Komatsu PC270-8 PC270LC-8 PC290LC-8 Excavator Shop Manual SEN06945-02 PDF

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Komatsu PC270-8 PC270LC-8 PC290LC-8 Excavator Shop Manual SEN06945-02 – PDF DOWNLOAD

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Komatsu PC270-8 PC270LC-8 PC290LC-8 Excavator Shop Manual SEN06945-02 – PDF DOWNLOAD 

Language : English
Pages : 1018
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC270-8 PC270LC-8 PC290LC-8 Excavator Shop Manual SEN06945-02 – PDF DOWNLOAD 

SERIAL NUMBERS
PC270- 20001 and up
PC270LC- 20001 and up
PC290LC- 30941 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

TABLE OF CONTENTS:

Komatsu PC270-8 PC270LC-8 PC290LC-8 Excavator Shop Manual SEN06945-02 – PDF DOWNLOAD

SERIAL NUMBERS
PC270- 20001 and up
PC270LC- 20001 and up
PC290LC- 30941 and up 

Cover 1
00 Index and foreword 3
Table of contents 4
Foreword and general information 11
Safety notice 11
How to read the shop manual 16
Explanation of terms for maintenance standard 18
Handling of electric equipment and hydraulic component 20
Handling of connectors newly used for engines 29
How to read electric wire code 32
Precautions when carrying out operation 35
Method of disassembling and connecting push-pull type coupler 38
Standard tightening torque table 41
Conversion table 45
01 Specification 51
Specification and technical data 53
Specification dimension drawings 53
Working range diagram 54
Specifications 55
Weight table 57
Table of fuel, coolant and lubricants 59
10 Structure, function and maintenance standard 61
Engine and cooling system 63
Engine related parts 63
Radiator, oil cooler, aftercooler and fuel cooler 64
Power train 65
Power train 65
Final drive 66
Swing machinery 68
Swing circle 70
Undercarriage and frame 71
Track frame and recoil spring 71
Idler 73
Carrier roller 75
Track roller 76
Track shoe 77
Hydraulic system 80
Hydraulic equipment layout drawing 80
Hydraulic tank and filter 82
Hydraulic pump 84
Pilot oil filter 106
Control valve 107
CLSS 118
Functions and operation by valve 122
Swing motor 160
Center swivel joint 168
Travel motor 170
PPC valve 182
Valve control 202
Solenoid valve 204
PPC accumulator 206
Anti-drop valve for boom 207
Anti-drop valve for arm 213
Return oil filter 219
Attachment circuit selector valve 220
Hydraulic cylinder 222
Work equipment 224
Dimensions of components 224
Cab and its attachments 230
Air conditioner piping 230
Electrical system 231
Engine control 231
Electrical control system 239
Monitor system 262
Sensor 288
KOMTRAX system 291
20 Standard value table 293
Standard service value table 295
Standard value table for engine related parts 295
Standard value table for chassis related parts 296
30 Testing and adjusting 307
Related information on testing and adjusting 309
Tools for testing, adjusting, and troubleshooting 309
Sketch of special tool 313
Engine and cooling system 314
Testing engine speed 314
Testing intake air pressure (boost pressure) 315
Checking exhaust gas color 316
Adjusting valve clearance 317
Testing compression pressure 319
Testing blow-by pressure 321
Testing engine oil pressure 322
Handling fuel system parts 323
Releasing residual pressure from fuel system 323
Testing fuel pressure 324
Testing fuel delivery, return and leak amount 327
Bleeding air from fuel circuit 330
Checking fuel circuit for leakage 331
Checking and adjusting air conditioner compressor belt tension 332
Replacing fan belt 333
Power train 334
Testing swing circle bearing clearance 334
Undercarriage and frame 335
Checking and adjusting track shoe tension 335
Hydraulic system 337
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 337
Testing control circuit basic pressure 340
Testing and adjusting oil pressure in pump PC control circuit 341
Testing and adjusting oil pressure in pump LS control circuit 344
Testing solenoid valve output pressure 349
Testing PPC valve output pressure 352
Adjusting play of work equipment and swing PPC valves 354
Checking parts which cause hydraulic drift of work equipment 355
Releasing residual pressure from hydraulic circuit 357
Testing oil leakage 358
Bleeding air from each part 361
Checking cab tipping stopper 363
Installation and adjustment of mirrors 364
Electrical system 367
Special functions of machine monitor 367
Handling voltage circuit of engine controller 422
Preparation work for troubleshooting of electrical system 423
Procedure for testing diodes 428
Pm Clinic service 429
40 Troubleshooting 435
Failure code table and fuse locations 440
Failure codes table 440
Fuse locations 445
General Information on troubleshooting 449
Points to remember when troubleshooting 449
Sequence of events in troubleshooting 450
Check before troubleshooting 451
Classification and procedures for troubleshooting 452
How to read electric wire code 456
Information in troubleshooting table 459
Connection table for connector pin numbers 461
T- branch box and T- branch adapter table 497
Troubleshooting by failure code (Display of code) 500
Failure code [989L00] Engine Controller Lock Caution 1 500
Failure code [989M00] Engine Controller Lock Caution 2 500
Failure code [989N00] Engine Controller Lock Caution 3 501
Failure code [AA10NX] Air Cleaner Clogging 501
Failure code [AB00KE] Charge Voltage Low 502
Failure code [B@BAZG] Eng Oil Press Low 504
Failure code [B@BAZK] Eng Oil Level Low 504
Failure code [B@BCNS] Eng Water Overheat 505
Failure code [B@BCZK] Eng Water Level Low 505
Failure code [B@HANS] Hydr Oil Overheat 506
Failure code [CA111] EMC Critical Internal Failure 506
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 507
Failure code [CA122] Chg Air Press Sensor High Error 508
Failure code [CA123] Chg Air Press Sensor Low Error 510
Failure code [CA131] Throttle Sensor High Error 512
Failure code [CA132] Throttle Sensor Low Error 514
Failure code [CA144] Coolant Temp Sens High Error 516
Failure code [CA145] Coolant Temp Sens Low Error 518
Failure code [CA153] Chg Air Temp Sensor High Error 520
Failure code [CA154] Chg Air Temp Sensor Low Error 522
Failure code [CA155] Chg Air Temp High Speed Derate 524
Failure code [CA187] Sens Supply 2 Volt Low Error 525
Failure code [CA221] Ambient Press Sens High Error 527
Failure code [CA222] Ambient Press Sens Low Error 529
Failure code [CA227] Sens Supply 2 Volt High Error 531
Failure code [CA234] Eng Overspeed 532
Failure code [CA238] Ne Speed Sens Supply Volt Error 533
Failure code [CA271] IMV/PCV1 Short Error 534
Failure code [CA272] IMV/PCV1 Open Error 535
Failure code [CA322] Inj #1 Open/Short Error 537
Failure code [CA323] Inj #5 Open/Short Error 539
Failure code [CA324] Inj #3 Open/Short Error 541
Failure code [CA325] Inj #6 Open/Short Error 543
Failure code [CA331] Inj #2 Open/Short Error 545
Failure code [CA332] Inj #4 Open/Short Error 547
Failure code [CA342] Calibration Code Incompatibility 549
Failure code [CA351] Injectors Drive Circuit Error 550
Failure code [CA352] Sens Supply 1 Volt Low Error 552
Failure code [CA386] Sens Supply 1 Volt High Error 554
Failure code [CA428] Water in Fuel Sensor High Error 555
Failure code [CA429] Water in Fuel Sensor Low Error 557
Failure code [CA435] Eng Oil Press Sw Error 559
Failure code [CA441] Battery Voltage Low Error 560
Failure code [CA442] Battery Voltage High Error 563
Failure code [CA449] Rail Press Very High Error 565
Failure code [CA451] Rail Press Sensor High Error 566
Failure code [CA452] Rail Press Sensor Low Error 568
Failure code [CA488] Chg Air Temp High Torque Derate 570
Failure code [CA553] Rail Press High Error 571
Failure code [CA559] Rail Press Low Error 572
Failure code [CA689] Eng Ne Speed Sensor Error 574
Failure code [CA731] Eng Bkup Speed Sens Phase Error 576
Failure code [CA757] All Continuous Data Lost Error 577
Failure code [CA778] Eng Bkup Speed Sensor Error 579
Failure code [CA1633] KOMNET Datalink Timeout Error 581
Failure code [CA2185] Throt Sens Sup Volt High Error 582
Failure code [CA2186] Throt Sens Sup Volt Low Error 583
Failure code [CA2249] Rail Press Very Low Error 584
Failure code [CA2311] IMV Solenoid Error 585
Failure code [CA2555] Grid Htr Relay Volt High Error 587
Failure code [CA2556] Grid Htr Relay Volt Low Error 589
Failure code [D19JKZ] Personal Code Relay Abnormality 591
Failure code [D862KA] GPS Antenna Discon 593
Failure code [DA22KK] Pump Solenoid Power Low Error 594
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 596
Failure code [DA29KQ] Model Selection Abnormality 602
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 604
Failure code [DAF8KB] Short circuit in camera power supply 611
Failure code [DAFGMC] GPS Module Error 613
Failure code [DAFRMC] CAN Discon (Monitor Detected) 614
Failure code [DGH2KB] Hydr Oil Sensor Short 619
Failure code [DHPAMA] F Pump Press Sensor Abnormality 620
Failure code [DHPBMA] R Pump Press Sensor Abnormality 622
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 624
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 626
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 628
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 630
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 632
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 634
Failure code [DHX1MA] Overload Sensor Abnormality (Analog) 636
Failure code [DW43KA] Travel Speed Sol Discon 639
Failure code [DW43KB] Travel Speed Sol Short 641
Failure code [DW45KA] Swing Brake Sol Discon 643
Failure code [DW45KB] Swing Brake Sol Short 645
Failure code [DW91KA] Travel Junction Sol Discon 647
Failure code [DW91KB] Travel Junction Sol Short 649
Failure code [DWA2KA] Service Sol Discon 651
Failure code [DWA2KB] Service Sol Short 652
Failure code [DWK0KA] 2-stage Relief Sol Discon 653
Failure code [DWK0KB] 2-stage Relief Sol Short 655
Failure code [DXA8KA] PC-EPC (F) Sol Discon 657
Failure code [DXA8KB] PC-EPC (F) Sol Short 659
Failure code [DXA9KA] PC-EPC (R) Sol Discon 661
Failure code [DXA9KB] PC-EPC (R) Sol Short 663
Failure code [DXE0KA] LS-EPC Sol Discon 665
Failure code [DXE0KB] LS-EPC Sol Short 667
Failure code [DXE4KA] Service Current EPC Discon 669
Failure code [DXE4KB] Service Current EPC Short 671
Failure code [DXE5KA] Merge-divider Main Sol Discon 673
Failure code [DXE5KB] Merge-divider Main Sol Short 675
Failure code [DXE6KA] Merge-divider LS Sol Discon 677
Failure code [DXE6KB] Merge-divider LS Sol Short 679
Failure code [DY20KA] Wiper Working Abnormality 681
Failure code [DY20MA] Wiper Parking Abnormality 683
Failure code [DY2CKA] Washer Drive Discon 685
Failure code [DY2CKB] Washer Drive Short 687
Failure code [DY2DKB] Wiper Drive (For) Short 689
Failure code [DY2EKB] Wiper Drive (Rev) Short 691
Troubleshooting of electrical system (E-mode) 693
Before carrying out troubleshooting of electrical system 693
Information in troubleshooting table 695
E-1 When starting switch turned ON, machine monitor displays nothing 696
E-2 When starting switch turned ON (before starting engine), basic check item lights up 698
E-3 Engine does not start (Engine does not crank) 701
E-4 Preheater does not operate 705
E-5 Automatic warm-up system does not operate (in cold season) 709
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked 710
E-7 Precaution lights up while engine is running 712
E-8 Emergency stop item lights up while engine is running 717
E-9 Engine coolant temperature gauge does not indicate normally 718
E-10 Hydraulic oil temperature gauge does not indicate correctly 719
E-11 Fuel level gauge does not indicate correctly 722
E-12 Contents of display by machine monitor are different from applicable machine 724
E-13 Machine monitor does not display some items 724
E-14 Function switch does not work 724
E-15 Auto-decelerator does not operate normally 725
E-16 Working mode does not change 726
E-17 Travel speed does not change 727
E-18 Alarm buzzer cannot be stopped 728
E-19 Windshield wiper and window washer do not operate 729
E-20 Power maximizing function does not operate normally 731
E-21 Swing holding brake does not operate normally 733
E-22 Travel alarm does not sound or does not stop sounding 735
E-23 Air conditioner does not operate normally (including air conditioner abnormality record) 737
E-24 While starting switch is in OFF position, service meter is not displayed 749
E-25 Machine monitor cannot be set in service mode 749
E-26 Monitoring function does not display lever control signal normally 750
E-27 KOMTRAX system does not operate normally 758
Troubleshooting of hydraulic and mechanical system (H-mode) 759
System diagram of hydraulic and mechanical system 759
Information in troubleshooting table 761
H-1 Speed or power of whole work equipment, swing, and travel is low 762
H-2 Engine speed lowers significantly or engine stalls 764
H-3 Work equipment, swing, and travel systems do not work 765
H-4 Abnormal sound comes out from around hydraulic pump 765
H-5 Auto-decelerator does not operate 766
H-6 Fine control performance or response is low 766
H-7 Speed or power of boom is low 767
H-8 Speed or power of arm is low 768
H-9 Speed or power of bucket is low 769
H-10 Work equipment does not move singly 769
H-11 Hydraulic drift of work equipment is large 770
H-12 Time lag of work equipment is large 772
H-13 When part of work equipment is relieved singly, other parts of work equipment move 772
H-14 Power maximizing function does not work 773
H-15 In compound operation of work equipment, speed of part loaded more is low 773
H-16 When machine swings and raises boom simultaneously, boom rising speed is low 774
H-17 When machine swings and travels simultaneously, travel speed is low 774
H-18 Machine deviates during travel 775
H-19 Travel speed is low 776
H-20 Machine is not steered well or steering power is low 777
H-21 Travel speed does not change or travel speed is low/high 778
H-22 Travel system does not move (only one side) 779
H-23 Upper structure does not swing 780
H-24 Swing acceleration or swing speed is low 782
H-25 Upper structure overruns remarkably when it stops swinging 783
H-26 Large shock is made when upper structure stops swinging 784
H-27 Large sound is made when upper structure stops swinging 784
H-28 Hydraulic drift of swing is large 785
H-29 Attachment circuit is not changed 786
H-30 Oil flow in attachment circuit cannot be controlled 786
Troubleshooting of engine (S-mode) 787
Method of using troubleshooting chart 787
S-1 Starting performance is poor 790
S-2 Engine does not start 791
S-3 Engine does not pick up smoothly 794
S-4 Engine stops during operations 795
S-5 Engine does not rotate smoothly 796
S-6 Engine lack output (or lacks power) 797
S-7 Exhaust smoke is black (incomplete combustion) 798
S-8 Oil consumption is excessive (or exhaust smoke is blue) 799
S-9 Oil becomes contaminated quickly 800
S-10 Fuel consumption is excessive 801
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 802
S-12 Oil pressure drops 803
S-13 Oil level rises (Entry of coolant/fuel) 804
S-14 Coolant temperature becomes too high (overheating) 805
S-15 Abnormal noise is made 806
S-16 Vibration is excessive 807
50 Disassembly and assembly 809
General information on disassembly and assembly 812
How to read this manual 812
Coating materials list 814
Special tools list 817
Sketches of special tools 821
Engine and cooling system 825
Removal and installation of fuel supply pump assembly 825
Removal and installation of fuel injector assembly 829
Removal and installation of engine front seal 838
Removal and installation of engine rear seal 841
Removal and installation of cylinder head assembly 844
Removal and installation of radiator assembly 858
Removal and installation of hydraulic oil cooler assembly 861
Removal and installation of aftercooler assembly 863
Removal and installation of fuel cooler assembly 865
Removal and installation of engine and hydraulic pump assembly 866
Power train 875
Removal and installation of final drive assembly 875
Disassembly and assembly of final drive assembly 876
Removal and installation of swing motor and swing machinery assembly 885
Disassembly and assembly of swing motor and swing machinery assembly 887
Removal and installation of swing circle assembly 896
Undercarriage and frame 897
Disassembly and assembly of carrier roller assembly 897
Disassembly and assembly of track roller assembly 898
Disassembly and assembly of idler assembly 899
Disassembly and assembly of recoil spring assembly 902
Removal and installation of sprocket 904
Expansion and installation of track shoe assembly 905
Removal and installation of revolving frame assembly 907
Removal and installation of counterweight assembly 0
Hydraulic system 911
Removal and installation of center swivel joint assembly 911
Disassembly and assembly of center swivel joint assembly 913
Removal and installation of hydraulic tank assembly 914
Removal and installation of control valve assembly 918
Disassembly and assembly of control valve assembly 923
Removal and installation of hydraulic pump assembly 927
Removal and installation of oil seal in hydraulic pump input shaft 931
Disassembly and assembly of work equipment PPC valve assembly 932
Disassembly and assembly of travel PPC valve assembly 934
Disassembly and assembly of hydraulic cylinder assembly 937
Work equipment 943
Removal and installation of work equipment assembly 943
Removal and installation of anti-drop valve assembly for boom 946
Removal and installation of anti-drop valve assembly for arm 949
Disassembly and assembly of anti-drop valve assembly 951
Cab and its attachments 952
Removal and installation of operator’s cab assembly 952
Removal and installation of operator cab glass (stuck glass) 955
Removal and installation of front window assembly 965
Removal and installation of floor frame assembly 972
Removal and installation of work equipment control lever assembly 976
Electrical system 989
Removal and installation of air conditioner unit assembly 989
Removal and installation of KOMTRAX communication modem assembly 992
Removal and installation of monitor assembly 993
Removal and installation of pump controller assembly 995
90 Diagrams and drawings 997
Hydraulic diagrams and drawings 999
Hydraulic circuit diagram 999
Electrical diagrams and drawings 1003
Electrical circuit diagram 1003
Connector arrangement diagram 1011
Index 1013

S.V  21/12/24