................................117 SAFETY LOCK VALVE..............................................................................................................................................................................120 PPC ACCUMULATOR................................................................................................................................................................................120 PPC SHUTTLE • TRAVEL JUNCTION VALVE............................................................................................................................................................121 EPC • SOLENOID VALVE...........................................................................................................................................................................128 HYDRAULIC CYLINDER.............................................................................................................................................................................133 ADDITIONAL FILTER FOR BREAKING.................................................................................................................................................................135 BOOM HOLDING VALVE.............................................................................................................................................................................136 WORK EQUIPMENT.................................................................................................................................................................................143 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE..........................................................................................................................................................144 ENGINE CONTROL SYSTEM..........................................................................................................................................................................145 ELECTRONIC CONTROL SYSTEM......................................................................................................................................................................151 MACHINE MONITOR SYSTEM.........................................................................................................................................................................175 20 TESTING AND ADJUSTING...........................................................................................................................................................................187 TABLE OF JUDGEMENT STANDARD VALUE..............................................................................................................................................................188 STANDARD VALUE TABLE FOR ELECTRICAL PARTS......................................................................................................................................................198 CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSORR............................................................................................................................206 ADJUSTING ENGINE SPEED SENSOR..................................................................................................................................................................207 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE..............................................................................................................................................208 TESTING CLEARANCE OF SWING CIRCLE BEARING......................................................................................................................................................210 TESTING AND ADJUSTING TRACK SHOE TENSION.......................................................................................................................................................211 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT..............................................................................................................212 TESTING AND ADJUSTING TVC VALVE OUTPUT (SERVO PISTON INPUT PRESSURE)...........................................................................................................................220 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL...............................................................................................222 TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE...............................................................................................................................................225 TESTING AND ADJUSTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE.................................................................................................................................227 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE..............................................................................................................................229 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE......................................................................................................................................................231 TESTING TRAVEL DEVIATION.......................................................................................................................................................................232 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT....................................................................................................................................233 MEASURING OIL LEAKAGE..........................................................................................................................................................................235 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..............................................................................................................................................237 BLEEDING AIR...................................................................................................................................................................................238 TROUBLESHOOTING................................................................................................................................................................................241 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................................................................................242 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................................................................................243 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..................................................................................................................................................244 CHECKS BEFORE TROUBLESHOOTING..............................................................................................................................................................251 CONNECTOR TYPES AND MOUNTING LOCATIONS.....................................................................................................................................................252 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................................................................................257 EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM......................................................................................................................................270 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL......................................................................................................................................271 METHOD OF USING JUDGEMENT TABLE............................................................................................................................................................279 METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................................................................................281 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...................................................................................................................................283 SERVICE CODE TABLE.........................................................................................................................................................................288 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)...............................................................................................................................289 N-1 [E218] COMMUNICATION ABNOMALITY....................................................................................................................................................290 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)............................................................................................................292 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM...............................................................................................293 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................................................................294 JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS.........................................................................................298 ELECTRICAL CIRCUIT DIAGRAM OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) .....................................................................................................300 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)......................................................................................................302 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...................................................................................................................303 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED..............................................................................................................304 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED..............................................................................................................305 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...................................................................................................................306 E-6 [E315] ABNORMALITY (SHORT CIRCUIT IN BATTERY RELAY OUTPUT).........................................................................................................................307 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED................................................................................................................................308 E-8 ENGINE DOES NOT START..............................................................................................................................................................310 E-9 ENGINE SPEED IS IRREGULAR..........................................................................................................................................................312 A) IDLING SPEED IS IRREGULAR.......................................................................................................................................................312 B) THERE IS HUNTING................................................................................................................................................................314 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)..............................................................................................................................316 E-11 ENGINE DOES NOT STOP..............................................................................................................................................................318 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)................................................................................................................320 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..................................................................................................................................................323 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................................................324 S-1 STARTING PERFORMANE IS POOR (STARTING ALWAYS TAKES TIME)...........................................................................................................................328 S-2 ENGINE DOES NOT START..............................................................................................................................................................329 (1) ENGINE DOES NOT RUN............................................................................................................................................................329 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).......................................................................................................330 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).....................................................................................................331 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...............................................................................................................................332 S-4 ENGINE STOP DURING OPERATIONS......................................................................................................................................................333 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..........................................................................................................................................334 S-6 ENGINE LACKS OUTPUT (NO POWER).....................................................................................................................................................335 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).....................................................................................................................................336 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)............................................................................................................................337 S-9 OIL BECOMES CONTAMINATED QUICKLY...................................................................................................................................................338 S-10 FUEL CONSUMPTION IS EXCESSIVE.....................................................................................................................................................339 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR LEVEL GOES DOWN.................................................................................................................340 S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE).........................................................................................................................341 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)..............................................................................................................................................342 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..................................................................................................................................343 S-15 ABNORMAL NOISE IS MADE............................................................................................................................................................344 S-16 VIBRATION IS EXCESSIVE............................................................................................................................................................345 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)................................................................................................................346 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM.........................................................................................................................347 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................................................................348 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS........................................................................................354 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE..................................................................................................................................................356 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)..............................................................................................................358 C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED......................................................................................................................359 C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED......................................................................................................................361 C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................363 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................365 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................367 C-10 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...............................................................................................................369 C-11 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENIOD SYSTEM IS DISPLAYED...............................................................................................................370 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED.................................................................................................................371 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED........................................................................................................372 C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED...................................................................................................................................373 C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................375 C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS...........................................................................................................................376 C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED....................................................................................................................377 C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED............................................................................................................378 C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED.....................................................................................................................379 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)................................................................................................................381 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE..................................................................................................................................................383 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................................................................385 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................386 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................................................................387 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................................................................388 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................389 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...................................................................................................................390 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................391 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................392 F-9 BIT PATTERN 21-(3) SWING LOCK DOES NOT LIGHT UP....................................................................................................................................393 F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP.....................................................................................................................394 F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP.............................................................................................................................395 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...................................................................................................................................396 TABLE OF FAILURE MODES AND CAUSES......................................................................................................................................................397 ALL WORK EQUIPMENT, TRAVEL, SWING......................................................................................................................................................401 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER.............................................................................................................401 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS......................................................................................................................403 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE..........................................................................................................................................404 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).........................................................................................................................................404 H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)..............................................................................................................405 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR...............................................................................................................................405 WORK EQUIPMENT.........................................................................................................................................................................407 H-7 BOOM IS SLOW OR LACKS POWER....................................................................................................................................................407 H-8 ARM IS SLOW OR LACKS POWER.....................................................................................................................................................409 H-9 BUCKET IS SLOW OR LACKS POWER..................................................................................................................................................411 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE..............................................................................................................................412 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET).................................................................................................................................412 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING......................................................................................................................................413 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.........................................................................................................................413 H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED.............................................................................................................414 H-15 LACK OF POWER WHEN PRESSURE RISES.............................................................................................................................................414 COMPOUND OPERATIONS....................................................................................................................................................................414 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW...............................................................................................................414 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW.....................................................................................................................................415 TRAVEL SYSTEM..........................................................................................................................................................................416 H-20 TRAVEL DEVIATION..............................................................................................................................................................416 H-21 TRAVEL SPEED IS SLOW..........................................................................................................................................................417 H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER..................................................................................................................................419 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED................................................................................................................421 H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)..........................................................................................................................................421 SWING SYSTEM...........................................................................................................................................................................422 H-25 DOES NOT SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY)......................................................................................................................422 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW.............................................................................................................................423 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY)...............................................................................................425 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)......................................................................................................................426 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..................................................................................................................................426 H-30 EXCESSIVE HYDARULIC DRIFT OF SWING............................................................................................................................................427 H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED..............................................................................................................................428 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).........................................................................................................................................430 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..........................................................................................................431 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE..................................................................................................................................................434 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED......................................................................................................................................436 M-1 [E102] ERROR IN CLOCK DATA IS DISPLAYED............................................................................................................................................436 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTRACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED.....................................................................437 M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED..........................................................................................................................................438 M-4 [E106] DROP IN ENGINE OIL PRESSURE HI DETECTED IS DISPLAYED........................................................................................................................438 M-5 [E108] ENGINE WATER TEPERATURE 105°C DETECTED IS DISPLAYED.........................................................................................................................439 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR THREE SECONDS.......................................................................................440 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT...........................................................................................442 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)........................................................................442 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES......................................................................................................443 M-10 PREHEATING IS NOT BEING USED BY (PREHEATING MONITOR LIGHT UP).....................................................................................................................445 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH..................................................................................................446 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP).....................................448 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEM, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)....450 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND.............................................453 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS..........................................................................................................................453 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)..............................................................................................454 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE...........................................................................................................................................455 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)...............................................................................455 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.............................................................................................................................................456 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY............................................................................................................................................456 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP..................................................................................................457 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH................................................................................................457 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING............................................................................................................................458 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED...............................................................................458 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM................................................................................................................................................459 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM.......................................................................................................................................460 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM..........................................................................................................................................461 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.............................................................................................................................................462 M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED.............................................................................................................463 30 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................469 METHOD OF USING MANUAL.........................................................................................................................................................................471 PRECAUTIONS WHEN CARRYING OUT OPERATION........................................................................................................................................................473 SPECIAL TOOL LIST..............................................................................................................................................................................475 GOVERNOR MOTOR ASSEMBLY........................................................................................................................................................................478 REMOVAL AND INSTALLATION...................................................................................................................................................................478 HYDRAULIC OIL COOLER ASSEMBLY..................................................................................................................................................................479 REMOVAL AND INSTALLATION...................................................................................................................................................................479 RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY........................................................................................................................................................480 REMOVAL....................................................................................................................................................................................480 INSTALLATION...............................................................................................................................................................................481 ENGINE, MAIN PUMP ASSEMBLY.....................................................................................................................................................................482 REMOVAL....................................................................................................................................................................................482 INSTALLATION...............................................................................................................................................................................485 DAMPER ASSEMBLY................................................................................................................................................................................486 REMOVAL AND INSTALLATION...................................................................................................................................................................486 FUEL TANK/HYDRAULIC OIL TANK ASSEMBLY..........................................................................................................................................................487 REMOVAL AND INSTALLATION...................................................................................................................................................................487 CENTER SWIVEL JOINT ASSEMBLY...................................................................................................................................................................489 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................489 TRAVEL MOTOR ASSEMBLY..........................................................................................................................................................................490 REMOVAL AND INSTALLATION...................................................................................................................................................................490 FINAL DRIVE ASSEMBLY...........................................................................................................................................................................491 REMOVAL AND INSTALLATION...................................................................................................................................................................491 SPROCKET.......................................................................................................................................................................................493 REMOVAL AND INSTALLATION...................................................................................................................................................................493 SWING MOTOR ASSEMBLY...........................................................................................................................................................................494 REMOVAL AND INSTALLATION...................................................................................................................................................................494 SWING MACHINERY ASSEMBLY.......................................................................................................................................................................495 REMOVAL AND INSTALLATION...................................................................................................................................................................495 SWING MOTOR....................................................................................................................................................................................497 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................497 REVOLVING FRAME ASSEMBLY.......................................................................................................................................................................504 REMOVAL....................................................................................................................................................................................504 INSTALLATION...............................................................................................................................................................................505 SWING CIRCLE ASSEMBLY..........................................................................................................................................................................506 REMOVAL AND INSTALLATION...................................................................................................................................................................506 IDLER, RECOIL SPRING ASSEMBLY..................................................................................................................................................................508 REMOVAL AND INSTALLATION...................................................................................................................................................................508 RECOIL SPRING ASSEMBLY.........................................................................................................................................................................509 DISASSEMBLY................................................................................................................................................................................509 ASSEMBLY...................................................................................................................................................................................510 IDLER ASSEMBLY.................................................................................................................................................................................511 DISASSEMBLY................................................................................................................................................................................511 ASSEMBLY...................................................................................................................................................................................512 TRACK ROLLER ASSEMBLY..........................................................................................................................................................................514 REMOVAL AND INSTALLATION...................................................................................................................................................................514 DISASSEMBLY................................................................................................................................................................................515 ASSEMBLY...................................................................................................................................................................................516 CARRIER ROLLER ASSEMBLY........................................................................................................................................................................518 REMOVAL AND INSTALLATION...................................................................................................................................................................518 DISASSEMBLY................................................................................................................................................................................519 ASSEMBLY...................................................................................................................................................................................520 TRACK SHOE ASSEMBLY............................................................................................................................................................................522 REMOVAL AND INSTALLATION...................................................................................................................................................................522 MAIN PUMP ASSEMBLY.............................................................................................................................................................................525 REMOVAL....................................................................................................................................................................................525 INSTALLATION...............................................................................................................................................................................526 CONTROL VALVE ASSEMBLY.........................................................................................................................................................................527 REMOVAL....................................................................................................................................................................................527 INSTALLATION...............................................................................................................................................................................528 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................529 LS SELECT VALVE ASSEMBLY.......................................................................................................................................................................533 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................533 LS SHUTTLE VALVE...............................................................................................................................................................................534 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................534 PRESSURE COMPENSATION VALVE ASSEMBLY...........................................................................................................................................................535 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................535 MAIN RELIEF VALVE ASSEMBLY.....................................................................................................................................................................537 DISASSEMBLY................................................................................................................................................................................537 ASSEMBLY...................................................................................................................................................................................538 LS CONTROL EPC VALVE ASSEMBLY..................................................................................................................................................................539 REMOVAL AND INSTALLATION...................................................................................................................................................................539 SOLENOID VALVE ASSEMBLY........................................................................................................................................................................540 REMOVAL AND INSTALLATION...................................................................................................................................................................540 PPC SHUTTLE VALVE ASSEMBLY.....................................................................................................................................................................541 REMOVAL....................................................................................................................................................................................541 INSTALLATION...............................................................................................................................................................................542 DISASSEMBLY................................................................................................................................................................................543 ASSEMBLY...................................................................................................................................................................................544 WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY.......................................................................................................................................................545 REMOVAL AND INSTALLATION...................................................................................................................................................................545 TRAVEL PPC VALVE ASSEMBLY......................................................................................................................................................................546 REMOVAL AND INSTALLATION...................................................................................................................................................................546 DISASSEMBLY ...............................................................................................................................................................................547 ASSEMBLY...................................................................................................................................................................................547 BOOM CYLINDER ASSEMBLY.........................................................................................................................................................................549 REMOVAL....................................................................................................................................................................................549 INSTALLATION...............................................................................................................................................................................550 ARM CYLINDER ASSEMBLY..........................................................................................................................................................................551 REMOVAL....................................................................................................................................................................................551 INSTALLATION...............................................................................................................................................................................552 BUCKET CYLINDER ASSEMBLY.......................................................................................................................................................................553 REMOVAL....................................................................................................................................................................................553 INSTALLATION...............................................................................................................................................................................554 HYDRAULIC CYLINDER ASSEMBLY....................................................................................................................................................................555 DISASSEMBLY................................................................................................................................................................................555 ASSEMBLY...................................................................................................................................................................................557 WORK EQUIPMENT ASSEMBLY........................................................................................................................................................................560 REMOVAL....................................................................................................................................................................................560 INSTALLATION...............................................................................................................................................................................561 BUCKET ASSEMBLY................................................................................................................................................................................562 REMOVAL....................................................................................................................................................................................562 INSTALLATION...............................................................................................................................................................................562 ARM ASSEMBLY...................................................................................................................................................................................562 REMOVAL....................................................................................................................................................................................562 INSTALLATION...............................................................................................................................................................................562 BUCKET, ARM ASSEMBLY...........................................................................................................................................................................564 REMOVAL....................................................................................................................................................................................564 INSTALLATION...............................................................................................................................................................................564 BOOM ASSEMBLY..................................................................................................................................................................................566 REMOVAL....................................................................................................................................................................................566 INSTALLATION...............................................................................................................................................................................567 OPERATOR'S CAB ASSEMBLY........................................................................................................................................................................568 REMOVAL....................................................................................................................................................................................568 INSTALLATION...............................................................................................................................................................................570 COUNTERWEIGHT..................................................................................................................................................................................571 REMOVAL AND INSTALLATION...................................................................................................................................................................571 GOVERNOR, PUMP CONTROLLER ASSEMBLY.............................................................................................................................................................572 REMOVAL AND INSTALLATION...................................................................................................................................................................572 MONITOR PANEL ASSEMBLY.........................................................................................................................................................................573 REMOVAL AND INSTALLATION...................................................................................................................................................................573 FINAL DRIVE ASSEMBLY...........................................................................................................................................................................579 DISASSEMBLY................................................................................................................................................................................579 ASSEMBLY...................................................................................................................................................................................590 SPECIAL TOOLS..............................................................................................................................................................................602 SWING MACHINERY ASSEMBLY.......................................................................................................................................................................609 DISASSEMBLY................................................................................................................................................................................609 ASSEMBLY...................................................................................................................................................................................625 SPECIAL TOOLS..............................................................................................................................................................................645 40 MAINTENANCE STANDARD............................................................................................................................................................................649 ENGINE MOUNT...................................................................................................................................................................................650 SWING MACHINERY................................................................................................................................................................................651 SWING CIRCLE...................................................................................................................................................................................653 FINAL DRIVE....................................................................................................................................................................................654 TRACK FRAME, RECOIL SPRING.....................................................................................................................................................................656 IDLER..........................................................................................................................................................................................657 CARRIER ROLLER.................................................................................................................................................................................659 TRACK ROLLER...................................................................................................................................................................................660 TRACK SHOE.....................................................................................................................................................................................661 CONTROL VALVE..................................................................................................................................................................................663 SUCTION-SAFETY VALVE...........................................................................................................................................................................671 SWING MOTOR....................................................................................................................................................................................672 WORK EQUIPMENT, SWING PPC VALVE................................................................................................................................................................673 TRAVEL PPC VALVE...............................................................................................................................................................................674 SERVICE PPC VALVE..............................................................................................................................................................................675 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.......................................................................................................................................................676 EPC SOLENOID VALVE.............................................................................................................................................................................677 CENTER SWIVEL JOINT............................................................................................................................................................................678 HYDRAULIC CYLINDER.............................................................................................................................................................................680 WORK EQUIPMENT.................................................................................................................................................................................681 90 OTHERS..........................................................................................................................................................................................689 ELECTRICAL CIRCUIT DIAGRAM - SHEET 1 OF 4......................................................................................................................................................690 ELECTRICAL CIRCUIT DIAGRAM - SHEET 2 OF 4......................................................................................................................................................691 ELECTRICAL CIRCUIT DIAGRAM - SHEET 3 OF 4......................................................................................................................................................692 ELECTRICAL CIRCUIT DIAGRAM - SHEET 4 OF 4......................................................................................................................................................693
DESCRIPTION:
KOMATSU PC150-6K PC150LC-6K SHOP MANUAL UEBM000701 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs , as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling eachr component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
S.S 22/12/24
